description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF INVENTION
As shown in FIG. 1, a typical computer system 10 has, among other components, a microprocessor 12 , one or more forms of memory 14 , integrated circuits 16 having specific functionalities, and peripheral computer resources (not shown), e.g., monitor, keyboard, software programs, etc. These components communicate with one another via communication paths 19 , e.g., wires, buses, etc., to accomplish the various tasks of the computer system 10 .
In order to properly accomplish such tasks, the computer system 10 relies on the basis of time to coordinate its various operations. To that end, a crystal oscillator 18 generates a system clock signal (referred to and known in the art as “reference clock” and shown in FIG. 1 as SYS_CLK) to various parts of the computer system 10 . Modem microprocessors and other integrated circuits, however, are typically capable of operating at frequencies significantly higher than the system clock, and thus, it becomes important to ensure that operations involving the microprocessor 12 and the other components of the computer system 10 use a proper and accurate reference of time.
Accordingly, as the frequencies of modem computers continue to increase, the need to rapidly transmit data between circuit interfaces also increases. To accurately receive data, a clock signal is often transmitted to help recover data transmitted to a receiving circuit by some transmitting circuit. The clock signal determines when the data should be sampled by the receiving circuit. In some cases, the clock signal may change state at the beginning of the time the data is valid. However, this is typically undesirable because the receiving circuit operates better when the clock signal is detected during the middle of the time the data is valid. In other cases, the clock signal may degrade as it propagates from its transmission point. Such degradation may result from process, voltage, and/or temperature variations that directly or indirectly affect the clock signal. To guard against the adverse effects of poor and inaccurate clock signal transmission, a delay locked loop (“DLL”) is commonly used to generate a copy of the clock signal at a fixed phase shift with respect to the original clock signal.
FIG. 2 shows a portion of a typical computer system in which a DLL 30 is used. In FIG. 2, data 32 is transmitted from a transmitting circuit 34 to a receiving circuit 36 . To aid in the recovery of the data 32 by the receiving circuit 36 , a clock signal 38 is transmitted along with the data 32 . To ensure that the data 32 is properly latched by the receiving circuit 36 , the DLL 30 (which in FIG. 2 is shown as being part of the receiving circuit 36 ) regenerates the clock signal 38 to a valid voltage level and creates a phase shifted version of the clock signal 38 . Accordingly, the use of the DLL 30 in this fashion ensures (1) that the data 32 is properly latched by triggering the receiving circuit 36 at a point in time in which the data 32 is valid and (2) that the clock signal 38 is buffered by the receiving circuit 36 .
FIG. 3 shows a configuration of a typical DLL 40 . The DLL 40 includes a cascade of two loops. The first loop 42 includes a voltage-controlled delay line 44 , composed of several delay elements 46 , that inputs a reference clock, ref_elk 48 , and outputs an output clock, out_elk 50 , that is shifted 180 degrees from the reference clock 48 . A delay of the voltage-controlled delay line 44 is controlled by a feedback system including a phase detector 52 , a charge pump 54 , and a bias generator 56 . The phase detector 52 detects any phase offset between the reference clock 48 and the output clock 50 and generates UP 58 and DOWN 60 pulses that control the charge pump 54 . Depending on the UP 58 and DOWN 60 pulses, the charge pump 54 transfers charge to or from a filter capacitor 62 , thereby generating a control voltage, V ctrl 64 . The bias generator 56 inputs the control voltage 64 and produces bias voltages V cn 66 and V cp 68 that adjust the delay of the delay elements 46 in the voltage-controlled delay line 44 such that the delay of the voltage-controlled delay line 44 is proportional to a phase shift of 180 degrees from the reference clock 48 .
The second loop 45 is an ‘interpolating’ loop that takes the outputs of the delay elements 46 in the voltage-controlled delay line 44 and produces an interpolated clock signal that is locked in phase, i.e., 0 degrees phase offset, with the reference clock 48 . This is accomplished through a plurality of stages. A first group of clock signal from a pair of successive delay elements 46 are selected by an analog multiplexer known as a ‘phase selector’ 70 . The selected delay element 46 outputs are then inverted by a phase inverter 72 is required. A phase interpolator 74 then interpolates between the output pair of clock signals from the phase inverter 72 , thereby generating a clock signal that is places between the phase inverter 72 outputs. The output from the phase interpolator 74 is then compared to the reference clock 48 using a digital phase detector 76 . The digital phase detector 76 detects the phase offset between the interpolated clock signal and the reference clock 48 , and its output serves as an input to a finite state machine 78 that adjusts (1) interpolating weights in the phase interpolator 74 , (2) select signals in the phase selector 70 , and (3) the phase inversion in the phase inverter 72 .
The use of DLLs, such as the one described above with reference to FIG. 3, is becoming increasingly important with the advent of modern high-speed high-bandwidth processors. Additionally, because a DLL typically occupies a significant amount of integrated circuit space, DLL implementation is becoming a significant concern for circuit designers and the like.
SUMMARY OF INVENTION
According to one aspect of the present invention, an integrated circuit having a delay locked loop comprises: a phase detector that inputs a reference clock signal and an output clock signal from the delay locked loop; a charge pump, responsive to an output from the phase detector, that outputs a control voltage signal; a bias generator that generates at least one bias signal dependent on the control voltage signal; a voltage-controlled delay line, responsive to the at least one bias signal, that outputs the output clock signal, where the voltage-controlled delay line comprises a plurality of delay elements that each comprise an NMOS device and a PMOS device; a first plurality of design-for-test devices positioned at inputs to NMOS devices in the plurality of delay elements; and a second plurality of design-for-test devices positioned at inputs to PMOS devices in the plurality of delay elements.
According to another aspect, an integrated circuit having a delay locked loop comprises: means for inputting a reference clock signal and an output clock signal from the delay locked loop; means for outputting a control voltage signal dependent on the means for inputting the reference clock signal and the output clock signal; means for generating at least one bias signal dependent on the control voltage signal; means for outputting the output clock signal dependent on the at least bias signal, where the means for outputting the output clock signal comprises a plurality of delay elements that each comprise an NMOS device and a PMOS device; first testing means for testing the delay locked loop, where the first testing means is positioned at inputs to NMOS devices in the plurality of delay elements; and second testing means for testing the delay locked loop, where the second testing means is positioned at inputs to PMOS devices in the plurality of delay elements.
According to another aspect, a method for manufacturing a delay locked loop comprises: operatively connecting a phase detector that is arranged to input a reference clock signal and an output clock signal from the delay locked loop to a charge pump, where the charge pump is arranged to output a control voltage signal; operatively connecting the charge pump to a bias generator, where the bias generator is arranged to output at least one bias signal dependent on the control voltage signal; operatively connecting the bias generator to a voltage-controlled delay line, where the voltage-controlled delay line comprises a plurality of delay elements that each comprise an NMOS and a PMOS device; positioning a first plurality of design-for-test device at inputs to NMOS devices in the plurality of delay elements; and positioning a second plurality of design-for-test devices at inputs to PMOS devices in the plurality of delay elements.
According to another aspect, a method for performing operations using a delay locked loop comprises: inputting a reference clock signal and an output clock signal from the delay locked loop; outputting a control voltage signal dependent on the means for inputting the reference clock signal and the output clock signal; generating at least one bias signal dependent on the control voltage signal; outputting the output clock signal dependent on the at least bias signal, where outputting the output clock signal is dependent on a plurality of delay elements that each comprise an NMOS device and a PMOS device; and testing the delay locked loop, where the testing uses a first plurality of devices positioned at inputs to NMOS devices in the plurality of delay elements.
According to another aspect, an integrated circuit having a delay locked loop comprises: a phase detector that inputs a reference clock signal and an output clock signal from the delay locked loop; a first design-for-test device positioned at an output of the phase detector; a charge pump, responsive to an output from the phase detector, that outputs a control voltage signal; a bias generator that generates at least one bias signal dependent on the control voltage signal; and a voltage-controlled delay line, responsive to the at least one bias signal, that outputs the output clock signal.
According to another aspect, an integrated circuit having a delay locked loop comprises: a phase detector arranged to input a reference clock signal and an output clock signal from the delay locked loop; a charge pump, responsive to an output from the phase detector, arranged to output a control voltage signal; a bias generator arranged to generate at least one bias signal dependent on the control voltage signal; a voltage-controlled delay line, responsive to the at least one bias signal, arranged to output the output clock signal; and a design-for-test device operatively connected to at least one selected from the group consisting the phase detector, the charge pump, the bias generator, and the voltage-controlled delay line.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a typical computer system.
FIG. 2 shows a portion of a typical computer system in which a DLL is used.
FIG. 3 shows a typical DLL.
FIG. 4 shows an approach used to implement design-for-test features.
FIG. 5 shows another approach used to implement design-for-test features.
FIG. 6 shows a circuit schematic of a portion of a DLL.
FIG. 7 shows a circuit schematic of a portion of a DLL.
FIG. 8 shows a circuit schematic of a portion of a DLL.
FIG. 9 shows a circuit schematic of a portion of a DLL.
FIG. 10 shows various signal paths of interest in a portion of a DLL.
FIG. 11 shows a portion of a DLL in accordance with an embodiment of the present invention.
FIG. 12 shows a circuit schematic of a portion of a DLL.
FIG. 13 shows a circuit schematic of a portion of a DLL.
FIG. 14 shows a circuit schematic of a portion of a DLL.
FIG. 15 shows a signal path of interest in a portion of a DLL.
DETAILED DESCRIPTION
Embodiments of the present invention relate to a technique for testing and verifying the operation of a DLL. More particularly, embodiments of the present invention relate to DLL design in which design-for-test (“DFT”) features, e.g., design-for-test devices, are implemented to test for, among others, stuck-at faults.
Testing for stuck-at faults requires that signal nodes in a design are made controllable and observable by a test apparatus. ‘Controllability’ is the ability to establish a desired value on a particular signal node by applying test stimuli. ‘Observability’ is the ability to determine the value of a particular signal node. FIGS. 4 and 5 show approaches in which controllability and observability are facilitated using design-for-test devices.
In FIG. 4, a first NOR gate 80 is positioned to receive a signal of interest 84 and second NOR gate 82 is positioned to receive an output of the first NOR gate 80 . Accordingly, by controlling the remaining inputs of the first and second NOR gates 80 and 82 , a desired voltage value may be established on the signal of interest 84 . To implement observability, an input to a scannable device 86 , such as a scannable flip-flop, is wire-ORed to the signal of interest 84 , thereby providing the ability to latch data on the signal of interest 84 .
In FIG. 5, a multiplexer 90 is positioned to receive the signal of interest 94 . In order to implement controllability, a select signal 92 to the multiplexer 90 is used to select what value to establish on the signal of interest 94 . For observability purposes, an input to a scannable device 96 , such as a scannable flip-flop, is wire-ORed to the signal of interest 94 , thereby providing the ability to latch data on the signal of interest 94 .
To better understand the application of DFT features in a DLL, FIGS. 6-9 show exemplary circuit schematics of portions of a first loop of a DLL. FIG. 6 shows a circuit schematic of a delay element 100 that is used in a voltage-controlled delay line of a DLL. The delay element 100 is essentially a differential buffer composed of an NMOS source-coupled differential input pair 102 and a PMOS resistive load 104 formed by diode-connected PMOS transistors 106 and triode-connected PMOS transistors 108 . The bias voltages of the tail-current NMOS transistors 110 and the triode-connected PMOS transistors 108 are adjusted to change the delay of the delay element 100 .
FIG. 7 shows a circuit schematic of a phase detector 120 that is used in a DLL. The phase detector 120 is essentially an S-R latch phase detector 124 augmented with pulse generators 122 at its reference clock and output clock inputs. The pulse generators 122 remove the dead-band of the S-R latch phase detector 124 .
FIG. 8 shows a circuit schematic of a charge pump 130 that is used in a DLL. The charge pump 130 either sources or sinks current at the V ctrl node (shown in FIG. 3) depending on values of UP and DOWN pulses (shown in FIG. 3) from a phase detector.
FIG. 9 shows a circuit schematic of a bias generator 140 that is used in a DLL. The bias generator 140 uses feedback to self-bias itself and generate bias voltages V cp and V cn (also shown in FIG. 3) depending on V ctrl . The bias voltage V cp and V cn bias delay elements in a voltage-controlled delay line of a DLL.
To implement stuck-at fault testing in the first loop of a DLL, a set of signal nodes on particular signal paths need to be selected and then these nodes need to be made controllable and observable. To this end, FIG. 10 shows various signal paths in the first loop of a DLL. For purposes of describing the present invention, the various signal paths fall into different categories and are described henceforth.
Category 1 paths 150 are signal paths that start from a phase detector 152 and go through a charge pump 154 , a filter capacitance 156 , a bias generator 158 , NMOS tail-current devices of delay elements in a voltage-controlled delay line 160 and end at the phase detector 152 . Category 2 paths 162 are signal paths the start from the phase detector 152 and go through the charge pump 154 , the filter capacitance 156 , the bias generator 158 , PMOS triode-connected load device of the voltage-controlled delay line 160 and end at the phase detector 152 . Category 3 paths 170 and category 4 paths 172 are feedback loop paths in the bias generator 158 .
Those skilled in the art will understand that, for purposes of illustration, only one signal path of each type of category is shown in FIG. 10 . However, these categories represent a plurality of signal paths of interest.
The determination of signal paths of interest as shown in FIG. 10 is used to determine the implementation of DFT features in a DLL. Accordingly, FIG. 11 shows a portion of a DLL in accordance with an embodiment of the present invention. To obtain controllability of category 1 and 2 signal paths ( 150 and 162 as shown in FIG. 10 ), a multiplexer 180 is positioned after the phase detector 152 . Those skilled in the art will understand that the positioning of the multiplexers 180 as such is desirable because the phase detector 152 outputs digital signals at the points at which the multiplexers 180 are positioned.
The category 1 and 2 signal paths ( 150 and 162 as shown in FIG. 10) are also connected together through bias voltages V cp and V cn from the bias generator 158 . To obtain controllability of these signal paths, the V cp and V cn signal lines are broken with a first set of multiplexers 190 before the inputs of the NMOS devices in the voltage-controlled delay line 160 and another set of multiplexers 200 before the inputs of the PMOS devices in the voltage-controlled delay line 160 .
To obtain observability of category 1 and 2 signal paths, the outputs of the phase detector 152 may be fed into observability flops 202 . In one or more embodiments, the phase detector 152 may be modified because its output pulses in normal operation might not be wide enough for the observability flops 202 to latch during testing. Thus, a multiplexer 204 may be substituted for an inverter in each of the input paths of the phase detector 152 to inhibit the generation of pulses during testing.
Because category 3 and 4 signal paths ( 170 and 172 as shown in FIG. 10) are local feedback loops in the bias generator 158 , these paths may be bypassed during manufacturing tests by positioning multiplexers 206 and 208 at locations as shown in FIG. 11 .
To further describe the application of DFT features in a DLL, FIGS. 12-14 show exemplary circuit schematics of portions of a second loop of a DLL. FIG. 12 shows a circuit schematic of a phase interpolator 210 that is used in a DLL. FIG. 13 shows a circuit schematic of a phase selector 220 that is used in a DLL. FIG. 14 shows a circuit schematic of a phase inverter 230 that is used in a DLL. Those skilled in the art will understand that the devices shown in FIGS. 12-14 are configured as source-coupled differential amplifiers.
To implement stuck-at fault testing in the second loop of a DLL, a set of signal nodes on particular signal paths need to be selected and then these nodes need to be made controllable and observable. To this end, FIG. 15 shows a signal path in the second loop of a DLL. With respect to the devices of the second loop of the DLL shown in FIG. 12-14, only one category of signal paths is defined. This signal path 234 begins at the input of the phase selector 220 and then traverses through the phase interpolator 210 and then ends at the phase detector 240 of the second loop. Because the output of the phase detector 240 is fed into a finite state machine (see FIG. 3) that typically already has scannable flip-flops, the signal path 234 is an open-loop path. Further, those skilled in the art will note that because the signal path 234 traverses through amplifiers that function as inverters during testing, the signal path 234 is similar in structure to a combinational logic path between two flip-flops in a typical digital design.
Those skilled in the art will understand that, for purposes of illustration, only one signal path is shown in FIG. 15 . However, this category of signal path of interest is representative of a plurality of signal paths of interest in the second loop of the DLL. Each of these signal paths may be enabled or disabled by a particular combination of phase selector, phase interpolator, and phase inverted codes that may be already present in the design of the second loop of the DLL. Accordingly, in one or more embodiments, these signal paths may not need any multiplexers to implement controllability.
Observability of the signal paths represented by the signal path 234 may be obtained by scanning a flip-flop into which that phase detector 240 outputs are fed into in normal operation. Accordingly, to enable testing for stuck-at-faults in the second loop of the DLL, two multiplexers (not shown) are positioned are respectively positioned in each of the input paths of the phase detector 240 in order to prevent the phase detector 240 from producing pulses during testing.
Advantages of the present invention may include one or more of the following. In some embodiments, because DFT features may be implemented in a DLL, testing of the DLL may be performed before an integrated circuit containing the DLL is packaged.
In some embodiments, because a DLL may be stuck-at-fault tested before an integrated circuit containing the DLL is packaged, expensive resource consumption associated with post-packaging design may be reduced.
In some embodiments, because a DLL may incorporate DFT features to test for stuck-at-faults, DLL performance may be analyzed, controlled, tested, and/or improved.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A delay locked loop implementing design-for-test features to test for, among other, stuck-at-faults is provided. The delay locked loop uses multiplexers as design-for-test devices for controllability purposes and flip-flops as design-for-test devices for observability purposes. Such implementation of design-for-test features within a delay locked loop allows for pre-packaging delay locked loop verification and testing. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 60/601,985, entitled “INTEGRATED RECONFIGURABLE WALL SYSTEM”, filed Aug. 17, 2004.
FIELD OF THE INVENTION
The present invention relates to a wall moveable system, and more particularly to a reconfigurable moveable wall system comprising reconfigurable components and design elements.
BACKGROUND OF THE INVENTION
Wall systems, or dividers as they are sometimes called, are used most commonly in an office environment to separate work areas and to give people privacy where permanent walls are lacking. It is beneficial to have a wall system that is easily movable and easily reconfigured given the ever changing needs and requirements in these environments. Another important aspect in an office is to maximize available space. Aesthetics are also important, including the ability to provide the aesthetic element independently of underlying structural componentry.
Previous wall systems have lacked some or all of these attributes. Some are difficult to reconfigure or to move without significant amounts of labour and dislocation. Most systems lack the flexibility to quickly change the height of a wall, or to use or substitute different types of panels, or replace a module in the middle of a wall without taking apart the entire wall. There also is a need to be able to use the wall system against an existing wall as a curtain wall for an integrated look and to provide the design flexibility needed in those spaces bordered by permanent walls.
SUMMARY OF THE INVENTION
In a preferred embodiment, the present wall system comprises at least one module, where each module includes a frame and a plurality of tiles mounted to the frame by means of a tile clip system. Clips are attached to the rear surface of each tile and the tile is then pressed into place, aligning the clips with a capture detail on the horizontal frame stringers. Tiles can span adjacent frames where required. Horizontal frame stringers may include a cantilever channel detail where desired to allow objects to be hung along the width. A single frame comprised of two verticals frame members and a plurality of horizontals stringers mounted to an existing wall by connecting the horizontal members to brackets attached to the existing wall allows tiles to be mounted as a curtain wall on the existing wall. Two frames may be supported back to back within a framework for modules used to divide adjacent work spaces. A spline is attachable to the top of the frame to extend the frame and allow for additional tiles to be added on to increase a module's height if so desired. The spline is also used to connect a different style of frame above the existing frame if so desired. For example, this allows a framed glass module to be attached above a framed wood substrate module. Two adjacent modules are connected using a removable zipper interface. The zipper contains two flexible gasket components. Where tiles will span adjacent frames or meet one another without a gap, the gaskets bend back behind the tiles. Where tiles do not span adjacent frames and a gap is wanted, the gaskets point outward from the frame, between the tiles. At the edge of a module where no other module is to be connected, a starter strip may be placed, wherein the starter strip includes an integral flexible gasket which conforms to the shape of the surrounding environment while providing both light and sound baffling. The cantilever channel between tiles allows for various accessories or mill work to be supported from the outside of the module at convenient locations and to be adjusted as needed.
The present wall system also includes a glass wall module, where each module includes a frame and a plurality of glass tiles mounted within the frame. The glass may be center mounted, front mounted or rear mounted. A channel within each end frame extrusion holds a full length gasket extrusion or notch. The glass is retained within the gasket extrusion, around the full perimeter of the glass tile. Extra horizontal or vertical extrusions are attached within the frame to further divide the module into smaller areas.
The present wall system also includes levelers. Levelers include upper, middle and lower sections. The upper section includes a hollow cylinder which is threaded along the interior, and a flat upper plated perpendicular to the leveler. The middle section is a hollow cylinder where the interior and exterior surfaces are threaded in opposite directions, with a fixed nut at one end of the middle section for adjustment. The lower section includes a solid cylinder threaded to correspond with the middle section, a fixed lower nut and an inverted V-shaped lower plate. The leveler is used by having the flat plate in the upper section engage a continuous channel in an the lowermost extrusion of a module's frame, and the lower plate engaging a continuous universal foot, located beneath each module. The V-shape of the lower plate distributes the weight of the wall in the direction of the connection channels of continuous universal foot. A leveler can be placed at any location along the width of the module, allowing for a plurality of levelers to be used if needed. Along the base of the universal foot is a plurality of grippers, which can be adapted for either carpet or hard flooring surfaces. The attachment of the leveler to the module is secure and without extra fastener requirement of any sort. Sliding the leveler plates into the extrusion channels, followed by the attachment of subsequent vertical members, secures the levelers in place.
A base trim is provided which, in one embodiment, can be removably secured to the universal foot to provide access to the levelers when needed but which otherwise provides a finished look to the modules. The base trim can be modular, or span multiple frames.
Wall modules can be adapted to include integrated rear projection video systems or digital whiteboards. Front projection screens or whiteboards can be mounted within the frame confines, or spanning adjacent frames.
The present wall system provides for true curved walls. Curved wall frames are comprised of straight vertical extrusions and stretch formed horizontal extrusions which are curved to the required radius. Glass or other substrate tiles are curved to match the radius of the frame and mounted in the same manner as planar wall modules.
The present wall system can incorporate universal slat wall constructions which would accept all standard slat wall accessories. The slat wall component is a horizontal structural extrusion, interlocking above and below the cantilever channel horizontal member or other slat wall extrusions.
The present wall system can also support desktops and work surfaces using support brackets in the cantilever channel.
The present wall system also integrates completely with a related furniture panel system. A furniture panel system is comprised of a frame and plurality of tiles attached to the frame. The furniture panel system is designed to serve as cubicle type dividers or desk type units, rather than full height walls. The integration to the furniture panel system is seamless, as the zipper connection detail, tile clip capture detail and cantilever detail are identical to the wall system connection details. All components used in or on the wall system can also be used in or on the furniture panel system.
According to the present invention then, there is provided a movable reconfigurable wall system comprising: at least one module having a front and rear surface, said at least one module having: vertical end frames disposed at least at its side edges, each said vertical end frame having a vertically extending flange directed toward said front surface and a vertically extending flange directed toward said rear surface; a plurality of horizontal stringers affixed between said pair of vertical end frames; and an aesthetic surface affixed to said stringers; and a removable connecting strip, said connecting strip adapted to affix about one of said two flanges on one of said vertical end frames and join said one of said two flanges to a corresponding flange on one of a second module, a wall bracket, a finishing trim or a connection post.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the applicant's integrated reconfigurable wall system will now be described in greater detail and will be better understood when read in conjunction with the following drawings in which:
FIG. 1 is an exploded perspective view of a module representative of the present tile cladded wall system;
FIG. 2 is a perspective view of a wall system including two adjacent modules, one tile cladded and one glass wall;
FIG. 3 is an enlarged view of a portion of the wall system of FIG. 3 showing the connection between adjacent modules;
FIG. 4 is an exploded view of FIG. 3 ;
FIG. 5 is a perspective view of a frame member including a finishing trim;
FIG. 6 is a perspective view of a frame member including a wall starter trim where a module meets an existing wall;
FIG. 7 is a perspective view of a height extension to an existing module;
FIG. 8 is a perspective view of a portion of a wall module showing the orientation of horizontal members with integrated cantilever channel;
FIG. 9 is an enlarged view of a portion of FIG. 8 showing cantilever bracket details and tile clip connection details;
FIG. 10 is a perspective view of a wall panel incorporating slat wall construction;
FIG. 11 is a side elevational view of the slat wall construction of FIG. 10 ;
FIG. 12 is a perspective view of the related panel furniture system utilizing the same connectors and slat wall extrusion to support a work surface;
FIG. 13 is a perspective, partially exploded view showing the assembly of a leg used to support the panel furniture system, utilizing the same connection zipper as the wall components of FIG. 12 ;
FIG. 14 is a perspective, exploded view of a leveller for use with the present wall system;
FIG. 15 is a perspective view of one embodiment of a leveller mounting system as it slides into the channel of a lower glass wall extrusion and universal foot extrusion;
FIG. 16 is a side elevational view of the base trim connection to the leveller assembly;
FIG. 17 is a perspective, schematic view of the present wall system including integrated media panels and storage areas;
FIG. 18 is a perspective, schematic view of the present wall system incorporating an integrated media center;
FIG. 19 is a plan view of a two-way rectilinear connector for the present wall system;
FIG. 20 is a plan view of an alternative (radial) two-way connector for the present wall system;
FIG. 21 is a plan view of a three-way connector for the present wall system;
FIG. 22 is a plan view of a variance of a 90 degree connector for the present wall system;
FIG. 23 is a plan view of a 120 degree connector for three merging walls according to the present wall system;
FIG. 24 is a plan view of an end vertical and gasket for abutting existing walls with the present wall system;
FIG. 25 is a plan view of a connector for connecting to existing walls according to the present wall system;
FIG. 26 is a side elevational view of a floor leveller and ceiling connector for a solid (tile clad) wall;
FIG. 27 is a side elevational view of a floor leveller and ceiling connector for a glass wall;
FIG. 28 is a plan view of two wall panels having a gap between adjoining panels;
FIG. 29 is a plan view of two wall panels directly abutting each other and being sealed with a zipper;
FIG. 30 is a plan view of two wall panels directly abutting each other and having a zipper with no fins;
FIG. 31 is a plan view of an end vertical and gasket for abutting existing walls with the present glass wall system; and
FIG. 32 is a plan view of a connector for connecting to existing walls according to the present glass wall system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 , the present invention is directed towards a wall system 10 made up of one or more modules 20 . Each module comprises a pair of vertical end frames 12 that will be spaced apart by the desired width of each module. Modules 20 may be clad with tiles 18 and can be one or two sided with a finished wall surface on both sides or a finished wall surface on one side only. Tiles 18 can be made of wood, plastic, metal fabric glass or other material, and end frames 12 may be interconnected by a plurality of horizontal stringers 8 that will be described in greater detail below.
With reference to FIG. 2 , the next adjacent module 20 can be identical to its neighbour, or, as shown in this figure, may consist of two vertical end frames 17 and one or more dividers 14 which can be, for example, glass or plastic if transparency is desired. End frames 17 used for such dividers are shaped as shown most clearly in FIG. 4 and include a notch 19 that receives and holds the divider's vertical edge.
Stringers 8 are horizontally spaced apart at intervals along the height of the module for strength and rigidity. To support objects, cantilever channel stringers 40 , including a cantilever channel portion 41 , are used, as shown in FIGS. 8 and 9 . Stringers 8 that do not include channel portion 41 can be used anywhere structure is required but the channel portion is not required for supporting objects. For example, the lowest stringer 8 a may not include cantilever channel portion 41 . The stringers are connected to end frames 12 by fasteners, usually threaded screws, in a manner to be described below.
If the module will be visible from both sides, finishing tiles 18 can be connected to the stringers on both sides of module 20 . It is not necessary that the tiles on one side of the wall be at all like the tiles on the other. They can be different materials or even aligned differently as shown in FIG. 1 , in which the tiles on one side of the module are horizontally mounted and the tiles on the other side of the wall are vertically mounted for a different look. The tiles can also span adjacent modules, if required. If only one side of the module will be visible, which can be the case for example if the module is used as a curtain wall to cover an existing wall, its necessary to apply tiles 18 to only one side of the module as needed.
The depth or thickness of the module can be selected by varying the width of frame 12 . For example, as will be described below, the modules can house a rear projection or digital video system and the greater depth is needed to enclose the componentry.
With reference to FIGS. 3 , 4 , 5 28 and 29 , each end frame 12 and 17 includes a pair of rearwardly extending L-shaped flanges 23 that align vertically with correspondingly positioned and shaped flanges 23 on opposite end frame 12 or 17 so that frames 12 and 17 can be connected together by connecting strips (“zippers”) 25 . If the adjacent module 20 itself comprises an end frame 12 as shown in FIGS. 28 and 29 , flanges 23 will abut and will be connected together in the same manner using zippers 25 . As shown most clearly in FIG. 28 , each of flanges 23 is formed with a bead 27 . Each zipper 25 is generally T-shaped in cross-sectional shape and includes a central spine 29 that fits between flanges 23 and a pair of arms 30 on opposite sides of the spine. Each arm includes a bead 31 that snap fits with beads 27 on flanges 23 for a secure but releasable connection. When two adjacent modules are connected together in this way, there is enough of a gap between them that the zippers can be accessed for removal, allowing an individual module to be removed should the need arise.
As illustrated in FIGS. 28 and 29 , each zipper can also include a pair of flexible extended fins 32 extending rearwardly from the spine 29 . Depending on the application, a user may wish adjacent modules to be abutted together completely or to have a gap between them. In FIG. 28 , a gap exists between the modules, and this gap is sealed using extending fins 32 . As will be appreciated by those skilled in the art, the width of the gap is variable since extensions 32 are flexible and can accommodate various widths.
If no gap is desired, or if tiles span adjacent modules, FIG. 29 illustrates an embodiment having adjacent panels. In this case extensions 32 are behind each panel, and the force of extensions 32 against the rearward side of the module creates an acoustic seal for the wall.
In an alternative embodiment illustrated in FIG. 30 , it is also possible to have a zipper 25 without extensions 32 . This may be desirable when modules 20 abut and an acoustical seal is not required.
FIG. 5 shows an end piece 35 similar to end frame 17 but lacking notch 19 . This end piece is therefore used to finish the vertical edge of module 20 using zippers 25 if no additional module is to be connected to it.
If either of frames 12 or 17 is to start, or end, at an existing wall, flexible starter strips 37 can snap-fit onto flanges 23 as shown most clearly in FIG. 6 . Starter strips 37 include curved flexible gaskets 38 which will conform to the shape of the existing wall and will provide sound and light barriers. This can also be seen in FIGS. 24 and 32 .
Alternatively, as illustrated in FIGS. 25 and 31 , a wall start 43 can be mounted to an existing wall to provide a start to a module. Wall start 43 is preferably an aluminum extrusion mounted vertically to an existing wall using known mounting techniques. The mounting technique of screws shown in FIG. 25 is not meant to be limiting.
Wall start 43 includes a flanges 23 and is connected to an end frame 12 or 17 using a zipper 25 . As indicated above, extensions 32 can provide a seal against the wall and panel.
To increase the height of an existing module 20 , or to combine a glass module above or below a tile-clad module, a spline 39 can be used to connect end frame 12 (or 17 ) to an extension frame 12 e as shown most clearly in FIG. 7 . Actually, as shown in this figure, extension frame 12 e is a length of frame 17 , which allows the lower portion of the wall to be hung with standard tiles and the upper extended portion of the wall to be finished in a glass or plastic divider 14 for a combination of finished looks. The upper and lower extrusions 90 , which complete the framing of divider 14 , will be described below in connection with a levelling system in which the same extrusion is used.
It is desirable that work surfaces, mill work and wall accessories such as trays or document holders be connectable to modules 20 . This can be easily achieved in the present system by using cantilever channel stringers 40 with channel brackets horizontally disposed in the channel between adjacent tiles 18 as shown most clearly in FIGS. 8 and 9 .
Each channel stringer 40 includes a central horizontally extending channel portion 41 with a generally L-shaped slot 42 formed along its length adapted to receive and engage a substantially L-shaped hook 45 formed on a wall accessory 47 such as the document holder shown in FIG. 8 . A pair of diagonally extending webs 49 connects channel portion 41 to upper and lower portions 51 and 53 respectively. Each portion includes a tile support 55 that is the connection point for the tiles 18 that are mounted above and below channel portion 41 . More specifically, the upper and lower edges of tiles 18 are provided with a connector strip 60 attached by means of screws, adhesive or any other suitable fastening. Each strip includes a pair of opposed flexible arms 62 to snap-fit with a generally arrow shaped bead 64 formed along the edge of flanges 67 that are formed on and extend the length of each upper and lower portion 51 and 53 . This allows individual tiles 18 to be removed or replaced without having to disassemble the entire wall. The flanges 23 formed on vertical end frames 12 and 17 that are connected together by zippers 25 are located sufficiently inwardly that the zippers will not interfere with the continuity of slot 42 from one module to the next so that wall accessories, mill work or work surfaces can be connected or moved between modules without interference.
The upper and lower edges of tiles 18 that abut channel portion 41 of each channel bracket are camphored for clearance as seen most clearly in FIG. 9 .
The upper and lower portions 51 and 53 of the channel stringer 40 are advantageously formed with longitudinally extended circular recesses 57 and inner channels 58 . Recesses 57 are adapted to receive screws used to connect end frames 12 or 17 to channel stringers 40 . Channels 58 can be used to support mounting hardware for audio-video equipment mounted within the modules, cable management clips or any other hardware to be housed or contained in the module's interior. Channels 58 are also used to connect a single-sided tile clad module to brackets attached to existing wall surfaces.
With reference to FIG. 10 , another embodiment of the invention is shown incorporating a section of standard slat wall 69 including slats 70 and slat wall channels 71 for connection to all slat wall accessories 47 . Slat wall panels can make up some or all of the panels incorporated into any one module 20 and the modules themselves are configured for use with end frames 12 and zippers 25 so that the modules themselves can be connected together in any desired combination. Slat wall modules can be one ( FIG. 11 ) or two sided ( FIG. 10 ) for use as either dividing or curtain walls.
As shown in FIG. 12 , in the applicant's related panel furniture system, a work surface or desktop 76 can be connected to modules 20 . The desktop 76 can hook into either cantilevered channel stringers 40 or into slat wall channels 71 and otherwise the construction of the individual modules 20 is the same as described above for wall system 10 . Furniture legs 80 shown in the example of FIG. 12 consist of a vertical frame 12 zipper connected to a finishing end extrusion 35 using zippers 25 as shown in FIG. 13 , in the same manner as the wall system 10 . The lower end of each furniture leg 80 is finished with a concentric sleeve 79 which conceals a threaded bolt 84 in the lower end of each leg which can be used for levelling.
As illustrated in FIG. 23 , three vertical extrusions 2310 are connected to each other to create the connection point for the three wall systems, and each wall meets the others at an angle of 120 degrees.
In the case of modules having tiles that extend all the way down to the floor, applicant has developed a leveller mounting system that allows levellers to be placed anywhere along the length of a module and extra levellers to be added where needed. There are two variations of the leveller mounting system shown in FIGS. 15 and 16 , one to be used with modules comprising tiles 18 , and the other with modules using glass or plastic dividers.
Referring first to FIG. 15 , this is the levelling system to be used with modules having glass or plastic dividers extending down to floor level. This system includes a structural extrusion 90 , which is generally an inverted U-shaped channel with a notch 92 to engage the lower edge of the glass or plastic divider, and a universal foot 100 .
Extrusion 90 and universal foot 100 are interconnected by means of dual threaded levellers 110 , an example of which is shown in FIG. 14 .
Leveller 110 has three distinct sections, an upper section 112 , a middle section 115 and a lower section 120 . Upper section 112 is cylindrical in shape and is internally left or right hand threaded. A plate 113 is connected to the section's upper end for a permanent connection thereto. Middle section 115 is both internally and externally threaded. The external threads will match the direction of the internal threads on upper section 112 while the internal threads will be in the opposite direction to match the external threading of lower portion 120 . A fixed middle nut 114 is disposed at the lower end of middle section 115 . Nut 114 can be used to turn middle section 115 relative to the upper and lower sections of the leveller.
As mentioned, the lower section 120 of the leveller is externally threaded and the threading will be in the opposite direction to the internal threading of upper section 112 . In this way, each turn of nut 114 doubles the expansion or contraction of the leveller to halve the levelling time. The lower end of section 120 includes its own fixed adjustment nut 124 and an inverted V-shaped lower plate 125 .
FIG. 15 shows how leveller 110 is installed. Plate 113 aligns with channels 94 in extrusion 90 to be slidable along the length of the channel to any desired location. The V-shaped lower plate 125 aligns with and slides into grooves 101 in foot 100 . Those levellers that fit at the end of a foot are slightly modified to include tabs 126 at the outer corners of plate 125 which prevent the plate from moving inwardly. When vertical end frames 12 or 17 are attached to extrusion 90 , plate 113 is prevented from moving outwardly so that the leveller is held in its position at the very end of foot 100 . Frames 12 or 17 are connected to extrusion 90 by means of screws that thread into one or more of circular slots 117 in the extrusion.
If modules 20 are situated atop carpet, toothed carpet grippers 130 are inserted into slots 129 in foot 100 . If the modules are installed on hard surfaces, nonskid grippers can be inserted instead. The grippers can be placed precisely where needed to bear the modules weight and can be easily moved, replaced or switched over as needed.
FIG. 16 shows a leveller 110 installed on modules 20 and illustrates the installation of base trim 140 used to conceal the levellers 110 when they're not being adjusted. In this view, plate 113 is again slidingly received into channels formed in the module's lowermost extrusion and plate 125 is received into grooves 101 in foot 100 . The base trim 140 includes baseboards 142 and snap pieces 144 . Snap pieces 144 snap-fit onto foot 100 as shown with grooves 145 and 147 on the snap piece engaging flanges 108 and 109 on the foot. Each snap piece includes a longitudinally extending elevated hook 149 and a similarly longitudinally extending channel 150 . Each baseboard includes a hook 143 to engage hook 149 on the snap piece, and a bead 153 that snap fits into channel 150 to retain the baseboards in a vertical position to provide a finished look. Because the baseboards are installed usually after the modules have been assembled together, the boards can span multiple modules for longer runs and fewer seams.
Reference is now made to FIGS. 26 and 27 . As illustrated, besides the bottom connection with the leveller (as described with relation to FIGS. 15 and 16 above), a ceiling connection is also preferred.
FIG. 26 shows a ceiling connection for a solid wall, such as those described above having tile cladding. A ceiling track 2601 is affixed to the ceiling above the area for the desired wall. Each module includes two horizontal uppers 2610 abut thereto (on either side of the ceiling track), the horizontal upper including an upper flange 2612 . A ceiling trim 2614 is affixed to upper flange 2612 . Ceiling trim 2614 is flexible and allows variable spacing of the wall with the ceiling. Specifically, the trim 2614 will flex to allow the wall to move closer or further from the wall as required based on levelling needs.
Horizontal upper 2610 further includes a bead 64 as described above to attach a tile to the horizontal upper. Further, recesses 2616 are used to attach horizontal uppers to frames 12 or 17 .
To affix a wall, an installer can first install ceiling track 2601 in the correct location. The wall is then created with levellers 110 in a lowermost position. The levellers 110 are then extended to level the wall and to further cause horizontal uppers 2610 to abut ceiling track 2601 on either side of ceiling track 2601 , as illustrated in FIG. 26 .
Alternatively, if a divider such as a glass panel is being used, a one piece upper 2701 can be used, as illustrated in FIG. 27 . The one piece upper 2701 comprises a flange 2712 to connect a ceiling trim 2714 to. Ceiling trim 2714 is preferably the same as ceiling trim 2614 . Upper 2701 further includes a channel 2716 for receiving a divider.
The present wall system 10 includes curved walls using curved aluminum stringers and extrusions and curved tiles 18 . In conventional systems, curved walls are constructed of faceted panels rather than true, radii arcs. A curved wall is illustrated in FIG. 19 .
With reference to FIG. 17 , a module 20 is shown in which a couple of tiles 18 have been replaced with an integrated media panel 190 . The panel can be a Fresnel lens, a plasma screen, an LCD screen or a digital whiteboard. Rear projection technology can be used to project images onto the Fresnel lens, or the digital whiteboard technology allows sketching, writing, layout or computer screen emulation. In the example shown, adjacent tiles 18 incorporate speakers 192 to provide sound. Tile 18 surrounding the screen area can be used for integrated storage areas.
With reference to FIG. 18 , there is shown schematically a module 20 with an integrated media center 200 suspended therein.
Various connectors are also provided to allow the present reconfigurable wall system to form corners. Reference is now made to FIGS. 19 , 20 , 21 and 22 .
FIG. 19 illustrates a two-way rectilinear connector 1910 . Connector 1910 includes a finished outer surface on sides 1912 and 1914 . Further, flanges 23 are provided on sides 1916 and 1918 . Flanges 23 can be used with zipper 25 to connect to end frames 12 or 17 . An extension 1920 extends between sides 1916 and 1918 to form a finished corner once modules 20 are connected to these sides. Further, sides 1912 and 1914 include an elongate end 1922 for hiding zipper 25 and creating a finished surface.
FIG. 20 is similar to FIG. 19 , with the principle difference being the radial finished outer surface 2012 replacing sides 1912 and 1914 . Otherwise similar reference numerals are used between FIGS. 19 and 20 .
FIG. 21 illustrates a three way connector for a “T” connection. Three modules 20 are connected to connector 2101 . Connector 2101 includes a finished outer surface 2112 . Flanges 23 are used to connect modules 20 . Extensions 1920 provide a finished look between adjacent modules 20 . Further, elongate end 1922 provides a finished look on the outside of the wall.
FIG. 22 illustrates an alternative 90 degree connector. In this case, an extrusion 2201 is affixed to the end of a module 20 . Two extrusions are connected using a connector 2312 . Since connector 2312 is flexible, an angle greater than or less than 90 degrees is possible. In a preferred embodiment, the swing on the connector is approximately 15 degrees.
The above-described embodiments of the present invention are meant to be illustrative of preferred embodiments and are not intended to limit the scope of the present invention. Various modifications, which would be readily apparent to one skilled in the art, are intended to be within the scope of the present invention. The only limitations to the scope of the present invention are set forth in the following claims appended hereto. | A movable reconfigurable wall system having at least one module having a front and rear surface, the at least one module having: vertical end frames disposed at least at its side edges, each the vertical end frame having a vertically extending flange directed toward the front surface and a vertically extending flange directed toward the rear surface; a plurality of horizontal stringers affixed between the pair of vertical end frames; and an aesthetic surface affixed to the stringers; and a removable connecting strip, the connecting strip adapted to affix about one of the two flanges on one of the vertical end frames and join the one of the two flanges to a corresponding flange on one of a second module, a wall bracket, a finishing trim or a connection post. | 4 |
CLAIM OF PRIORITY
[0001] This application claims priority to U.S. provisional patent application Ser. No. 60/843,030 filed on Sep. 8, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a human body circulatory aid and/or thermal energy transfer.
BACKGROUND OF THE INVENTION
DVT Apparatuses
[0003] Gaymar Industries, Inc. is the assignee of this application and expired U.S. Pat. No. 4,597,384. The '384 patent is incorporated herein by reference as disclosing a well-made deep vein thrombosis cuff. In the '384 patent, Gaymar wrote, “[T]herapeutic and prophylactic devices for the alleviation of deep venous thrombosis by mechanical as opposed to chemical means. Deep venous thrombosis (DVT) is a condition in which clotting of venous blood occurs generally in the lower extremities due to lack of sufficient muscular activity in the lower extremities. Thus it is important that the velocity of blood flow in the patient's extremities be maintained at the requisite level in order to prevent pooling of blood in such extremities so that stasis of blood will not develop. This is particularly important since it is well known that stasis of blood is a significant cause leading to the formation of thrombi in the patient's extremities which could ultimately cause the death of the patient.
[0004] Devices are presently in use for the purpose of increasing blood velocity to prevent problems set forth above. Many of these devices comprise compression sleeves which fit over and around the limb requiring care. Fluid pressure producing means are provided for sequentially inflating the compression sleeve and allowing for a simultaneous deflation of all sleeve components.
[0005] Applicant's U.S. Pat. No. 4,453,538 which is entitled “Medical Apparatus” and issued on Jun. 12, 1984, is hereby and herewith incorporated for all of its disclosure into this application. Among other features this patent describes a flexible pad formed for external enwrappment about a patient's limb. The pad includes a plurality of relatively large individual fluid receiving cells adapted to receive and retain sufficient fluid to exert pressure upon the enwrapped limb for a specified period of time. More particularly, the cells are sequentially pressurized starting at the limb extremity and proceeding in the direction of the patient's heart. It is desirable that the sleeve compression pressure proceed smoothly and [progressively] along the patient's limb from the extremity heartward. Most pressure sleeves currently in use cannot do this. In fact most of them leave continuous pressure gaps between respective sleeve portions. Such results are undesirable.
[0006] In view of the foregoing it is an object of [the '384 patent] to provide a compression sleeve for a patient's limb which will provide a smooth pressure flow with no pressure gaps extending completely around the patient's limb.
[0007] It is yet another object of [the '384 patent] to provide a device for use in applying successive compressive pressures against a patient's limb to produce a smooth pumping action from the patient's limb extremity heartward.
[0008] It is a still further object of [the '384 patent] to provide a sleeve for use in applying compressive pressures against a patient's limb wherein the sleeve comprises a plurality of laterally extending separate fluid pressure members arranged longitudinally along the sleeve from a lower portion of the encased limb to the upper portion thereof with the adjacent lateral edge portions of adjacent pressure members being curved upwardly and then downwardly in unison whereby the respective contiguous edges thereof follow each other so that when pressure is sequentially applied from the lowermost pressure members upward there will never be a continuous circumferential pressure gap on any lateral circular portion of the encased limb.
[0009] Another object of [the '389 patent] is to provide a device of the type described in the proceeding object and further wherein the successive pressurization of each pressure member from the lowermost heartward produces a plurality of circumferential spaced radially inward maximum and minimum forces interdigitated with successive pressure members having similar maximum and minimum forces to produce a smooth gap free pressurization from start to finish.”
[0010] Gaymar's apparatus is just one of many types of deep vein thrombosis (DVT) apparatuses. There are numerous designs for such DVT apparatuses. Representative samples of such DVT apparatus designs are found, and hereby incorporated by reference, in the following U.S. Pat. Nos.: 2,531,074 to Miller, Nov. 21, 1950; 4,091,804 to Hasty, May 30, 1978; 4,269,175 to Dillon, May 26, 1981; 4,343,302 to Dillon, Aug. 10, 1982; 4,396,010 to Arkans, Aug. 2, 1983; 4,989,589 to Pekanmaki et al., Feb. 5, 1991; 4,311,135 to Brueckner et al., Jan. 19, 1982; 5,080,089 to Mason et al., Jan. 14, 1992; 5,186,163 to Dye, Feb. 16, 1993; 5,383,894 to Dye, Jan. 24, 1995; 5,554,103 to Zheng et al., Sep. 10, 1996; 5,591,200 to Cone et al., Jan. 7, 1997; 5,626,556 to Tobler et al., May 6, 1997; 5,795,312 to Dye, Aug. 18, 1998; 5,830,164 to Cone et al., Nov. 3, 1998; 5,876,359 to Bock et al., Mar. 2, 1999; 5,997,540 to Zheng et al., Dec. 7, 1999; and 6,176,869 to Mason et al., Jan. 23, 2001.
[0011] Some of the above-identified references disclose DVT apparatuses having a therapy pad with at least two chambers and each chamber receives, through a conduit, a fluid from a source (a “fundamental compression therapy pad design”). The fluid can (a) return to the source through a return conduit or the original conduit (“recirculation systems”), (b) be directed toward a receiving unit (not the source) through a return conduit (“receiving system”), or, alternatively, (c) permeate through apertures in the chambers (normally using air as the fluid and commonly referred to as a “low air-loss system”). The alternative method is preferred if the fluid is a gas; and the former methods are desired if the fluid is a liquid (like an aqueous fluid or a non-aqueous fluid) or a gas (like air). In any case, the fluid is pressurized. The fluid pressure in each chamber can be the same or different, depending on the desired result. For example, the fluid in:
(a) chamber 1 is 50 mm Hg, chamber 2 is 50 mm Hg and so on; (Uniform pressure) (b) chamber 1 is 80 mm Hg, chamber 2 is 40 mm Hg, and chamber 3 is 20 mm Hg; (Sequential downward pressure) (c) chamber 1 is 60 mm Hg, chamber 2 is 40 mm Hg, chamber 3 is 60 mm Hg, and chamber 4 is 20 mm Hg; (Alternating Uniform/Sequential Downward Pressure) (d) chamber 1 is 50 mm Hg, chamber 2 is 30 mm Hg, chamber 3 is 50 mm Hg, and chamber 4 is 30 mm Hg; (Alternating distinct uniform pressure) or (e) combinations thereof.
[0017] The fluid can also have a desired temperature. As disclosed in U.S. Pat. No. 2,531,074 to Miller at col. 1, lines 50-56; DVT apparatus can control the fluid temperature. The fluid temperature, however in the cited references, is uniform in each chamber of the therapy pad.
[0018] The fluid receiving cells can be made of a single material or a plurality of materials. Whatever number of materials are used, the material that contacts the patient's skin should be of a material or combination of materials that effectively transfers thermal energy to the patient or receives thermal energy from the patient (hereinafter “Transfer Material”). Examples of such transfer materials that have been used in the past include and are not limited to polymeric materials like polyethylene, polymeric materials with metallic materials (like rivets) positioned on and within the polymeric material, metallic-polymeric materials, and metallic materials.
[0019] All of the above variations of (a) fluid pressures, (b) recirculation systems, (c) constant fluid temperature in each chamber, (d) air-loss systems, (e) compression DVT systems, and (f) fundamental compression therapy pad designs, revert at least to the late 1970's.
Hypo/Hyperthermia Control Devices
[0020] In this application, we need to also discuss hypo/hyperthermia blankets. One type of hyper/hypothermia blankets are forced-air blankets. Those blankets have been litigated for many years. One such case is Augustine Medical, Inc. v. Gaymar Indus., Inc. (the assignee of this application), 181 F. 3d 1291, 50 USPQ2d 1900 (Fed. Cir. 1999). In that case, Judge Radar concluded that Gaymar's forced-air blankets did not infringe any of Augustine's patents at issue, and wrote, “Convective thermal blankets inflate to direct warm (or cool) air onto a person. Surgeons often use these blankets during and after an operation to prevent or treat hypothermia caused by surgical conditions. Hypothermia results when a patient's body temperature drops below a certain threshold. Surgery often presents the threat of hypothermia. A patient's body temperature may drop significantly during surgery because anesthesia prevents the patient's body from regulating its own temperature. Additionally, operating rooms—kept cool to accommodate the surgeon's working conditions and to reduce the spread of germs—can chill patients. Moreover, surgery often calls for administration of cool intravenous fluids at a time when the patient's body cavity is open.
[0021] A convective thermal blanket over the patient is thus necessary to prevent or treat hypothermia during and after surgery. Heated air from a warming unit inflates the blanket. Once inflated, the blanket directs heated air onto the patient through small holes (or “exit ports”) in the undersurface of the blanket. With careful use, a convective blanket regulates patient temperature and prevents hypothermia. . . . [Gaymar's blankets] feature an inflatable quilt-like structure [, . . . ] attach two sheets of the same amount of flexible, lightweight material around their periphery and at various spots along their surfaces. In operation, heated air flows onto a patient's body from holes in the undersurface of [Gaymar's blankets], but [Gaymar's blankets] do not form a self-supporting or Quonset hut-like structure. Instead, [Gaymar's blankets] lie flat when inflated on a flat surface and rest substantially on a patient when in use. . . . Gaymar began selling forced-air blankets in March 1992.” And one of those blankets is Gaymar's THERMACARE quilt.
[0022] Alternatively, other types of hypo/hyperthermia blankets are sold by Gaymar. An example of these blankets is Gaymar's DHP 600 hyper/hyperthermia blanket. That blanket operates differently from the forced-air blankets. Those blankets overlay a user and receive a fluid having a predetermined temperature. The fluid circulates through a cavity defined in the blanket that is to be positioned on a patient. The fluid (a) transfers its thermal energy to the patient and/or (b) receives the patient's thermal energy to control the patient's body core temperature. A description of those blankets is set forth in U.S. Pat. No. 6,375,673, which is hereby incorporated by reference in this application and which is licensed to the assignee of this application.
[0023] These blankets are extremely effective in altering the body core temperature of a patient. A problem with these devices is that some people claim those prior art hypo/hyperthermia blankets are bulky and difficult to use because those blankets cover too much of the patient. To address that problem, applicants have found a solution. The solution is set forth in the present application.
Negative Therapy Devices
[0024] Stanford University is the assignee of U.S. Pat. Nos. 5,683,438; 6,602,277; 6,673,099; 6,656,208; 6,966,922; 7,122,047; and 6,974,442. These patents disclose devices that create a negative pressure about a portion of a patient's body having a venous plexus. A venous plexus is a vascular network formed by numerous anastomoses between veins. The venous plexus is normally located at the patient's foot area and hand area. The negative pressure is applied, and simultaneously thermal energy (cold or warm) is applied to the venous plexus area that is subject to negative pressure.
[0025] Applying a negative pressure condition to a portion of the body (a) lowers the vasoconstriction temperature and/or (b) increases vasodilation in the body portion that is enclosed. The negative pressure conditions may be provided using any convenient protocol. In many embodiments, the negative pressure conditions are provided by enclosing a patient's venous plexus area in a sealed enclosure, where the pressure is then reduced in the sealed enclosure thereby providing the desired negative pressure. In many of the embodiments, the negative pressure is allowed to leak to the ambient environment through a seal so it does not create a tourniquet effect. A tourniquet effect is undesirable because it terminates the blood flow which is contrary to the intent of Stanford's negative pressure, thermal energy device.
[0026] Negative pressure includes conditions where a pressure is lower than ambient pressure under the particular conditions in which the method is applied, e.g., 1 ATM at sea level. The magnitude of the decrease in pressure from the ambient pressure under the negative pressure conditions in one example is at least about 20 mmHg, preferably at least 30 mmHg, and more preferably at least about 35 mmHg, where the magnitude of the decrease may be as great as 85 mmHg or greater, but preferably does not exceed about 60 mmHg, and more preferably does not exceed about 50 mmHg. When the method is performed at or about sea level, the pressure under the negative pressure conditions generally may range from about 740 to 675 mmHg, preferably from about 730 to 700 mmHg and more preferably from about 725 to 710 mmHg.
[0027] In practicing the exemplary methods, the negative pressure conditions during contact with the patient's skin may be static/constant or variable. Thus, in certain examples, the negative pressure is maintained at a constant value during contact of the surface with the low temperature medium. In yet other examples, the negative pressure value is varied during contact, e.g., oscillated. Where the negative pressure is varied or oscillated, the magnitude of the pressure change during a given period may be varied and may range from about 85 to 40 mmHg, and preferably from about 40 to 0 mmHg, with the periodicity of the oscillation ranging from about 0.25 sec to 10 min, and preferably from about 1 sec to 10 sec.
[0028] The negative pressure is applied to the certain venous plexus area to create vasodilation. That vasodilation results in the thermal energy (1) effectively transferring its thermal energy to the patient to warm the patient's body core temperature, or (2) effectively receiving the patient's thermal energy to cool the patient's body core temperature.
[0029] Stanford University disclosed that the thermal energy can be provided from outside the enclosure—for example a heat lamp—if the enclosure allows such thermal energy to penetrate through it or within the enclosure. Within the enclosure, the thermal energy can be provided by an electric thermal blanket or pad; or a conductive conduit or pad that allows a fluid having a desired temperature to flow through it. In both internal thermal energy providing embodiments and variations thereof, the patient's venous plexus is applied to the thermal energy providing device to transfer thermal energy to the patient and/or receive thermal energy from the patient. PS “Third Space” in the Human Body
[0030] Current scientific literature reveals that inflammatory mediators initiate a biochemical chain of events that increase capillary permeability. These mediators include pharmacologically active amines such as histamine and 5-hydroxytryptamine, polypeptides such as bradykinin, kallikrein and leukotoxine, the prostaglandins, and various complements including derivatives thereof. These mediators act specifically on the junction of the endothelial cells of capillaries so that the junctions cannot contain colloids such as serum albumin within the vessel. The serum albumin escapes into the interstitium creating a nonfunctional “third space”, the volume of which increases proportionally to albumin leakage and the presence of cytokines as well as proteolytic enzyme activities within the matrix. This leakage further widens capillary membrane-mitochondrial distances creating problems of poor diffusion and transport between the circulatory system and the functional cells resulting in cellular anoxia, a cellular energy deficit, and acidosis, and possibly leading to sequential organ failure.
[0031] In the past, the problem of the creation of the third space has been approached through pharmacological means. The present invention approaches the problem by controlling the patient's temperature, applying compression therapy to the patient and/or applying pressure therapy to the patient.
SUMMARY OF THE INVENTION
[0032] The present invention is directed to a device that provides thermal energy therapy, compression therapy and negative pressure therapy simultaneously and/or in conjunction with each therapy. The outcome of the present invention is that a patient's bodily fluids can be maintained, controlled, and/or adjusted with decreased medication dependence. Using these three therapies individually does not obtain these desired results of controlling, maintaining or adjusting the patient's bodily fluid. This combination of therapies is beneficial to the patient.
BRIEF DESCRIPTION OF THE FIGURES
[0033] FIG. 1 illustrates a schematic drawing of a first embodiment of the present invention.
[0034] FIG. 2 illustrates an alternative embodiment of FIG. 1 .
[0035] FIG. 3 illustrates a third alternative embodiment of FIG. 1 .
[0036] FIG. 4 illustrates a fourth alternative embodiment of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0037] The present invention is a combination of a compression therapy, thermal therapy and pressure therapy to operate in concert with each other to treat more than just deep vein thrombosis and body core temperature. The combination is designed to move bodily fluids in the lymphatic system, secondary venous system, and artery system in a controllable manner to obtain desired results. Desired results include and are not limited to controlling and/or manipulating the patient's blood pressure and bodily fluid volume. By controlling and/or manipulating the patient's blood pressure and bodily fluid, the present invention offers more medical assistance than expected.
[0038] Applying cold thermal energy therapy causes vasoconstriction and warm thermal energy therapy causes vasodilation. Compression therapy causes vasoconstriction and moves the blood in the direction of the compression therapy—normally toward the heart. Cold thermal energy therapy and compression therapy increases the patient's blood pressure. However, cold thermal energy therapy, compression therapy and negative pressure therapy reperfuses blood (and other bodily fluids) from the third space. Obviously, too much cold thermal energy therapy, compression therapy and negative pressure therapy is not good, therefore the present invention is able to provide the opposite therapy to obtain the desired balance for the desired results. This combination of therapies have never been incorporated together to control the bodily fluids, including an not limited to cardiac output control. Instead, medication in combination with one of these therapies has been standard bearer up to today.
[0039] As illustrated in FIG. 1 , the present invention can be a conventional negative pressure, thermal energy device 400 and a conventional compression therapy device 410 interconnected to a controller 420 to operate both devices simultaneously and/or in conjunction with each other to obtain the desired results. An example of the conventional negative pressure, thermal energy device 400 is manufactured by AVACore's core control device (located in Ann Arbor, Mich.). An example of the conventional compression therapy device 410 is disclosed in Gaymar's U.S. Pat. No. 4,597,389. FIG. 1 illustrates these devices 400 and 410 positioned about a patient's foot and leg, but FIG. 1 is merely being used for illustrative purposes and it is understood that these devices, individually or collectively, can also be positioned on the foot, the leg, a hand, an arm, a hand and an arm, and combinations thereof.
[0040] The thermal energy provided to the conventional negative pressure, thermal energy device 400 and the conventional compression therapy device 410 can come from the same source or different sources 415 . The sources can be (a) fluid providers such as Gaymar's MEDI-THERM heating/cooling unit; Gaymar's THERMACARE device; electrical sources; and/or air or fluid pumps with coolers and/or heaters; (b) electrical providers (not applicable for the conventional compression therapy device 410 ); (c) irradiant heat devices like a heat lamp (not applicable for the conventional compression therapy device 410 ) or (d) combinations thereof.
[0041] Some of those sources can provide thermal energy at a single temperature. Other sources can provide thermal energy at various temperatures. And other sources can provide a fluid to (a) the conventional compression therapy device 410 at temperature T 1 and (b) the conventional negative pressure, thermal energy device 400 at temperature T 2 , wherein T 1 and T 2 can be the same or different. Moreover, some sources can provide a fluid to (a) the conventional compression therapy device 410 at temperature T 1 for a first fluid pressure member 411 and at temperature T 2 for a second fluid pressure member 412 (as illustrated in FIG. 2 ) and (b) the conventional negative pressure, thermal energy device 400 at temperature T 2 , wherein T 1 , T 2 , and T 3 can be the same, different, or combinations thereof.
[0042] In addition to controlling the temperature of the fluid's thermal energy that enters the conventional compression therapy device 410 , the thermal energy source 415 controls the pressure of the fluid that enters the conventional compression therapy device 410 as illustrated in FIG. 1 . Alternatively and as illustrated in FIG. 2 , the thermal energy source 415 can provide a fluid having (a) a first pressure (P 1 ) to the first fluid pressure member 411 and (b) a second pressure (P 2 ) to the second fluid pressure member 412 , wherein P 1 and P 2 can be the same or different.
[0043] The compression therapy device 410 can offer static compression therapy, sequential compression therapy, or variations thereof.
[0044] Reverting to FIG. 1 , the first fluid pressure member 411 is interconnected to the second fluid pressure member 412 through a conduit 413 . Depending on the shape and size of the conduit 413 , conduit 413 can maintain or adjust the fluid pressure that enters the second fluid pressure member 412 from the first fluid pressure member 411 . For example, if the conduit 413 tapers from the first fluid pressure member 411 to the second fluid pressure member 412 then the fluid pressure is greater in the second fluid pressure member 412 than the first fluid pressure member 411 . If the conduit 413 tapers in the opposite direction, then the fluid pressure in the first fluid pressure member 411 is greater than the fluid pressure in the second fluid pressure member 412 .
[0045] The negative pressure created in the conventional negative pressure, thermal energy device 400 is provided by a conventional negative pressure providing device 402 . The conventional negative pressure providing device 402 can be any system that creates negative pressure within the enclosure of the conventional negative pressure, thermal energy device 400 . The negative pressure is created in the enclosure of the conventional negative pressure, thermal energy device 400 at area 403 .
[0046] The controller 420 has an input system that allows a user to program (a) when to operate the thermal energy source(s) 415 and negative pressure providing device 402 , (b) how much (i) thermal energy is directed from the thermal energy source 415 to the conventional negative pressure, thermal energy device 400 and the conventional compression therapy device 410 and (ii) negative pressure to create in the conventional negative pressure, thermal energy device 400 , and (c) the temperature of the thermal energy directed to the conventional negative pressure, thermal energy device 400 and the conventional compression therapy device 410 . The controller 420 can be electrically interconnected to the conventional negative pressure, thermal energy device 400 and the conventional compression therapy device 410 , or alternatively, the user could manually operate each device separately. The former embodiment is preferred because it provides the opportunity to control the devices simultaneously and in conjunction with each other to obtain the desired results.
[0047] FIGS. 1 and 2 illustrated that the conventional negative pressure, thermal energy device 400 and the conventional compression therapy device 410 are separate devices. FIG. 3 illustrates that the conventional negative pressure, thermal energy device 400 and the conventional compression therapy device 410 can be combined together to form a single unit device 500 .
[0048] The single unit device 500 encloses the patient's body part (hand, arm, hand and arm, leg, foot, or leg and foot). The single unit device 500 has a proximal end 503 and a distal end 504 . The distal end 504 is sealed. The proximal end 503 has an opening that allows a patient's body part to enter into the single unit device 500 . The proximal end 503 has a leaky seal 506 .
[0049] The leaky seal 506 allows the area 403 to have and maintain a negative pressure environment without creating a tourniquet effect to the patient. Area 403 is positioned between fluid pressure members 411 , 412 and 417 and the patient's skin.
[0050] Third fluid pressure member 417 operates in the same way as fluid pressure members 411 and 412 as described above. That means fluid pressure member 417 receives a fluid from thermal energy source 415 at temperature T 4 wherein T 1 , T 2 , T 3 and T 4 can be the same, different, or combinations thereof. Likewise, the fluid pressure in the third fluid pressure member 417 can be P 3 , wherein P 1 , P 2 and P 3 can be same, different or combinations thereof.
[0051] The thermal energy therapy is provided to the patient through the fluid pressure members 411 , 412 , and 417 . Simultaneously or not, fluid pressure members 411 , 412 , and 417 can be providing compression therapy to the patient.
[0052] Alternatively, the seal 506 can be positioned anywhere within fluid pressure members 411 , 412 and 417 , not just at the proximal end 503 , as illustrated in FIG. 4 .
Alternative Embodiments
[0053] The compression therapy unit 410 or the single unit device 500 can use a fluid recirculation system, a receiving system, or, a low air-loss system (only with a gaseous fluid).
[0054] As illustrated in FIG. 2 , the thermal energy source 415 provides a first fluid having T 1 and P 1 to the first fluid pressure member 411 through conduit 555 and a second fluid (the second fluid and the first fluid can be the same fluid or different fluids) having T 3 and P 2 to the second fluid pressure member 412 through conduit 557 . Conduits 555 and 557 interconnect to the respective member 411 , 412 and the fluid source 415 through a quick disconnect interconnection system (for example a Colder quick disconnect unit) 559 a - d . A quick disconnect interconnection system allows a user to disconnect the conduits from either the respective member 411 , 412 and the fluid source 415 and connect the conduits to different members or different outlets of the fluid source. In other words, the older interconnection system or equivalent thereof allows the member 411 to originally have the first fluid, then the second fluid and then the first fluid again.
[0055] In another embodiment illustrated in FIG. 4 , the first fluid pressure member 411 overlies at least a portion of the second fluid pressure member 412 . In each member 411 , 412 , the pressure may or may not be the same. The temperature in each member 411 , 412 can be the same or different. The fluid that enters each member 411 , 412 can also be the same or different. This embodiment ensures that the desired pressure is applied and in some cases increased at the transition point between the fluid pressure members 411 , 412 .
[0056] The conduit 413 can also be an orifice between two fluid pressure members. For example, the orifice can be an opening within heat sealed members that allows fluid to flow between the members. The orifice and the conduit 413 can also have check valves or membrane valves, not shown, that prevent the fluid from re-entering a particular fluid pressure member. Examples of membrane valves include and are not limited to tricuspids designs, bicuspids designs, poppet styles or flap designs.
[0057] Alternatively, the conduit 413 can have a thermal energy adjuster 558 . The thermal energy adjuster 558 has the capability to alter the temperature of the fluid going between two fluid pressure members. The thermal energy adjuster 558 is any conventional device that can alter a fluid's temperature. An example of a thermal energy adjuster 558 is thermal coil in, exterior to, or combinations thereof to the conduit 558 . Another example is a thermal blanket on the exterior surface of the conduit 558 .
[0058] The present invention is positioned on a patient and a medical person monitors the patient's blood pressure, body core temperature, heart rate, and heart rhythms. Depending on the patient's presentation, the medical person (or persons) alters the present invention's therapies (compression, thermal energy and negative pressure) to obtain the desired result. It has been confirmed this invention can control and/or manipulate the flow of the patient's blood (and other bodily fluids) without medication. Obviously, the present invention solves a problem by potentially decreasing the quantity of patient medication.
[0059] It is appreciated that various modifications to the inventive concepts described herein may be apparent to those of ordinary skill in the art without departing from the scope of the present invention as defined by the herein appended claims. | The present invention is directed to a device that provides thermal energy therapy, compression therapy and negative pressure therapy simultaneously and/or in conjunction with each therapy. The outcome of the present invention is that a patient's bodily fluids can be maintained, controlled, and/or adjusted with decreased medication dependence. Using these three therapies individually does not obtain these desired results of controlling, maintaining or adjusting the patient's bodily fluid. This combination of therapies is beneficial to the patient. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to systems and methods for summarizing text, and more particularly toward combining text summarizations.
[0003] 2. Discussion of Background Art
[0004] The accessibility to and the need to understand information have significantly grown in the past several decades. Managing such huge quantities of information often then, becomes more of a burden than a resource. In response, the field of automated Text Summarization (TS) has developed. Text summarization defines a variety of techniques for reducing a set of source text into a relatively shorter set of summarized text.
[0005] Techniques used within the summarization field include Text Extraction (TE) and Text Abstraction (TA). Text extraction generally involves selecting a subset of “important” sentences, such as headlines leading sentences in a paragraph, proper nouns or phrases, citations, boldface or italic type, and etc. within a source text, which are then combined into what becomes a summarized text. Text Abstraction has a similar goal, however techniques for “interpreting/conceptualizing” the text are used.
[0006] Text summarization techniques are applicable to white papers, periodicals, legal documents, Internet searches, as well as many other information processing domains.
[0007] Due to the importance of text summarization, many companies have introduced summarization products that work to varying degrees. In fact, some summarizers tend to work better on some types of source text, but not others. Improvements in the field tend to be incremental and isolated, resulting in a patchwork of summarization strengths.
[0008] Some attempts have been made to combine multiple summarization techniques into a single product; however, these combinations tend to require generation of a completely new set of code that integrates the different techniques in a very detailed and involved way. Such code would need to be supplemented and perhaps even completely rewritten each time a new summarization technique was created.
[0009] Currently, however, there are no text summarization products that are able to quickly leverage the unique strengths currently found in existing text summarization systems, as well those yet to be developed.
[0010] In response to the concerns discussed above, what is needed is a system and method for text summarization that overcomes the problems of the prior art.
SUMMARY OF THE INVENTION
[0011] The present invention is a system and method for combining text summarizations. The method of the present invention includes the elements of: receiving a source text having a set of source text portions; generating a set of source text summarizations, each having a set of summarization portions, from the source text; calculating a portion score for each of the source text portions based on the source text portion's appearance in the summarizations; and populating a combined text summarization with those source text portions whose portion score exceeds a predetermined threshold. The system of the present invention includes all means for implementing the method.
[0012] These and other aspects of the invention will be recognized by those skilled in the art upon review of the detailed description, drawings, and claims set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a dataflow diagram of one embodiment of a system for combining text summarizations;
[0014] [0014]FIG. 2 is a flowchart of one embodiment of a method for combining text summarizations;
[0015] [0015]FIG. 3 is one source code embodiment for aligning text within the method;
[0016] [0016]FIG. 4 shows one embodiment of a look-up table for word score calculation;
[0017] [0017]FIG. 5 is one source code embodiment for populating a combined summarization within the method;
[0018] [0018]FIG. 6 is a dataflow diagram of one embodiment of a system for calibrating summarizers based on source text domain;
[0019] [0019]FIG. 7 is a dataflow diagram of one embodiment of a system for weighting summarizations based on source text domain; and
[0020] [0020]FIG. 8 is a flowchart of one embodiment of a method for calibrating summarizers and weighting summarizations based on source text domain.
[0021] Appendix A is an exemplary set of source text;
[0022] Appendix B is a “Copernic” text summarization of the source text;
[0023] Appendix C is a “Text Analyst” text summarization of the source text;
[0024] Appendix D is a “Zentext” text summarization of the source text; and
[0025] Appendix E is one possible combination of the text summarizations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] The present invention is a system and method that leverages the unique text summarization strengths of many current, and future, text summarization systems. The invention uses existing summarizers to process a set of source text, and then itself processes the source text as well as the summarizations produced by the existing summarizers. This technique is a generic combination algorithm, which can receive as input summarizations from many different summarization systems. As a result, the present invention produces a summarization that is more relevant than any individual summarizer.
[0027] [0027]FIG. 1 is a dataflow diagram of one embodiment of a system 100 for combining text summarizations. FIG. 2 is a flowchart of one embodiment of a method 200 for combining text summarizations. FIGS. 1 and 2 are now discussed together using both functional and logical descriptions.
[0028] The method 200 begins in step 202 , where a source text 102 to be summarized is received as input by a predetermined set of N summarizers (S i , where “i” ranges from 1 to N), 104 through 108 . The source text (T) includes a variety of source text portions, such as: letters, words, phrases, sentences, paragraphs, sections, chapters, titles, citations, footnotes, hyperlinks, as well as many other text portions known to those skilled in the art. For the purposes of the present discussion, the term text portion is herein defined to include any of the information contained in the source text, be it as small as a single letter, or as large as the entire source text.
[0029] To simplify the present discussion, source text words are used as exemplary source text portions, even though the present invention is applicable to all text portions. The source text 102 includes a set of “n” source words (W 1 , W 2 . . . W n ), with W i being a word. Thus, T={W 1 ,W 2 . . . W n }. Each word is separated from other words by blanks, line breaks and/or paragraph breaks. An exemplary set of source text is shown in Appendix A. The exemplary set of source text is 1145 words long.
[0030] In step 204 , the summarizers (Si) 104 through 108 , generate a corresponding set of source text summarizations (T i , where “i” ranges from 1 to N), 110 through 114 . The summary (T i ) includes a set of “m” summarization words {A 1 , A 2 . . . A m }, where “m” tends to differ from summarizer to summarizer.
[0031] Text Extraction (TE) is one summarization technique that can be used. In TE, source text portions deemed to be the “most significant” within the source text are literally picked out and added to the summary without further processing. Most of the differences between different summarizers are directly related to how each individual summarizer determines which portions of the source text are “most significant.”
[0032] The summaries are condensed versions of the source text, which usually is only 10-25% of the source text's original length. For example, Appendix B shows a “Copernic” summarization of the source text, which is 328 words long; Appendix C shows a “Text Analyst” summarization of the source text, which is 251 words long; and Appendix D shows a “Zentext” summarization of the source text, which is 319 words long. Copernic, Text Analyst, and Zentext are three popular commercial summarization software packages.
[0033] In the present invention, each summarizer preferably processes the source text 102 in parallel, speeding source text processing and the present invention's operating efficiency.
[0034] While some summarizers provide information on how their summary corresponds to the source text (for example, the 5 th word in the summary is the 10 th word in the original text), most summarizers just generate a summary without direct reference to the original source text.
[0035] As a result, in step 206 , an alignment/mapping module 116 aligns the set of summarizations with (i.e. mapped to) the source text. Thus, summary text T i ={A 1 , A 2 . . . A m }, when mapped to (i.e. aligned with) the source text (T), yields {W P 1 , W P 2 . . . W P m }, in which W Pi =A i and P 1 <P 2 . . . <P m . The variable “P i ” identifies which word A i is in the source text (T). FIG. 3 is one source code embodiment for aligning text within the method, written in a “C” language style.
[0036] Next in step 208 , the alignment/mapping module 116 also generates an array indicating which words each of the text summarizers have included in their summaries. Thus, each word (W i ) in the source text (T) has an associated word inclusion array {a i1 ,a i2 . . . a iN }, indicating which of the N summarizers included which word (W i ) in their summary.
[0037] In one embodiment, “a ij ” has a integer value of either “0” or “1”, with “0” indicating that the summary does not include the word, and “1” indicating that the summary does include the word. For example, referring to Appendices B thorough D, each of the three summarizers choose the word “metaphor” from the source text, thus the array associated with the word “metaphor” is {1,1,1), whereas the word “spectacle” appears only in Appendix summaries B and D, and the array associated with the word “spectacle” is {1,0,1 }.
[0038] In a second embodiment, “a ij ” can have a fractional value somewhere between “0.000” and “1.000”. This fractional value depends not only on whether the summary includes the word, as described above, but also on how each of the summarizers rates the importance of that word within the source text. For example, one summarizer might rank pronouns as higher in importance than other words in the source text, whereas another summarizer might rank words within a first sentence of every paragraph within the source text as of greater importance.
[0039] Next in step 210 , a word scoring module 118 calculates a word score S(W i ) for each word W i in the source text (T), as a function of each word's appearance in the summarizations. There are many alternate functions for calculating the word score S(W i ). For instance, source text words can be scored using a summation function, such as:
S ( W i ) = ∑ j = 1 N a ij
[0040] ,where array values {a i1 , a i2 . . . a iN } are summed from each of the N summarizers. The score can be normalized by dividing it by N.
[0041] In step 212 , a combination module 120 populates a combined text summarization (T o ) 122 with combined summarization words. The combined summarization words are those source words W i in the source text 102 whose word score S(W i ) is above a predetermined threshold. For example, Appendix E is one possible combined summarization, using an equal weighting function and a threshold (TH) of 2, yielding a 227-word combined summarization. FIG. 5 is one source code embodiment for populating a combined summarization within the method. The source code is written in a “C” language style.
[0042] [0042]FIG. 6 is a dataflow diagram of one embodiment of a system 600 for calibrating summarizers based on source text domain. FIG. 7 is a dataflow diagram of one embodiment of a system 700 for weighting summarizations based on the source text domain. And, FIG. 8 is a flowchart of one embodiment of a method for calibrating summarizers and weighting summarizations based on the source text domain. FIGS. 6, 7 and 8 are now discussed together.
[0043] Source texts summarized by the present invention, are expected to cover a wide range of subjects. These subjects can be broadly grouped into corpora, which are herein described as a set of text domains. Due to the varied authorship techniques common to each text domain, off-the-shelf summarizers tend to be optimized for just a few particular text domains. For instance, since newspaper articles tend to follow a common construction format, newspaper article summarizers are optimized to capture “titles,” “leading paragraphs,” and perhaps “final paragraphs.” In contrast, summarizers optimized for scholarly papers may search for and focus on “abstract” and “conclusion” sections. As a result, a summarizer that generates relevant summaries for a first text domain may fail to do so for other text domains.
[0044] In the embodiment of the present invention, discussed with respect to FIGS. 1 and 2 above, an implicit assumption was that each of the summarizers performed almost equally well on all source texts. As a result, the combined text summarization 122 was effectively populated by majority voting.
[0045] However, in an improvement to the invention discussed above, a system and method for calibrating and weighting the summarizers 104 through 108 is now disclosed. Calibration tailors operation of the present invention to allow for variations in summarizer performance over differing text domains.
[0046] In step 802 , a set of text domain classes are identified within which the present invention is expected to operate. Next in step 804 , a set of source calibration texts, representative of a text domain class, within the set of text domain classes, are selected.
[0047] In step 806 , a Ground Truth Summarization (GTS) 604 is accessed for each of the source calibration texts 602 within a text domain class. GTS's are typically created by an expert in the corresponding text domain class.
[0048] Then in step 808 , each of the summarizers 104 through 108 generates a calibration summarization 606 through 610 for each of the source calibration texts 602 . In step 810 an alignment/mapping module 116 aligns the set of calibration summarizations 606 through 610 with the source text, and generates corresponding word inclusion arrays.
[0049] Next in step 812 , a weighting optimization module 612 provides a default set of summarizer weights (r j ) 614 , preferably all equal in value, to a modified word scoring module 616 . In step 814 , the modified word scoring module 616 calculates a modified word score S(W i ) for each word W i in the source text (T), using the summarizer array values and weights (r j ) 614 .
[0050] As discussed with respect to FIGS. 1 and 2 above, there are many alternate functions for calculating the word score S(W i ). In a first embodiment, source text words can be scored using a modified summation function, such as,
S ( W i ) = ∑ j = 1 N r j a ij
[0051] , where j identifies a summarizer from which an array value a ij is obtained, and that summarizer's corresponding weighting value r j .
[0052] In a second embodiment, source text words are scored using a weighted exponential function, such as,
S ( W i ) = ∏ j = 1 N a ij r j
[0053] , in which the summarizer weights are in the form of exponentials. This embodiment is preferred when the summarization techniques used in summarizers 104 through 108 are relatively independent.
[0054] In a third embodiment, source text words can be scored using a neural network, such as a Multiple Layer Perception (MLP) network, with {a i1 , a i2 , . . . , a iN } as the input. Or in a fourth embodiment, S(W i ) can be obtained using a look-up table where each array value of {a i1 ,a i2 . . . ,a iN } is either 0 or 1. In this case, the total number of combinations of {a i1 , a i2 . . . , a iN } is limited to 2 N. The table can be filled experimentally or through any systematic approach, such as described later. An advantage of the look-up table includes increased speed, since actual word score calculation is done off-line; and, increased flexibility, since arbitrary functions can be realized with look-up tables without reprogramming the system 100 . For example, FIG. 4 shows one embodiment of a look-up table 400 for word score calculation. In this embodiment, it is presumed to have only three summarizers (i.e. N=3).
[0055] In step 816 , the combination module 120 populates a combined weighted text summarization (T w ) 618 with words W i in the source calibration text 602 whose word score S(W i ) is above a predetermined threshold.
[0056] In step 818 , the weighting optimization module 612 compares the Ground Truth Summarization 604 to the combined weighted text summarization (T w ) 618 . In step 820 the optimization module 612 provides a new set of summarizer weights (r j ) 614 to the modified word scoring module 616 and stores the new weights in a summarizer weighting table 620 .
[0057] In step 822 , the method 800 repeats steps 814 through 818 , until the weighting optimization module 612 decides that the summarizer weights (r j ) 614 have been optimized for the text domain class associated with the set of source calibration texts.
[0058] Optimization preferably occurs when the set of summarizer weights (r j ) yields a “best-fit” between the Ground Truth Summarization 604 and the combined weighted text summarization (T w ) 618 . To this end, a variety of cost/target functions may be used, such as the Mean Square Error (MSE):
Cost = ∑ i = 1 q ( S ( W i ) - g i ) 2 where g i = { 1 ( W i is in the ground truth summary ) 0 ( W i is not in the ground truth summary ) ,
[0059] q is the number of words in the source text. Numerical analysis software, such as MatLab, can be used to implement the optimization.
[0060] Next in step 824 , the weighting optimization module 612 stores a final set of optimized summarizer weights (r j ) in the summarizer weighting table 620 .
[0061] In step 826 , steps 806 through 820 are repeated for each of the text domain classes.
[0062] Next in step 828 , a source text domain class identifier module 702 , identifies a text domain class within which a new set of source text, such as the source text 102 , is included. Identification can be performed by requesting that a user identify the text domain class by selecting from a set of text domains presented to him/her. Alternatively, identification may be automatically performed by analyzing keywords within the source text 102 in order to determine the text domain class into which the source text 102 falls.
[0063] In step 830 , the identifier module 702 selects a set of summarizer weights (r j ) 614 from the summarizer weighting table 620 corresponding to the text domain class within which the new source text falls, and provides the selected weights to the modified word scoring module 616 . Then in step 832 , a new combined weighted text summarization (T w ) 618 is generated for the new source text, as described in step 814 and 816 , using the selected weights, after which the method 800 ends.
[0064] While one or more embodiments of the present invention have been described, those skilled in the art will recognize that various modifications may be made. Variations upon and modifications to these embodiments are provided by the present invention, which is limited only by the following claims. | The method of the present invention discloses: receiving a source text having a set of source text portions; generating a set of source text summarizations, each having a set of summarization portions, from the source text; calculating a portion score for each of the source text portions based on the source text portion's appearance in the summarizations; and populating a combined text summarization with those source text portions whose portion score exceeds a predetermined threshold. The system of the present invention discloses all means for implementing the method. | 6 |
TECHNICAL FIELD
[0001] The invention relates to the manufacturing of small size orifices in glass-like materials.
STATE-OF-THE-ART
[0002] When dealing with nanotechnology, e.g. when the dimensions of an orifice only have a few nanometers, specific effects may arise. Especially the resistive pulse technique (also called Coulter counter technique) may benefit from this technique. It is a versatile method to count and characterize single cells, colloids, molecules or even sequence DNA 1-3 . An electric potential is applied through a small orifice incorporated into a membrane or cone. This potential creates an ionic current whose amplitude depends, besides parameters such as ionic concentration and surface charge, on the volume and size of the orifice 4 . Orifices with diameters in the nanometer range are named nanopores, which are divided into solid-state and biological nanopores 5 . The smaller this nanopore is, the bigger is the current blockade from translocating molecules, which increases the signal-to-noise ratio.
[0003] Classical solid-state nanopores have seen a large variety of different techniques emerging in the last decade to decrease their size 6-11 . Smaller diameters are favorable since they permit to detect smaller molecules because the current change due to the analyte entering the nanopore increases with smaller nanopores 12 . First experiments were performed by Storm et al. who shrunk nanopores in silicon oxide from 40 to about 3 nm in diameter using a transmission electron microscopy (TEM) beam 13,14 . The shrinking was explained by the surface stress causing the fluidized silicon oxide to contract in order to minimize the surface of the nanopore. This was followed by experiments where scanning electron microscopes (SEM) were used to either shrink nanopores by silicon oxide deposition 15 or thermal induced shrinking 16,17. The importance of thermal heating was recently demonstrated by Asghar et al. who caused nanopores to decrease in diameter by heating them up in an oven to about 1000 degree Celsius 18 . Since carbon deposition is often observed under SEM irradiation nanopore shrinking was also investigated with energy-dispersive X-ray spectroscopy (EDX) by Prabhu et al. who could rule out significant carbon deposition 19,20 . The shrink rates were also examined as a function of the SEM magnification showing a positive linear response to the magnification 19 . In contrast a power law dependence was observed for the beam potential (also called extra-high tension, EHT), where smaller shrink rates were observed at higher voltages 19,21 . This was supported by Monte-Carlo simulations showing increased penetration depths for electrons at higher beam potentials. The higher penetration depths cause smaller energy densities and hence less thermal heating leading to smaller shrink rates. Both shrinking techniques with a TEM or SEM have the advantage to allow live observation of the shrinking process. This permits to stop the shrinking process at any desired size. A new approach was pursued by Ayub et al. who electrodeposited Pt on the planar membrane nanopore interface while already immersed in the ionic solution 22 . The electrodeposition process is monitored in situ and can be stopped at any desired conductance level. Another technique is atomic layer deposition (ALD), which deposits angstrom thick layers of i.e. aluminum oxide to decrease the nanopore size 23,24 . Compared to electronic microscopy shrinking, above mentioned methods do not permit to see the size of the nanopore but to deduce the diameter from the conductance.
[0004] All these previous experiments focused on planar membranes made out of silicon-like materials fabricated in complementary metal-oxide-semiconductor (CMOS) techniques such as etching and vapor deposition. Especially invention WO 2004/078640 focuses on several occasions on the use of membranes (page 3 line 17, page 6 line 25, page 7 line 29, page 8 line 5 and 17). The disadvantage of using planar orifices in membranes is that they cannot be approached to a surface in the distance of a few nanometers. Due to roughness of the membrane or of the surface itself this will cause the breaking of the thin and fragile membrane. For this purpose conical shaped orifices from pipette pulling machines are used since several years in application like patch clamping (also called stochastic sensind), scanning ion conductance microscopy (SICM), scanning electrochemical microscopy (SECM) or near-field scanning optical microscopy (NSOM). There the conical orifice has to be approached to a cell surface or substrate surface and be robust enough to not break if touching the substrate. The use of nanopores in planar membranes instead would have not been possible. A helping comparison is the necessity of using a sharp tip when revealing the topography of a surface with an atomic force microscopy (AFM). A flat tip, which is like a big membrane would only result in bad resolved images of the surface. Very similar to this comparison is the difference between an orifice in a membrane to an orifice in a cone leading to different uses of this completely different geometries.
GENERAL DESCRIPTION OF THE INVENTION
[0005] The present invention relates to the manufacturing of small size orifices in glass-like materials wherein said material has a tubular shape, for instance a conical tubular shape. The invention may be advantageously used with nanocapillaries. A nanocapillary is a glass cone with the orifice at its tip. This structure is very different from an orifice in a CMOS fabricated planar membrane and is made using a so called pipette puller. The pipette puller was originally fabricated for patch and voltage clamping techniques. A laser heats a hollow glass capillary in the middle. The glass can be made out of element, which becomes viscous when heated and becomes solid when cooled down to temperature below 100 degrees. Exemplary elements and alloys are silicon, oxide, aluminum, metals, steel and titanium. Two clamps pull from both sides of the capillary. The heated spot elongates and shrinks in its diameter until a point where the shrunken and heated part breaks and the capillary separates into two capillaries. These two capillaries have a conical shape with an orifice at its tip. Until now imaging of these nanometer sized tip with an SEM were only possible when the tips were coated with a conducting material such as gold or platinum 25 . However due to improved scanning electrons microscopy detectors uncoated glass capillaries, could be imaged under an SEM. While doing these image recordings the inventors accidentally realized that shape changing orifice was not caused by charging effects by the electron beam but by the heating of the electron beam. Such an effect has never been reported for conical glass capillaries until now.
[0006] The area of this orifice can be shrunken under irradiation such as electron, ion or photon radiation. Increasing the current of irradiation increases the shrink rate, increasing the acceleration potential of the irradiating particles reduces the shrink rate. Imaging the orifice with an electron microscope allows to see the shrinking process and stop at the desired size. Furthermore, the shrink rate can be fine-tuned by changing the current, magnification or acceleration potential.
[0007] Other applications which would benefit from controllable orifice shrinking of glass nanocapillaries include for example near-field scanning optical microscopy, scanning ion conductance microscopy, scanning electrochemical microscopy, glass nanopore membranes, micro electrode cavity arrays, electron spray techniques, mass spectroscopy, surface Raman spectroscopy, patch clamping, plasma physics, fluorescent detection of molecules translocating through nanocapillaries, filter techniques, 3D and 2D printing techniques, capillary electrophoresis, combination of nanocapillaries with optical tweezers, cell surgery for sample injection or removal, highly charged ion physics for plasma analysis, dark field microscopy and soft x-ray scanning microscopy.
[0008] Besides solid-state nanopores in silicon dioxide, silicon nitride or metal membranes, glass nanocapillaries have emerged in the last years as a cost-effective and versatile source of nanopores for single molecule detection 25 . They are fabricated using a laser pipette puller and not classical etch and evaporation techniques used in CMOS production lines. The pipette puller heats the cylindrical hollow capillary and stretches it at the same time. This causes the glass capillary to shrink in diameter at the heated spot and finally break into two conical tips defined as nanocapillaries. Depending on the parameters used during the fabrication such as pull strength or heat different end diameters can be reached ranging from micro- to tens of nanometers 26,27 . This wide range of end diameters, a fast, cheap and user-friendly fabrication process, and no need for clean rooms or TEMs is an advantage comparing it to the fabrication needs for other solid-state nanopores. Reliably diameters of 30 nm can be reached using laser pullers, however to increase the sensitivity for smaller molecules smaller diameters would be essential 28 . Hence, a technique would be needed to further decrease the diameter of the laser-pulled glass nanocapillaries.
[0009] Glass nanocapillaries fabricated directly from a laser pipette puller, have not yet benefited from a shrinking method with live optical monitoring of the shrinking nanocapillary. Quartz Nanopore Membrane (QNM) require the incorporation of a sharp polished Pt wire into a glass membrane, which is etched away while monitoring the conductance of the opening nanopore 29 . A similar technique is used by Gao et al. who corrode a nanopore into a sealed capillary pipett using an HF solution 28 . Again the pore opening is controlled non-optically by measuring the conductance. A novel technique where the pore diameter can even be changed in situ was presented by Platt, Willmott and Lee who use a tunable pore made out of thermoplastic polyurethane membrane 30 .
[0010] The invention covers a method to shrink glass (made out of quartz or borosilicate glass) nanocapillaries to any size from up to 200 nm to a few nanometers or even to the complete closure of the nanopore. The shrinking occurs while observing the glass nanocapillary under an SEM allowing precise control of their size by terminating the process at any desired diameter. The shrinking is fast reaching 0.25 nm/s and can be changed by adjusting the beam current or the electron acceleration voltage. This method has various applications like in the resistive pulse technique, where small diameters increase the sensing sensitivity. This is due to the increase in the amplitude of the current change, when the molecule enters the nanopore. In the future this will facilitate the detection of very small and short polymers 31 . The increase in the current amplitude will be demonstrated showing an increase from about 50 pA for single DNA strand for an unmodified nanocapillary to over 300 pA for a shrunken nanocapillary. Other applications which will benefit from a smaller diameter of the nanocapillary include near-field scanning optical microscopy (NSOM), scanning electrochemical microscopy (SECM), 2D/3D printing, scanning ion conductance microscopy or nanobilayer coated glass capillaries 32-34 . Advantages of this process are that the shrinking can be parallelized to multiple of cones by exposing them all to the heat or radiation source. Furthermore by use of the microscopy technique such as the electron microscope the shrinking can be observed live. Here the electron beam acts as a heating source as well as a mean to image the feature.
[0011] One of the important features of the invention is the shrinking of orifices in a tubular glass-like materials, eg a cone, from hundreds of nanometer in size to a few nanometers. The shrinking should be observable by microscopy technique such as an electron microscope. This allows stopping the shrinking at any desired feature size. The cone results from fabrication in a pipette puller designed to fabricate cones with orifices in glass capillaries and fibers.
[0012] Another important feature of the invention is the use of a radiation beam (made of particles and/or waves) to heat and then shrink the materials.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The invention will be better understood below with some examples and some illustrations.
[0014] Of course the invention is not limited to those examples.
BRIEF DESCRIPTION OF THE FIGURES
[0015] FIG. 1 . (a) Scheme of the conical end of the nanocapillary. The shaded area depicts the region, which is imaged by the SEM beam. The Radius R is the penetration depth of the electron beam calculated by the theoretical penetration formula given by Kanaya-Okayama. (b) SEM in-lens image of a quartz nanocapillary magnified 196 kX times at a stage angle of 60 degrees to increase the three dimensional perception. The electron high tension was at 3.0 kV, the beam current was at 171 pA and the working distance was 3.3 mm. (c) Shrunken nanocapillary after 14 minutes of irradiation under constant angle and beam parameters. The process of deformation is also shown in a video in the SI (SI_movie — 1.avi). Clearly a reshaping of the nanocapillary is visible precluding the possibility of significant carbon deposition. This was supported by EDX measurements included in the supplementary information in FIG. 1 , FIG. 2 . and Table 51.
[0016] FIG. 2 . (a) Top side SEM in-lens image of a nanocapillary before the shrinking process at time t=0. The beam parameters were hold constant at an electron high tension of 4 kV, beam current of 119 pA, a magnification of 200 kX times and a working distance of 5.1 mm. Analysis of the black hole in the middle with ImageJ resulted in a diameter (d) of 42 nm. (b) After two minutes of constant imaging under the SEM beam first contraction of the diameter can be observed. Analysis of the black pore resulted in an inner diameter of 33 nm. (c) Past 4 minutes after starting to image the nanopore had further shrunken reaching a diameter of 23 nm. (d) A final diameter of 11 nm was reached after 6 minutes. The beam parameters were held constant over the whole shrinking process. Note that the process of shrinking is uniform from all sides.
[0017] FIG. 3 . EDX spectrum recorded for the nanocapillary shown in FIG. 1 ( a ). Working distance was 8.1 mm, with an acceleration potential of 3 kV, a beam current of 119 pA and a magnification of 153 kX. The areas of the different peaks were calculated to deduce the relative chemical composition of the nanocapillary. The composition before and after the shrinking is displayed in Table 51.
[0018] FIG. 4 . (a) Diameter shrinking over time while irradiated by the SEM beam. The diameter at the different time points was normalized by dividing by the initial diameter at time zero. The shrinking was recorded with a constant beam current of 119 pA but varying beam potential (also called EHT for extra-high tension) between 1.5 kV to 6 kV. Interestingly the smaller the electron high tension is, the faster the shrinking of the diameter takes place. While the diameter shrinks to 0.5 of the initial diameter after 150 seconds at 1.5 kV it takes over 600 seconds to reach this ratio at 6 kV. (b) In contrast to the FIG. 4 ( a ) the beam potential was held constant at 3 kV and the beam current was varied from 30 to 231 pA. For a beam current of 231 pA the nanocapillary shrinks to 25% of its initial size after only 150 seconds while a low beam current of 30 pA it reaches only 75% of its original diameter after more than 450 seconds. (c) Shrink rate of the nanocapillary as a function of the beam parameters such as beam current (black lower abscissa) and electron high tension (blue upper abscissa). The shrink rate was calculated from the previous diameter-time dependence in FIG. 4 . (a) and (b) by calculating the slope using a linear fit. The shrink rate shows a linear dependence from the beam current (hollow black circles); while a power law becomes apparent for the relation between the shrink rate and the beam potential (hollow blue squares). This is expected from the Kanaya-Okayama formula (equation (1)). The filled blue square at beam potential 3 kV was recorded at a beam current of 243 pA twice as high than the other data points at 119 pA. The doubled shrink rate is in agreement with the linear dependence between the beam current and the shrink rate.
[0019] FIG. 5 . (a) Nanocapillary before starting the shrinking process with a diameter of about 71 nm. The beam potential was 6 kV, the beam current 171 pA, the working distance 5.1 mm, and the magnification was 292 kX. The scale bar represents 50 nm. (b) After 12 minutes of SEM irradiation with constant parameters the nanocapillary had shrunken to a diameter of about 11 nm and was used for DNA translocation experiments. The scale bar represents 50 nm.
[0020] FIG. 6 . (a) Current in dependence of the applied potential for a nanopore shrunken under an SEM beam to 11 nm and an unmodified nanopore of approximately 47 nm. The KCl solution was 1 M for both nanocapillaries and resulted in a conductance of 21 nS for the shrunken nanocapillary and 128 nS for the unmodified nanocapillary. The inset shows the shrunken nanocapillary with a diameter of around 11 nm. The white scale bar represents 20 nm. (b) Current as a function of time showing the translocation of λ-DNA with three exemplary current drops (blue line) at 0.5 V. The current was normalized to zero to improve comparison between the events. The black line is a CUSUM fit described by Raillon et al. The graph in the right is the histogram of the current traces (blue line) and the fits (black line) for hundreds of events. The histogram shows the quantification of the events with the biggest peak at zero current representing zero DNA strands inside the open nanopore. The blue line is generated from the raw current signal, while the black line results from the CUSUM fit′. The second and third peaks around 49 pA and 109 pA are caused by one and two DNA molecules residing inside the nanocapillary, respectively. (c) Three exemplary current traces (green line) recorded for DNA translocation through the 11 nm big nanocapillary at 0.5 V. The black line is the result from the CUSUM fit. The right graph is a histogram from several hundreds of events similar to the ones displayed on the left side. The green line is generated from the raw current data, while the black line results from the CUSUM fit. (d) Current drop as a function of the number of DNA strands for the nanocapillary with an inner diameter of 11 nm (green hollow circles) and 47 nm (blue circles) when applying 0.5 V. The values were obtained by fitting a Gauss function to the peaks generated from the CUSUM in the histograms of FIG. 6 . (b) and (c). With current drops of 323 pA for one DNA molecule for the 11 nm nanocapillary compared to only 49 pA for the 47 nm nanocapillary a clear increase in the current blockage for smaller nanocapillaries can be observed.
[0021] FIG. 7 . Percentage of the different folded states of the DNA inside the shrunken (blue spheres) and unmodified nanocapillary (green circles). When translocating through the shrunken nanocapillary more than 75% of the events are caused by an unfolded DNA strand while less than 25% are in folded or multiple folded states (blue spheres at # DNA 2 and 3). In contrast only about 50% of the DNA is unfolded when translocating through an unmodified and bigger nanocapillary (green circle at 1 DNA strand). While over 35% of the DNA is translocating in a folded state (green circle at 2 and 3 # DNA).
[0022] Table S1. Comparison of the chemical composition determined by EDX measurements before and after the shrinking of the glass nanocapillary. The respective nanocapillary before and after shrinking can be seen in FIG. 2 . The relative composition percentage of carbon (C) did only increase by 1.1% (from 17.8% to 18.9%) representing only small increase not able to explain the shrinking from 179 to 93 nm in horizontal and 106 to 29 nm in vertical direction.
[0023] The quartz capillaries were purchased with an inner and outer diameter of 0.3 and 0.5 mm (Hilgenberg, Germany). The capillary were pulled with the laser pipette puller P-2000 (Sutter, USA). The pulling parameters were Heat 550, Filament 0, Velocity 50, Deletion 130 and Pull 150 resulting in a single pull after an activated laser for about 1.05 seconds. This resulted in nanocapillaries with a taper length of approximately 4 mm. Detailed description of capillary pulling can be found in previous publications 25,35 .
[0024] The resulting nanocapillaries from the pull were imaged under a Field Emission Scanning electron Microscope (FESEM or SEM). The Merlin SEM (Zeiss, Germany) did not necessitate the presence of a conducting layer on the glass nanocapillaries when imaging with the in-lens detector. This allowed determining the diameter of every nanocapillary before assembling it into the measuring cell, which was not possible before 25 . SEM imaging was performed under a working distance between 2 and 9 mm, magnifications between 10 k and 500 k, beam currents between 10 and 5000 pA and acceleration voltages of 0.1 to 100 kV. EDX measurements were also possible, permitting it to measure the chemical composition before and after the shrinking. EDX measurements were performed using the AZtexEnergy software under a working distance of about 8 mm and beam potentials of 3 kV or higher.
[0025] The nanocapillaries were assembled into a PDMS cell, whose two reservoirs were only connected by the glass orifice 4 . The bottom of the PDMS cell sealed with a 0.15 mm thick cover glass (Menzel-Glasser, Germany). The reservoirs were filled with a potassium chloride (KCl) solution of 1 mol/L (M), 1 mM Tris and 0.1 mM EDTA buffer at pH 8. The solution was cleared from contaminating particles using an anotop 25 filter (Watman, USA). To remove air bubbles inside the nanocapillary after addition of the buffer solution the PDMS cell was degased inside a desiccator using a vacuum line 35 . Oxygen plasma for minutes did improve this step by rendering the surface hydrophilic.
[0026] To apply a potential and measure the ionic current the current amplifier Axopatch 200B was used (Axon Instruments, USA) with a low pass Bessel filter at 10 kHz and a PXI-4461 DAQ card (National Instruments, USA) sampling at a frequency of 100 kHz. The electrodes were made out of chlorinated silver electrodes (Ag/AgCl) which were placed on both sides of the nanocapillary to measure the ionic current through the nanocapillary. The DNA translocation events were recorded and analyzed using a custom written LabVIEW program and a CUSUM algorithm, respectively 36,37 .
[0027] The inventors surprisingly found that the diameter of nanocapillaries made out of quartz or borosilicate glass shrinks similar to silicon nanopores when imaged under SEM electron beam 19 . This enables one to reach any desired diameter with nanocapillaries. This has an important impact on many fields such as an increased sensitivity for the resistance pulse technique or on the resolution of the scanning electrochemical microscopy 12,32 .
[0028] FIG. 1 ( a ) presents a schematic representation of nanocapillary showing the conical shape and the region of the tip, which contains a single nanopore. The shaded circle depicts the area, which is irradiated by the electron beam when imaged by the SEM. The penetration depth of the electron entering the quartz glass made out of mainly SiO 2 can be estimated by the Kanaya-Okayama depth penetration formula:
[0000]
R
=
0.0276
AU
1.67
Z
0.89
ρ
μm
.
(
1
)
[0029] The expression describes the penetration depth R of the electrons in dependence from the beam potential (kV), U, the atomic weight (g/mol), A, the atomic number, Z, and the density of the imaged material (g/cm 2 ), ρ. The penetration depth R is depicted in FIG. 1 ( a ) with a black circle. From this equation one can see, that the penetration depth, R, increases with higher beam potentials, U. Using the penetration depth an electron density, d e , can be defined as:
[0000]
d
e
=
N
e
1
2
π
R
3
4
/
3
.
(
2
)
[0030] N e represents the number of electrons and ½ πR 3 4/3 stands for the hypothetical penetration volume represented by a half sphere. Calculating the electron density (d e ) once can see that increasing the penetration depth, R, by having higher beam potentials decreases d e . Increasing the beam current (number of electrons per time) increases the number of electrons and therefore augments the electron density. If one assumes a linear dependence between the electron density and the energy density it can be predicted that the energy density and hence the thermal heating will increase with higher beam currents or with smaller beam potentials. FIG. 1 ( b ) shows a side view of a nanocapillary with a vertical inner diameter of about 175 nm at a working distance of 3.3 mm, a beam current of 171 pA and a beam potential of 3.0 kV. While holding the magnification constant at 196 kX and imaging the nanocapillary for 14 minutes the diameter shrinks approximately to 83 nm (see FIG. 1 ( c )). To facilitate determination of the inner diameter, nanocapillaries were aligned concentric to the electron beam. This enabled precise determination of its inner diameter (see FIG. 2 ( a ) to ( d )). The image sequence shows the constant shrinking of the nanocapillary under a beam potential of 4 kV, a beam current of 119 pA, a working distance of 5.1 mm and a magnification of 200 kX. The nanocapillary at time zero in FIG. 2 ( a ) has an inner diameter of 42 nm, which constantly shrinks reaching 33 nm after 2 minutes ( FIG. 2 ( b )), 23 nm after 4 minutes ( FIG. 2 ( c )) and 11 nm after 6 minutes ( FIG. 2 ( d )). Carbon deposition was ruled out by Energy dispersive X-ray spectroscopy (EDX). EDX measurements have been performed before and after shrinking of the quartz nanocapillaries to measure the increase in the carbon composition. Similar measurements were already done by Prabhu et al. who investigated shrinking in silicon nitride nanopores 19 . Spectra like in FIG. 3 were recorded using the AZtecEnergy software package, while having a working distance of about 8 mm and an acceleration potential of 3 kV. The software measured the chemical composition of our sample and allowed to quantify the relative amount of carbon on the nanocapillary before and after the shrinking. FIG. 3 shows the spectrum before shrinking the nanocapillary, showing typical elements composing a quartz glass like oxygen (O), aluminum (Al), silicon (Si) and carbon (C). After 16 minutes of SEM irradiation the nanocapillary had shrunken from a vertical high of 106 nm to approximately 29 nm. The EDX measurement before and after the shrinking showed an increase of the carbon composition from 17.8 to only 18.9% (see Table 51). This increase of only 1.1% can be excluded to play an important factor in the shrinking process, which decreased the horizontal diameter from 179 to 93 nm and the horizontal diameter from 106 to 29 nm. The other chemical elements did also not show notable increase in the composition.
[0031] To compare the effect of different parameters such as the beam potential or beam current a normalized diameter unit was chosen. For that the diameter value, D, was divided at time Δt by the initial diameter value, D 0 , at time point zero (t=0). FIG. 4 ( a ) shows the shrinking in the normalized diameter when imaged at different beam potentials ranging from 1.5 kV to 6 kV and a constant beam current of 119 pA. One can see that at lower potentials the shrinking process happens much quicker reaching 25% of the initial size already after 150 seconds at 1.5 kV. At higher beam potentials the shrinking process manifests much slower reaching only 50% after 600 seconds at 6 kV. The opposite behavior can be seen when the beam potential was held constant at 3 kV and the beam current was changed. In this case lower beam current values induce a slow shrinking and high values and fast shrinking (see FIG. 4 ( b )). While a beam of 30 pA causes the nanocapillary to shrink to only 75% after 450 seconds the nanopores shrinks to 25% of its initial size after only 150 seconds when imaged at 231 pA. FIGS. 2 ( a ) and ( b ) support our prediction, which anticipates faster shrinking with increasing beam currents but lower shrink rates with increasing beam potentials. To quantify the shrink rate the diameter changes were fitted with a linear function and the resulting slope was plotted in dependence of the beam current and the beam potential (see FIG. 4 ( c )). The shrink rate as a function of the beam current shows a linear dependence with a rate ranging from about 0.02 nm/s at 30 pA to 0.25 nm/s at 231 pA (black circles in FIG. 4 ( c )). In contrast, the shrink rate shows power law dependence when plotted as a function of the beam potential (blue squares in FIG. 4 ( c )). Both dependences agree with our model. The number of electrons increases linearly with the beam current, augmenting the energy density inside the glass. This causes thermal heating of the nanocapillary and its diameter shrinking due to the surface stress (see equation (2)). But when the beam potential is increased the penetration depth of the electron entering the glass is increased. This diminishes the energy density, resulting in less heating and therefore smaller shrink rates with increasing beam potentials (see equation (1) and (2)).
[0032] The ability to shrink nanocapillaries to any size has wide applications. One of them is the resistive pulse technique, which profits from a smaller nanocapillary with an increase in the signal amplitude 12,38 . To prove this a nanocapillary was shrunken to a diameter of 11 nm and incorporated into a PDMS cell (see FIGS. 5 ( a ) and ( b )). The nanocapillary was filled with a 1 M KCl buffer solution and the current was measured of a range of potentials (see green circles in FIG. 6 ( a )). Fitting this IV-curve with a linear function reveals the slope which gives a conductance of 21 nS. To illustrate the effect of the shrinking an IV-curve was also recorded with an unmodified nanocapillary (see blue circles in FIG. 6 ( a )). The unshrunken nanocapillary with an approximated diameter of 47 nm showed a higher conductance of 128 nS than the 11 nm nanocapillary with only 21 nS. Next, a 0.5 μg/μL λ-DNA solution of the same ionic strength was added to the reservoir in front of the shrunken and unmodified nanocapillary. A positive potential was applied to the electrode inside the nanocapillary causing the λ-DNA to translocate into the nanocapillary and reduce the ionic current 39 . FIGS. 6 ( b ) and ( c ) show exemplary current traces recorded at 0.5 V. It is characterized by quantized decreasing steps, revealing the number of DNA strands inside the unmodified (blue trace) and shrunken nanocapillary (green trace) 25,40 . The black line is a fit by a previously described CUSUM algorithm by Raillon et al. The algorithm allows the analysis of noisy data by generating better resolved histograms 37 . This becomes visible when looking at the histogram in FIG. 6 ( c ) where the CUSUM generates peaks (black line) which are better pronounced than the peaks from the raw data (green line). The first and biggest peak represents the open pore current and is normalized to zero pA to better compare events in case of drifting baseline current. The second and third peak represent one or two DNA strands inside the nanocapillary 25,40. The peaks from the CUSUM fit in the histograms were fitted with Gauss functions to determine their position and plotted in FIG. 6 ( d ) against the number of DNA strands. As predicted the current decreases due to DNA strands inside the nanocapillary are much bigger when translocating through a smaller nanocapillary than a bigger nanocapillary. While a single DNA strand causes reduction of 49 pA in the unmodified nanocapillary the DNA inside the shrunken nanocapillary (11 nm diameter) generates a more than six time stronger decrease of 323 pA. This expected increase in the signal amplitude permits detecting smaller molecules such as single stranded DNA, RNA or even proteins.
[0033] The size effect of the nanocapillary has also been investigated on the folding ratio of the translocating DNA. For this the number of data points within each folded state (one, two and three or more DNA strands inside the nanocapillary) was summed up and divided by the total number of states. FIG. 7 . shows this distribution of the folding states. When translocating through the small, shrunken nanocapillary the DNA prefers an unfolded state with over 75% of all current decreases being due to one DNA strand inside the constriction (blue sphere at one # DNA). Less than 25% are caused by folded DNA strands (blue spheres at 2 and 3 # DNA molecules). In contrast, when the DNA moves through an unmodified, big nanocapillary (about 47 nm diameter) more than 37% of the events are caused by two DNA strands compared to only 20% when using a shrunken nanocapillary. In consequence fewer events are caused by unfolded DNA inside the nanocapillary making less than 55% of all possible configurations (see green circle at 1 # DNA). This finding shows that smaller nanocapillaries favor unfolded over folded DNA when translocating as shown for similar systems like solid-state nanopores in silicon membranes′.
[0034] Smaller diameter will increase the resolution of scanning electrochemical microscopy or surface near-field optical microscopy, which are both based on conical glass capillaries. Also, 3D and 2D printing resolution could benefit from small conical pores.
[0035] It has been shown that nanometer-sized orifices in quartz and borosilicate glass can be reshaped using an ordinary scanning electron microscope. The shrinking of the nanocapillary occurs within minutes which allow stopping the process at any desired size ranging from 100 to a few nanometers. The shrinking process was explained with a model based on the penetration depth by Kanaya-Okayama. The model predicts a linear dependence of the shrinking rate from the beam current and a power law dependence for the beam potential. This was shown experimentally for various beam currents and beam potentials. This finding enables to fine-control the shrinking by accelerating or decelerating it, permitting to reach small diameters within seconds or switch to slow and well controlled shrink rate if desired. Interesting avenues to pursue include testing the effect of different pipette shapes and SEM instruments on the shrinking behavior. Further, it has been shown that shrinking the inner diameter of nanocapillaries increases the signal amplitude caused by the translocation of DNA. In the future this will make it possible to detect smaller molecules like RNA or proteins translocating through nanocapillaries. Besides improving the resistive pulse technique it will also enhance other techniques like SECM, SNOM, SICM, 2D or 3D-printing.
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(40) Li, J.; Gershow, M.; Stein, D.; Brandin, E.; Golovchenko, J. A. Nat. Mater. 2003, 2, 611-615. | The ability to reshape nanopores and observe their shrinkage under an electron microscope is a powerful and novel technique 14,17 . It increases the sensitivity of the resistive pulse sensing and enables to detect very short and small molecules 12,31 . However, this has not yet been shown for glass having a tubular shape, for instance nanocapillaries. In contrast to their solid-state nanopore counterparts 25 , nanocapillaries are cheap, easily fabricated and in the production do not necessitate clean room facilities. Nanocapillaries made out of glass-like materials such as quartz or borosilicate glass can be shrunken under a scanning electron microscope beam. Since the shrinking is caused by the thermal heating of the electrons, increasing the beam current increases the shrink rate. Higher acceleration voltage on the contrary increases the electron penetration depth and reduces the electron density causing slower shrink rates. This allows to fine control the shrink rate and to stop the shrinking process at any desired diameter. A shrunken nanocapillary may detect DNA translocation with six times higher signal amplitudes than an unmodified nanocapillary. The invention opens a new path to detect small and short molecules such as proteins or RNA with nanocapillaries and also increase the sensitivity of other techniques such as SNOM or SCIM, which also rely on conical glass capillaries. | 2 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 10/397,972, now U.S. Pat. No. 6,886,575, the entire disclosure of which is expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a locking assembly, and more particularly to a locking assembly for use with a foldable walker or a foldable rollator.
2. Related Art
Prior art locking mechanisms used in connection with foldable walkers have suffered from various drawbacks. The drawbacks stem from the limited manual dexterity of handicapped people. For example, some prior art assemblies are operated through use of a lever. At least one of these devices requires the user of the walker to push down on the lever to allow for the walker to be folded. However, certain people with limited dexterity may be incapable of exerting enough downward force to activate such a lever and thus will be unable to operate the locking assembly. Also, the lever handles of the prior art are often narrow. This presents additional problems for users having diminished manual dexterity. The narrowness of the handle makes finding and gripping the lever difficult. This is particularly true for users having a debilitating disease affecting their fingers, such as rheumatoid arthritis.
Still other prior art locking assemblies for walkers utilize a pin actuating plunger located remotely from the handles of the walker. Often, these prior art pin actuating plungers are positioned on a cross brace away from a walker's handles. In this configuration, a handicapped person with limited dexterity is required to release his/her grip on the handles in order to operate the pin actuating plunger mounted on the cross brace. However, during the period in which the handicapped user has released the handle, the handicapped user is unbalanced, creating a greater likelihood that the user may fall. Moreover, by positioning the pin actuating plunger on a cross brace, the handicapped user with limited dexterity is required to use two hands in order to fold each side brace, e.g., using one hand to depress the plunger while the other hand folds in the side brace. These problems described in connection with walkers are amplified with rollators, because the wheels of the rollator add another level of instability.
Based upon the foregoing, there is a need for a locking assembly for use with a foldable walker or a foldable rollator, which is both economical to manufacture and relatively easy to operate by people with limited dexterity.
SUMMARY OF THE INVENTION
Embodiments of the present invention overcome the above-described shortcomings of prior foldable walkers and rollators, and satisfy a significant need for a foldable walker and/or a foldable rollator that is relatively easy to configure between folded and unfolded positions by persons of limited dexterity. Accordingly to an exemplary embodiment of the present invention, a locking assembly is provided for use with a cylindrical member concentric with and rotatably mounted in a tubular member. The locking assembly may include a locking pin positioned parallel to a longitudinal axis of each of the two members and located external thereto. The locking pin is movable between a first position in which the two members are held in a locked state and a second position in which the members are in an unlocked state so that the two members are able to rotate in relation to each other. A lock plate is secured to one of the two members and extends transversely to the longitudinal axis thereof. The lock plate has an aperture adapted to receive a locking end of the locking pin when the pin is in the first position. A lever assembly is provided for moving the locking pin from its first position to its second position to permit rotation of the cylindrical member in relation to the tubular member. This lever assembly includes a housing member attached to another of the two members, and an actuating lever having a force-applying handle end and a housing attach end. A portion of the actuating lever is operatively connected to the locking pin. The housing attach end of the actuating lever is pivotally received by the housing member so that when an upward force is applied to the handle end, the actuating lever pivots with respect to the housing member and moves the locking pin to its second position thereby allowing the two members to be movable relative to each other.
According to another exemplary embodiment of the invention, a foldable walker is provided having a pair of side frames each of which has a substantially vertical front tubular leg. The foldable walker further includes a cross brace having a pair of substantially vertical end sleeves in which the tubular legs are concentrically contained so that the tubular legs are rotatable between a locked state and an unlocked state.
A locking assembly is also provided and is associated with each tubular leg. The locking assembly includes a first body portion having a first bore through which extends the tubular leg along a first longitudinal axis. A fastener rigidly connects the first body portion to the tubular leg, the fastener extending transversely to the first longitudinal axis and into both the first body portion and the tubular leg. A locking pin is movable between a first position in which the tubular leg and sleeve are in a locked state and a second position in which the tubular leg and sleeve are in an unlocked state. A second body portion rigidly connected to the first body portion has a second bore through which extends the locking pin along a second longitudinal axis wherein the first and second longitudinal axes are in relatively parallel position. A lock plate is rigidly connected to the end sleeve and extends transversely to the first and second longitudinal axes. The lock plate has an aperture which is adapted to receive a locking end of the locking pin when the locking pin between its first and second positions, an actuating lever is provided which has a force applying handle end and a body attach end operatively connected to at least one of the first and second body portions. A portion of the actuator lever between the force applying handle end, the actuating lever points with respect to the body portions and moves the locking pin from its first position to its second position, thereby allowing the tubular leg to be moved relative to the corresponding end sleeve.
According to another embodiment of the present invention, a foldable rollator is provided and includes a locking assembly for selectively locking side frames of the rollator. Each of the side frames includes a substantially vertical front tubular leg, and a locking mechanism in accordance with the present invention which is associated with each side frame. A cross-brace having a pair of substantially vertical end sleeves is provided, wherein tubular legs of the side frames are contained within the end sleeves and are pivotable with respect thereto. The locking assembly allows the side frames to be rotated between a locked state and an unlocked state.
The present invention also provides a method for folding a foldable rollator. The method comprises the steps of holding the hand grips of the first and second side frames; grasping first and second handles of the first and second locking assemblies; pulling the first and second handles up towards the hand grips to unlock the first and second locking assemblies; and rotating the first and second side frames toward the cross brace and into a folded position. Further, the method can include the step of unfolding the rollator for use, comprising rotating the first and second side frames away from the cross brace into locked positions substantially perpendicular to the cross brace.
Objects and advantages of the present invention will become apparent from reading the following description of the invention wherein reference is made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the system and method of the present invention may be obtained by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:
FIG. 1 is a perspective view of a foldable walker with one side frame in its folded position and a second side frame in its unfolded position; and
FIG. 2 is an enlarged exploded perspective view of the locking assembly portion for the foldable walker of FIG. 1 .
FIG. 3 is a perspective view of a foldable rollator, with one side frame in a folded position and a second side frame in an unfolded position.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which an exemplary embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is 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.
Referring now to the drawings wherein the showings are for purposes of illustrating an exemplary embodiment of the invention only and not for purposes of limiting same, FIG. 1 shows a walker 10 which includes a pair of spaced side frames 12 and 14 and a cross brace 16 for connecting the two side frames. Side frames 12 and 14 , and cross brace 16 can be made from a lightweight and sturdy metallic material such as conventional aluminum or steel. Preferably, the metallic material of the side frames and cross brace is tubular in nature to reduce the weight of the walker. Since the right side frame 14 is identical to left side frame 12 , the description of the two is identical. Thus only the left side frame 12 will be described in detail herein.
The left side frame 12 includes a top substantially horizontal support arm joining substantially vertical front and rear legs 20 and 22 . A non-sliding hand grip 24 fits snugly around the horizontal support arm 18 . The hand grip 24 is preferably formed from a suitable conventional polymeric material.
Releasably connected to the ends of the front and rear tubular legs 20 and 22 are front and rear telescoping tubular leg extensions 26 and 28 , respectively. These telescoping extensions allow the walker to be adjusted in accordance with the height of the individual user. The telescoping extensions are connected to the legs using a snap button and corresponding biasing spring (not shown in the drawings). Because use of snap buttons and biasing springs to provide for walker legs having adjustable lengths is very well known in the art, details of the snap buttons and biasing springs will not be described for reasons of simplicity.
A crutch tip 50 is adapted to fit on the ground-engaging ends of the tubular leg extensions 26 , 28 to prevent sliding movement between the walker 10 and the ground. In contrast to the metallic nature of the cross brace 16 and the side frames 12 and 14 , crutch tips 50 are preferably made from a suitable conventional thermoplastic material.
A side brace 54 is connected between legs 20 and 22 of each side frame 12 and 14 to prevent a spreading of the legs 20 and 22 of the walker 10 when the walker 10 is supporting the weight of the user.
The cross brace section 16 comprises a cross bar connected to a pair of substantially vertical end sleeves 60 and 62 which snugly embrace and surround intermediate portions of the front legs 20 of side frames 12 and 14 , respectively.
For convenience of handling and storage, each side frame 12 and 14 may be folded inwardly relative to the cross brace 16 as shown by arrow A in FIG. 1 with respect to side frame 12 . Yet, to make the walker stable during use, the side frames 12 and 14 are required to be locked to the end sleeves 60 and 62 , respectively, to prevent rotation when in the operative, open position as shown in FIG. 1 with respect to side frame 14 .
Accordingly, a novel locking assembly 70 cooperates with each of the front legs 20 and its associated end sleeves 60 , 62 to lock the walker in its operative position, as shown in FIG. 1 for side frame 14 , or to enable the walker to be relatively easily folded into its folded, storage position, as shown in FIG. 1 for side frame 12 . The locking assembly will be described only with respect to right side frame 14 and end sleeve 62 . However, it should be appreciated that an identical locking assembly is provided for left side frame 12 and end sleeve 60 .
FIG. 2 illustrates the locking assembly 70 in an exploded perspective form. The locking assembly 70 may include a locking pin 72 formed of a suitable metallic material extending through a pin bore 74 of a pin housing 76 . A connecting rod 86 engages with a portion of locking pin 72 and is utilized to control the position of locking pin 72 within pin bore 74 . For example, connecting rod 86 engages with a portion of locking pin 72 somewhat proximal to end 78 thereof. It is understood that connecting rod 86 may engage with another portion of locking pin 72 . In the exemplary embodiment shown in FIG. 2 , connecting rod 86 is pivotally connected to locking pin 72 .
A locking end 88 of locking pin 72 is adapted to snugly extend through an opening 90 of a lock plate 92 to lock front leg 20 and end sleeve 60 together and retain the walker in the operative, open position. It will be appreciated that the lock plate 92 is fixedly attached, such as by welding, to the outer periphery of end sleeve 60 and extends substantially normal thereto. A biasing spring 94 may surround some or all of the locking pin 72 within the pin bore 74 . The spring has a first end 96 which may sit on a pin shoulder seat 98 and a second end 100 which abuts an inner shoulder of the pin bore 74 . The biasing spring 94 normally urges the pin locking end 88 into the lock plate opening 90 when they are aligned as shown in FIG. 2 .
The pin housing 76 is generally cylindrical having a longitudinal bore 104 extending therethrough and adapted to receive the front leg 20 . Pin housing 76 may include a recess 106 defined along an upper edge of pin housing 76 and dimensioned to receive a pivot extension. Recess 106 cooperates with the pivot extension to provide a fulcrum about which an actuating lever 84 may rotate. Fasteners in the form of pop rivets (not shown) or the like may extend through pin housing 76 and the side frame so as to provide a rigid connection there between. It should be appreciated that the locking assembly prevents any upward sliding motion of the cross brace 16 .
The actuating lever 84 may include pivot extension 112 that extends from a housing attach end 122 of actuating lever 84 . Pivot extension 112 engages with recess 106 of pin housing 76 so as to provide a fulcrum of actuating lever 84 , as described above. Pivot extension 112 may, for example, have a bulbous shape and be capable of movement within recess 106 so that actuating lever 84 may also have a transverse bore 118 which is aligned with the housing bore 104 to accommodate the front leg 20 . The bore 118 is sized or otherwise configured to allow actuating lever rotation about the previously described fulcrum while the tubular front leg 20 is extended there through.
Connecting rod 86 may be connected between actuating lever 84 and locking pin 72 . An end of connecting rod 86 may be pivotally attached to a portion of actuating lever 84 between handle portion 120 and housing attach end 122 of actuating lever 84 . To unlock front leg 20 from end sleeve 60 , locking pin 72 must be pulled upwardly so that the locking end 88 thereof is completely removed from the lock plate opening 90 . This action is accomplished by conveniently and efficiently pulling upwardly, using finger-applied pressure, on handle portion 120 of the actuating lever 84 . This, in turn, causes connecting rod 86 to be pulled in a substantially upward direction so as to raise the locking pin 72 within pin bore 74 . Once the locking pin 72 is completely withdrawn from the lock plate opening 90 , front leg 20 may then be rotated by the patient using hand-applied pressure onto hand grip 24 of the side frame 14 until the side frame 14 is in the folded position. In this way, the right side frame 14 can be folded substantially against the cross brace 16 , since the locking end 88 of locking pin 72 will merely slide over the flat surface of the lock plate 92 and not be fixed thereto.
As illustrated in FIG. 1 , the handle portion 120 of actuating lever 84 extends beneath hand grip 24 . Because of the proximity between the handle portion 120 and hand grip 24 , a handicapped user need only to extend one or more of his/her fingers so as to engage with the handle portion 120 while the palm and thumb of the same hand continue to engage with the hand grip 24 . During this time, the user of the walker may continue to use the walker as a support device and will be less likely to lose his/her balance when folding the walker. When the handle portion 120 is manipulated, the corresponding side frame may be folded inwardly while the user's hand continues to grasp the hand grip 24 of the side frame. In this way, the locking assembly 70 may be actuated and the corresponding side frame may be placed in the folding position without the user having to release his/her grip on hand grip 24 .
Thus, it is very easy and convenient for the handicapped person to release the locking pins 72 and rotate the side frames 12 and 14 from their open operable positions to their folded storage positions. The folded walker can easily be unfolded by rotating the side frames 12 , 14 outwardly until the respective locking pin 72 snaps into the respective lock plate opening 90 .
FIG. 3 shows a rollator 210 which includes a pair of spaced side frames 212 and 214 and a cross brace 216 for connecting the two side frames. Side frames 212 and 214 , and cross brace 216 can be made from a lightweight and sturdy metallic material such as conventional aluminum or steel. Preferably, the metallic material of the side frames and cross brace is tubular in nature to reduce the weight of the rollator. The right side frame 214 is identical to left side frame 212 .
The left side frame 212 includes a top substantially horizontal support arm 218 joining substantially vertical front and rear legs 220 and 222 . A non-sliding hand grip 224 fits snugly around the horizontal support arm 218 . The hand grip 224 is preferably formed from a suitable conventional polymeric material.
Releasably connected to the ends of the front and rear tubular legs 220 and 222 are front and rear telescoping tubular leg extensions 226 and 228 , respectively. These telescoping extensions allow the rollator to be adjusted in accordance with the height of the individual user. The telescoping extensions can be connected to the legs using a snap button and corresponding biasing spring (not shown in the drawings), which are well known in the art.
Forward wheels 250 are attached to the ends of the tubular leg extensions 226 , and are pivotable with respect thereto to allow a user to steer the rollator 210 in any desired direction. Rear wheels 251 are attached to the ends of the tubular leg extensions 228 , and could be fixedly or pivotally attached thereto. The rollator 210 could be provided with forward wheels only, i.e., no rear wheels, as is known in the art. A wheel locking device 253 could be provided on the wheels 251 to prevent movement of the rollator 210 .
A side brace 254 is connected between legs 220 and 222 of each side frame 212 , 214 . The side brace 254 reinforces the side frame 212 to prevent spreading of the legs 220 and 222 of the 210 when the rollator 210 is supporting the weight of the user.
The cross brace section 216 comprises a cross bar connected to a pair of substantially vertical end sleeves 260 and 262 which snugly embrace and surround intermediate portions of the front legs 220 of side frames 212 and 214 , respectively.
For convenience of handling and storage, each side frame 212 and 214 may be folded inwardly relative to the cross brace 216 as shown in FIG. 3 with respect to side frame 212 . Yet, to make the rollator stable during use, the side frames 212 and 214 are locked to the end sleeves 260 and 262 , respectively, to prevent rotation when in the operative, open position as shown in FIG. 3 with respect to side frame 214 .
The locking assembly 270 , which can be the same as shown in FIG. 2 and described herein, cooperates with each of the front legs 220 and its associated end sleeves 260 , 262 to lock the rollator in its operative position, as shown in FIG. 3 for side frame 214 , or to enable the rollator to be relatively easily folded into its folded, storage position, as shown by arrow B in FIG. 3 for side frame 212 . The locking assembly can be actuated by a user extending one or more fingers to engage the handle portion 284 to pull up the handle to unlock the side frames 212 , 214 and permit them to pivot to a flat position against the cross brace 216 .
The present invention also provides a method for folding a foldable rollator. The method comprises the steps of holding the hand grips of the first and second side frames; grasping first and second handles of the first and second locking assemblies; pulling the first and second handles up towards the hand grips to unlock the first and second locking assemblies; and rotating the first and second side frames toward the cross brace and into a folded position. Further, the method can include the step of unfolding the rollator for use, comprising rotating the first and second side frames away from the cross brace into locked positions substantially perpendicular to the cross brace. When the handles are pulled upward, the locking pins are removed from the locking plates of the first and second assemblies by the actuating levers to unlock the assemblies
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A locking assembly is disclosed for use with a walker or a rollator having foldable side members. The locking assembly includes a locking pin movable between a first position in which the corresponding side member is held in a locked, unfolded state and a second position in which the side member is in an unlocked, folded state. A lock plate extends transversely to the longitudinal axis of the corresponding side member, and includes an aperture adapted to receive a locking end of the locking pin when the pin is in its first position. A lever is coupled to the locking pin such that when the lever is pivoted by upwardly applied pressure, the locking pin is moved from its first position to its second position to permit rotation of the corresponding side member to its folded state. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to an energy plant for exploiting geothermal energy by circulating a fluid such as water through a geological formation. The invention also relates to a method for establishing a geothermal energy plant.
BACKGROUND
[0002] Even in regions of the world that are not geologically active, the vertical temperature gradient in the earth crust usually exceeds 20° C./km Hence at a depth of 5000 m, rock temperatures exceeding 100° C. are expected. There are large geographical variations. In some areas not considered geologically active, thermal gradients in the crust exceed the indicated number by a factor of two or more. Gradients lower than 20° C./km appear to be uncommon. High gradients are typically experienced where insulating layers of rock are stacked on top of heat producing rock or intrusions of eruptive rock. Hot Dry Rock (HDR) is rock formations with low porosity and with no natural aquifers. In such rocks heat transfer takes place mainly through conduction. Given the very low conductivity of most types of rock, heat transfer must be expected to be low in the rock. Therefore, efficient methods must be devised in order to extract heat from the rock.
[0003] Several methods for exploiting the significant thermal energy stored in HDR formations have been proposed and tested. The most common method consists of drilling one or more water injection holes and a production hole at a different location. By fracturing the rock between the injection and production holes, a closed circuit for water flow can be established in the rock. While drilling costs can be lower than for many alternatives, there are several practical challenges related to the proposed methods. First, it is difficult to control the fracturing process and thereby the establishment of the heat exchanger in the geological formation. Second, water flow in the heat exchanger is difficult to control and optimize as the water will tend to follow the path of least hydraulic resistance and not the path for optimal heat production. Thirdly, the fractured volume is difficult to maintain as the fractures may get clogged and cannot easily be re-opened. Research and development of fractured rock designs has been pursued for half a century with limited practical success.
[0004] Recently, methods for extraction of energy from HDR formations depending heavily on drilling technology have been proposed. US 2007/0245729 A1, DE 10 2005 036 472, EP 1 995 457, US 2007/02457729 A1, US 2011/0048005 A1 and US 2011/0061382 A1 describe energy plants applicable for HDR, essentially producing from a set of separate wells with supply and return holes widely separated and connected by single horizontal production holes.
[0005] A large number of wells are needed to allow a reasonable large heat output, and supply and return holes widely separated would give a rather impractical plant design. In U.S. Pat. No. 5,515,679, U.S. Pat. No. 7,251,938, and U.S. Pat. No. 6,247,313 the hot liquid is returned through a common return hole, and injection and return holes need not be separated. US2011/0067399 A1, CA2679905 A1, , DE 43 19 111 A1, US2008/0169084 A1 and WO 2010/021618 A1 describe energy plants applicable for HDR consisting of single wells with integrated supply, production and return holes. The wells consist of single a hole with an internal pipe separating water flow downward and upward water flow. The water is injected in the outer annulus and is gradually heated until reaching the lower end of the pipe where it returns in the inner pipe or vice versa. An alternative version of such a well is given in U.S. Pat. No. 6,000,471 where water injection and return takes place through separate holes, a more expensive alternative. The challenge for all such solutions is to ensure sufficient heat transfer from the rock. A large number of such wells would be required in order to obtain a satisfactory amount of energy output. With significant cost of drilling it would be impractical to establish multiple injection and return wells. Alternatively the method must be combined with fracturing of the rock and to ensure circulation of fluid in the rock. As discussed above, U.S. Pat. No. 6,247,313 describes a geothermal energy plant for HDR formations consisting of multiple production holes and at least one supply and one return hole. The energy plant offers the solution to many of the challenges related to the previously presented inventions. Heat is efficiently being extracted from the rock formation by optimized spacing of production holes. Drilling costs are kept reasonably low by reducing the number of supply and return holes. The concept assumes at least one supply and one return hole. Furthermore, the production holes are assumed to be inclined between 20 and 50 degrees relative to the vertical axis.
[0006] Whereas HDR can most efficiently be established through drilling of a set of multiple production holes through the rock formation, it is important to minimize drilling costs. Typically drilling cost constitutes 90% of the cost of establishing the geothermal plant. Supply and return holes are particularly expensive to drill and do not contribute much to heat production. Hence their length should be minimized.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a geothermal energy plant design combining the supply and return holes and thereby allowing a significant reduction of drilling cost and risk related to plant manufacture. Further cost reduction is allowed by the invention as drilling patterns are optimized with respect to energy output versus drilling costs. Two complementary concepts are presented. In rock formations with high temperature gradients a design with essentially “vertical” production holes can be advantageous due to the simplicity with which the plant can be established. In rock with relatively low temperature gradients energy output is optimized and total cost is reduced by making production holes essentially “horizontal”. However, the two concepts, or some combination of the two, are applicable for both low and high temperature gradients, and the design will be chosen based on the actual application and operating conditions of the plant. A method for establishing the presented design of a geothermal energy plant is also claimed.
[0008] These and further advantages can be achieved with the invention as defined by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will be further explained by Figures and examples where:
[0010] FIG. 1 shows a schematic cross-section of a geothermal energy plant designed for areas with high thermal gradients,
[0011] FIG. 2 shows a three-dimensional drawing of the geothermal energy plant described in FIG. 1 ,
[0012] FIG. 3 shows an alternative three-dimensional drawing of the geothermal energy plant described in FIG. 1 ,
[0013] FIG. 4 shows a schematic cross-section of an alternative geothermal energy plant designed for areas with high thermal gradients,
[0014] FIG. 5 shows a three-dimensional drawing of the geothermal energy plant described in FIG. 4 ,
[0015] FIG. 6 shows an alternative three-dimensional drawing of the geothermal energy plant described in FIG. 4 ,
[0016] FIG. 7 shows a schematic cross-section of a geothermal energy plant designed for areas with low thermal gradients,
[0017] FIG. 8 shows drilling of the combined supply and return center hole common to all the energy plant designs described in this document,
[0018] FIG. 9 shows the sidetrack drilling of one of the lower production holes for the energy plant described in FIG. 7 ,
[0019] FIG. 10 shows the sidetrack drilling of one of the upper production holes for the energy plant described in FIG. 7 ,
[0020] FIG. 11 shows a schematic cross-section of an alternative geothermal energy plant designed for areas with low thermal gradients,
[0021] FIG. 12 shows a three-dimensional drawing of the geothermal energy plant described in FIG. 7 and FIG. 11 ,
[0022] FIG. 13 shows an alternative three-dimensional drawing of the geothermal energy plant described in FIG. 7 and FIG. 11 ,
[0023] FIG. 14 shows an alternative three-dimensional drawing of the geothermal energy plant described in FIG. 7 and FIG. 11 ,
[0024] FIG. 15 shows a schematic cross-section of an alternative geothermal energy plant designed for areas with low thermal gradients,
[0025] FIG. 16 shows a three-dimensional drawing of the geothermal energy plant described in FIG. 15 ,
[0026] FIG. 17 shows an alternative three-dimensional drawing of the geothermal energy plant described in FIG. 15 ,
[0027] FIG. 18 shows drilling of the lower part of the return hole for the energy plant described in FIG. 15 ,
[0028] FIG. 19 shows the sidetrack drilling of one of the lower production holes for the energy plant described in FIG. 15 ,
[0029] FIG. 20 shows the sidetrack drilling of another of the lower production holes for the energy plant described in FIG. 15 ,
[0030] FIG. 21 shows the sidetrack drilling of one of the upper production holes for the energy plant described in FIG. 15 ,
[0031] FIG. 22 shows the sidetrack drilling of another of the upper production holes for the energy plant described in FIG. 15 ,
[0032] FIG. 23 shows the installation of the insulating pipe separating supply and return flows for the energy plant described in FIG. 15 ,
[0033] FIG. 24 shows a schematic cross-section of an alternative geothermal energy plant designed for areas with low thermal gradients,
[0034] FIG. 25 shows a schematic cross-section of an alternative geothermal energy plant designed for areas with low thermal gradients,
[0035] FIG. 26 shows the concept related to “horizontal” production holes,
[0036] FIG. 27 shows the concept related to “vertical” production holes.
DETAILED DESCRIPTION OF THE INVENTION
[0037] FIG. 26 illustrates the concept related to “horizontal” production holes, while FIG. 27 illustrates the concept related to “vertical” production holes. The main feature common to both concepts is the combined supply and return hole consisting of the borehole with an inner insulated pipe and a seal in the annular space separating the supply fluid flow from the return fluid flow. The insulated pipe can, for example, be a metal pipe with an outer layer of thermally insulating material or consist of only thermally insulating material. There exist various types of seals that can be used. The borehole is extended below the seal with the same or a smaller diameter hole forming a part of the return fluid flow. Casing in the upper part of the borehole is installed as required.
[0038] In FIG. 26 the production holes are drilled with an essential horizontal pattern near the bottom of the borehole giving the highest rock temperature and energy output per meter of production hole.
[0039] In FIG. 27 the production holes are drilled with an essentially vertical pattern starting higher up in the borehole where the rock temperature is lower and the energy output per meter of the production hole will be lower than the corresponding values in the concept shown in FIG. 26 . Depending on the operating conditions the energy output per meter of the production hole for the concept with the horizontal pattern can be 30 to 40% or more higher than the corresponding output for the concept with a vertical pattern.
[0040] The combined supply and return hole together with the production holes form a closed loop for the fluid flow as illustrated by the arrows.
[0041] The number of production holes will be adjusted according to the total energy output requirement from the plant. Typically the borehole can be 5000 meters deep and the production holes 2000 meters long with a 10 to 20 centimeter diameter. For a thermal energy output of say 2000 kilowatts the borehole diameter is typically 30 to 35 centimeters.
[0042] FIG. 1 shows a schematic cross-section drawing of an energy plant for rock R regions with high thermal gradients. The well consists of a combined supply hole 20 and return hole 1 indicated by 22 , 22 ′ extending from the surface S to a first manifold zone 8 at a given design depth of typically several thousand meters. A casing is shown at 21 . The combined hole below the casing is denoted 22 ′, while its extension corresponding to the casing is denoted 22 . Several production holes ‘P’ 3 , 4 and the return hole 1 ′ extend from the manifold zone 8 to the lowermost part of the plant where they merge in a second manifold zone 9 . The length of the production holes must be determined based on the local thermal gradient and the required energy-output. The length is typically several hundred or a few thousand meters long. The holes may be perfectly vertical or inclined relative to the vertical. Fracturing may be performed at the bottom of the well to produce a closed circuit. While there may be several production holes ‘P’ 3 , 4 ; 3 ′, 4 ′, there is only one return hole 1 , 1 ′. The diameter of the return hole may be larger than those of the production holes. As there are several production holes ‘P’, the water volume passing through the return hole needs to be several times the volume passing through a single production hole. The uppermost part of the return hole 1 is separated from the supply hole 20 by a pipe 5 . The supply hole 20 is formed as an annulus supplying the cold water. The annulus is formed by a pipe 5 consisting of an insulating material or a metallic pipe provided with insulation and separates the return hole 1 and the supply hole 20 .
[0043] For the proposed design the diameter of the lower part of the return hole 1 ′, i.e. the part below the manifold zone 8 need to be less than that of the combined supply and return hole 22 , 22 ′. In the transition between the lowermost supply hole and the combined return and supply hole there can be placed an anchor 6 for a whip-stock (not shown) under its manufacture. This anchor is designed in such a way that it is possible to drill through it or guide tubing or similar through it, for example for the purpose of cleaning the holes. The anchor can also include a seal 66 separating and isolating the supply and return flows. In one alternative, the anchor can be removed and be replaced with a seal 66 to seal off the annulus (supply hole 20 ) between the pipe 5 and the combined hole 22 ′. In the annulus between the pipe 5 and the combined hole 22 , there can be arranged spacers to stabilize the pipe 5 (not shown).
[0044] FIG. 2 shows a three dimensional schematic drawing of the same type of plant design as shown in FIG. 1 . The lower return hole 1 ′ and the combined supply and return hole 22 , 22 ′ are in the center of the plant. A casing 21 supports the walls of the combined supply and return hole. The production holes ‘P’ 3 , 4 surround the lower part of the return hole 1 ′. The design need not be symmetric nor do the holes need to be spaced at regular intervals around a circumference. The manifold zone is slightly indicated at pos. 8 . The holes should however be spaced more than 50 m apart to ensure optimal energy output during the entire life of the plant. The holes merge in a manifold zone 9 . The combined supply and return hole 22 , 22 ′ extends to the earth's surface S. At the surface there is a energy plant that includes a circulation pump 10 and a heat exchanger 19 . Hot liquid (water) is distributed to heat consuming appliances such as a radiator 18 , a warm air heater 17 and a hot water tank 16 . The hot liquid (water) provided by the well could also be used in heat pumps. Generation of electricity can be an option.
[0045] FIG. 3 shows an alternative three-dimensional drawing of the plant design shown in FIG. 1 . The lower return hole 1 ′ and the combined supply and return hole 22 , 22 ′ are in the center of the plant and forms a central hole. A casing 21 supports the walls of the combined supply and return hole 22 . For this application multiple production holes ‘P’ 3 , 4 branch out 12 from each of the original branches from the manifold zone 8 of the combined supply and return hole 22 , 22 ′. This may be achieved by using a whip-stock which is common technology in oil well drilling. It is also possible to establish the proposed design by branching production holes directly out from the center hole using only one whip-stock in the center hole. A large number of production holes can be arranged in such a parallel manner, and the plant design is expandable. Neither the return hole 1 ′ nor the production holes ‘P’ 3 , 4 need to be vertical as shown in the figure, but rather inclined relative to the vertical in some way. The production holes need not converge at the return hole at the same position in a manifold zone 9 . Fracturing may be employed to enhance circulation and simplify plant completion. The combined supply and return hole extends to the earth's surface S. Topside items 10 , 16 - 19 are the same as for FIG. 2 .
[0046] FIG. 4 shows a schematic cross-section drawing of an alternative energy plant for regions with high thermal gradients. The well also consists of a combined supply and return hole extending from the surface to a manifold zone 8 at a given design depth of typically several thousand meters. Several production holes ‘P’ 33 ′ & 33 , 34 ′ & 34 and the return hole 1 , 1 ′ extend from the manifold zone 8 to the lowermost part of the plant where they merge in a manifold zone 9 . The length of the production holes must be determined based on the local thermal gradient and the required energy-output. However, production holes may typically extend a few thousand meters. The holes may be perfectly vertical or inclined. While there may be several production holes there is only one return hole. The diameter of the return hole may be larger than those of the production holes. The water volume passing through the return hole needs to be several times the volume passing through a single production hole. The uppermost part of the return hole 1 is isolated from the annulus 20 supplying the cold water by a pipe 5 comprising thermally insulating material. For the proposed design the diameter of the lower part of the return hole 1 ′ need to be less than that of the combined supply and return holes. In the transition between the lowermost supply hole and the combined return and supply hole there is an anchor 6 for a whip stock. This anchor must be designed in such a way that it makes it possible to drill through it or guide tubing or similar through it. Further, a seal 66 is arranged to separate the supply and return flows. At the bottom of the central hole there is another whip stock 29 ′ supported by anchor 6 ′ allowing drilling of lower holes 33 , 34 meeting upper holes 33 ′, 34 ′ in connection points 11 , 11 ′. In the case that the production holes are mainly vertically aligned, it would not be feasible to use a single whip stock to produce lower and upper holes, because it would be too long. The hole connecting the production and return holes may be inclined relative to the horizontal. Fracturing may be performed at the connection points 11 , 11 ′ to ensure a closed circuit.
[0047] FIG. 5 shows a three-dimensional application of the design presented in FIG. 4 . There is a common supply and return hole 22 , 22 ′ partly protected by a casing 21 extending to a pre-defined depth. The casing may not be required in non-porous rock. Below the casing production holes depart from the central hole in sidetracks drilled using a whip stock in different positions. For the design shown in FIG. 5 when viewing from the top the production holes ‘P’ 33 ′ & 33 , 34 ′ & 34 are placed on a circle surrounding the central return hole 1 ′. As in FIG. 4 , there is shown connection points 11 , 11 ′ between lower holes 33 , 34 and holes 33 ′, 34 ′. Other designs and configurations could also be used. Topside items 10 , 16 - 19 describe the top side energy plant in the same way as in FIG. 2 .
[0048] FIG. 6 shows an alternative three-dimensional design of the energy plant presented in FIG. 4 . For this geometry fewer holes are initially side-tracked from the central hole, but new side-tracking is then subsequently performed from the holes running from the initial side-tracks as shown in 12 . The same approach is applied for the holes 33 running from the end of the return hole 1 ′ to the mainly vertical holes 33 ′. Hole 33 ′ could also be sidetracked directly from the central hole, i.e. the hole that after installation represents the common hole 22 , 22 ′, removing the need for multiple side tracking. Items 10 , 16 - 19 describe the top side energy plant in the same way as in FIG. 2 .
[0049] FIG. 7 shows a schematic cross-section drawing of an energy plant for regions with low thermal gradients. In such cases it is advantageous to make production holes as close to horizontal as possible to optimize heat production. The well consists of a combined supply and return hole 22 , 22 ′ extending from the surface to a manifold zone 8 at a given design depth of typically several thousand meters. (The drilling of the well and how it is established is described in more details in FIG. 8-10 ). Several production holes ‘P’ 33 ′ & 33 , 34 ′ & 34 and the return hole 1 ′ extend from the manifold zone 8 to the lowermost part of the plant where they merge in a manifold zone 9 . The length of the production holes must be determined based on the local thermal gradient and the required energy-output. The typical length of a production hole exceeds thousand meters. The holes are inclined, but may in the case of low thermal gradients be mainly horizontally directed. While there may be several production holes there is only one return hole. The uppermost part of the return hole 1 is isolated from the annulus supplying the cold water by a pipe 5 comprising a thermally insulating material. In the transition between the lowermost supply hole and the combined return and supply hole there is a seal 66 preventing return flow from merging with the supply flow. The upper 33 ′ 34 ′ and lower 33 , 34 holes are in most cases closely spaced for this design (typically a few hundred meters or less), and merged in connections 11 , 11 ′. The holes 33 , 34 connecting the upper holes and return hole may be inclined relative to the horizontal. Fracturing may be performed at the connection points 11 , 11 ′ to ensure closing of the circulation circuit.
[0050] FIG. 8 shows drilling of the combined supply and return center hole 22 , 22 ′ common to all the energy plant designs described in this document. The drill for hole 22 ′ is shown as item 51 while the casing supporting the drilled hole 22 is shown as item 21 . The extension of the casing will be determined based upon the characteristics of the ground to be drilled in. In particular if there are layers of loose rock or gravel a casing is necessary to keep the combined supply and return hole free of foreign matters. The casing may be made with an insulating material. It should be understood that the diameter of the drill when drilling hole 22 ′ need to be adapted to that of the casing. In this embodiment, the combined hole 22 ′ extends beyond the casing 21 in order to allow for side-track drilling at different depths. The surface is indicated at S, the rock at R. A drill string is shown at 52 .
[0051] FIG. 9 shows the application of a smaller drill 51 ′ and drill string 52 ′ during drilling of one of the lower production holes 34 . The larger drill 51 and drill string 52 shown in FIG. 8 have been retracted. A whip-stock 29 ′ and anchor 6 ′ has been placed in the lowermost part of the return hole to allow sidetracking at different positions. In the Figure, it is shown that the drill 51 ′ can be guided to the side and downwards by the geometry of the whip-stock. A casing is shown at pos 21 .
[0052] FIG. 10 shows the drill 51 ′ and drill string 52 ′ during drilling one of the upper holes 34 ′. The drill and string and also the whip-stock shown in FIG. 9 have been retracted. Following this, a whip-stock 29 that represent an assembly with a larger vertical extension than that shown in FIG. 9 is installed. This allows sidetrack drilling at a given vertical position. By this arrangement, an uppermost hole 34 ′ can be drilled towards a lowermost hole 34 using one of several existing techniques for guided drilling. A completed circulation path or production hole ‘P’ is shown with an upper hole 33 ′ and a lower hole 33 . At the connection point 11 local fracturing may ensure efficient circulation.
[0053] For the completion of the installation, i.e. to become as that disclosed in FIG. 7 , the drill string and drill are retracted and the whip-stock is removed. The anchor can be left in the bore and a shorter whip-stock 29 ′ can be put in. Then the pipe 5 can be installed into the combined supply and return center hole 22 , 22 ′. The end of the pipe 5 ends somewhere between the upper ends of the upper holes 33 ′, 34 ′ and the upper ends of the lower holes 33 , 34 , whereby the pipe 5 is sealed against the wall of the bore 1 ′ by means of a seal 66 to separate the supply and return flows in production holes ‘P’ 33 ′ & 33 , 34 ′ & 34 respectively. In this manner a manifold zone 8 can be created.
[0054] FIG. 11 shows a schematic cross-section drawing of an alternative energy plant for regions with low thermal gradients. Similar to that of the plant shown in FIG. 7 , the well also consists of a combined supply and return hole 22 , 22 ′ extending from the surface to a manifold zone 8 at a given design depth of typically several thousand meters. Several production holes 33 ′ & 33 , 34 ′ & 34 and the return hole 1 ′ extend from the manifold zone 8 to the lowermost part of the plant where they merge in a lower manifold 9 . The uppermost part of the return hole 1 is when the installation has been completed, insulated from the annulus supplying the cold water by a pipe 5 comprising an insulating material.
[0055] For this proposed design the diameter of the lower part of the return hole 1 ′ is made smaller than that of the combined supply and return hole 22 , 22 ′. This makes it possible to reduce the drilling costs. In the transition between the lowermost part of the combined return and supply hole 22 , 22 ′ there is an anchor 6 for a whip stock. This anchor is designed in such a way that it is possible to drill through it or guide tubing or similar through it. Preferably, this is done before the pipe 5 is installed. At the bottom of the return hole there is a whip-stock 29 ′ allowing drilling of lower holes 33 , 34 meeting holes 33 ′, 33 in connections 11 , 11 ′. The holes ( 33 , 34 ) connecting the upper holes 33 ′, 34 ′ and return hole 1 ′ may be inclined relative to the horizontal. When the assembly is completed, the whip-stock and the anchor can be removed, and the insulated pipe 5 can be installed with a seal 66 at its lower part that separates the supply and return flows.
[0056] FIG. 12 shows a three-dimensional design of the energy plant presented in FIG. 7 and FIG. 11 . Production holes ‘P’ 33 & 33 ′ are side-tracked from the combined supply and return hole 22 ′. The return hole 1 ′ extends further. At the bottom of the plant the lower holes 33 are side-tracked from the return hole 1 ′. Topside items 10 , 16 - 19 describe the top side energy plant in the same way as in FIG. 3 . The length of the production holes may be several thousand meters. The inclination of the production holes may be close to horizontal and the holes may be curved in either the shown direction or preferably in the opposite direction. A casing is shown at pos. 21 .
[0057] FIG. 13 shows an alternative three-dimensional design of the energy plant presented in FIG. 7 and FIG. 11 . Upper holes 33 ′ are side-tracked from the combined supply and return hole 22 ′. Further sidetracking is subsequently performed in order to allow the production holes to extend parallel to great depth. The return hole 1 ′ extends further after side-tracking. At the bottom of the plant the lower holes 33 are side-tracked from the return hole 1 ′. Further side-tracking is performed in order to extend holes further and to allow the lower part of the production holes to meet up with the upper part of the production holes. Both for the upper and lower part of the production holes it is also possible to establish the design by only performing side-tracking once from the center hole. Topside items 10 , 16 - 19 describe the top side energy plant in the same way as in FIG. 3 . A casing is shown at pos. 21 .
[0058] FIG. 14 shows an alternative three-dimensional design of the energy plant presented in FIG. 7 and FIG. 11 . Upper holes 33 ′ are side-tracked from the combined supply and return hole 22 ′. However, for this design there is only one upper production/supply hole 33 ′ for each set of lower production holes 133 ′, 133 ″, 133 ′″, 133 ′″. The return hole 1 ′ extends further after side-tracking. At the bottom of the plant the lower holes 133 ′, 133 ″, 133 ′″, 133 ″″ are side-tracked from the return hole 1 ′. Further side-tracking is performed in order to extend holes further and to allow the lower part of the production holes to meet up with the upper part of the production holes. Items 10 , 16 - 19 describe the top side energy plant in the same way as in FIG. 2 .
[0059] FIG. 15 shows an alternative schematic cross-section drawing of the energy plant for regions with low thermal gradients. The well consists of a combined supply and return hole 22 , 22 ′ extending from the surface to a manifold zone 8 at a given design depth of typically several thousand meters. Several production holes ‘P’ 33 ′ & 33 . 34 ′ & 34 and the return hole 1 ′ extend from the manifold zone to the lowermost part of the plant where they merge in a manifold zone 9 . The uppermost part of the return hole 1 is separated from the annulus 20 supplying the cold water by a pipe 5 comprising an insulating material and further provided with a seal 66 . For the proposed design the diameter of the lower part of the return hole 1 ′ is less than that of the combined supply and return holes. In the transition between the lowermost combined return and supply hole 22 ′ and return hole 1 ′ there is an anchor 6 for a whip stock. This anchor is designed in such a way that it makes it possible to drill through it or guide tubing or similar through it. At the bottom of the central hole there is a whip stock 29 ′ allowing drilling of lower holes 33 , 34 meeting holes 33 ′, 34 ′ in connection points 11 , 11 ′. The holes 33 , 34 connecting the upper holes 33 ′, 34 ′ and return hole 1 ′ may be inclined relative to the horizontal.
[0060] FIG. 16 shows a three-dimensional design of the energy plant presented in FIG. 15 . Production holes 3 are side-tracked from the combined supply and return hole 22 , 22 ′. The return hole 1 ′ extends further. At the bottom of the plant the lower production holes 34 are side-tracked from the return hole 1 ′. Topside items 10 , 16 - 19 describe the top side energy plant in the same way as in FIG. 2 .
[0061] FIG. 17 shows an alternative three-dimensional design of the energy plant presented in FIG. 15 . Upper holes 34 ′ are side-tracked from the combined supply and return hole 22 ′.
[0062] The return hole 1 ′ extends further. At the bottom of the plant a lower hole 12 is side-tracked from the return hole 1 ′. The lower holes 133 ′, 133 ″, 133 ′″, 133 ″″ are further side-tracked to allow for parallel flow paths through the rock. Items 10 , 16 - 19 describe the top side energy plant in the same way as in FIG. 2 .
[0063] FIGS. 18-23 show the process of establishing the energy plant shown in FIG. 17 . FIG. 18 shows drilling of the lower part of the return hole 1 ′. Item 51 ′ is the drill, item 21 is the casing, item 52 ′ the drill string. FIG. 19 shows side-track drilling to establish a lower hole 34 . Item 29 ′ is a whip-stock and item 6 ′ an anchor. A second lower hole 33 is drilled in FIG. 20 . FIG. 21 shows the drilling of an upper hole 33 ′ to meet up with the lower hole 33 . A removable whip-stock 29 is applied in order to allow side-track drilling of the upper hole. Item 51 ′ is the drill. In FIG. 22 a second upper hole 34 ′ is drilled 51 ′ in order to meet the lower hole 34 . The whip-stock 29 is in an upper position. FIG. 23 shows the installation of an insulating pipe 5 separating the supply and return flow by creating an annulus 20 for supply and a return hole 1 . After installation of the pipe, the seal is installed.
[0064] FIG. 24 shows a schematic cross-section drawing of an alternative energy plant for regions with low thermal gradients. The main difference between this design and the design described in FIG. 15 is the sidetracking 100 performed at the bottom of the common supply and return hole 22 ′. In contrast to the solution shown in FIG. 11 and FIG. 15 , the solution shown in FIG. 24 does not require the use of a removable whip-stock 29 and an anchor which can be drilled through in case of possible extension of the plant. The solution is only relevant if the distance between the upper and lower production holes is large and separate whip-stock must be used for upper and lower production holes. The plant shown in FIG. 7 can be expanded or maintained only by removing the insulating pipe.
[0065] FIG. 25 shows an alternative three-dimensional design of the energy plants presented in FIG. 15 and FIG. 24 . The fluid is supplied through an annulus 20 of the combined supply and return hole 22 , 22 ′. Return and supply flows are separated by pipe 5 together with a seal 66 . A casing 21 prevents loss of fluid to the surroundings. The flow is guided through a side-tracked hole 44 to the side-tracked upper holes 33 ′, 34 ′. Whip-stock 29 is used for sidetracking hole 44 . Upper holes 33 ′, 34 ′ are sidetracked from hole 44 by use of whip-stock 29 ″. Lower holes 33 , 34 are connected to the return hole 1 ′ and further to the upper holes 33 ′, 34 ′ at contact points 11 , 11 ′, respectively. The return hole 1 ′ is drilled by sidetracking from hole 22 ′ and use of whip-stock 29 . By further drilling and use of whip-stock 29 ′ the lower holes 33 , 34 can be made. A side tracked hole 44 ′ between hole 22 ′ and hole 44 has a removable plug 111 that separates the supply and return flows. The advantage of the proposed solution is that the pipe 5 need not be removed during well-clean up and even plant expansion (by drilling). Only plug 111 must be removed or retrieved to gain access to the upper holes 33 ′, 34 ′. In order to gain access to the lower holes 33 , 34 the upper whip-stock 29 must be moved to a proper position.
[0066] Even though the figures all show pipes 5 which are insulated, the pipes may or may not be thermally insulated. | A plant for exploiting geothermal energy by circulating water or another fluid through a non-porous geological formation at a substantial depth below the earth surface, comprising multiple heat absorbing/production holes penetrating the said formation, with a total length of several kilometers and spaced more than 50 m apart. The production holes are connected to the surface by one single combined supply and return hole in which upward and downward flow is separated by a pipe comprising an insulating material and a seal. At the given positions of the common supply and return hole manifold zone designs connect the hole to the multiple production holes. The supply and return holes and production holes are closed circuits for transport of a fluid such as water through the said formation. A method for designing and establishing the plant is also disclosed. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a novel method for the preparation of a 1-alkynylsilyl compound or 1-alkynyl silane compound.
1-Alkynylsilyl compounds are useful as an intermediate for the synthetic preparation of various kinds of silicon-containing organic compounds. Several methods are known in the prior art for the preparation of such a 1-alkynylsilyl compound and the most typical among them is the method disclosed in Journal of the American Chemical Society, volume 74, page 4853 (1952) and Doklady Akademii Nauk S.S.S.R., volume 93, page 293 (1953), according to which a Grignard reagent 1-alkynylmagnesium bromide prepared from a 1-alkyne compound and ethylmagnesium bromide is reacted with a trihydrocarbyl monochlorosilane to cause substitution of the 1-alkynyl group for the silicon-bonded chlorine atom in the strating silane whereby a trihydrocarbyl 1-alkynylsilane is obtained.
This method is, however, not satisfactory as an industrial process because the production cost of the desired compound is high due to the low availability and expensiveness of the starting 1-alkyne compound and to the large loss of the solvent or difficulty in the recovery of the solvent which is a water-soluble solvent such as tetrahydrofuran.
SUMMARY OF THE INVENTION
An object of the present invention is therefore to provide a novel and economical method for the synthetic preparation of a 1-alkynylsilyl compound or, in particular, 1-alkynyl silane compound free from the above described problems and disadvantages in the prior art methods.
Thus, the method of the present invention for the preparation of a 1-alkynylsilyl compound comprises the steps of:
(a) reacting a hydrocarbyl-substituted acetylene compound represented by the general formula R 1 C.tbd.CH, in which R 1 is a monovalnet hydrocarbon group, or a substituted or unsubstituted allene compound represented by the general formula R 2 CH═C═CH 2 , in which R 2 is a hydrogen atom or a monovalent hydrocarbon group, with metallic sodium in an inert organic solvent to form a substituted sodium acetylide in the reaction mixture;
(b) admixing the reaction mixture with an organic polar solvent; and
(c) admixing the reaction mixture containing the substituted sodium acetylide and the organic polar solvent with a trihydrocarbyl monohalogenosilane represented by the general formula R 3 SiX, in which X is a halogen, e.g. chlorine, atom and R is a substituted or unsubstituted monovalent hydrocarbon group each independent from the others.
The 1-alkynylsilyl compound obtained by the above described method is represented by the general formula of either R 1 C.tbd.CSiR 3 or R 2 CH 2 C.tbd.CSiR 3 , in which R, R 1 and R 2 each have the meaning as defined above, according to the type of the starting compound which may be the hydrocarbyl-substituted acetylene compound or the substituted or unsubstituted allene compound, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the above described method of the present invention, the starting material may be a relatively inexpensive dienic compound such as allene, 1,2-butadiene and the like obtained in large quantities in the petrochemical industry and no disadvantageous loss of the solvent is involved in the process so that the desired 1-alkynylsilyl compound can be produced with an outstandingly low cost.
The atarting material in the inventive method belonging to one of the alternative classes is a hydrocarbyl-substituted acetylene compound represented by the general formula R 1 -CH, in which R 1 is a monovalent hydrocarbon group such as alkyl, aryl and alkenyl groups. Particular examples of such a hydrocarbyl-substituted acetylene compound include alkylacetylenes such as methylacetylene and ethylacetylene, arylacetylenes such as phenylacetylene and tolylacetylenes and alkenylacetylenes such as 4-hexen-1-yne. The starting material of the other class is a substituted or unsubstituted allene compound represented by the general formula R 2 CH═C═CH 2 , in which R 2 is a hydrogen atom or a monovalent hydrocarbon group which can be an alkyl or aryl group. Particular examples of such an allene compound include allene, 1,2-butadiene and 1,2-pentadiene.
The first step of the inventive method is the reaction of the above described starting compound with metallic sodium in an inert organic solvent to form a substituted sodium acetylide. The inert organic solvent should be an aromatic hydrocarbon solvent such as toluene and xylene, an aliphatic hydrocarbon solvent such as heptane and octane or an ether solvent such as dibutyl ether and diphenyl ether. The reaction is performed with introduction of the starting unsaturated compound, i.e. substituted acetylene or substituted or unsubstituted allene compound, by dropwise addition or by bubbling into a fine dispersion of metallic sodium in the inert organic solvent. The concentration of the metallic sodium in the organic solvent should be such that from 100 to 1000 g or, preferably, from 200 to 400 g of the organic solvent contain 1 mole, i.e. 23 g, of metallic sodium. The overall amount of metallic sodium in the dispersion should be in the range from 0.3 to 1 mole or, preperably, from 0.5 to 0.7 mole per mole of the starting unsaturated compound to be introduced into the dispersion of the metallic sodium. The reaction temperature should be in the range from 80° to 130° C. or, preferably, from 95° to 115° C. More preferably, the reaction is performed at a temperature higher than 97° C. which is the melting point of metallic sodium because the reaction velocity is greatly increased when the metallic sodium is in the molten state. A reaction temperature higher than 130° C. should be avoided because the substituted sodium acetylide as the reaction product may be decomposed at such a high temperature.
The next step of the inventive method is the reaction of the thus formed substituted sodium acetylide with a trihydrocarbyl monohalogenosilane or a trihydrocarbylsilyl halide of the formula R 3 SiX, in which R and X each have the meaning defined above. In this case, it is essential that the reaction is performed in the presence of a polar organic solvent which is selected from the class consisting of dimethylformamide, dimethylacetamide, dimethyl sulfoxide, hexamethyl phosphoric triamide and the like. The amount of such a polar organic solvent to be added to the reaction mixture should be in the range from 1 to 10 parts by weight per 100 parts by weight of the inert organic solvent used in the first step and contained in the reaction mixture.
The monovalent hydrocarbon group denoted by R in the general formula R 3 SiX for the trihydrocarbyl monohalogenosilane as one of the reactants is selected from the class consisting of alkyl, aryl and alkenyl groups. Substituted monovalent hydrocarbon groups obtained by the replacement of a part or all of the hydrogen atoms in the above named classes of hydrocarbon groups with substituents such as halogen atoms and cyano groups are also suitable. Particular examples of such a silane compound include trimethyl chlorosilane, triethyl chlorosilane, dimethyl propyl chlorosilane, dimethyl phenyl chlorosilane, dimethyl vinyl chlorosilane, dimethyl chloromethyl chlorosilane and the like.
The silylation reaction of the substituted sodium acetylide is performed by adding such a silane compound to the reaction mixture containing the acetylide and admixed with the above mentioned polar organic solvent. The amount of the silane compound should preferably be in the range from 0.8 to 1.2 moles per mole of the substituted sodium acetylide in the reaction mixture. The reaction temperature is preferably in the range from about 20° C. to about 60° C.
The 1-alkynylsilyl compound obtained by the method of the present invention is useful as an intermediate in the synthesis of an organic compound having a specific geometrically isomeric structure by virtue of the characteristic triple bond in the molecule so that the compound is industrially important in the manufacture of various kinds of biologically active compounds including medicines and agricultural chemicals. Further, such a compound is also useful as a monomeric compound in the preparation of organic semiconductors, gas-permeable polymeric materials and the like.
In the following, the method of the present invention is described in more detail by way of examples.
EXAMPLE 1
Into a reaction flask of 500 ml capacity were introduced 250 g of xylene and 23 g of metallic sodium which was finely dispersed in xylene to have a particle diameter of 20 μm or smaller. This reaction mixture was heated and kept at a temperature of 100° to 110° C. and gaseous 1,2-butadiene was introduced thereinto for 1 hour at a rate of 1 liter/minutes to give sodium ethylacetylide quantitatively.
The mixture of sodium ethylacetylide in xylene was admixed with 10 g of dimethylformamide and 108.5 g of trimethyl chlorosilane were added dropwise into the reaction mixture at 40° to 50° C. over a period of 1 hour. After completion of the dropwise addition of the silane, the reaction mixture was further agitated for additional 1 hour keeping the temperature at 50° C. and then poured into 200 ml of a 20% hydrochloric acid. The organic solution was taken by phase seperation and distilled to give 118 g of trimethyl 1-butynylsilane. The yield was 93.7% based on the amount of the metallic sodium.
EXAMPLE 2
The experimental procedure was substantially the same as in Example 1 excepting the dropwise addition of 153 g of phenylacetylene in place of the introduction of the gaseous 1,2-butadiene to give 132 g of trimethyl phenylethynyl silane. This yield was 88% of the theoretical value based on the amount of the metallic sodium. | The invention provides a novel and economical route for the synthetic preparation of a 1-alkynyl trihydrocarbyl silane compound. The method comprises the steps of reacting metallic sodium with a hydrocarbyl-substituted acetylene or allene compound to form a substituted sodium acetylide and reacting the acetylide with a trihydrocarbyl monohalogenosilane in the reaction mixture which is admixed with a polar organic solvent such as dimethylformamide. | 2 |
RELATED APPLICATION
This application is a continuation-in-part of my application Ser. No. 760,017, filed Jan. 17, 1977, now abandoned.
BACKGROUND AND SUMMARY OF THE INVENTION
Unfilled chemically cross-linked polyethylene has long been recognized by the power cable industry as an insulation material characterized by very low dielectric losses, high dielectric strength, and excellent physical properties. Its most undesirable properties are relatively high hardness and minimum flexibility. Installation costs increase substantially due to the longer time involved making splices and terminations. Compositions based upon ethylene-propylene copolymers and terpolymers and other elastomers have found application in power cables because of their inherently greater flexibility and ease of installation, substantially reducing those costs.
Ethylene-propylene rubbers have been amorphous materials and required reinforcement from added fillers such as hard calcined clays to achieve their necessary physical strength to be used in insulation. Polyethylene, being crystalline in structure, does not require additional reinforcement, therefore unfilled compositions are practical and are used in most power cable applications above 2 kV rating. An unfilled polymer system provides the highest degree of electrical properties, and conversely, the addition of fillers detracts from the inherently good electrical properties of ethylene-propylene rubbers in proportion to the amount of filler employed.
In my invention, both the highest degree of electrical characteristics of an unfilled polymer system and the inherent flexibility of rubber have been combined into a composition suited to power cable applications which include both low and high voltage varieties. This has been accomplished by physically combining polyethylene and an ethylene propylene copolymer or ethylene propylene terpolymer together with a suitable antioxidant and a peroxide curing agent to bring about a cross-linked composition. The ratios in the polymer system can be varied to provide more or less flexibility as desired without appreciably altering other physical properties and without significant changes in electrical characteristics. The resultant compounds are inherently tough, flexible and of the highest degree of electrical properties comparable to those of a typical unfilled chemically cross-linked polyethylene. The cross-linking itself can also be achieved in the absence of chemical cross-linking by irradiation curing.
Based upon limited data available at this time, the life span of the compounds included in this invention will exceed the normal life span of typical unfilled chemically cross-linked polyethylene compounds. Other properties such as low temperature flexibility, weatherability, resistance to deformation and mechanical damage are at least the equivalent of cross-linked polyethylene and typical ethylene propylene copolymers.
A study of a-c dielectric strength has indicated that the new compositions exceed ethylene propylene rubber formulations by a marked degree and slightly surpass the breakdown voltage achieved by the unfilled cross-linked polyethylene.
This invention includes a novel method of mixing the components of the composition. Raw polyethylene and ethylene propylene copolymer, preferably with 15% crystallinity, are purchased in the form of pellets. These original pellets remain intact throughout the entire pre-blending cycle which both intermixes the polymers themselves and provides for the addition of the anti-oxidant and peroxide curing agent by absorption through the pellet surfaces. This is a modification of the patented Furukawa (U.S. Pat. No. 3,455,752) mixing process for cross-linkable polyethylene. Modifications in the mixing are necessary due to the dual polymer system involved. Final mixing is achieved by the screw in the barrel of the extruder which homogenizes the ingredients of the polymer system to form the insulation before extruding it on the final cable product. At this stage, the polymers are fluxed into each other forming a complete matrix, and the additives are uniformly dispersed in the polymer blend. This is a distinct difference from the original Furukawa process which does not require two polymers to be fluxed in the final extrusion operation.
Other objects, features and advantages of the invention will appear or be pointed out as the description proceeds.
BRIEF DESCRIPTION OF DRAWING
In the drawing, forming a part hereof, in which like reference characters indicate corresponding parts in all the views:
FIG. 1 is a transverse cross-section through a cable made in accordance with this invention; and
FIG. 2 is a flow diagram illustrating the method of this invention.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 shows a high-voltage power cable 10 having a center stranded conductor 12 covered by a semi-conducting conductor shield 14. Preferably, an emission shield 16 is applied over the outside of the conductor shield 14.
The insulation for the cable, which insulation is designated by the reference character 20, is applied over the emission shield 16, or the conductor shield 14, if there is no emission shield. The insulation 20 is a mixture of polyethylene and ethylene propylene copolymer.
The ethylene propylene copolymer is not filled as was the ethylene propylene rubber of U.S. Pat. No. 3,579,610, in which I was a co-inventor. The EPR of patent '610 was 40% ethylene, but the ethylene propylene copolymer of this invention is 78 ±3% ethylene; and has 15% crystallinity but the EPR of patent '610 was entirely amorphous. Ordinarily, ethylene propylene rubber cannot be used for insulating electric cables unless a filler is added to the ethylene propylene rubber to give it the physical properties necessary for use in a cable, such as abrasion resistance, cut-through resistance and temperature characteristics. When subjected to a higher temperature for curing, the polyethylene and ethylene propylene rubber are cross-linked with themselves and to each other.
The polyethylene is crystalline and imparts to the ethylene propylene copolymer the properties that it needs for use as a cable insulation; and these improved physical properties are obtained without impairing the electrical characteristics of the ethylene propylene copolymer. Fillers have been used to impart the required physical properties but at the expense of the electrical characteristics which are essential for best insulating results. The benefits which this invention derives electrically are due to the fact that the system does not contain reinforcing mineral fillers.
The proportion of polyethylene to ethylene propylene copolymer can be a ratio of 1:1. However, the proportions can be changed over a wide range. The amount of polyethylene must be sufficient to provide the insulation with the necessary physical strength; but the ethylene propylene copolymer must be present in sufficient amount to substantially increase the flexibility of the polyethylene for the reasons explained in the summary at the beginning of this specification. The ratio of the polyethylene to the ethylene propylene copolymer can vary from 80:20 to 20:80. The preferred range, however, is 60:40 to 40:60.
Referring again to FIG. 1. the insulation 20 is covered with a semi-conducting insulation shield 22 over which a corrugated metal shield 24 is applied. This corrugated metal shield 24 is preferably made by folding a transversely corrugated metal tape longitudinally around the cable core. Other types of shield can be used, such as metal tape or wire shield. An outer jacket 26 is extruded over the metal shield 24.
FIG. 2 is a flow diagram illustrating the successive steps in the preferred method of this invention. In order to obtain economy in the manufacture of the cable shown in FIG. 1, polyethylene pellets, which are hard at room temperature, and ethylene propylene copolymer pellets, which are soft and rubbery at room temperature, are placed in a ribbon blender which mixes them together as pellets. This mixture is then transferred to an extruder which is heated.
The heat in the extruder barrel and the work done on the pellets by the screw in the extruder barrel softens the pellets and thoroughly mixes the materials of the pellets together so that they are fluxed into each other forming a complete homogeneous matrix.
If additional ingredients, such as an antioxidant and peroxide curing agent, are added to the pellets, these additional ingredients diffuse through the walls of the pellets, and mix with the polyethylene and ethylene propylene copolymer without waiting for the pellets to be fluxed into each other by the extruder.
The conductor 12 passes through the extruder head via a guider tip, and the insulation is extruded over the conductor at the tip in accordance with conventional extrusion practice.
This invention does permit an improvement in the extrusion process which has not been possible with insulation made entirely of ethylene propylene rubber and filler.
The insulating material of this invention can be forced through a fine mesh screen or plate in the extruder at a location between the end of the screw and the tip of the extruder. The mixture of the two base polymers, polyethylene and ethylene propylene copolymer, can be forced through a screen having the equivalent of a 325 mesh, and this eliminates from the insulation any solid impurities 1.7 mils in size. The elimination of particles larger than 1.7 mils, or the breaking-up of the particles which do pass through the screen, greatly increase the effectiveness of the insulation by making it capable of withstanding higher voltage stress per mil of insulation thickness.
The preferred material for the ethylene propylene copolymer is available from Exxon Chemical Co., and its address is P.O. Box 201, Florham Park, N.J. 07932. The particular copolymer that I have used for the invention described in this specification is designated by the Exxon Chemical Co. as "Vistalon 702", and it is approximately 15% crystalline. Exxon Chemical Co. makes another copolymer of ethylene and propylene designated as "Vistalon 404" which has substantially no crystallinity. This amorphous copolymer cannot be used for my invention becuase it requires a filler in order to have the strength necessary for the insulation.
An equivalent material to that claimed in the specification is a copolymer of an ethylene and propylene in which diene is added to make a terpolymer. This material designated as "Nordel 2722" is a available from DuPont of Wilmington, Del. For purposes of the claims this Nordel 2722, without filler, is to be considered a mechanical equivalent of the copolymer of ethylene and propylene with some crystallinity. There may be other products that I do not know of which are chemical equivalents of the copolymers of ethylene and propylene with crystallinity sufficient for making insulation when mixed with polyethylene and without any filler in the insulation.
The expression "ethylene propylene copolymer" is used herein in a broad sense to include such copolymers even though additional copolymerized monomer may be present in the Nordel ethylene diene terpolymer described above.
The expression "unfilled" as used herein, designates an insulation in which no material, usually clay, has been added to the insulation conpound for the purpose of increasing the mechanical strength of the insulation. Such filler degrades the electrical characteristics of the insulation.
The preferred embodiments of the invention have been illustrated and described, but changes and modifications can be made and some features can be used in different combinations without departing from the invention as defined in the claims. | This invention is an improved insulation for electric cables and an improved method of making the insulation. Cross linked polyethylene insulation is too stiff, particularly in high voltage cables which require a thick layer of insulation. Copolymers of polypropylene have electrical properties substantially equal to those of polyethylene, but do not have the necessary physical strength and have to be filled with clay or other filler that provides the required strength but degrades the electrical characteristics. A novel feature of this method is the utilization of the screw of the extruder to effect a mixing of the ingredients in an improved polymer system for cable insulation. | 1 |
FIELD OF THE INVENTION
This invention relates generally to wireless headsets and more specifically to wireless headsets having BLUETOOTH communication capabilities.
BACKGROUND OF THE INVENTION
Modern wireless headsets provide greater convenience and safety to the users of such devices as office telephones, by allowing the user partially or completely hands free operation of the telephone. By the use of such devices, office workers may simultaneously speak to customers or business associates upon the telephone while making entries into a computer, using other office equipment and other diverse tasks. Such headsets normally comprise some sort of head band or ear clip to retain the headset in the proper position, a microphone located near the mouth, and such wireless equipment as is necessary to communicate with a base unit or master unit located at or on the office telephone, cellular telephone, or similar device.
Bluetooth (Trademark of Bluetooth SIG, Inc) is a rapidly evolving wireless communications standard for small devices having link and application layer definitions for communications protocols, bandwidths and so on. Bluetooth enabled devices use the 2.4 to 2.4835 GHz band in most nations, a loosely regulated band of the frequency spectrum allowing high bandwidth, short range communications using 625 microsecond time division packets. Within the overall band, frequency hopping among 79 frequencies at a full duplex 1600 hops per second provides the ability to operate in a network of similar Bluetooth enabled devices with multiple simultaneous connections established.
This ability to allow multiple simultaneous connections is particularly important in the Bluetooth enabled workplace. For example, it would be pointless to have multiple Bluetooth enabled devices attempting access to a Bluetooth enabled printer if only one at a time may actually connect with the printer. Similarly, a workplace using multiple Bluetooth enabled headsets would drown in a sea of babble if different frequencies between master units and headsets were not available for each headset user. On the other hand, the ability offered by Bluetooth to handle in one network more than one connection allows each headset user to communicate properly with their headset's master unit, or to use the headset for short range office communications with other Bluetooth enabled headsets, master units and other devices.
This ability requires several types of identification, called “access procedures” in the Bluetooth specification core documents. Two in particular are important in the context of the present invention. The first type of identification is the “page/page scan/response”, used to establish communications between two Bluetooth enabled devices. In essence, the Bluetooth device initiating the contact will send out a packet identifying the device with which it desires contact and a communications channel will be opened up. The second type of identification is the “inquire scan/inquire response” in which a Bluetooth unit attempts to determine in fact what other Bluetooth enabled devices are within radio range, and to establish a “pairing” with the other unit. The second type is importance in that certain security keys and clock offsets are exchanged at that time, allowing the two units to communicate securely thereafter.
A number of Bluetooth related patent applications may be found in the art, some of which relate to the first type of situation, that is, to establishing a connection between two Bluetooth devices which have already established a “pairing” with each other.
Publication No. 2002/0115425 dated Aug. 22, 2002 to Olson et al for WIRELESS DEVICE AUTHENTICATION AT MUTUAL REDUCED TRANSMIT POWER teaches that Bluetooth enabled devices may be “authenticated” at a lower power setting. One advantage of such a low power authentication is that it reduces the chance that the security keys and clock offsets might be intercepted by a Bluetooth enabled device set to eavesdrop. More importantly, for devices such as headsets which have minimal user interfaces, the “power down” setting (reduced power, NOT power off) renders the device only able to communicate with other units at extremely close range, such as one meter. The proposed advantage, and also the disadvantage of such a system, is that Bluetooth registration will only occur with the given, close proximity unit.
Publication No. 2002/0111140 dated Aug. 15, 2002 to Kim for WIRELESS HEADSET CAPABLE OF AUTOMATIC LINK CONNECTION AND METHOD FOR CONTROLLING THE SAME teaches a headset having a folding microphone tube. When the microphone tube is unfolded, the device is turned on and Bluetooth registration occurs automatically, followed by an inquiry of the other type to determine if any connection is desired.
Publication No. 2002/0111138 dated Aug. 15, 2002 to Park for LINK CONNECTION METHOD BETWEEN COMMUNICATION TERMINALS EQUIPPED WITH BLUETOOTH WIRELESS DEVICES teaches automatic attempts to “re-link” Bluetooth devices (re-establish a connection) even when power is not turned on and off, such as after one device is taken out of range of the other device. Thus, this device does not deal with inquiry mode operations in which two or more Bluetooth units pair.
Publication No. 2002/0132582 dated Sep. 19, 2002 to Mooney for CELL PHONE EXTENSION USING WIRELESS PICONET teaches that two or more Bluetooth enabled cell phones might be linked by the Bluetooth protocol, one to act as a gatekeeper and the other one to act as a terminal.
Publication No. 2002/0115471 dated Aug. 22, 2002 to De Loye et al for METHOD FOR HANDLING CALLS RECEIVED AT A WIRELESS MOBILE TERMINAL COMPRISING A SHORT-RANGE INTERFACE CORRESPONDING WIRELESS MOBILE TERMINAL AND COMPUTER PROGRAM teaches use of devices having differing capabilities, such as using a headset to re-transmit print requests to a printer.
Publication No. 2002/0082057 dated Jun. 27, 2002 to Kim for SYSTEM AND METHOD FOR UTILIZING MOBILE COMMUNICATION TERMINAL AS WIRELESS HEADSET allows Bluetooth links to a PC, for use of a wireless headset with Internet Telephony.
Publication No. 2002/0045454 dated Apr. 18, 2002 to Iwata for RADIO COMMUNICATION CONNECTION DESTINATION SPECIFYING METHOD deals with infrared and radio links using the Bluetooth protocol.
Publication No. 2002/0021800 dated Feb. 21, 2002 to Bodley for HEADSET COMMUNICATION UNIT teaches a design for a hinge mechanism on a headset.
Publication No. 2002/0031645 dated Oct. 18, 2001 to Jarrett for MULTI-PURPOSE MOBILE CORDLESS PHONE SYSTEM teaches connection of fixed phones and cordless telephones or cellular telephones using protocols such as Bluetooth.
Finally, the only issued patent, U.S. Pat. No. 6,255,800 issued Jul. 3, 2001 to Bork for BLUETOOTH ENABLED MOBILE DEVICE CHARGING CRADLE AND SYSTEM teaches a charging cradle for cell phones and the like, the charging cradle is connected to a PC and may be Bluetooth enabled.
In general, Bluetooth enabled devices suffer from complexity of operation in terms of pairing the device to previously unknown Bluetooth devices. Many Bluetooth devices require that the user must access a sequence of menus on some type of LCD or CRT display, push buttons to indicate what is desired, and only then can pairing occur.
It would be advantageous to provide a method by which Bluetooth enabled devices could be easily paired with other Bluetooth enabled devices, yet with a minimal user interface that allowed smaller, lighter weight, less expensive and simpler devices.
SUMMARY OF THE INVENTION
General Summary
The present invention provides a Bluetooth enabled headset/master unit set which allows easy pairing of Bluetooth devices. The miniature headset of the present invention may be of a reduced size and weight due to the ease of pairing/authentication.
Pairing of the headsets and master units may be accomplished by a push button method: the master unit has a “pairing” button which when pushed, automatically causes the master unit to mate with nearby units, possibly at a lower power setting.
Pairing of the headsets and master units may be accomplished in an even simpler way, in which not even a button is necessary. In this embodiment of the invention, removal and replacement of the power supply of the unit (batteries in a wireless headset embodiment, batteries or a power switch in a master unit embodiment) is sufficient to cause the authentication/inquiry mode to begin operation, resulting in pairing with nearby Bluetooth enabled devices. In a sub-embodiment of this embodiment, the removal and replacement of the power supply must occur within a set time frame such as 45 seconds.
Device and method embodiments are taught.
Summary in Reference to Claims
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide an improved Bluetooth enabled device for use as part of a wireless headset system, the device comprising: a power supply; a transceiver in electrical communication with the power supply; a link manager in electrical communication with the power supply, the link manager controlling the operations of the transceiver; wherein the link manager automatically enters an inquiry substate following an interruption of the power supply to the link manager.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a device further comprising a wireless headset.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a device further comprising a master unit.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a device further comprising: a timer controlling entry of the link manager into the inquiry substate.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a device wherein the timer only allows the link manager to enter the inquiry substate if the interruption in the power supply meets a first time criteria.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a device wherein meeting the first time criteria further comprises one member selected from the group consisting of: subceeding a maximum time, exceeding a minimum time, equaling a time allotment, and combinations thereof.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method of pairing devices of a Bluetooth enabled wireless headset system, the method comprising the steps of: a) utilizing a prior connection state as needed; b) after a power interruption, determining if a time criteria is met; c) if the time criteria is met, automatically entering an inquiry substate; d) if the time criteria is not met, automatically returning to the prior connection state; and e) returning to step a).
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method wherein meeting the first time criteria further comprises one member selected from the group consisting of: subceeding a maximum time, exceeding a minimum time, equaling a time allotment, and combinations thereof.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method wherein the power interruption is caused by the user pushing a button on the device.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method of pairing devices of a Bluetooth enabled wireless headset system, the method comprising the steps of: a) placing the units near to each other; Bluetooth) interrupting power to one of the units; c) automatically entering the inquiry substate following the interruption of the power supply.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method wherein the device further comprises a wireless headset.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method wherein the device further comprises a master unit.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method wherein the device further comprises: a timer controlling entry of the device into the inquiry substate.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method wherein the timer only allows the link manager to enter the inquiry substate if the interruption in the power supply meets a first time criteria, and further wherein the method comprises the following step after step b and before step c:
b2) if the interruption in the power supply meets a first time criteria, executing the following step c.
It is therefore another aspect, advantage, embodiment and objective of the present invention to provide a method wherein meeting the first time criteria further comprises one member selected from the group consisting of: subceeding a maximum time, exceeding a minimum time, equaling a time allotment, and combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a device according to a first embodiment of the present invention.
FIG. 2 is a schematic block diagram of three piconets having four Bluetooth enabled devices, showing the context of use of a second and third embodiment of the present invention.
FIG. 3 is a flowchart of a fourth method embodiment of the present invention.
FIG. 3 a is a flowchart of a fifth embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 is a block diagram of a device according to a first embodiment of the present invention. An improved Bluetooth enabled device 100 for use as part of a wireless headset system has a power supply 108 , a transceiver 106 in electrical communication with the power supply 108 , a link manager 102 in electrical communication with the power supply 108 , the link manager controlling the operations of the transceiver 106 ; and a timer 104 controlling the actions of transceiver 106 . Device 100 may be a wireless headset itself, or device 100 may be a master unit. In general, both types of units may be used in a single wireless headset system. While there are substantial differences between the two types of devices, for purposes of the present invention, they may be treated very similarly. For example, the wireless headset normally has a microphone, a microphone tube, an earphone, a retainer to hold the device onto the head of the user and so on, however, these are not shown in FIG. 1 . Similarly, the base unit/master unit may comprise a connection to a telephone or other device, but this is not shown in FIG. 1 . In the headset embodiment of the invention, power supply 108 is most likely to be a set of batteries, re-chargeable or non-rechargeable, whereas in the master unit may have be plugged into local current such as 110 VAC. In either type of power supply, the current works the same way.
Bluetooth transceiver 106 is normally an unlicensed transceiver having a short range, both attributes due to its operation in the 2.4 GHz bandwidth. The spread spectrum, frequency hopping signal will move among 79 different frequencies ranging from 2.400 to 2.4835 GHz in most nations, in other nations the frequency may be different without impact on the present invention. Time Division Multiplexing is used with a 625 microsecond slot length: this necessitates each Bluetooth device to maintain an internal clock and knowledge of the clock offsets of other devices, a fact relating to the present invention. Frequency modulation occurs in the Gaussian Frequency Shift Keying method with a BT of 0.5 and a modulation index ranging from 0.28 to 0.35.
Interference standards utilized allow up to seven simultaneous connections to be maintained. However, the number of headset/master unit combinations (and other types of Bluetooth devices) which may exist in one group of units (called a piconet) is not limited as some connections may be terminated and units placed into “park” mode. Thus, only units which are actively communicating with each other need have open channels. This fact will be alluded to later, in relation to the difference between establishing a connection and establishing a pairing.
Link manager 102 will operate transceiver 106 to provide communications for the actual headset/master unit functions, the “payload” of the Bluetooth device. Link manager 102 carries out several functions in order to do this.
The process of concern in the present invention is the “inquiry procedure”. In the inquiry procedure, two Bluetooth units which have not previously communicated will establish the ability to communicate together. To understand why this is necessary, it is necessary to understand the nature of a Bluetooth piconet, an example of which is shown in FIG. 2 .
FIG. 2 is a schematic block diagram of three piconets having four Bluetooth enabled devices, showing the context of use of a second and third embodiment of the present invention. Overall piconet 202 has two subnets, 204 , 206 . Subnet 204 has two component devices of a wireless headset system: wireless headset 214 and master unit 212 . Wireless headset 214 may be worn by a user for voice communications with whatever device master unit 212 may be connected to. In FIG. 2 this is shown as a telephone, however, it may be a telephone, another audio device (such as a computer programmed to accept voice commands and input), or another device. Note that while headset 214 is schematically depicted to have a vertical antenna, the antenna is in all preferred embodiments internal to the headset device. The depiction is merely for clarity of understanding.
Piconet 206 , on the other hand, has printer 208 and computer 210 . These devices will be doing entirely different types of communication over the Bluetooth channels open between them. Overall piconet 202 may have all four devices in it, or more, not pictured. At any time, several devices may be communicating with other devices. Obviously, in such an arrangement, some type of addressing and encryption system becomes a necessity. Should headset unit 214 begin a packet broadcast, it is necessary that only master unit 212 receive the packets, not printer 208 or computer 210 .
The security system utilized by the Bluetooth standard involves two units establishing communications links. First, the clock offsets discussed earlier must be sent and received, allowing the units to synchronize operations when communicating. Secondly, the two units must establish an initialization key using random numbers, device identifiers, and various addresses. This initialization key allows later establishment of one or more link keys, which provide secure communications. Carrying out this process, and methods of easing the process for users, are the topics of the present application. In general, this is called an “inquiry procedure”. The inquiry procedure involves two substates which the Bluetooth devices may enter. In the “inquiry substate”, a unit will attempt to discover what other units may be present. A unit which is allowing itself to be discovered will enter the “inquiry scan substate” in which it sends an “inquiry response”. The present invention involves automatic initiation of these substates. Should a unit discover by this means a unit with which it has not previously communicated, it will automatically trade clock and key information so that in the future, connections between the two units may be established for useful communication.
After a number of units have been “paired”, communications between members of the piconet becomes possible. Since the units will not all be communicating at the same time, it is necessary to distinguish active and inactive units, and sever connections between inactive units. This in turn means the units will have various states they may be in at any time, and procedures for calling each other into and out of such states. The two major states are self explanatory: CONNECTION and STANDBY. Three substates used to pair devices have been discussed: inquiry, inquiry scan, and inquiry response.
Four additional states are used in establishing a present connection between two units which have previously been paired. Page, page scan, master response and slave response may not concern the present invention although in general establishment of such an open channel involves link manager 102 sending a page to another known unit and receiving a page scan in response. This ability to terminate a connection and reestablish the same connection later should NOT be confused with the previously discussed inquiry procedures. In particular, prior art relating to establishing or re-establishing “a connection” does not relate to the present invention, which involves establishing or re-establishing “a pairing” between two devices.
Establishment of a pairing may be difficult in prior art: devices may require users to navigate complex menus shown on displays. This increases the size, complexity, un-reliability and weight of Bluetooth devices. In particular, headsets should have minimal user interfaces. In the present invention, this is handled by minimizing the user interface to a single button on a headset, or by entirely eliminating the user interface and requiring automatic initiation of an inquiry procedure at power up, or at power up under certain circumstances.
In one presently preferred embodiment and best mode presently contemplated for carrying out the invention, link manager 102 automatically enters an inquiry substate following an interruption of the electricity from power supply 108 to link manager 102 . In another preferred embodiment of the present invention, timer 104 controlling entry of link manager 102 into the inquiry substate is used. In a subembodiment, timer 104 only allows link manager 102 to enter the inquiry substate if the interruption in the power supply meets a first time criteria. Meeting the first time criteria may further comprise one member selected from the group consisting of: subceeding a maximum time, exceeding a minimum time, equaling a time allotment, and combinations thereof. Thus, timer 104 may only cause link manager 102 to enter the inquiry substate if the time of interruption of electrical supply subceeds (is less than) a given time such as 2 minutes, or only if the time exceeds (is greater than) a given time such as 45 seconds, or is equal to a time allotment such as 20 seconds. Combinations of these may be used, such as 45 seconds or less. More complex combinations may also be used, such as less than 45 seconds or more than 5 minutes. Various types of convenience may be provided by this means. For example, in one embodiment, only time interruptions of 45 seconds or less will cause the entry into the desired substate. Interruptions greater than that time frame will not trigger inquiry procedures such as inquiry, inquiry scan or inquiry response, and thus the user will be spared the time taken during the inquiry procedures at start. By this means, the user may change the batteries on a battery powered device, or change electrical outlets on an AC device, without causing the inquiry procedures.
In other embodiments of the present invention, inquiry procedures may be initiated at the push of a button, thus drastically minimizing the user interface required on small devices such as the headset or the master unit. Most Bluetooth chip sets may be augmented with the addition of such circuitry or programming as in necessary to cause the immediate entry into inquiry substate without further ado.
Furthermore, in combined embodiments of the invention, the push of a button may even serve to interrupt the electrical supply for a predetermined length of time (time allotment), thus initiating the sequence outlined previously.
FIG. 3 is a flowchart of a fourth method embodiment of the present invention. FIG. 3 a is a flowchart of a fifth embodiment of the present invention, the two embodiments are related. The process outlined may occur inside of the Bluetooth unit.
The method of fifth embodiment ( FIG. 3 a ) will be discussed before the method of the fourth embodiment. It may comprise the steps of:
a) Start operations. ( 350 ) b) Manual power up of the device ( 352 ). This step may comprise pushing a button, plugging the device in, or advantageously, putting batteries into a device. c) A timer may be initialized, for example, to execute the following operations a number of times “X”, or for given number of clock cycles “Y” or other time criteria as needed. ( 354 ) d) A time expire condition is checked, that is has the time criteria been met? This may constitute a count down to zero from a time, or a count up from zero to the time criteria set, etc. ( 356 ) e) If time has not expired, carry out steps 358 , 360 , 362 , and if necessary 364 and 366 . f) Increment, decrement or otherwise alter the timer. This may occur in terms of updating a data field or it may be an automatic operation of the chipset clock. ( 358 ) g) Step 360 indicates the unit enters an inquiry mode. Note that the unit may automatically reduce power, thus entering a “short range mode” (indicated on FIG. 3 a by the annotation (SR) at step 360 ). This short range mode is useful for preventing units from attempting to pair with too many other units in the larger area. The inquiry mode may be the Bluetooth inquiry mode, or it may constitute sending out a single inquiry, or inquiry page, or inquiry scan. f) At step 364 , if another Bluetooth unit is not detected, operation returns to step 356 . If a Bluetooth unit is detected, step 366 must be carried out as well. g) At step 366 , the unit pairs with the newly found Bluetooth unit, by storing identity and/or code and/or timing information and by offering to the other unit the same information. As stated previously, this may involve use of such substates as the inquiry page and inquiry scan, etc. Thereafter, the unit may return to normal operations at step 368 . h) After timer expiration ( 356 ) or detection of another Bluetooth unit ( 364 , 366 ) the unit enters normal mode.
These steps may be altered in yet further sub-embodiments of the invention. For example, after detection of a known Bluetooth unit at step 364 , the device of the present invention may search again for a certain time for an unknown Bluetooth unit. Or multiple new units may be registered, by altering this control logic. Such sub-embodiments are within the abilities of one skilled in the art after reading this patent document and are included within the scope of the appended claims.
The method of the fourth embodiment ( FIG. 3 ) of pairing devices of a Bluetooth enabled wireless headset system comprises the steps of:
a) utilizing a prior connection state as needed; ( 304 ) b) after a power interruption, determining if a time criteria is met; ( 306 , 308 ) c) if the time criteria is met, automatically entering an inquiry substate; ( 310 ) d) if the time criteria is not met, automatically returning to the prior connection state; and e) returning to step a).
This represents a simplified method. As discussed previously, additional steps and capabilities may be added without departing from the scope of the appended claims.
As noted previously, meeting the first time criteria may in embodiments further comprise one member selected from the group consisting of: subceeding a maximum time, exceeding a minimum time, equaling a time allotment, and combinations thereof.
More generally, another method embodiment of the present invention for pairing devices of a Bluetooth enabled wireless headset system comprises the steps of:
a) placing the units near to each other; b) interrupting power to one of the units; b2) if the interruption in the power supply meets a first time criteria, executing the following step c. c) automatically entering the inquiry substate following the interruption of the power supply.
The units may automatically reduce transmission power at the time of pairing without departing the scope of the present invention.
The disclosure is provided to allow practice of the invention by those skilled in the art without undue experimentation, including the best mode presently contemplated and the presently preferred embodiment. Nothing in this disclosure is to be taken to limit the scope of the invention, which is susceptible to numerous alterations, equivalents and substitutions without departing from the scope and spirit of the invention. The scope of the invention is to be understood from the appended claims. | The present invention provides a Bluetooth enabled headset/master unit set which allows easy pairing of Bluetooth devices. The miniature headset of the present invention may be of a reduced size and weight due to the ease of pairing/authentication.
Pairing of the headsets and master units may be accomplished by a push button method: the master unit has a “pairing” button which when pushed, automatically causes the master unit to mate with nearby units, possibly at a lower power setting.
Pairing of the headsets and master units may be accomplished in an even simpler way, in which not even a button is necessary. In this embodiment of the invention, removal and replacement of the power supply of the unit (batteries in a wireless headset embodiment, batteries or a power switch in a master unit embodiment) is sufficient to cause the authentication/inquiry mode to begin operation, resulting in pairing with nearby Bluetooth enabled devices. In a sub-embodiment of this embodiment, the removal and replacement of the power supply must occur within a set time frame such as 45 seconds.
Device and method embodiments are taught. | 8 |
FIELD OF THE INVENTION
The invention relates to a fastening system for detachably fastening and positioning a compaction module on a drafting unit of a spinning machine, wherein the compaction module has a carrier, which is provided with at least one suction channel, which is connected to suction inserts of compaction elements that are movably mounted on the carrier.
The invention further relates to a coupling device, which comprises the fastening system configured according to the invention, for connecting a suction channel, which is integrated in the carrier of the compaction module, to a suction tube, which is connected to a central suction channel.
BACKGROUND
Document PCT/CH2011/000280, which was not previously published, illustrates and describes an embodiment of a detachably installed compaction module for the fiber material that is output by a drafting unit (e.g., a twin drafting system) of a spinning machine (e.g., a ring spinning machine). In this case, the compaction module comprises a carrier on which rotatably mounted suction drums are attached. Suction inserts are provided inside the suction drums and are connected to a suction channel, which is installed inside the carrier. At the free of the carrier, at which the suction channel also terminates, the carrier is provided with a U-shaped end piece via which the carrier is slid onto a suction tube. In so doing, the outlet opening of the suction channel comes into overlap with an opening in the suction tube, thereby establishing a connection between the suction inserts and a vacuum source, which is connected to the suction tube. The dimensions of the U-shaped end piece of the carrier and of the outer diameter of the suction tube are selected such that the carrier is held on the suction tube by means of the clamping effect between the end piece and the suction tube, and a pivot movement of the carrier and therefore of the compaction module in the circumferential direction of the suction tube is made possible. By means of this pivot movement, the compaction module is pivoted from a working position into an idle position and, conversely, from an operating position into an idle position.
The disadvantage of the known embodiment is that an additional extraction tube must be installed. A further difficulty is that of quickly and exactly positioning the carrier on the suction tube in order to ensure that the opening of the suction channel comes into alignment with the corresponding opening on the suction tube. Additional guides may need to be installed on the suction tube for this purpose. Special sealing elements need to be installed in order to sufficiently seal off the suction channel and the inner region of the suction tube in the region of the coupling point from the surroundings.
SUMMARY OF THE INVENTION
It is an object of the invention to eliminate the disadvantages of known solutions and to provide fastening means for installing an additional compaction module on drafting systems of spinning machines via which the respective compaction module can be installed and removed quickly and easily and in an exact position relative to the drafting unit. Likewise, a coupling device for connecting a central suction channel of the spinning machine to the suction inserts of the compaction module using a fastening mechanism designed according to the invention is proposed, by means of which the compaction module can be easily installed on pre-existing drafting units of spinning machines without special and additional suction tubes having special sealing elements.
Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
The objects are achieved on the one hand by virtue of the fact that the fastening mechanism is composed of at least one clamping element, which has retaining elements that ensure fixed and positioned fastening on the spinning machine, and which is provided with a first receiving slot, which is open on one side and has a retaining section, by means of which a retaining element that is fastened on the carrier can form a positive-fitting clamped connection.
The fastening mechanism, i.e., the clamping element, is fastened on the spinning machine in a defined and predetermined position by means of the proposed retaining member and is therefore aligned exactly with the position of the respective drafting unit.
Via the further proposed receiving slot, which is open on one side, the carrier can be easily and quickly moved, via a retaining element that is fastened on the carrier, into a fixed position in which the retaining element assumes a positive-fitting clamped connection with a retaining section in the region of the receiving slot.
The term “receiving slot” is intended to mean, for example, a narrow opening that extends in the longitudinal direction (e.g., an elongated hole) which is open on one side for the insertion of a retaining element (e.g., a pin or a bolt). In order to support the insertion, this opening can be formed to diverge in the insertion region. In this case, the retaining section can have a greater inner diameter than the receiving slot, and therefore the retaining element that is inserted into the receiving slot is locked and fixed in the retaining section by means of elastic deflection of at least one of the elements of the clamping element that form the slot. In order to obtain this effect, the outer dimension of the retaining element approximately corresponds to the inner diameter of the retaining section and is greater than the smallest inner diameter of the slot in the region between the opening of the slot and the retaining section.
The mentioned clamping element is preferably made of a plastic (e.g., a plastic injection-molded part) in order to permit elastic deflection of the clamping element in the region of the receiving slot.
It is further provided that the fastening mechanism is formed by two clamping elements, which are fastened spaced apart from one another on the spinning machine.
The two clamping elements thereby support the carrier on two sides by means of one retaining element in each case, said retaining element being held in the retaining section of the respective clamping element.
The two clamping elements can have the same shape.
It is also conceivable to connect the two clamping elements to one another via webs.
Moreover, it is provided that the positive-fitting connection between the retaining section and the respective retaining element of the carrier allows a pivot movement of the carrier in a pivot plane that extends parallel to the plane of the first receiving slot, wherein the respective clamping element comprises stops for limiting this pivot movement.
The shape of the retaining section is matched to the shape of the retaining element in order to allow the compaction module to pivot. Preferably, the retaining element is composed of a round bolt, whereas the retaining section has a circular cross-section. As a result, the retaining elements (e.g., a bolt) can rotate in the locking position in the retaining section in order to allow the carrier of the compaction module to pivot. In order to limit this pivot movement so as to hold the compaction module in a certain idle position, stops are provided on the clamping elements, against which the carrier rests when the pivot movement occurs. In the operating position, the carrier is held via an appropriately formed locking device, which is described in more detail in the exemplary embodiments that follow.
In order to form a coupling point for the connection of a suction tube that is connected to a vacuum source, it is further proposed that the respective clamping element is provided with a second receiving slot that is open on one side and has a retaining section, which can form a positive-fitting connection to a retaining element of a tube element, which is connected to the suction tube.
Therefore, it is possible to assign an additional function to the clamping element, namely, in addition to the function of fastening the compaction module to the spinning machine, that of functioning as a coupling point with a suction tube that establishes the connection of the suction channel to a vacuum source. In this case, it must be ensured that the connection between the suction channel remains sealed off from the surroundings even when the compaction module pivots.
Preferably, it is provided that the longitudinal axes of the first and second receiving slots intersect at an angle. Thus, installation and removal of the compaction module and the tube element of the suction tube can be carried out without any problems. The longitudinal axes, which extend in the longitudinal plane of the respective receiving slot, can intersect at an angle, for example between 60° and 120°.
In order to ensure that the tube element for the connection to the suction tube remains within a predetermined position range on the clamping element, the respective clamping element has—as seen in the extension of the second receiving slot—a pocket-shaped receptacle that is open on one side and is provided for fixing a web that is fastened on the tube element. The positioning of the tube element relative to the clamping element and therefore relative to the suction channel of the carrier of the compaction module is thereby ensured.
In order to easily and quickly install the clamping elements on the spinning machine, it is proposed that the retaining means of the respective clamping element is formed by a U-shaped base section that is installed below the first receiving slot. Moreover, it is proposed that the limbs of the U-shaped base section are each provided with an opening for receiving a fixing element.
It is therefore possible to install the fastening mechanism or the clamping elements on a carrier element (e.g., a shaft) mounted on the spinning machine in a simple, quick, and positionally accurate manner, for example.
In order to obtain a simple and functionally reliable coupling device, comprising the fastening mechanism or the clamping elements proposed according to the invention, for connecting a suction channel that is integrated in the carrier of the compaction module, to a suction tube that is connected to a central suction channel, it is proposed that an end ring is installed on the end of the suction channel that is located in the region of the fastening mechanism, the end ring projecting over the suction channel in the longitudinal direction and being provided with an annular outer surface that extends conically inward and is directed away from the suction channel, and on which a conically outwardly extending annular inner surface of a tubular element rests, at least in part, the tube element held in the respective retaining section of the second receiving slot by two clamping elements that are fastened spaced apart from one another on the spinning machine, and that the suction tube sealingly rests with its inner surface on the outer circumference of the free end of the tube element. In this case, the conically extending annular outer surface of the end ring—as seen in the axial direction—can have a surface that is slightly outwardly curved (convex) in order to allow slight movement between the described outer surface of the end ring and the conically extending inner surface of the tube element. This movement occurs during the pivoting of the compaction module in a predefined region.
By means of the proposed coupling device, the compaction module can be easily retrofitted onto existing drafting units without the use of additional extraction channels. Since the extraction tubes for extracting fibers are typically connected to the suction channel of the compaction module, existing couplings can be used to connect the suction channel to a central extraction channel. That is, in a conventional spinning machine without a compaction module, the coupling for the fiber extraction device, once this fiber extraction device has been removed, can be used directly for the connection of the retrofitted compaction module in order to connect to a vacuum source.
In order to connect a flexible suction tube to the tube element in a simple and sealed manner, it is proposed that the outer circumference of the tube element on which the suction tube rests is provided with a helically extending elevation. By means of the helical elevation, it is possible to rotate the suction tube and thereby slide said suction tube onto the end piece of the tube element with relatively little force.
In order to better seal off the region of the annular surfaces of the end ring and the tube element, which lie one on top of one another and extend conically, from the surroundings, it is further proposed that an annular elastic sealing element sealingly rests on the outer circumference of the tube element that extends across the region of the conically outward extending annular inner surface, said sealing element projecting above the tube element and sealingly resting on the conically inwardly extending annular outer surface of the end ring that is located outside of the tube element.
In order to keep the vacuum conditions, and therefore the compaction of the fiber material, approximately constant at the individual compaction modules along the entire length of the spinning machine, it is proposed that different tube elements are used, which have through-openings having different inner diameters that are suitably adapted to the distance to the vacuum source. The different tube elements can have different colors in order to prevent mix-ups.
Preferably, it is further proposed that the clamping elements are fastened on a shaft that is installed in the longitudinal direction of the spinning machine. The shaft can be provided with through-openings, through which fixing elements extend, the fixing elements extending into the openings of the limbs of the U-shaped receptacle of the respective clamping element in order to fasten the clamping elements. This makes it possible to fasten the clamping elements on the available drafting units of the spinning machine in a quick and positionally accurate manner.
In order to fasten the clamping elements, it is proposed that the opening of one of the two limbs of a clamping element is provided with a thread and the fixing element is a screw, the threaded end of which extends beyond the shaft.
Naturally, there are many other possibilities for fastening the clamping elements on the spinning machine in a positionally accurate manner and with proper orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the invention are illustrated and described in greater detail with reference to the following exemplary embodiments, in which:
FIG. 1 shows a schematic side view of a spinning station comprising a fastening means, which is claimed according to the invention, for attaching a compaction module on a drafting unit;
FIG. 2 shows an enlarged side view in the region of the fastening means having an appropriately formed coupling device;
FIG. 3 shows a partial view Y according to FIG. 2 ;
FIG. 4 shows an enlarged partial view X according to FIG. 2 ; and
FIG. 5 shows a reduced-size view N according to FIG. 1 .
DETAILED DESCRIPTION
Reference will now be made to embodiments of the invention, one or more examples of which are shown in the drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention. For example features illustrated or described as part of one embodiment can be combined with another embodiment to yield still another embodiment. It is intended that the present invention include these and other modifications and variations to the embodiments described herein.
FIG. 1 shows a schematic side view of a spinning station 1 of a spinning machine (ring spinning machine) comprising a drafting unit 2 , which is provided with a feed roller pair 3 , 4 , a middle roller pair 5 , 6 , and a delivery roller pair 7 , 8 . An apron 12 , 13 is wrapped around each of the middle rollers 5 , 6 , respectively, each apron being held in the illustrated position thereof around a cage, which is not illustrated in greater detail. The upper rollers 4 , 6 , 8 of the mentioned roller pairs are formed as pressure rollers, which are rotatably mounted via schematically illustrated axles on a pivotably mounted pressure arm 10 . The pressure arm 10 is mounted so as to be pivotable about an axle 15 and is acted upon by a spring element F, as is schematically illustrated. This spring element can also be an air hose, for example. The rollers 4 , 6 , 8 are pressed against the lower rollers 3 , 5 and 7 of the roller pair by means of the schematically illustrated spring load. The roller pairs 3 , 5 , 7 are driven via a drive, which is not illustrated. The driven lower rollers 3 , 5 , 7 drive the pressure rollers 4 , 6 , 8 and the apron 13 via friction by means of the apron 12 . The circumferential speed of the driven roller 5 is slightly higher than the circumferential speed of the driven roller 3 such that the fiber material, which is fed to the drafting unit 2 in the form of a roving L, is subjected to a draft between the feed roller pair 3 , 4 and the middle roller pair 5 , 6 . The main draft of the fiber material L takes place between the middle roller pair 5 , 6 and the delivery roller pair 7 , 8 , wherein the delivery roller 7 has a substantially higher circumferential speed than the middle roller 5 .
As is apparent from FIG. 5 (a reduced-size view N according to FIG. 1 ), a common pressure arm 10 is assigned to each of two adjacent drafting units 2 (twin drafting system ZS). Since the elements of the adjacent drafting units and the compaction modules are the same, some of which are disposed in mirror-image positions, the same reference numbers are used for these parts.
The drafted fiber material V that is delivered by the respective delivery roller pair 7 , 8 is redirected downward and enters the region of a suction zone Z of a downstream suction drum 17 of a compaction module VM. The respective suction drum 17 is provided with perforations or openings O, which extend around the circumference of said suction drum.
As illustrated schematically in FIG. 5 , in each case two suction drums 17 are assigned to a twin drafting system ZS, said suction drums being rotatably mounted on a shaft 22 , which is fastened on a carrier 20 . Fixed suction inserts 18 ( FIG. 5 ), which are connected to the carrier 20 , extend into the respective suction drums 17 . As illustrated schematically in FIG. 1 , the suction inserts 18 are provided with air channels LK, which lead to a suction slot S that is disposed on a subregion of the circumference of the respective suction insert 18 in the region of the suction zone Z, wherein the suction slot is opposite the openings O of the suction drum 17 .
The air channels LK of the suction inserts 18 are connected to a suction channel SK, which extends within the carrier 20 to an outlet opening 30 . The outlet opening 30 can have a circular shape. As shown in particular in the enlarged views of FIG. 2 and FIG. 4 , in the present exemplary embodiment, a circumferential recess 23 is provided in the region of the outlet opening 30 and within the suction channel SK, into which said recess a circumferential rib 28 of an end ring 31 protrudes. The end ring 31 is held via the rib 28 , in the axial and radial directions, on the carrier 20 at the outlet opening 30 .
The end ring 31 has a circular through-opening 35 , which has an inner diameter L 1 and is disposed coaxially opposite a through-opening 37 of an attached tube element 19 , wherein the through-opening 37 has an inner diameter L 2 .
A flexible suction tube 16 , for example, is slid on the outer circumference 27 of an annular end 25 of the tube element 19 , the suction tube being connected, at the other free end, to an extraction channel 85 via a schematically illustrated coupling point 26 . The extraction channel 85 is connected to a vacuum source SP.
A helical elevation 86 ( FIG. 2 ) is attached on the outer circumference 27 in order enable the suction tube 16 to be slid more easily onto the end 25 of the tube element 19 and in order to obtain a good seal between the outer circumference 27 of the end 25 and the inner surface 66 of the suction tube 16 . Due to the flexibility of the suction tube, the inner surface 66 of the suction tube 16 adapts to the structure of the outer circumference 27 having the elevation 86 , thereby ensuring a secure seal and, in addition, ensuring that the suction tube is securely held on the tube element.
The tube element 19 , starting from the through-hole 37 , is provided with a conically outwardly extending inner surface 29 of an opening 47 , wherein the inner surface 29 rises (diverges) in the direction of the end ring 31 . The end ring 31 is provided with an end piece 51 , which protrudes in the direction of the tube element 19 and is provided with a conically extending outer surface 52 , on which the inner surface 29 of the opening 47 rests, at least in part. The conically extending outer surface 52 is formed so as to slope (converge) in the direction of the tube element 19 . The end of the outer surface 52 is provided with a curvature (radius) 53 in order to allow the carrier 20 , with the end ring 31 , to pivot relative to the tube element 19 .
The carrier 20 can be composed of two half shells, for example, which are fastened against one another and, in the assembled state, form the suction channel SK. Rather than having a circular cross-section, the outlet opening 30 can also have a rectangular cross-section. In this case, the end ring 31 is also provided with a rectangularly extending rib 28 in the region of the recess 23 . The through-opening 35 would also be circular in this case, as would be the outer surface 52 of the end piece 51 of the end ring 31 , in order to allow the coupling with the downstream tube piece 19 in the region of the coupling point KS.
As is apparent in particular from the enlarged view of FIG. 2 and FIG. 3 , the carrier 20 of the compaction module VM is attached via two clamping elements 11 , which are fastened on a shaft at a distance a. In this case, the clamping elements 11 have a U-shaped base section 54 comprising two limbs E 1 , E 2 , which U-shaped base section 54 is open on one side and via which the respective clamping element 11 is supported on a shaft 59 . The shaft 59 is connected to the machine frame of the spinning machine. The shaft 59 is provided with through-openings 58 , which are incorporated at an axial distance b, for positioning and fixing the respective clamping element 11 on the shaft 59 in the circumferential direction. Screws M protrude through the through-openings 58 and protrude, via the threaded section M 1 thereof, into threaded bores 63 and, via the head M 2 thereof, into bores 64 of the base region 54 of the respective clamping element 11 .
The clamping elements 11 comprise a receiving slot 50 , which is open on one side and is provided with a retaining section 48 that has a greater inner diameter than the receiving slot 50 . The retaining section 48 can be circular, for example, wherein a bolt 45 is held in the retaining section by means of a clamping force. A bolt 45 is fastened on the carrier 20 , on each of two opposing sides, by means of which bolts said carrier is held via the retaining sections 48 of two clamping elements 11 which are fastened on the shaft 59 at a distance a. In order to more easily insert the carrier 20 into the receiving slot 50 via the bolts 45 , the receiving slot is provided with surfaces that diverge outwardly in the region of the opening. The clamping elements 11 can be composed of an elastically resilient material (e.g., plastic) in order to allow the retaining web 46 to undergo an elastic deflection when the bolt 45 is moved into the region of the retaining section 48 . Due to the circular clamped connection between the retaining sections 48 and the bolts 45 , the carrier 20 and, therefore, the compaction module VM are able to pivot about the central axis W of the retaining section 48 .
In the operating position of the compaction module VM ( FIG. 1 ), the suction drums 17 (or a friction ring that is connected to the suction drums) rest on the circumference of the driven delivery rollers 7 , wherein the fiber material V to be compacted is located between the suction drums 17 and the delivery rollers 7 , and is clamped therebetween. The compaction module VM is fixed in this position by means of a web 62 , which rests on a web 49 that is fastened on the carrier 20 . In order to obtain a desired contact pressing force of the suction drums 17 on the delivery roller 7 , the web is attached on a leaf spring 68 , which is fastened on the pressure arm 10 by means of screws 69 .
After the pressure arm 10 is released and transferred into an upper position, which is illustrated by dashed lines, the compaction module VM also pivots, due to its own weight, into a lower position which is illustrated by dashed lines. This pivot movement is limited in the downward direction by a stop 65 , which is attached on the respective clamping element 11 . Such a position is shown by dashed lines in FIG. 2 .
A nip roller 33 , which forms a clamping line P with the respective suction drum 17 in the illustrated operating position, is provided subsequent to the suction zone Z, across which the suction slot S of the respective suction insert 18 also extends. The nip rollers 33 of the illustrated twin drafting system ZS are held in the operating position thereof via a dead point position and are rotatably mounted on an axle 32 , which is mounted in a pressure arm 72 . A spring element is installed in the pressure arm 72 , via which the axle 32 is displaced and loaded, within a schematically indicated guide slot, in the direction of the respective suction drum 17 . The pressure arm 72 is provided with axles 24 via which said pressure arm is pivotably fastened to a bearing element 80 on the carrier 20 . By means of the pivot movement, the pressure rollers 33 can be pivoted into an idle position.
The compaction of the fiber material will not be discussed in greater detail here, since this is sufficiently known from other publications.
The clamping line P, which is produced by the clamping roller 33 , simultaneously forms a so-called “twist stop gap” from which the fiber material is fed, in the form of a compacted yarn FK and while receiving a twist, in the conveyance direction FS to a schematically illustrated ring spinning device. This is provided with a ring 39 and a traveler 40 , wherein the yarn is wound onto a tube 41 in order to form a bobbin 42 (cop). A thread guide 43 is disposed between the clamping line P and the traveler 40 . The ring 39 is fastened on a ring frame 44 , which moves up and down during the spinning process.
If thread breakage occurs between the clamping line P and the bobbin 42 , the yarn FK, which is still being delivered via the clamping point P, is sucked up via the suction channel SK, via the respective extraction tube 75 that is installed on the carrier element 20 , through an opening in the conveying channel 20 under the effect of a vacuum, which is generated via the vacuum source SP, and is fed to an extraction channel 85 . The respective extraction opening 38 of the extraction tubes 75 is assigned to the corresponding yarn path.
An annular elastic sealing element 60 (in short: “seal”) is provided for sealing off the coupling point KS between the end ring 31 and the tube element 19 from the ambient air. The seal 60 comprises a web 70 via which the seal is held in a circumferential groove 71 , which is incorporated on the outer circumference 88 of the tube element 19 . The free end 74 of the seal, which is opposite the web 70 , rests sealingly on the downwardly slanting outer surface 52 of the end ring 31 . It is therefore ensured that the coupling point KS is always sealed off from the ambient air, even if a relative movement between the end ring 31 and the tube element 19 occurs. It is therefore also possible to compensate for tolerances between the end ring 31 and the tube element 19 .
Two coaxially opposed bolts 76 are installed on the tube element 19 in order to hold the tube element in the coupling position which is illustrated in FIG. 2 , wherein the bolts are held in a further retaining section 78 of a further receiving slot 77 , which is open on one side, by two clamping elements 11 which are fastened on the shaft 59 at a distance a from one another. The retaining section 78 has a greater inner diameter than the smallest inner diameter of the receiving slot 77 , which is directly adjacent to the retaining section. In order to improve insertion into the respective receiving slot 77 , these receiving slots are provided with insertion surfaces which extend in a diverging manner in the direction of the opening. That is, the inner diameter of the receiving slot 77 increases in the direction of the insertion opening. Due to the elastic material that was selected for the clamping elements 11 , the retaining web 79 which extends adjacent to the receiving slot 77 can elastically deflect when the bolts 76 move into the retaining sections 78 until the bolts are located in the respective retaining section 78 . The bolts are fixed in this position by means of the elastic springback of the retaining webs 79 .
The receiving slots 50 and 77 of the respective clamping element 11 are disposed such that the longitudinal axes thereof, LA and LB, respectively, which extend in the longitudinal planes of the receiving slots, intersect at an angle c of between 60° and 120°.
In order to ensure that the tube element 19 for the connection to the suction tube 16 remains within a predetermined position range on the clamping element 11 , it is proposed that the respective clamping element has—as seen in the extension of the second receiving slot 77 —a pocket-shaped receptacle 83 , which is open on one side and is provided for fixing a web 89 that is fastened on the tube element 19 . The positioning of the tube element 19 relative to the clamping element 11 , and therefore relative to the suction channel SK of the carrier 20 of the compaction module VM, is thereby ensured.
As illustrated schematically in FIG. 3 , the web 89 of the tube element 19 is formed such that, in the installed position ( FIG. 2 ) of the tube element 19 , the web protrudes into a pocket-shaped recess 83 of each of two clamping elements 11 that are fastened on the shaft 59 at a distance a, and is fixed therein.
In order to adjust the suction power in accordance with the length of the spinning machine, tube elements 19 can be used that have a different inner diameter L 2 of the through-opening 37 . It is thereby ensured that approximately the same vacuum conditions exist on all compaction modules VM. The different tube elements can have different colors in order to prevent mix-ups. The use of the tube element that is installed between the suction channel SK of the compaction module VM and the suction tube 16 makes it possible to easily adapt the suction power of the compaction station to the location of the vacuum source SP.
Modifications and variations can be made to the embodiments illustrated or described herein without departing from the scope and spirit of the invention as set forth in the appended claims. | A fastening mechanism is provided to detachably fasten and position a compaction module on a drafting unit of a spinning machine, wherein the compaction module has a carrier, which is provided with at least one suction channel that is connected to suction inserts of compaction elements that are movably mounted on the carrier. A coupling device using the fastening mechanism. In order to ensure simple and positionally accurate attachment of a compaction module, the fastening mechanism is composed of at least one clamping element that has retaining elements for fixed and positioned fastening on the spinning machine and is provided with a first receiving slot, which is open on one side and has a retaining section, by means of which a retaining element fastened on the carrier can form a positive-fitting clamped connection. | 3 |
This disclosure is based upon Swiss Application No. 1333/00, filed on Jul. 6, 2000 and International Application No. PCT/CH01/00408, filed Jun. 29, 2001, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to a method for producing markings on a textile fabric and a thread-like structure used for this purpose.
A method for tracking textile product webs by a plurality of production steps is known from the individual conference report: “Textiltechnisches Seminar, Textile Messtechnik, (Textile Technology Seminar, Textile Measuring Method), ETH Zurich, St. Gallen, CH, Nov. 26, 1998, pages 1 to 4”, wherein markings are incorporated into the product web, allowing relative determination of position. In the process, the markings are produced by incorporating at least partially electrically conductive yarn. For this purpose very flexible and break-resistant wire is used which, in portions, is spun with cotton into a yarn. The markings formed by the electrically conductive yarn portions are detected in a capacitor which determines the yarn portions by the changed capacity between the capacitor plates.
A drawback of this known method is that it is very difficult to spin short portions of wire of this type. This means that these portions inevitably comprise a certain length which leads to the markings produced in this way being indistinct and covering whole regions. Moreover, they can only be detected by a capacitor and this represents a limitation within today's current broader detection systems.
SUMMARY OF THE INVENTION
The invention, as characterised in the claims, therefore achieves the object of providing a method for producing markings on a textile fabric which survives all the following processing steps and allows clear marking of positions on the textile fabric.
This is achieved according to the invention in that according to the method, during production of the fabric, at least in one edge region, a thread-like structure is included, consisting of a support around which a filament is wound, the filament dividing the support into marking zones and marking-free zones. The filament in the marking zones preferably has, measured per unit of length, a high number of windings and, in the marking-free zones, a comparatively low number of windings. The winding around the support is produced by controlled fancy twisting of support and filament, the division into marking zones and marking-free zones taking place by control of the fancy yarn doubling frame used. The thread-like structure is included during production of the fabric preferably by weaving into the fabric. The filament consists of an electrically conductive wire, the diameter of which is smaller than the diameter of the support and in the marking zones it substantially forms mutually adjacent windings on the support. In the textile fabric, in at least one edge region, a thread-like structure is provided, consisting of a support around which a filament is wound and which divides the support into marking zones and marking-free zones. In a woven fabric the thread-like structure is preferably woven into the central region of the so-called edge.
The advantages achieved by the invention are in particular that a method is provided with which faults in the textile fabric, for example, can be indicated by a position reference which can be traced back even after a plurality of processing steps. Processing steps of this type are known, for example, by names such as scorching, desizing, mercerising, bleaching, washing, drying, etc. The filament may be formed here in such a way that the markings achieved therewith can be detected both capacitatively and visually and therefore measuring processes known from the measurement of yarns can be used. The method according to the invention can be used, in particular, also in conjunction with processes and devices for inspection of the products and in the process, for example even after weaving a woven fabric, can be used to reliably rediscover detected faults even after processing of the product web, although the detectability of the fault has changed in the meantime.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described hereinafter in more detail with the aid of an example and with reference to the accompanying drawings, in which:
FIG. 1 is an illustration of a textile fabric,
FIG. 2 is an illustration of a thread-like structure used therein and
FIG. 3 is a signal course with markings.
DETAILED DESCRIPTION
FIG. 1 shows a portion 1 of a textile fabric, such as, for example, a woven fabric, with a so-called edge 2 on which markings 3 , 4 , 5 , 6 , 7 have been applied which are continued in imaginary lines in the transverse direction of the fabric 1 . These markings 3 to 7 are achieved in that a warp thread is woven into a thread-like structure according to the invention. As a thread-like structure of this type can also be included as a weft thread, markings are produced, represented by lines 8 , 9 , 10 , 11 , 12 , although in reality there are obviously no lines, but only markings on the edge of the relevant structure. Imaginary lines 8 to 12 of this type may usually also be defined by the mass of spacings, as the fabrics do not usually change their original size in the transverse direction and are usually cut according to their length. However, it cannot be assumed that the fabric is divided by the markings into a plurality of fields, such as for example field 13 . As in this precise field 13 there is a fault 14 , this fault can also subsequently be traced at any time, proceeding from the markings.
FIG. 2 shows a thread-like structure 15 according to the invention, consisting of a support 16 and a filament 17 wound around the carrier 16 . In the process, marking zones 18 , 19 , 20 are produced and, therebetween, marking-free zones 21 , 22 , 23 which can form markings 3 to 7 ( FIG. 1 ) in the fabric 1 . It can be seen that the number of windings of the filament 17 on the support 16 is substantially higher in the marking zones 18 , 19 , 20 than in the marking-free zones 21 , 22 , 23 . In the marking zones 18 , 19 , 20 , the windings of the filament 17 are located next to one another, practically without a gap.
FIG. 3 shows a signal course 25 with striking deviations 26 , 27 , 28 etc. as can be produced by the markings 3 to 7 , etc. in the fabric 1 when the edge 2 traverses a suitable measuring apparatus such as, by way of example, a measuring capacitor.
The mode of operation of the invention is as follows:
Firstly, a thread-like structure 15 has to be produced according to the invention. For this purpose, a yarn or a twisted thread is taken, for example, as the support 16 , comprising a diameter, such as the yarn or twisted thread also comprises in the fabric 1 to be marked. A wire with substantially smaller diameter is used as the filament 17 , so it can easily be wound onto the yarn or twisted thread. Mentioned here as an example is a yarn with 30 tex as support and a copper lacquered wire of about 0.08 mm diameter as filament. The support 16 is preferably connected to the filament 17 in a fancy yarn doubling frame of known construction, the filament being processed as the fancy twisted thread is conventionally processed, but with the particular feature that the take-off speed of the support 16 is controlled in such a way that it is alternately fast and slow. During the high take-off speed, the marking-free zones 21 , 22 , 23 are produced with a very large pitch of the windings, and during the low take-off speed, the marking zones 18 , 19 , 20 are produced with very small pitch of the windings.
The thread-like structure 15 is then incorporated into the textile fabric 1 during production thereof. In the case of non-woven or knitted fabrics it is included. In woven fabrics it is woven in as warp thread approximately in the centre in the edge 2 , or optionally included additionally in an end region 24 as a weft thread. Thus the fabric now has markings spanning a virtual matrix along lines 3 to 7 and 8 to 12 on the fabric.
The markings 3 to 7 on the fabric can now be scanned by means known per se, such as are known from yarn testing, in other words by optically or capacitatively working sensors 29 moved relative to the fabric 1 as shown by arrow 30 . For visual scanning a coloured filament is desired and for capacitative scanning, a metal filament is desired. Particularly advantageous therefore, is a coloured metal wire, for example a so-called copper lacquered wire, i.e. a copper wire lacquered in colour on its surface. The markings now produce a characteristic signal course 25 ( FIG. 3 ) with striking deviations 26 to 28 in a suitable sensor 29 , these deviations 26 to 28 being fed to a processor which carries out a suitable evaluation, for example in that it numbers and stores consecutive deviations. The signals may then also be related to faults 14 on the fabric 1 , so specific signals or numbers are then associated with the fault. These are, however, purely expert measures which can be carried out in the most varied ways and are therefore not shown in detail here, as they do not impinge on the core of the invention.
There are obviously also various possibilities of forming the markings with the filament; for example, an equal number of windings may always be provided in the marking zones or the number of windings may be graduated according to the criteria to be preset and markings may be applied to the thread-like structure, which markings are to be associated with various categories. However, it is also conceivable to construct a binary code by suitable selection of the numbers of windings, so each marking is unique in comparison to the other markings. Two filaments, for example with different diameter, can therefore be wound onto a support, thus forming main and secondary markings which bring about deviations with different amplitudes in the detected signal course. | A method for creating markings on a planar textile body and a thread-like body for carrying out the method. According to the invention, the markings on a planar textile body can survive all following process steps and permits a clear marking of position on the textile surface. During production of the planar body, a thread-like body is included, which comprises a support with a filament wound around the support. The support is divided into marked zones and mark-free zones. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 11/613,231, filed Dec. 20, 2006, now U.S. Pat. No. 7,567,801, which is a continuation of U.S. patent application Ser. No. 11/027,233, filed Dec. 30, 2004, now U.S. Pat. No. 7,209,738, which is a continuation of U.S. patent application Ser. No. 09/473,604, filed Dec. 29, 1999, now U.S. Pat. No. 6,898,427, all of which are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for extending coverage for a portable communications device such as an interactive (two-way) communications device. In particular, the present invention relates to extending coverage for a two-way pager in areas where the pager cannot transmit to a receiving station and/or receive from a transmitting station.
BACKGROUND OF THE INVENTION
Interactive two-way pagers and a pager network system in support thereof are known. Examples of such two-way pagers include the RESEARCH IN MOTION (RIM) “BLACKBERRY” two-way pager designed and/or marketed by RESEARCH IN MOTION Limited of Waterloo, Ontario, Canada and the MOTOROLA two-way pager designed and/or marketed by MOTOROLA Corporation of Schaumberg, Ill., USA. Such pagers typically include a battery compartment for receiving a battery, a processor, memory, a data screen for displaying alpha-numeric data, a micro-size keyboard for entering alpha-numeric data, a radio receiver for receiving data over air, and a radio transmitter for transmitting data over air. Accordingly, data may be transmitted from one pager and received by another by way of the network system. Likewise, data from a source external to the network system may be received by a pager, and such pager may transmit data to a destination external to the network system. In addition, such pagers typically include a serial port or the like by which data may be uploaded and/or downloaded, for example during pager initialization, set-up, and upgrade at a pager sales and/or service center.
Examples of pager network systems include the MOBITEX network designed and/or marketed by ERICSSON MOBILE COMMUNICATIONS AB of Sweden and the REFLEX network designed and/or marketed by MOTOROLA Corporation of Schaumberg, Ill., USA. Such network systems (“networks”) typically include one or more base stations, where each base station has associated with it a plurality of geographically spaced base transmitters, each of which can potentially transmit the data received by the radio receiver of the pager, and a plurality of geographically spaced base receivers, each of which can potentially receive the data transmitted by the radio transmitter of the pager. The base transmitters and the base receivers are spread out over a network coverage area, and each is assigned particular transmitting or receiving frequencies by its respective base station.
As should be appreciated, each base station is responsible for directing pager data to its ultimate destination or from its ultimate source. Such base station also assigns the frequencies to the base transmitters and base receivers, keeps track of the locations of pagers with respect to base transmitters and base receivers, assigns each pager to a particular base transmitter and to a particular base receiver as the pager is moved through the network coverage area, or at least through the portion thereof that the base station is responsible for, and transmits information to each pager regarding the assigned base transmitter and assigned base receiver and/or frequencies thereof, among other things. Since the pager must acknowledge receipt for data verification purposes and the like, among other things, the pager must always be in two-way communication with the network, even if only receiving data from such network.
Typically, the base transmitters operate at a relatively high power, owing to the fact that each pager is battery-operated and the receiver therein operates at a relatively low power. Also owing to the fact that each pager is battery-powered and the transmitter therein likewise operates at a relatively low power, the base receivers are typically concentrated at a higher number per geographical area than the transmitter base stations in the network coverage area. Accordingly, it is statistically more likely that a pager is closer to a base receiver than to a base transmitter. Correspondingly, it is also more likely that a pager in a fringe (i.e., area on the edge) or marginal (i.e., an area with poor transmission quality) portion of the network coverage area can receive data from a base transmitter, but that a base receiver cannot receive data from such pager, owing to the relatively low transmitting power of such pager.
The network coverage area for a pager network is typically finite. For example, such network coverage area may roughly correspond to a state or region, a portion of a state or region, a metropolitan area, a metropolitan area extending over portions of several states or regions, or the like. Accordingly, through cooperative service agreements between networks, ‘roaming’ pager coverage may be provided for a pager outside the network coverage area of its ‘home’ network. With such cooperative service agreements, the over-all pager coverage area encompasses a large portion of urban areas in the United States, and many rural areas too. Inevitably, though, there are significant portions of the United States where pager coverage is not available. As should be appreciated, coverage for a pager is not available anywhere the pager cannot communicate with both a base receiver and a base transmitter to achieve the aforementioned two-way communications link. For example, coverage is not available in fringe or marginal portions of the network coverage area or the over-all pager coverage areas (if roaming coverage is provided), as was pointed out above, and in areas external to the network coverage area or the over-all pager coverage areas (if roaming coverage is provided). This is true even if the pager can communicate with a base transmitter. Of course, coverage will also not be available anywhere the pager cannot communicate with a base transmitter, but for the reasons specified above, it is more likely that loss of communication with any base receiver will occur first, or at least concurrently.
Equally inevitably, individuals with two-way pagers or the like visit areas where coverage is not available, both in and out of the United States, and such individuals would like some sort of continued two-way paging service even though in such areas without coverage. Accordingly, a need exists for a method and apparatus to provide coverage for a two-way pager or the like, especially when the pager is outside the aforementioned coverage area.
SUMMARY OF THE INVENTION
In the present invention, a portable communications device (PCD) such as a pager is coupled to a first network by way of a second network when the PCD is out of radio communication with the first network. The PCD leaves a first network mode and enters a second network mode. The PCD then establishes a network connection with the first network by way of the second network, and enters into communication with the first network by way of the second network.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of preferred embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. As should be understood, however, the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
FIG. 1 is a block diagram showing a two-way pager or the like and a base station in accordance with one embodiment of the present invention;
FIG. 2 is a block diagram showing the two-way pager or the like and the base station of FIG. 1 in accordance with another embodiment of the present invention; and
FIG. 3 is a flow chart depicting steps employed with the two-way pager and the base station of FIGS. 1 and 2 in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Certain terminology may be used in the following description for convenience only and is not considered to be limiting. The words “left”, “right”, “upper”, and “lower” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” are further directions toward and away from, respectively, the geometric center of the referenced object. The words “vertical” and “horizontal” in the present application designate orientations with respect to an object when such object is positioned in a particular and/or customary manner, but do not restrict the present invention to the object in such position. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.
Referring now to FIG. 1 , a pager 10 or the like and a base station 12 or the like are shown in accordance with one embodiment of the present invention. As was discussed above, and as shown, a typical two-way pager 10 is intended to be in communication with a pager network 13 and may include a battery compartment for receiving a battery 14 , a processor 16 , memory 18 , an output device such as a data screen 20 for displaying alpha-numeric data, an input device such as a micro-size keyboard 22 for entering alpha-numeric data, a radio receiver 24 for receiving data over air, and a radio transmitter 26 for transmitting data over air. Notably, any particular two-way pager 10 may be employed without departing from the spirit and scope of the present invention, and such pager 10 need not necessarily include all of the aforementioned elements 14 - 26 , again without departing from the spirit and scope of the present invention. For example, such pager 10 need not necessarily have the keyboard 22 or the data screen 20 , and could instead or in addition have a speaker and/or a microphone, a video and/or still camera and/or a video screen, and/or the like.
Importantly for purposes of the present invention, the pager 10 also includes an externally accessible serial port 28 or the like by which data may be uploaded and/or downloaded. As was discussed above, such serial port 28 has heretofore been employed for services such as pager initialization, set-up, and upgrade at a pager sales and/or service center. Nevertheless, the pager 10 is capable of interacting with a device in the field by way of such serial port 28 .
In one embodiment of the present invention, and as seen in FIG. 1 , when the pager 10 is in an area where coverage is not available, such pager 10 may be placed in a cradle 30 or the like and thereby establish contact with the base station 12 by way of a network 32 such as a public switched (i.e., land line) telephone network, a mobile switching (i.e., mobile or cellular) network, an external computing network such as the Internet, an internal computing network, and the like. The public switched telephone network or the mobile switching network are most likely preferred due to their availability even in many remote and even wilderness locations. Such public switched telephone network or the mobile switching network may also be employed to dial into the aforementioned internal or external computing networks.
Preferably, the cradle 30 includes a serial port connector 34 for coupling with the serial port 28 of the pager 10 . As may be appreciated, the cradle 30 and the pager 10 may be constructed such that a positive connection between the serial port connector 34 and the serial port 28 is achieved merely by inserting such pager 10 into such cradle 30 . For example, the cradle 30 and the pager 10 may include keying features for guiding and aligning such pager 10 and such cradle 30 during coupling to achieve such positive connection. Such keying features (not shown) may include but are not limited to complementary grooves and ridges, protrusions and recesses, and the like.
Also preferably, the cradle 30 includes a network connector 36 or the like for coupling the cradle 30 and by extension the pager 10 to the network 32 . Of course, depending on the network 32 , the network connector 36 will vary. For example, for the public switched telephone network, the network connector 36 is merely a telephone connector that receives a connector on one end of a telephone cord, where the other end is appropriately coupled to such network. For the mobile switching network, the network connector 36 may be a port that couples via an appropriate cable to a corresponding port on a mobile phone which in turn is registered on such network. Alternatively, the functional components of such mobile phone are integrated within such network connector 36 . Other appropriate network connectors 36 may be employed based on the network 32 employed without departing from the spirit and scope of the present invention.
The cradle 30 further preferably includes a network communications device 38 for interfacing between the serial port connector 34 and the network connector 36 . Of course, depending on the network 32 , the network communications device 38 will vary. For example, for the public switched telephone network and the mobile switching network, the device 38 is an appropriately configured modem of a type that is typically employed for such purpose. For the internal or external computing network, the device 38 is an appropriately configured network interface such as a network interface card. Other appropriate network communications devices 38 may be employed based on the network 32 employed without departing from the spirit and scope of the present invention. In any instance, the device 38 receives data from the pager 10 by way of the serial port 28 thereof and sends such data to the network 32 , and also receives data from the network 32 and sends such data to the pager 10 by way of the serial port 28 thereof.
The cradle 30 may have its own power source, such as a battery or an AC power converter, and/or may derive its power from the received pager 10 . Of course, if power use is more than minimal, it may be preferable that the cradle 30 have its own power source so as not to excessively draw down the battery of such pager 10 . If the cradle 30 has its own power source, such cradle 30 may supply additional power to the pager 10 so as to conserve the battery of such pager 10 and/or provide a power boost to the pager 10 .
The base station 12 is a traditional base station in the sense that it performs all the normal base station functions with regard to directing data to and from the pager 10 . However, in one embodiment of the present invention, such base station 12 is a non-traditional base station in that it does not have any associated base transmitters or base receivers, and therefore need not concern itself with frequency assignment, pager tracking, pager assignment, and the like. Instead, such base station 12 is a dedicated base station solely for servicing pagers 10 through the network 32 . Accordingly, the base station 12 is coupled to and is a portal between the network 32 and the pager network 13 or the like. In such an instance, the base station 12 may include a server 40 coupled to the network 32 and to the pager network 13 and programmed to emulate all necessary two-way base station functions. Of course, to couple to the network 32 , the base station 12 may also have a network communications device 38 similar to the network communications device 38 in the cradle 30 (e.g., a modem). Moreover, to couple to multiple cradled pagers 10 by way of the network 32 , multiple network communications devices 38 may be employed if necessary. To couple to the pager network 13 , an appropriate network connection 42 may be employed. The details of the couplings, the connections, and the emulation are generally known and therefore need not be described herein in further detail. Of course, the base station 12 may in fact be a non-dedicated base station that directs data from both the network 32 and traditional base transmitters and base receivers without departing from the spirit and scope of the present invention.
In operation, and referring now to FIG. 3 , when two-way operation of the pager 10 is disrupted because such pager 10 is out of range or is otherwise unable to contact its pager network 13 , the user thereof appropriately places such pager 10 into the cradle 30 (step 301 ) so that the serial port 28 of the pager 10 is coupled with the serial port connector 34 of the cradle 30 . In addition, such user appropriately couples the cradle 30 to the network 32 by way of the network connector 36 (step 303 ) and whatever appropriate coupling is necessary (a telephone cable, for example, in the case of a public switched telephone network).
Preferably, the pager 10 and the processor 16 therein are programmed to sense the connection to the cradle 30 , and thereby enter a ‘cradled’ mode (step 305 ) where the radio transmitter 26 and radio receiver 24 therein are not employed. Instead, in such ‘cradled’ mode, the pager 10 and the processor 16 therein preferably gain the attention of and establish control over the network communications device 38 (e.g., the modem) (step 307 ) within the cradle. Alternatively, the user may desire or be required to positively command the pager 10 to enter the cradled mode. Thereafter, the pager 10 and the processor 16 therein employ the network communications device 38 to establish a network connection with the base station 12 by way of the network 32 (step 309 ), and then the pager 10 and processor 16 therein enter into two-way communication with the base station 12 by way of the network 32 (step 311 ) to send and receive pager information.
Preferably, during the time when two-way operation of the pager 10 is disrupted because such pager 10 is out of range or is otherwise unable to contact its pager network 13 , and before the pager 10 enters into two-way communication with the base station 12 , any outgoing data from the pager 10 (such as outgoing messages and other outgoing information) is held in the memory 18 of the pager, and any incoming data destined for the pager 10 (such as incoming messages and other incoming information) is held in an appropriate memory location of the pager network 13 . Accordingly, upon establishing two-way communication between the pager 10 and the base station 12 by way of the network 32 , such incoming and outgoing data is released and exchanged therebetween. Moreover, upon establishing two-way communication between the pager 10 and the pager network 13 by way of the base station 12 and the network 32 , additional incoming and outgoing data (such as new messages and other information) may be composed and exchanged therebetween.
When the user wishes to end the session, such user may command the pager 10 to do so (step 313 ). The pager may also automatically end the session after a pre-determined period of in-activity, among other things. The user can then remove the pager 10 from the cradle 30 (step 315 ) and de-couple the cradle 30 from the network 32 by way of the network connector 36 (step 317 ). Preferably, upon sensing removal from the cradle 30 , the pager 10 returns to a ‘normal’ mode. Alternatively, the user positively commands the pager 10 to return to normal mode. In one embodiment of the present invention, the user can leave the pager 10 in the cradle 30 and allow the pager 10 to automatically make a connection to the base station 12 by way of the network 32 on a periodic or predetermined basis.
Even if coverage is available for the pager 10 in the normal mode by way of the pager network 13 , such pager 10 may still be placed in cradled mode to establish two-way communication between the pager 10 and the base station 12 by way of the network 32 without departing from the spirit and scope of the present invention. Reasons for doing so may include anticipation of more reliable two-way communication, and availability of higher data transmission speeds, among other things, as well as user choice or preference.
In a variation on the embodiment of the present invention shown in FIG. 1 , the actual structure of the cradle 30 is dispensed with, and the pager 10 or the like is coupled directly to the network communications device 38 . Such direct coupling may for example be achieved by way of a serial port connector 34 at the end of a cable which is appropriately attached to such network communications device 38 .
In another embodiment of the present invention, and referring now to FIG. 2 , the cradle 30 of FIG. 1 is omitted, but the necessary contents and/or functionality therein are re-located to the pager 10 ′, as is shown. Thus, the serial port connector 34 of FIG. 1 is no longer necessary, as the network communications device 38 and the connection between such network communications device 38 and the serial port 28 of the pager 10 ′ are internal to such pager 10 ′. The network communications device 38 (e.g., a modem) may thus comprise a chip set within the pager 10 ′, or the processor 16 of the pager 10 ′ may be programmed with the functionality of such device 38 . The network connector 36 is still necessary but is now mounted directly to the pager 10 ′ by appropriate means. Preferably, the network connector 36 is a micro-size connector to conserve space, and may for example be of a type that ‘flips out’ from the pager 10 ′ in a known manner.
In operation, the non-cradled pager 10 ′ of FIG. 2 by definition cannot automatically sense a connection to any cradle 30 . Accordingly, such pager 10 ′ must be positively commanded to enter ‘cradled’ mode, or must automatically sense a connection to the network connector 36 to enter ‘cradled’ mode. Likewise, such pager 10 ′ must be positively commanded to enter ‘normal’ mode, or must automatically sense a disconnection from the network connector 36 to enter ‘normal’ mode. Otherwise, the steps shown in FIG. 3 are performed in substantially the same manner.
Of course, the present invention also encompasses the use of two-way networked data communications devices and portable communications devices other than the pager 10 . Similarly, the present invention encompasses the use of one-way pagers 10 and other similar devices. Likewise, the data from and to the pager 10 or the like may be directed by devices other than a base station 12 , emulated or otherwise.
The programming necessary to effectuate the present invention, such as the programming run by the processor 16 of the pager 10 and the programming run by the server 40 of the base station, is known or is readily apparent to the relevant public. Accordingly, further details as to the specifics of such programming is not believed to be necessary herein.
As should now be understood, in the present invention, a method and apparatus are provided to support coverage for a two-way pager or the like, especially when the pager is outside the coverage area of its pager network. Changes could be made to the embodiments described above without departing from the broad inventive concepts thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims. | A portable communications device (PCD) is coupled to a first network by way of a second network. The PCD is normally in radio communication with the first network, and is coupled to the first network by way of the second network when the PCD is out of radio communication with the first network. In particular, the PCD is coupled to the second network, and is caused to leave a first network mode and enter a second network mode. A network connection is established with the first network by way of the second network, and communication with the first network is entered into by way of the second network. | 7 |
RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 60/870,830, filed Dec. 19, 2006; and is a continuation-in-part of U.S. application Ser. No. 11/868,253, filed Oct. 5, 2007, which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
This invention relates generally to machines and systems for loading cartons. More specifically, the invention relates to apparatuses and methods for preparing end-loadable cartons for loading.
BACKGROUND OF THE INVENTION
Certain cartons include flaps or other elements that are stowed beneath the top wall of the carton. For instance, some cartons are expandable or can otherwise be arranged to include an expanded open-top portion, which is sometimes referred to as a chimney. The expanded portion of the carton increases the volume or capacity of the carton and allows a consumer to, for example, pour ice into the expanded portion and on top of the contents of the carton. Thus, these cartons are sometimes referred to as ice-pack cartons. It is also desirable for such cartons to retain liquid that may accumulate in the bottom of the carton. In certain ice-pack carton configurations, extension panels and gusset panels, or other panels, are elements that are stowed beneath the top wall of the carton and form at least a portion of an expandable structure that allows for the expansion of the carton.
Stowed elements of an ice-pack type carton in particular can undesirably inhibit machine loading of articles into the carton. This is because the placement of the extension panels and gusset panels beneath the top wall of the carton can at least partially obstruct sliding movement of articles that are introduced into the carton via an open end thereof when the carton is arranged as a tubular structure for loading. The stowed elements prevent smooth mechanical loading and may cause the articles to tip. One method of preventing the articles from tipping is to hand load the cartons. However, hand-loading is an inefficient method of loading large quantities of cartons.
Another approach to prevent the articles from tipping or being obstructed as they are loaded is to arrange the extension panels and gusset panels such that they are secured to and stowed against the outside of the top wall or end walls, so that the interior of the carton is free from obstructions. However, stowing the extension and gusset panels against the outside of the carton is a less aesthetically appealing design since the walls of the carton are then not clean or continuous.
Thus, a heretofore unaddressed need exists in the industry to provide an apparatus and method for loading cartons having an inwardly-extending feature such as a chimney-forming expansion element that is stowed inside the carton.
SUMMARY OF THE INVENTION
The shortcomings of the prior art are overcome by a system, method and apparatus for loading a carton having an inwardly-extending element that is stowed underneath a top wall of the carton such that loading of the carton is not hindered.
The present invention provides a method of preparing a carton for loading and further provides an apparatus for facilitating the method.
The invention provides a carton formable from a blank into a tubular structure, which structure has elements that are stowed beneath the top wall of the carton when the carton is loaded with articles such as cans. The elements that extend inwardly into the tubular structure/carton and that are stowed beneath the top wall thereof hingedly adjoin the top wall and adjoin respective end flaps. In an aspect of the invention, the stowable elements and the respective end flaps adjoined thereto are foldable with respect to one another.
The method taught by the invention comprises engaging the end flaps such that the respective adjoining elements are pivoted upwardly into face-contacting position with the underside of the top wall.
The apparatus taught by the invention engages the end flaps of cartons as those tubular structures are moved along a path so as to cause the respective adjoining, inwardly-extending elements to pivot upwardly. In one aspect, the apparatus comprises a guide that downwardly deflects an end flap thereby causing the respective adjoining, inwardly-extending element to pivot upwardly. In another aspect, the apparatus further provides a means for both deforming and deflecting an end flap so as to inhibit undesired folding of an end flap and element with respect to one another and thereby promote pivoting.
The foregoing has broadly outlined some of the aspects and features of the present invention, which should be construed to be merely illustrative of various potential applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exemplary embodiment of a blank for forming an exemplary expandable carton.
FIGS. 2-9 are perspective views of the blank of FIG. 1 showing the set up of a carton formed from the blank of FIG. 1 .
FIG. 10 is a perspective view of the carton formed from the blank of FIG. 1 .
FIG. 11 is a perspective view of an exemplary embodiment of an apparatus for loading a carton.
FIG. 12 is a side elevation view of a carton illustrating a step of an exemplary embodiment of a method of loading the carton.
DETAILED DESCRIPTION
As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
Referring now to the drawings, wherein like numerals indicate like elements throughout the several views, the drawings illustrate certain of the various aspects of exemplary embodiments of an apparatus and method for folding and loading a carton that includes an inwardly-extending structure. Specifically, the apparatus and method are focused towards folding expansion feature elements that are stowed inside the cartons such that the expansion elements do not impede end loading of the carton.
The apparatus and methods described herein are described with respect to an exemplary embodiment ice-pack carton 200 that is formed from a blank 100 . The carton 200 and blank 100 forming the carton are also described in co-pending U.S. application Ser. No. 11/868,253, filed Oct. 5, 2007, which application is hereby incorporated by reference in its entirety. The apparatus and the methods of the invention are not only applicable to the exemplary embodiment of the carton shown, but are also applicable to alternative types of cartons having inwardly-extending features that are stowed against the interior surface of a carton wall.
Referring to FIG. 1 , the blank 100 is preferably a single sheet of suitable substrate. It is to be understood that, as used herein the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, and the like. The carton may include a water-resilient coating on at least one surface and may be equipped with features that prevent liquid from leaking from the bottom of the carton. In the exemplary embodiment, the blank is designed for packaging beverage cans. It is envisaged that other articles and/or different arrangements of articles may be contained within the carton and that the blank may therefore be sized accordingly.
As used herein, the terms “fold line” and “severance line” refer to all manner of means for indicating optimal fold or cut locations, respectively, including frangible or otherwise weakened lines, perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, scored lines, slits, printed lines, any combination thereof, and the like. To aid in distinguishing the features of the blank 100 and tubular structure T, fold lines are shown as dashed lines in FIG. 1-9 .
The blank 100 includes a series of primary panels which define the walls of a tubular structure T (shown in FIGS. 8 and 9 ) that defines the body of the expandable carton 200 that is shown in FIG. 10 . The blank 100 includes first side panels 110 , 118 that are partial side panels, a top panel 112 , a second side panel 114 that is a full side panel, and a bottom panel 116 . The primary panels are hingedly connected one to the next along fold lines. First side panel 110 is hingedly connected to the top panel 112 along fold line 120 , the top panel 112 is hingedly connected to the second side panel 114 along fold line 122 , the second side panel 114 is hingedly connected to the bottom panel 116 along fold line 124 , and the bottom panel 116 is hingedly connected to first side panel 118 along fold line 126 .
End flaps are hingedly connected to opposite ends of each primary panel along fold lines. Certain of the end flaps form end closure structures at respective open ends of the tubular structure T and thereby define the end walls of the expandable carton 200 . The blank 100 is substantially symmetric such that the end flaps that are hingedly connected to opposite ends of each primary panel are substantially identical. Accordingly, the end closure structures of the carton 200 are substantially identical and like references have been used with a suffix “a” or “b” affixed to distinguish one end of the carton from the other. Thus, the description of an element or group of elements having a suffix “a” is generally applicable to a like-numbered element or group of elements having a suffix “b.” In several instances herein, for clarity, only one of the like elements may be described unless a description of the other or both of the like elements is useful for understanding the invention.
First side end flaps 130 a , 138 a are hingedly connected to first side panels 110 , 118 along fold lines 140 a , 148 a , respectively. A top end flap 132 a is hingedly connected to top panel 112 along fold line 142 a . A second side end flap 134 a is hingedly connected to second side panel 114 along fold line 144 a . Lastly, a bottom end flap 136 a is hingedly connected to bottom panel 116 along fold line 146 a . The bottom end flap 136 a is preferably long enough to cover an entire open end of the tubular structure T and can include a fold line F to facilitate folding and loading the carton 200 . The top end flap 132 a includes first extension panels 170 a , 172 a which are separated by a tear strip 190 , which is defined by severance lines 164 a , 164 b and will be described in further detail below.
The first extension panels 170 a , 172 a are hingedly connected to second extension panels 174 a , 176 a along fold lines 178 a , 180 a , respectively. Each of the fold lines 178 a , 180 a extends convergingly from fold line 142 a to a cutout (which may also be considered a notch or a void) V that separates the second extension panels 174 a , 176 a and defines a distal end of the top end flap 132 a . The second extension panels 174 a , 176 a are further hingedly connected to tabs 182 a , 184 a along fold lines 186 a , 188 a , respectively. It should be noted that the side end flaps 130 a , 134 a are separated from the tabs 182 a , 184 a , respectively, along cut lines C.
Certain of the end flaps are connected to adjacent end flaps by respective intervening gusset panels. The bottom end flap 136 a is connected to the side end flaps 134 a , 138 a by gusset panels 171 a , 173 a , respectively. The side end flaps 134 a , 138 a are hingedly connected to gusset panels 171 a , 173 a along a fold line 175 a , 177 a , respectively. The gusset panels 171 a , 173 a are further hingedly connected to the bottom end flap 136 a along fold lines 154 a , 156 a , respectively.
The second extension panels 174 a , 176 a include distal edges E 1 , E 2 . The width of the cutout V is defined by the edges E 3 , E 4 of the second extension panels 174 a , 176 a , respectively, and the cutout V is further defined by an edge E 5 of the top end flap 132 a.
The tear strip 190 extends across the top panel 112 to define side expansion panel portions 192 , 194 of the top panel 112 . The tear strip 190 further extends across the top end flaps 132 a , 132 b to define the first extension panels 170 a , 172 a . The opposing distal ends of the severance lines 164 a , 164 b extend to the cutouts V, terminating at the convex distal edges E 5 , respectively. The first extension panels 170 a , 172 a are hingedly connected to respective portions 192 , 194 of the top panel 112 along fold line 142 a so as to remain connected thereto after removal of the tear strip 190 .
Erecting the carton 200 from the blank 100 may be accomplished with the folding operations as described herein. The operations can be performed entirely or in part by automatic erecting machinery or manually. The method of performing the erecting process is not limited to the exemplary method described. Particularly, the order of the steps can be altered according to manufacturing requirements, steps may be added or omitted, and the means for securing components to one another may vary. The surfaces of sheet material may be secured together by suitable means for securing, such suitable securing means including tape, staples, interlocking folds, VELCRO®, glue or other adhesives, combinations thereof, and the like.
A first phase of setup can be performed on what is typically referred to as Inplant Equipment (IPE). Specifically, the blank 100 can be folded and secured into a collapsed tubular structure that can thereafter be erected into a loadable condition without additional gluing. The loadable condition is achieved when an open-ended tubular structure T can be loaded through one or both ends and then sealed, as described in further detail below.
Referring to FIGS. 2 and 3 , the inside surface of the blank 100 is folded along fold line 142 a such that inside surfaces of the top end flaps 132 a , the second extension panels 174 a , 176 a , and the tabs 182 a , 184 a are in a face-contacting arrangement with the inside surfaces of the first side panel 110 , the top panel 112 , and the second side panel 114 , respectively.
Referring to FIGS. 3-5 , the blank 100 is folded along the fold lines 178 a , 180 a such that the outside surfaces of the second extension panels 174 a , 176 a are in a face-contacting arrangement with the outside surfaces of the top end flap 132 a generally and its constituent elements first extension panels 170 a , 172 a , respectively. Thereby, the portions of the second extension panels 174 a , 176 a and the tabs 182 a , 184 a that are adjacent to the edges E 1 , E 2 overlap one another and are secured to one another. Tabs 182 a , 184 a are secured to one another to form a composite top end flap X 1 that at least partially forms an end closure structure of the carton, as described in further detail below. The second extension panels 174 a , 176 a are secured to one another and, along with the first extension panels 170 a , 172 a , define a two-ply expandable structure (also considered to be an expansion feature) X 2 . As the portions of the second extension panels 174 a , 176 a and the tabs 182 a , 184 a are secured to one another, the fold lines 186 a , 188 a substantially align to define a fold line 186 a / 188 a along which the end flap X 1 is hingably connected to the expansion feature X 2 . More specifically, the composite end flap X 1 and the pair of second extension panels 174 a , 176 a are joined to one another along the fold line 186 a / 188 a . Further, the end flap X 1 and the pair of second extension panels 174 a , 176 a are at least initially coplanar with respect to one another across the line 186 a / 188 a . The line 186 a / 188 a does not serve as a fold line until the end flap X 1 is folded downwardly to close the end of the tubular structure T. The fold line 186 a / 188 a is aligned with or is otherwise substantially adjacent to fold line 142 a along which the expansion feature X 2 is hingedly connected to the top panel 112 .
Referring to FIGS. 6 and 7 , glue or other adhesive is applied to at least one of the inside surface of the first side panel 118 and the outside surface of the first side panel 110 so that the portion of the first side panel 118 adjacent to the edge 119 overlaps and is secured to the first side panel 110 . Similarly, the first end flaps 130 a , 138 a overlap and are secured to one another. Referring to FIG. 7 , the collapsed tubular structure T of the carton 200 is formed as the first side panels 110 , 118 are secured to one another to form a composite first side panel 110 / 118 and the first side end flaps 130 a , 138 a are secured to one another to form a composite first side end flap 130 a / 138 a.
The carton is now in a collapsed tubular condition which is ready for the second phase of setup, including automatic erecting, loading and sealing using outplant equipment (OPE). OPE, including the apparatus of the invention that is described in further detail below, is typically located in a bottling or packaging facility that is distinct from the location where the tubular structures T and the collapsed cartons 200 are formed. Those skilled in the art will be familiar with the equipment and methods for erecting, loading, and sealing a tubular carton. Therefore, only operations specific to the embodiments described herein will be detailed.
As shown in FIGS. 8 and 9 , the cartons are erected as tubular structures T. The primary panels that define the tubular structure T and the end closure structures define the walls of the carton 200 . The top panel 112 defines a top wall 212 , the side panels 110 / 118 , 114 define side walls 210 , 214 , and the bottom panel 116 defines a bottom wall 216 . The side 130 a / 138 a , 134 a and bottom 136 a end flaps can be arranged to align with a respective wall of the carton 200 or can otherwise be folded outwardly to facilitate loading. Accordingly, articles, such as cans, can be easily loaded into the carton 200 .
Referring to FIG. 10 , an end wall 218 which can be seen and an opposing end wall 22 that cannot be seen in this view are formed from the various flaps that are overlapped and adjoined to form end closures for the tubular structure.
Referring to FIG. 11 , an apparatus 300 is illustrated that includes means for deflecting the end flap X 1 according to the exemplary method. The apparatus 300 , or a packaging machine of which the apparatus 300 is a part, includes a conveyor N on which tubular structures T are supported and transported in a flow direction F. In the exemplary embodiment, means for deflecting the end flap X 1 includes a guide 310 that extends substantially parallel to the flow direction F. The guide 310 is dimensioned and positioned such that, as a carton 200 is transported by the carton conveyor N within contacting proximity of the guide 310 , the angled upstream end of the guide 310 contacts the end flap X 1 to pivot the expansion feature X 2 about the fold line 142 a . The end flap X 1 continues to deflect or pivot until it comes in contact with the bottom edge of the guide 310 , where the end flap X 1 is held at a maximum deflected position until reaching the end of the guide 310 . It should be understood that the end flap X 1 is deflected or pivoted by a certain amount such that the extension feature X 2 is deflected a certain amount and such that the end flap X 1 and the extension feature X 2 remain substantially coplanar. Thereafter, the articles can be loaded through the first open end of the tubular structure T. It should be understood that the guide 310 is disposed adjacent to the second open end of the tubular structure T.
Referring to FIG. 12 , when the carton 200 is erected as a tubular structure T, the expansion features X 2 in effect become inwardly-extending structures that tend to extend into the open ends of the tubular structure T or to otherwise obstruct the open ends of the tubular structure T. The end flaps X 1 extend outwardly from the open ends of the tubular structure T. To aid in this portion of the description, the end flaps X 1 and expansion features X 2 will be denoted by the alphabetical suffixes “a” and “b” that have been previously used herein to distinguish features at opposing ends of the carton 200 . As articles are loaded through a first open end of the tubular structure T, the articles contact a first expansion feature X 2 b and displace the first expansion feature X 2 b toward the top wall 212 so as to properly position the first expansion feature X 2 b . As the articles continue to move through the tubular structure T toward a second open end of the tubular structure T, the articles would tend to contact a second expansion feature X 2 a that is hinged at the opposing end of the carton tubular structure T. If this contact were to occur the articles might displace the second expansion feature X 2 a towards the open end so as to improperly position the second expansion feature X 2 a or the articles might be made to tip over.
The exemplary method and apparatus will facilitate loading the carton 200 such that the second expansion feature X 2 a is properly positioned and does not cause the articles to tip over. Specifically, the exemplary methods and apparatuses position the second expansion feature X 2 a such that the second expansion feature X 2 a is stowed along the inside surface of the top wall 212 . To displace the second expansion feature X 2 a from the second or non-loading end of the tubular structure T, the corresponding end flap X 1 a is contacted, deflected, or pivoted such that the second expansion feature X 2 a deflects or pivots toward the inside surface of the top wall 212 of the tubular structure T. For example, the end flap X 1 a can be pressed downwardly so as to press the second expansion feature X 2 a or the distal end of the second expansion feature X 2 a against the inside surface of the top wall 212 . As those skilled in the art will recognize, at minimum, the deflection of the end flap will at least cause the distal end of the second expansion feature X 2 a to be raised above the height of the articles such that the articles can slide underneath the second expansion feature X 2 a . In certain embodiments, the distal end is flush with the top wall, while in certain embodiments, the entire expansion feature X 2 a is flush with the top wall.
In alternative embodiments, means for deflecting can include guide structures that travel along a path in the flow direction F and extend downwardly or otherwise transversely with respect to the flow direction F to contact the end flaps X 1 or the top walls of the cartons 200 . For example, means for deflecting can include a plunger apparatus with plungers that extend to deflect the end flaps X 1 . As another example, the plungers can have a substantially flat shape and extend into the open end of the carton to hold the expansion features against the inside surface of the top wall 212 . Thereby, the articles can slide underneath the plunger as they are loaded and the plunger is thereafter removed before forming the end closure.
In certain embodiments, the apparatus 300 may also include means for deforming the end flap X 1 to prevent the end flap X 1 and the expansion feature X 2 from folding along the fold line 186 a / 188 a . In certain embodiments, means for deforming includes the guide 310 wherein the guide 310 is disposed to engage the end flap X 1 in such a manner that it deforms sufficiently to inhibit the end flap X 1 and the expansion feature X 2 from folding along the fold line 186 a / 188 a . In alternative embodiments, means for deforming includes the plunger apparatus described above. For example, the plunger apparatus can include plunger elements with pointed ends that contact a central portion of the end flap X 1 and/or a central portion of the top wall 212 such that the end flap X 1 and expansion feature X 2 bow, thereby making it difficult to fold the end flap X 1 and expansion feature X 2 along the fold line 186 a / 188 a . In other embodiments, the material properties of the carton 200 are such that the end flap and expansion feature X 2 do not fold along the fold line 186 a / 188 a as the end flap X 1 is contacted or deflected and means for deforming is omitted.
The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims. | A substantially tubular end-loadable carton ( 200 ) comprising a top wall ( 212 ), an inwardly-extending structure (X 2 ) foldably adjoining said top wall ( 212 ) stowable in a substantially flat-face position with an underside of said top wall ( 212 ), and a top end flap (X 1 ) connected to said inwardly-extending structure is translated in a direction (F) and a flap deflector ( 310 ) is disposed to engage and deflect the end flap (X 1 a ) downwardly and thereby cause the inwardly-extending structure (X 2 a ) to pivot upwardly inside the carton ( 200 ) into substantially flat-face position with the underside of the top wall ( 212 ) of the carton ( 200 ). | 1 |
BACKGROUND
[0001] As credit card fraud and identify fraud becomes more prevalent, credit card issuers and personal information providers (government agencies, etc) are requiring greater security by companies that process transactions using credit cards or other personal information. The software applications used by these companies must meet strict standards for credit card processing required by credit card issuers and personal information. The standards include providing secure processing and storage of credit card information, and other privacy identifiers such as driver's license, banking or other financial data as for example as may be achieved by suitable encryption of credit card identifiers, identification numbers or bank account numbers. However, it is very difficult for companies with existing credit card and other identifiable information (driver's license, social security numbers, banking information, etc) to meet these requirements.
SUMMARY
[0002] A method and apparatus is provided for privacy identifier remediation using a secure server installation. The secure server installation abstracts privacy identifiers from its server, network, application and database environments, thus reducing investment in securing, segregating and/or isolating these environments in their entirety. The secure server installation intercepts transactions using privacy identifiers that are sent from front end applications to back end applications, and forwards tokens in replacement of privacy identifiers for processing by the back end applications. The secure server component also acts as a mediation gateway to connect to external agencies or processing systems. In an embodiment, the privacy identifiers comprise credit card numbers.
[0003] These and other aspects of the apparatus and method are set out in the claims, which are incorporated here by reference.
BRIEF DESCRIPTION OF THE FIGURES
[0004] Embodiments will now be described with reference to the figures, in which like reference characters denote like elements, by way of example, and in which:
[0005] FIG. 1 is schematic showing the processing components of an embodiment of a secure server installation and its environment;
[0006] FIG. 2 is flow diagram illustrating method steps of a privacy identifier remediation process;
[0007] FIG. 3 is a flow diagram illustrating further method steps of a privacy identifier remediation process;
[0008] FIG. 4 shows details of the process of FIG. 2 applied to the specific example of credit cards; and
[0009] FIG. 5 shows details of the process of FIG. 3 applied to the specific example of credit cards.
DETAILED DESCRIPTION
[0010] In the claims, the word “comprising” is used in its inclusive sense and does not exclude other elements being present. The indefinite article “a” before a claim feature does not exclude more than one of the claim feature being present. Each one of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the claims.
[0011] In FIG. 1 , secure server installation 10 is physically isolated in a secure location and logically connected via firewall 12 and router 14 to a variety of front end servers 16 , back end systems 18 , systems 20 and external processing systems. The front end servers 16 comprise any server or device that captures one or more privacy identifiers such as credit card data, social insurance numbers, bank account numbers, driver's license numbers, contract numbers and phone numbers from a person such as a customer or consumer. The back end systems 18 comprise for example application and database servers that process privacy transactions, that is, a transaction that involves a privacy identifier. The systems 20 comprise privacy data validation servers, and may include for example end systems and users that need to connect to the secure server installation 10 for purposes of maintenance & operations, monitoring, logging of privacy data for purposes of audits, financial reporting and investigations. The connection links between the elements shown in FIG. 1 represent logical connections formed upon request over any communications link including optical fiber, wireless and wired connections, and may include intervening networks of any suitable kind such as portions of the internet. SSL or equivalent or better communications security should be used to secure communications, and for that purpose the secure server installation 10 may be connected via a firewall 12 to the router 14 by an SSL device 15 such as an SSL accelerator, as for example an SSL accelerator from F 5 Networks.
[0012] The secure server installation 10 comprises in the embodiment shown a first server 22 , referred to here for convenience as the Avalon server 22 (token management server), a second server 24 , referred to here for convenience as the HSM server (hardware security module) and a third server 26 , which acts as a database server. Other configurations of fewer or more servers could be used, and the entire functionality of the secure server installation in some embodiments could comprise a single server. The servers 22 , 24 and 26 are connected together in this embodiment via multiple IP/Ethernet inter-connects in a bind configuration (for example an Ether-Channel) into a switch 28 such as a Cisco L2 or L3 switch. Database server 26 in this embodiment connects to a storage system, for example a disk array 27 , via a suitable switch 29 , such as a Brocade FC switch. Other arrangements may be used for storage, such as flash memory, tape or optical disk.
[0013] In operation, the system of FIG. 1 operates as follows according to the steps of FIG. 2 and 3 . The process steps may be applied to any privacy identifier for example a credit card transaction, as for example when a customer seeks to purchase services using a credit card. As shown in FIG. 2 , beginning with step 30 , a front end server 16 captures a privacy identifier (PI) (as for example credit card data that may include a credit card identifier (CCI) and, in step 32 , forwards the privacy identifier to the secure server installation 10 . At the secure server installation, the privacy identifier is encrypted in step 34 . In addition, a token uniquely associated with the privacy identifier is generated by an irreversible function in step 36 . The token and encrypted privacy identifier and key hash of the privacy identifier are stored in a manner that they are associated with each other in step 38 . The token is then forwarded to a back end server 18 in step 40 for further processing according to the nature of the transaction in step 42 , where the token is processed as a proxy for the privacy identifier.
[0014] As shown in FIG. 3 , the transaction may in some embodiments proceed as follows for the purpose of validating the privacy transaction, as for example a credit card validation where credit card data, and in some embodiments other privacy data, is validated. In step 44 , the back end servers 18 request privacy identifier validation by generating a validation request message, and sending the validation request message to a information validation server 20 such as a credit card validation server. The validation request message contains the token and not the privacy identifier. At the secure server installation 10 , the token is removed from the validation request message and replaced by the privacy identifier in step 46 . In step 48 , the validation request message is forwarded to an end system 20 , such as a information validation server. Upon validation of the request, in step 50 a confirmation message is returned to the back end user 18 that requested validation. The privacy identifier (PI) is not included in the confirmation message to 18 . If there is a privacy identifier (PI), it is removed by secure server installation 10 .
[0015] As outlined below, in one exemplary embodiment applied to credit card identifiers, although similar operations may also be applied to other privacy identifiers, the Avalon server 22 is configured to generate unique and meaningless tokens, to request a search and match of tokens for association of correct credit card identifiers and an authentication code for the credit card identifiers via database server 26 , to extract credit card identifiers and insert tokens for internal backend system processing and to extract tokens and insert credit card identifiers for external communications processing for payment validation.
[0016] A token is substituted for a privacy identifier for all back end transactions. The token is unique to the privacy identifier and meaningless in relation to the privacy identifier. That is, the privacy identifier cannot be determined from the token. One manner of accomplishing generation of a meaningless token is to select a length of characters by an irreversible function such as generating the token in sequential order as credit card identifiers are processed by the Avalon server 22 . The token may thus be obtained by looking up an ordered sequence of tokens, and selecting an unused token from the ordered sequence. A suitably long token should be adopted to cover variable length privacy identifiers. The characters may include any suitable characters, such as numerals and letters but may include other characters.
[0017] In one embodiment, all tokens have a one-to-one relationship with privacy identifiers such as credit card numbers and other privacy identifiers. Thus, in the case where the privacy identifier is a credit card number, no matter how many times a customer issues a credit purchase with the same credit card identifier, the transactions may always use the same token that was issued the first time the customer completes a transaction using the secure server installation 10 . The same applies to other privacy identifiers. If an individual provides the same ID for any number of financial transactions, the token associated with that ID will always be the same one utilized during the processing of the transaction.
[0018] By selecting a suitably long token, for example in one embodiment a numerical entity 21 digits long, there will never be more tokens issued to any particular individual than the total possible number of unique credit card identifiers and other privacy identifiers that an individual possesses and uses in the system. For example, as an extreme scenario, if an individual uses 40 different credit card identifiers and provides 40 pieces of different ID for various financial transactions, this individual would require a total of 80 unique tokens from the secure server installation 10 . If we consider a total adult population of 500,000,000 (500 Million) for this scenario, the total number of tokens that the secure server installation would need to issue is 40,000,000,000 (40 Billion) tokens (80×500 Million). Thus, a token of length 21 digits will not be exhausted in practice. However, longer tokens could be used.
[0019] Tokens in one embodiment are issued in a sequential format for every request the system receives. Each request received however is completely random with no discernable pattern or ability to anticipate the type of value associated with the token. Token requests may come in from a variety of front end servers 16 and the generated token delivered to any of a large number of back end servers 18 . The token requests may be processed in batches amongst other individual requests coming into the back end servers 18 . Token requests may be associated with different types of identifiers (credit card verses other privacy identifiers), different credit card suppliers, different privacy identifiers (such as drivers license, bank account, PIN, Student Card, Government Employee #, etc. . . . ) and may be issued during any time of the day. Accordingly, due to the randomness, types of requests and data to be tokenized being sent to the secure server installation 10 , it is quite impossible to define or construct a usable pattern of token issuing.
[0020] Request for tokens are restricted to specific applications whose authorization and authentication is tracked each time those applications need to communicate with the secure server installation 10 . Once communication and access have been granted to the system, the activity to request a token, encryption/decryption or hashing service may be monitored, tracked and written to a log file. Tracking software may also be applied to the back end servers 18 which need to connect to the secure server installation 10 . Thus there are multiple areas where processes are in place to ensure the secure request and issuing of tokens. The same security measures apply to those teams which need to access secure server installation 10 such as audit teams, reverse payment teams, system administrators and security officers. Thus only those systems and/or individuals with strict secure pre-defined credentials are able to request a credit card identifier for decryption by submitting a token. Each role of the audit teams, reverse payment teams, system administrators and security officers are granted specific levels of security without overlap of the other roles, further reducing risk.
[0021] Tokens are stored in the clear within the backend systems 18 . If the token is sufficiently long, such as for example longer than any credit card or other privacy identifier, the token has no meaning that can be deduced from its length. In addition, even if the token was truncated, the specific format of the digits' numbering scheme would not meet the validation process of a credit card identifier. By generating the token from an irreversible function such as a sequential number generator, the token is completely independent of the credit card or privacy identifier randomly submitted by a particular person or business for the secure server installation 10 to process. Further, there is no association between the token and credit card identifier except for the token being the prime search key to find the encrypted credit card identifier which enables the completion of the requested financial transaction by a particular backend system 18 . Additionally, this process is a one-way stream in which the back end system 18 cannot and does not see the privacy identifier when a transaction is processed. The secure server installation 10 is the last step in the communication stream between the back end servers 18 and external privacy identifier processing servers.
[0022] Referring to FIG. 4 , further details of operation of a secure server installation are described in an exemplary embodiment applied to credit card transactions. The same process of token insertion and credit card identifier (CCI) encryption process may be applied to other privacy identifiers as for example bank account identifiers.
[0023] Step 60 Front End Server 16 →Avalon Server 22 (Token Request) A process of credit card remediation begins with generation of a token request by a front end server 16 during a credit card processing request. The front end server 16 may be a web tier application that requires use of a credit card payment to complete a transaction. The front end server 16 will need to communicate with a back end server 18 for the purpose of completing the transaction. The normal transaction process using a credit card is commenced, but the front end server 16 pauses the transaction process for the time required to send the credit card identifier to the secure server installation 10 for a token request/receipt. Communication stream between the front end server 16 and secure server installation 10 is secured via SSL.
[0024] Step 62 Avalon Server 22 →HSM Server 24 (Encryption Request) The Avalon server 22 at the secure server installation 10 receives credit card identifier and sends it to the HSM Server 24 for encryption and generation of the keyed hash of credit card identifier, for example by a KEYed Hash process.
[0025] Step 64 HSM (Encryption) The HSM server 24 encrypts the credit card identifier (using a strong encryption KEY # 1 hash, as for example using a 1024 bit key) and builds an authentication code corresponding to the credit card identifier for look up purposes. The cryptography key for decryption is kept at the HSM server 24 . An example of an authentication code is a keyed hash based on the credit card identifier+a 256 bit KEY (using Key # 2 ) The strength of encryption KEY # 1 and KEY # 2 should be sufficiently strong to meet security standards applicable to the transaction process. An example authentication code is a keyed-hash message authentication code, or HMAC, calculated using a cryptographic hash function in combination with a secret key. As with any MAC, it may be used to simultaneously verify both the data integrity and the authenticity of a message. Any suitably strong iterative cryptographic hash function, such as MD5,SHA-1 or better, may be used in the calculation of an HMAC for this purpose. The cryptographic strength of the HMAC depends upon the cryptographic strength of the underlying hash function, on the size and quality of the key and the size of the hash output length in bits.
[0026] Step 66 HSM Server 24 →Avalon Server 22 (Return CCI) The HSM server 24 returns the encrypted Credit card identifier and authentication code to the Avalon server 22 .
[0027] Step 68 Avalon Server 22 →Database Server 26 (Existing Token?) In an embodiment, before creating a token, the Avalon Server 22 sends the authentication code and, in some embodiments, an entity type to the database server 26 to search for an existing token. An entity type may be an additional security code based on a feature of the transaction being paused, as for example based on the credit card issuer (such as VISA™). Look up in the database server 26 is done via the authentication code and the entity type to lower or avoid the possibility of collisions (or token mismatch).
[0028] Step 70 Database Server 26 →Avalon Server 22 (Existing token returned) If a match on authentication code and entity type is found, the database server 26 returns the token matched.
[0029] Step 72 Database Server 26 →Avalon Server 22 (No existing token) If no match is found, the database server 26 returns a “null” response indicating to the Avalon server 22 that a new token must be created.
[0030] Step 74 Avalon server 22 (Create token). If no existing token is returned from the database server 26 , the Avalon server 22 generates a new token as for example a unique sequential and meaningless number. The Avalon server 22 associates the token with an encrypted credit card identifier, the authentication code, and entity type, and also any other suitable identification information, such as a table name or key label, used by the database.
[0031] Step 76 Avalon server 22 →Database Server (Store Token). In this step, the Avalon server 22 sends the token, encrypted credit card identifier, authentication code, entity type and other suitable identification information to the database server 26 for processing and storage. The database server 26 returns an acknowledge message when this process is complete.
[0032] Step 78 Avalon server 22 →Back End Server 18 (Forward Token). Once an acknowledge response from the database server 26 has been received, the Avalon server 22 sends the token to the back end server 18 , where the token is used by the back end server 18 to carry out the transaction requested by the front end server 16 that requested the transaction and originally forwarded the credit card identifier that has now been substituted by the token.
[0033] Referring to FIG. 5 , steps 80 - 96 detail the payment confirmation process.
[0034] Step 80 Back End Server 18 →Secure server installation 10 (Verification Request) If credit card verification is required, the following steps may be taken. Once the back end server 18 has completed its processing, the back end server 18 sends its financial transaction data stream (which includes the unique token) to the secure server installation 10 for credit card identifier lookup and re-insertion. Communication stream between the two entities is secured via SSL.
[0035] Step 82 Avalon server 22 (Token/CCI Exchange Request) The Avalon server 22 receives the data stream from the back end server 18 and pauses the transaction process for the time required to extract unique token, look up credit card identifier in the database 27 and re-insert credit card identifier in the data stream.
[0036] Step 84 Avalon server 22 →Database Server 26 (Find encrypted CCI). Avalon server 22 sends the token to the database server 26 for encrypted credit card identifier look up.
[0037] Step 86 Database Server 26 →Avalon server 22 (Return encrypted CCI) The database server 26 receives unique token, searches for matching token and associated encrypted credit card identifier. The database server 26 sends the encrypted credit card identifier to the Avalon server 22 .
[0038] Step 88 Avalon server 22 →HSM Server 24 (Request CCI). The Avalon server 22 receives the encrypted credit card identifier with the cryptography key label and sends it to the HSM server 24 for decryption.
[0039] Step 90 HSM Server 24 →Avalon server 22 (Decryption and CCI Insertion) The HSM server 24 receives encrypted credit card identifier, decrypts and sends the decrypted CCI to the Avalon server 22 . The Avalon server 22 receives decrypted credit card identifier and inserts into transaction stream in place of token.
[0040] Step 92 Avalon server 22 →Private Information Validation Company 20 (Payment Completion Request, for example).The transaction stream from the back end server 18 with decrypted or real credit card identifier is sent to the Credit Card Validation Company 20 for payment process completion.
[0041] Step 94 Private Information Validation Company 20 →Avalon server 22 (Payment Completion). The Private Information Validation Company 20 returns payment confirmation details to Avalon server 22 . If the Private Information Validation Company 20 returns the private information identifier as part of its confirmation data to Avalon server 22 , the private information identifier is stripped out prior to re-directing the completed transaction stream back to the back end server 18 .
[0042] Step 96 Server 18 →Front End Server 16 (Complete Transaction). The completed transaction with associated confirmation data is sent to the originating front end server 16 . The transaction terminates where it originated from. A user could be a connected user to server 16 (a web browser for example).
[0043] The Avalon server 22 is configured for example using suitable software to generate unique & meaningless sequential numbers for variable field length credit card identifiers and privacy identifier fields. The tokens should thus have a sufficient number of digits to cover various length identifiers. While one type of encryption KEY may be used for the credit card identifier, other encryption keys may be used for other fields, such as privacy identifier fields, that require encryption. The Avalon server 22 may in some embodiments track, monitor, log and audit all activity relating to credit card processing done by the secure server installation 10 . If separate servers 22 , 24 and 26 are used, they should be clustered for reliability.
[0044] The HSM server 24 should be permitted to communicate only with the Avalon server 22 by suitable identification measures. In some embodiments, for strictest security, no device other than the Avalon server 22 should be able to issue requests to the HSM server 24 . Some systems 20 may be permitted access to the Avalon server 22 for purposes of maintenance, operations, audits and investigations.
[0045] The HSM Server 26 provides encryption, decryption, authentication code, keyed hash generation and key management for the secure server installation 10 .
[0046] Immaterial modifications may be made to the embodiments described here without departing from what is covered by the claims. | A secure server installation is provided that abstracts credit card identifiers from its server, network, application and database environments, thus reducing investment in securing, segregating and/or isolating these environments in their entirety. The secure server installation intercepts credit card transactions sent from front end applications to back end applications, and forwards tokens in replacement of credit card identifiers for processing by the back end applications.
The same secure server installation can be applied for the encryption, storage (data-at-rest), transmission of private data within a network of other private or sensitive data not limited to social insurance numbers, drivers license numbers, phone numbers, bank account numbers, etc. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electric can opener for cutting open a can and more specifically to an electric can opener which can be operated in the hand of a user.
2. Description of the Prior Art
A can opener of this type consists of a body which is fitted with a cutter, a can driving wheel and an electric motor, and of a grip portion projecting forwardly from the body. When a can is cut open with such a can opener, it is supported with the grip portion grasped by the palm of one hand of the user and with both the can driving wheel and the cutter held on the can. In this case, however, the hand grasping the grip portion has to not only bear the weight of the can opener but also to prevent the heavy body situated before the grip portion from turning downwardly. Namely, a large downward force is exerted on the forefinger of the hand grasping the grip portion, while an equally large upward force is exerted on the palm near the base of the thumb of the hand. It thus involves great difficulty to hold stably the body of the can opener, and the can driving wheel and the cutter are hard to be operably held on the can.
SUMMARY OF THE INVENTION
This invention aims at providing an electric can opener wherein the above mentioned points are excluded.
Namely, an object of the present invention is to provide an electric can opener which a user can operate in his one hand when cutting open the lid of a can.
Another object of the present invention is to provide an electric can opener which is easily held with its thick grip portion grasped fitly by the paln of the user's hand.
Still another object of the present invention is to provide an electric can opener wherein a power source unit for feeding an electric motor can be accomodated in said thick grip portion.
If the grip portion can serve also as the casing of the power source unit, an isolate casing for the power source unit is unnecessary. The electric can opener can consequently be made small-sized and easily be handled.
Still another object of the present invention is to provide an electric can opener which, being held by the user's hand, is sufficiently balanced by positioning the power source unit inside the grip portion. Namely, since the power source unit is positioned inside the grip portion, the weight of the side of it opposite to the body is increased. A certain weight can thus be exerted on the little finger apart from the body as well as on the forefinger close to the body. As a consequence, the whole area of the palm can be applied on the outer surface of the grip portion, and the electric can opener can stably be held. In this manner, the can driving wheel can be held on the can more easily and exactly than in the case of a conventional can opener.
Other objects and advantages of the invention will become apparent during the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show the embodiments of the present invention in which:
FIG. 1 is a front elevational view of an electric can opener;
FIG. 2 is a plane view of the electric can opener;
FIG. 3 is a perspective view showing the electric can opener in use;
FIG. 4 is a perspective view showing the electric can opener and a power source unit taken out of it;
FIG. 5 is a perspective view showing the electric can opener, the power source unit taken out of it and a can opener attachment dismounted from the can opener;
FIG. 6 is a fragmental section taken along a line VI--VI in FIG. 1;
FIG. 7 is a section taken along a line VII--VII in FIG. 2;
FIG. 8 is a fragmental section taken along a line VIII--VIII in FIG. 1;
FIG. 9 is a perspective view of the can opener attachment;
FIG. 10 is an exploded perspective view of the can opener attachment;
FIG. 11 is a view showing the electric can opener with one element of a housing thereof taken away and with a housing of the power source unit broken longitudinally;
FIG. 12 is a partial view of the electric can opener with the electric power source unit extracted;
FIG. 13 is a fragmental sectional view showing the process to extract the power source unit;
FIG. 14 is a fragmental section taken along a line XIV--XIV in FIG. 2;
FIG. 15 is a section taken along a line XV--XV in FIG. 11;
FIG. 16 is a section taken along a line XVI--XVI in FIG. 11;
FIG. 17 is a view showing the housing of the power source unit with one element thereof dismounted;
FIG. 18 is an electric circuit diagram;
FIG. 19 is a view showing a process to cut open a can lid;
FIG. 20 is a view showing the relationship among the components of the force exerted on a cutter;
FIG. 21 is a perspective view showing an operation to insert the blade contacts of the power source unit into a domestic wall outlet;
FIG. 22 is a view showing the power source unit being charged; and
FIG. 23 is a perspective view showing a different method of using the electric can opener.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to drawings, the embodiments of the present invention are now explained. A housing 10 consists of a front element 10a and a rear element 10b, each being molded out of synthetic resins. These elements are jointed mutually by positioning a support pole 11 molded integrally with the front element 10a oppositely to a counter stud 12 via a support plate 13 and by screwing the front end of a fastening threaded bar 14, passed through the counter stud 12, into the support pole 11, as best seen in FIG. 7. The housing 10 is divided broadly into three parts, i.e., a body 15, a grip portion 16 and a joint portion 17.
The members provided in the body 15 are first explained. A drive shaft hole 20 and a mount hole 21 are formed in the front member 10a. Under the drive shaft hole 20 is protrudingly provided a can receiver 22, while under the mount hole 21 is projecting a can positioning piece 23. A can driving wheel 25 is secured on the front end of a drive shaft 24 inserted through said drive shaft hole 20, and a gear 26 is attached integrally on the rear end of said drive shaft 24. A pinion 28 is provided on the rotary shaft of an electric motor 27 mounted on the support plate 13. This pinion 28 cooperates with the aforementioned gear 26 via a couple of large and small gears 29 and 30 carried by the support plate 13 and via another couple of large and small gears 32 and 33 supported by the support plate 13 and by the large and small gears 29 and 30.
Now inside the housing 10, a holder means 36 as shown in FIG. 11 is provided in the proximity of the mount hole 21. This holder means 36 is mounted, movably in indicated directions, on a pin 37 fixed against the housing. An opening 38 is formed in the intermediate portion of said holder means 36, while on the free end of the holder means 36 is provided a detach button 39 for the holder means, extending upwardly through an opening 40 bored through the housing. A biasing spring 41 is disposed between the free end of said holder means 36 and the housing. This spring 41 is adapted to bias said holder means 36 in such a direction and a manner as to locate the lower edge 38a of the opening 38 slightly under the axis of the mount hole 21. A push out piece 42 is provided in close proximity of the holder means 36. This push out piece 42 is made of a resilient sheet metal, and is fixed, at the base portion thereof, to a support 43 formed integrally with the front element 10a by means of a set screw 44. The free end portion 45 of the push out piece 42 is positioned so as to oppose the opening 38.
A can opener attachment 48 adapted to be mountable on and dismountable from the body 15 is now explained. First, this attachment 48 includes a base plate 49 made of synthetic resins as apparently shown in FIGS. 9 and 10. From a corner portion of the base plate 49 does project a metallic pivot shaft 50 with the head portion thereof embeded in said base plate 49. The free end 51 of the pivot shaft 50 is made tapered as is clearly shown in FIGS. 6, 9 and 10. The pivot shaft 50 is formed near the free end thereof with an annular engagement groove 52. An operation piece 49a is formed integrally with another corner of the base plate 49. On the rear surface of the base plate 49 is fixed the intermediate portion of a V-shaped leaf spring 53. The upper portion 53a of this leaf spring 53 is adapted to bias downwardly a cutter, as hereafter described, and the lower portion 53b is adapted to push down a seam 54a of a can 54. A cutter 55 is rotatably mounted on the base portion of the pivot shaft 50 and the drop out thereof is prevented by a stop ring 56 fitted in the groove 50a of the pivot shaft 50. A pin 57a fixed on the base plate 49 is inserted in an elongated arcuate hole 57. Said cutter 55 is downwardly biased by the upper portion 53a of the leaf spring 53 and the upper edge of the elongated hole 57 is in abutment with the pin 57a. On the upper portion of the base plate 49 is removably mounted a can holder 58 by means of a fastener 59. This can holder 58 is provided with an arm 60 with the base portion thereof secured on the base plate 49 by the fastener 59. The front end of the arm 60 is provided with a magnet 61 for attracting the can lid cut off.
A switch 65 accomodated in the body 15 includes a switch base 66 attached to the element 10a. A fixed contact 67 and the base portion of a resilient leaf contact 68 are secured on the switch base 66. The free end of the leaf contact 68 is provided with a movable contact adapted to contact with and to detach from the fixed contact 67. A push button 70 secured on the front end of the leaf contact 68 projects through an opening 71 formed in the element 10a to under the operation piece 49a of the can opener attachment 48. A connection terminal 72 secured to the fixed contact 67 extends towards a space 78, defined in the grip portion 16, for accomodating a battery case. Another connection terminal 74 extending into the space 78 is fixed on the terminal base 73 mounted on the element 10a. Lead wires 75 of the electric motor 27 are connected to this connection terminal 74 and to the base portion of the resilient leaf contact 68.
Next, a hold means 80 provided inside the joint portion 17 is made of synthetic resins and the base portion 81 thereof is interposed and secured between a side plate 82 of the element 10a and an opposing piece 83 confronting the side plate 82. The hold means 80 is provided with a push portion 84 projecting through an opening 85 and a hold piece 86 projecting through an opening 87.
A power source unit 90 is now explained. A housing 91 consists of two elements 91a and 91b. These elements are unified by setting legs 92 formed integrally with the element 91b on short counter studs 93 formed integrally with the element 91a, inserting long screws 94 from the side of the studs 93 and screwing it into the legs 92. The free ends of connection terminals 96 and 97 fixed to the elements 91b and 91a are disposed in rectangular openings 95 and 95 formed in the front end of the housing 91. The free ends of these connection terminals 96 and 97 are both U-shaped and the tips thereof are further enclosed by terminal boxes 98 provided integrally with the respective elements 91b and 91a. A battery or a group of cells 100 is provided in the middle of the space inside the housing 91 and is supported by battery supports 101 formed integrally with the element 91a or 91b. As the battery 100, a chargeable nickel-cadmium battery is used. Two blades 103 and 103 adapted to be inserted in a wall outlet project through an opening 102. The base portions 103a of these blades 103 are bent in the form of the letter L and are positioned fixedly against the housing 91 by adapting engage pieces 104 formed integrally with the element 91a of the housing into openings made in said base portions. Leg portions 106 of a spacer 105 made of insulating material are interposed between both the blades 103 and hold fixedly the same in position. A charging transformer 107 is set in position with the bottom portion of an iron core 108 thereof put in the spacer 105. The iron core 108 of the transformer 107, in the shown situation, is urged by the element 91b of the housing. Primary lead wires 109 are connected to the base portions 103a of the blades 103. The secondary lead wires of the transformer 107 are connected across the terminals of the battery 100 through a rectifier 160 and a charging resistor 111.
The power source unit 90 constructed as described above is inserted in the space 78 defined inside the grip portion 16, and front connection terminals 96 and 97 are connected to the connection terminals 72 and 74 respectively. In this case, the connection terminals 72 and 74 introduced through the opening 95 into the terminal boxes 98 and 98 are closely put between the front ends of the connection terminal 96 and 97 and the side walls 98a of the terminal boxes 98, and consequently the electrical connections between the connection terminals 96 and 72 and between the connection terminals 97 and 74 can be maintained in good condition. In the shown situation, the hold piece 86 in the hold means 80 is adapted in an engage recess 112 formed on the housing 91, and the power source unit 90 is thus prevented from dropping out from the space 78. In the above situation, protection plates 88 formed integrally with the housing 10 are disposed at both sides of the blades 103 and protect them against damage.
The electric can opener constructed as described above is used in the situation as shown in FIG. 3. Namely, the grip portion 16 is grasped by one hand of the user and the operation piece 49a is operated by the thumb of the hand.
In the next, in cutting open the can, the operation piece 49a is turned up from the position shown in FIG. 19(A) to that in FIG. 19(B) and the cutter 55 is upwardly brought over the top of the can driving wheel 25. In this situation, the can driving wheel 25 is put under the seam 54a of the can 54 held by the other hand of the user, and the can positioning piece 23 is simultaneously abutted on the upper edge of the seam 54a. The operation piece 49a is then released to the lower position and the tip of the cutter 55 is brought into contact with the can lid 54b closely inside the seam 54a. In this situation, the seam 54a of the can 54 is still held on the can driving 25 even if though the user detaches his hand from the can 54. Next, the operation piece 49a is pushed down as shown in FIG. 19(D) and the lower portion 53b of the leaf spring 53 is abutted on the seam 54a, urging the seam 54a against the can driving wheel 25. As the operation piece 49a is further lowered down, the operation piece 49a pushes down the push button 70 and the power source switch 65 is closed. As the result of this operation, the battery 100 feeds the electric motor 27, which then rotates. The torque of the electric motor 27 is transmitted through gears to the can driving wheel 25, which is rotated in the direction shown by the arrow and rotates the can 54. As the operation piece 49a is lowered down, the cutter 55 is pressed against the can lid 54b by the upper portion 53a of the leaf spring 53 and the cutter 55 is forced on the can lid 54b by the abutment of the pin 57a against the lower edge of the elongated hole 57. The cutter 55 is then exerted on by a friction force which is directed to the left in FIG. 19(D) as the result of the friction between the cutter 55 and the can lid 54b. This force results in a clockwise torque around the pivot shaft 50 and, on account of this torque, the cutter 55 cuts into the can lid 54b, thus beginning to cut open the can 54. In FIG. 20 showing the relationship between the force and the torque, a drag force F due to the rotation of the can 54 is exerted on the point P, the point of contact between the cutter 55 and the can lid 54a, around the axis O of the pivot shaft 50. Since, however, the point O is situated over the point P with a certain angle between the can lid 54a and the line OP and is advanced than the point P in the turning direction of the can 54, the drag force F can be decomposed into a component f 2 along the line PO and another component F 1 exerted downwardly and parpendicularly to the line PO. With the angle α between the component f 1 and the drag force F, the component f 1 can be written as f 1 =F·cos α. Since the angle α, however, is set so as to give a condition f 1>f 2 , the clockwise torque around 0 becomes L·F·cos α where L is the distance between the points 0 and P. Since the cutter 55 cuts deeply into can lid 54b under the torque due to the turning of the can 54, it is unnecessary, at the start of cutting of the cutter 54 into the can lid 54b, to push down the operation piece 49a strongly. Next, while cutting open the can, the cutter 55 is continuously subject to said torque and gives continuously the clockwise torque around the pivot shaft 50 as shown in FIG. 19(D) through the pin 57a to the base plate 49. The operation piece 49a thus continues to press the push button 70 and the power switch 65 is kept closed, the can lid being continuously cut open, even though the user detaches his hand from the operation piece 49a. Then, after the completion of the cutting open of the can, the torque applied on the cutter as the result of the turning of the can lid 54b dissapears, and consequently the torque applied on the plate 49 dissapears too. Accordingly, the base plate 49 is slightly returned in the counterclockwise direction by the reaction force against the force with which the lower portion 53b of the leaf spring 53 pushes downwards the seam 54a. The operation piece 49a thereby moves upwards to cease to urge downwardly the push button 70, opens the power switch 65 and stops the power feed to the electric motor 27, stopping the turning of the can 54. In this situation, since the seam 54a of the can 54 rests on the can driving wheel 25 and the cutter 55 is positioned inside this seam 54a, the can does not fall off by any means. Next, when the can 54 is to be detached, it is held by the hand of the user and the operation piece 49a is then pushed up to raise the cutter 55 higher than the upper edge of the seam 54a of the can 54 as shown in FIG. 19(B), the can being detached in this situation.
The pushbutton 39 is now pushed in for the purpose of dismounting the can opener attachment 48 from the body 15. The holder means 36 is then moved downwardly and the periphery 38a of the opening 38 is made to disengage with the engagement groove 52 on the pivot shaft 50. The pivot shaft 50 is forwardly pushed out by the front end 45 of the push out piece 42 which is always under a biasing force. The attachment 48 can thereafter be detached from the body by pulling manually the pivot shaft 50 out of the mount hole 21. The can opener attachment 48 detached in this manner can easily be washed. When the washed attachment 48 is remounted on the body 15, the pivot shaft 50 is pushed into the mount hole 21. In this case, since the free end 51 of the pivot shaft 50 is made tapered as shown, the lower edge 38a of the opening 38 in the holder means 36 is urged downwardly as seen in FIG. 6 by the tapered free end surface 61 of the inserted pivot shaft. When the pivot shaft 50 is further pushed in until the engagement groove 52 opposes the lower edge 38a, the lower edge 38a comes into engagement with the engagement groove 52 by the biasing force of the spring 41 and such situation results that the pivot shaft 50 is prevented from dropping out from the mount hole 21.
The battery 100 is charged when its discharge has considerably proceeded. The charging of the battery is done as follows. First the push portion 84 is moved so that it may retreat into the opening 85 as shown in FIG. 13. The hold means 80 bends due to its proper resiliency and the hold piece 86 disengages with the recessed portion 112, retreating into the opening 87. In this situation, the power source unit 90 is outwardly pulled from the space 78 in the grip portion 16. The blades 103 and 103 of the power source unit 90 are thereafter inserted into a domestic wall outlet 113 as shown in FIGS. 21 and 22. The AC voltage, which is applied across the blades 103 from the wall outlet in this situation, is stepped down by the transformer 107. The stepped-down low AC voltage is rectified by a rectifier 110, being transformed into a DC voltage. This DC voltage is supplied to the battery 100 through a resistor 111, and charges the battery 100.
Next after the battery has completely been charged, the power source unit 90 is returned into the space 78 in the grip portion 16. In this case, since the front surface 86a of the hold piece 86 is tapered as shown, the hold piece 86 is smoothly brought into the opening 87 by making the front portion of the power source unit 90 advance from the left to the right as seen in FIG. 12. In this situation, the power source unit 90 is further thrusted into the space 78. When the connection terminals 96 and 97 have come into contact with the terminals 72 and 74 respectively, the hold piece 86 is restored to the position as shown in FIG. 11 by the resilient force of the hold means and projects through the opening 87 to engage with the recessed portion 112.
Next in FIG. 23 is shown a situation where a large can 114 is cut open with use of the above mentioned can opener. When such a large can 114 is cut open, it is placed, for example, on a table, and the can driving wheel 25 and the cutter 55 are applied to the seam 114a of the can 114 by the operation same as that mentioned above. After the cutter has been cut into the can lid 114b similarly as aforementioned, the electric can opener runs automatically around the periphery of the seam 114a, cutting open the can lid 114b. | An electric can opener operable in one hand of a user includes a body, a rotatable can driving wheel mounted on the front surface of the body, a cutter similarly mounted on the body, an electric motor accommodated inside the body to actuate the can driving wheel, a hollow cylindrical grip portion projecting from the body, and a power source unit contained in the grip portion to feed the electric motor. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to and the benefit of the filing date of copending Provisional Application entitled “SETTOP CABLE TELEVISION CONTROL DEVICE AND METHOD INCLUDING BOOTLOADER SOFTWARE AND CODE VERSION TABLE FOR MAINTAINING AND UPDATING SETTOP RECEIVER OPERATING SYSTEM SOFTWARE,” assigned Ser. No. 60/180,284, filed on Feb. 4, 2000, and is hereby incorporated herein by reference.
TECHNICAL FIELD
The present invention relates generally to cable television, and, more particularly, to a settop receiver and method including a software component and frequency acquisition method for updating settop receiver operating system software.
BACKGROUND OF THE INVENTION
Cable television systems typically employ a receiver, or settop box, at each customer premises to receive and decode the programming transmitted to the user from a central location (commonly referred to in the industry as the “headend”) via the cable infrastructure. The settop box typically includes a receiver, decoder, processing circuitry and operating system software. The settop box is capable of receiving the programming information via the cable and transforming the received signal to a format that can be presented to the viewer via a television set. The operating software contained in conventional settop boxes is typically contained in a memory device and is fixed at the time the settop box is manufactured. This arrangement is sometimes referred to as “firmware” because to change, or upgrade, the operating software requires the removal of the existing memory device and the insertion of a new device containing the new or upgraded software code.
Similarly, problems with the software code that may render the settop box unable to receive and decode the programming signal can be remedied only by replacing the device containing the code, or by requiring a separate communication link between the headend and the settop box for remotely programmable memory elements. If the code resides in firmware, then manual removal and replacement is required. Unfortunately, replacing the software code requires a costly trip to the customer location to perform the change, or requires that the customer return the settop box to a facility to have the repair performed. Similarly, upgrading the operating software code via a separate communication link is costly and inefficient. Using this method, updating settop box groups, or settop boxes from different manufacturers becomes impossible.
Therefore, it would be desirable to have a way to upgrade the settop box operating software without physically removing and replacing the memory device in which the code resides.
SUMMARY OF THE INVENTION
The preferred embodiment of the invention provides a settop receiver and method including a software component and frequency acquisition method for updating settop receiver operating system software.
In architecture, the preferred embodiment of the invention includes a settop cable television control device, comprising a tuner, a receiver connected to the tuner and a processor connected to the receiver. The settop cable television control device also includes a first memory element connected to the processor, a second memory element connected to the processor, a first code portion permanently residing in the first memory element, and a second code portion residing in the first memory element, wherein upon initialization of the control device the first code portion is executed by the processor to determine whether the second code portion is capable of operating the control device.
The preferred embodiment of the invention may also be conceptualized as a method for operating a settop cable television control device, the method comprising the steps of: receiving a signal in a tuner, communicating the signal to a receiver connected to the tuner and communicating the signal to a processor connected to the receiver. The method also includes the steps of executing a first code portion, the first code portion residing in a first memory element connected to the processor, executing a second code portion, the second code portion residing in the first memory element connected to the processor, wherein upon initialization of the control device the first code portion is executed by the processor to determine whether the second code portion is capable of operating the control device.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention, as defined in the claims, can be better understood with reference to the following drawings. The components within the drawings are not necessarily to scale relative to each other, emphasis instead being placed upon clearly illustrating the principles of the present invention.
FIG. 1 is block diagram illustrating the cable television system architecture in which the bootloader of the preferred embodiment of the invention resides;
FIG. 2 is a block diagram illustrating the layout of the contents of the flash memory (in which the bootloader of the preferred embodiment of the invention is located) and DRAM of FIG. 1 , while the DRAM is used during a download operation;
FIG. 3 is a flow chart illustrating the processing during the startup phase of the bootloader of FIG. 2 ;
FIG. 4 is a flow chart illustrating the frequency hunt procedure of the bootloader of FIG. 2 ; and
FIG. 5 is a flow chart illustrating the process of obtaining download information and executing the download sequence of the operating system/control program.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is block diagram illustrating the architecture of the cable television system 100 in which the software code, hereinafter referred to as “bootloader” code, or “bootloader”, of the preferred embodiment of the invention resides. Cable television system 100 includes central distribution point, or head end, 101 connected via connection 102 to settop receiver 150 . Head end 101 is responsible for video distribution and provides control functions to settop receiver 150 , the control functions including the assigning of rights to the settop receiver 150 and downloading software to the settop receiver 150 . Connection 102 , while illustrated as a single connection, includes a single direction downstream quadrature amplitude modulation (QAM) channel over which program video data is transmitted from the headend 101 to the settop receiver 150 . Connection 102 also includes a bi-directional quadrature phase shift keying (QPSK) communication channel over which control information is exchanged between the headend 101 and the settop receiver 150 . In addition, many intermediate devices and types of network transport mediums are also typically included in the connection 102 , as would be understood by those reasonable skilled in the art of the present invention. As illustrated by out-of-band (OOB) transceiver 105 , the exchange of information using the QPSK channel of connection 102 is independent of the QAM channel to which the settop receiver 150 is tuned.
Settop receiver 150 includes tuner 104 , which receives the radio frequency (RF) signal via connection 102 and delivers the RF signal via connection 109 to QAM receiver 106 . QAM receiver 106 decodes the QAM signal received over connection 109 and provides, over connection 111 , a digital data stream to filter block and (direct memory access) DMA channels 108 . Filter block and DMA channels 108 are part of the broadband interactive processor (BIP) 107 . The BIP 107 also includes central processing unit (CPU) 119 .
The CPU 119 communicates with dynamic random access memory (DRAM) 250 , non-volatile random access memory (NVRAM) 126 and with flash memory 200 via communication bus 114 . The BIP 107 also communicates via serial control bus 116 to control the operation of tuner 104 and QAM receiver 106 . The BIP 107 also communicates, via connection 117 , the received digital data stream from QAM receiver 106 to MPEG decoder 112 for transmission to a television set. Except as noted herein, the operation of tuner 104 , QAM receiver 106 , BIP 107 and CPU 119 are conventional and are known to those skilled in the art of cable television systems.
In accordance with an aspect of the invention, and to be described in detail with respect to FIGS. 2–5 , flash memory 200 includes bootloader code 300 in a write protected portion of flash memory 200 . The bootloader code 300 typically fits within a 32 kilobyte first sector (sector 0) of flash memory 200 .
The settop receiver 150 also includes front panel display 121 , which is used to communicate the status of the settop receiver 150 to a user, and includes keyboard 124 , which includes buttons (not shown) that allow a user to input various control information to settop receiver 150 . The settop receiver 150 also includes a data port 127 , which can receive software input from, for example, a portable memory element, commonly known as a smart card 129 , via connection 128 .
FIG. 2 is a block diagram illustrating the layout of the contents of the flash memory 200 (in which the bootloader of the preferred embodiment of the invention is located) and DRAM 250 of FIG. 1 , while the DRAM 250 is used during a download operation. The DRAM 250 in FIG. 2 is illustrated as it is configured during the download of operating system/control program software from the head end 101 ( FIG. 1 ). DRAM 250 includes a number of different portions. For example, portion 251 includes variables, portion 252 includes packet buffers, portion 254 includes control structures for the downloaded software, and portion 256 is the image collection buffer in which an image (copy) of the downloaded software is temporarily stored before transfer to flash memory 200 . The image collection buffer 256 is the portion of DRAM 250 in which downloaded software is temporarily stored. The program image of the downloaded software is then transferred from DRAM 250 via connection 202 to flash memory 200 .
Flash memory 200 includes memory portion 201 in which the downloaded operating system/control program is stored, or is written to from DRAM 250 , and also includes sector 257 in which the bootloader code 300 of the present invention resides. Sector 257 is preferably the first sector, commonly referred to as “sector 0”, in flash memory 200 , and is a write protected portion of flash memory 200 . In this manner, the bootloader code 300 resident in sector 257 will not be overwritten and will always be present to perform recovery functions when the settop receiver 150 is inoperative. The bootloader resides in firmware that cannot be altered through download.
The bootloader 300 is a set of instructions that is executed directly by the CPU 119 within settop receiver 150 immediately upon reset of the settop receiver 150 . The bootloader 300 contains checkup and recovery procedures, thus ensuring basic equipment operation even if the balance of the operating system software is corrupted or missing from the settop receiver 150 . System configuration resulting from a system reset places the flash memory 200 at the appropriate physical address so that the bootloader 300 can be accessed by BIP 107 during a reset or a restart. As shown in FIG. 2 , and for illustration only, the bootloader 300 resides in memory sector “0” of flash memory 200 . The following describes the general functionality of the bootloader, which will be described in greater detail below with respect to FIGS. 3 , 4 and 5 .
The bootloader 300 checks its own integrity by running a cyclical redundancy check (CRC) on itself and will report any failures via light emitting diodes (LEDs) on front panel display 121 of settop receiver 150 ( FIG. 1 ). The bootloader 300 will also check for the existence of operating system/control program software within portion 201 of flash memory 200 and will start the operating system software if the correct image is verified. The bootloader 300 will also download the operating system/control program from head end 101 via connection 102 ( FIG. 1 ) if it detects a lack of, or a corrupt version of, the operating system/control program software in flash memory 200 . This download may be preceded by hunting for the correct download stream on connection 102 , and includes collection of image carrying packets and programming of flash memory. The bootloader 300 also processes key press events on keyboard 124 ( FIG. 1 ) during startup and performs auxiliary functions as requested. Such functions include, for example, a forced download even if the operating system/control program checks valid, a technician test mode and the ability to load the diagnostics code and execute it instead of the operating system/control program.
The bootloader 300 can also load (to DRAM 250 ) a software image through the data port 127 or from an optional smart card device, such as smart card 129 ( FIG. 1 ). The bootloader 300 also provides operating system/control program upgrade service, which includes the automatic processing of deferred requests to upgrade the operating system/control program software 201 . The bootloader 300 will also accommodate emergency reload requests. The bootloader also has a built in function that enables checking of security data on the download image to verify and validate the source.
FIGS. 3 through 5 are flow charts illustrating various aspects of the operation of the bootloader 300 of FIG. 2 . The flow charts of FIGS. 3 through 5 show the architecture, functionality, and operation of a possible implementation of the bootloader software of FIG. 2 . In this regard, each block represents a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks might occur out of the order noted in FIGS. 3 through 5 . For example, two blocks shown in succession in FIGS. 3 through 5 may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved, as will be further clarified hereinbelow.
The bootloader logic of the preferred embodiment of the invention can be implemented in software, hardware, or a combination thereof. In a preferred embodiment(s), the bootloader logic is implemented in software or firmware that is stored in a memory and that is executed by a suitable instruction execution system (microprocessor). If implemented in hardware, as in an alternative embodiment, the bootloader logic can implemented with any or a combination of the following technologies, which are all well known in the art: a discrete logic circuit(s) having logic gates for implementing logic functions upon data signals, an application specific integrated circuit having appropriate logic gates, a programmable gate array(s) (PGA), a field programmable gate array (FPGA), etc.
Furthermore, the bootloader software, which comprise an ordered listing of executable instructions for implementing logical functions, can be embodied in any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions.
In the context of this document, a “computer-readable medium” can be any means that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer readable medium can be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a nonexhaustive list) of the computer-readable medium would include the following: an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic), a random access memory (RAM) (magnetic), a read-only memory (ROM) (magnetic), an erasable programmable read-only memory (EPROM or Flash memory) (magnetic), an optical fiber (optical), and a portable compact disc read-only memory (CDROM) (optical). Note that the computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via for instance optical scanning of the paper or other medium, then compiled, interpreted or otherwise processed in a suitable manner if necessary, and then stored in a computer memory.
Turning now to FIG. 3 , shown is a flow chart illustrating the processing during the startup phase of the bootloader 300 of FIG. 2 . In block 301 , the settop receiver 150 is reset. This can be accomplished by powering down the settop receiver 150 and activating the settop receiver 150 to begin power up, or can be initiated by pressing a reset button located on keyboard 124 of the settop receiver 150 . Once the reset is performed in block 301 , then in block 304 the DRAM memory 250 is enabled and the presence of a smart card 129 at data port 127 is determined. A smart card can be any insertable, portable memory device that includes executable code and can be inserted into data port 127 of settop receiver 150 .
In block 306 it is determined whether the presence of a smart card was detected in block 304 . If there is a smart card present in settop receiver 150 and the smart card responds with the correct override code, then in block 308 the bootloader 300 will load an executable image from the smart card into DRAM 250 , and subsequently, into flash memory 200 , as described above with respect to FIG. 2 . In block 316 , the bootloader 300 executes the newly acquired control program software instead of the remainder of the bootloader code. This aspect of the invention provides the method to correct the situation in which there is a serious anomaly, or bug, in the bootloader code.
If it is determined in block 306 that there is no smart card present in settop receiver 150 , then in block 307 the bootloader code 300 will perform a cyclical redundancy check (CRC) on itself.
In block 309 it is determined whether the CRC check determines that the bootloader 300 is operable. If the CRC does not check, then in block 312 a failure indicator, which can be an LED on the front panel display 121 , of settop receiver 150 ( FIG. 1 ), is illuminated and displays an error code. At this point it is assumed that the bootloader 300 may still be sufficiently operable to run so the startup sequence is continued in block 314 as if it were determined in block 309 that the CRC determined that the bootloader 300 is operable.
Next, in block 314 , the bootloader 300 reads the keyboard 124 to determine whether any user initiated functions have been requested. The bootloader 300 also checks the CRC of the NVRAM 126 , and checks for any key overrides input through keyboard 124 to settop receiver 150 . User initiated functions include auxiliary functions supporting test, maintenance and manufacturing. Key overrides occur when the settop receiver 150 is directed to download new operating system/control program software even if the existing software checks valid.
In block 319 it is determined whether the CRC checks performed in block 314 indicate correct content of the NVRAM portion used by the bootloader 300 . If corrupt data is indicated, then in block 321 an error message is displayed on the front panel display 121 of settop receiver 150 and default content is applied. This means that the bootloader 300 will not use any saved data to determine its next action, such as deferred download request, last known download frequency, last CVT version, etc. Next, the process continues at block 322 .
If in block 319 it was determined that the CRC check of the NVRAM performed in block 314 indicates correct NVRAM data, then in block 322 the bootloader 300 checks for the existence of operating system/control program 201 ( FIG. 2 ) and will check the integrity thereof. This integrity check is performed by checking for the operating system signature and performing a CRC check on the operating system of the control program software. In block 322 the bootloader 300 also checks for a forced or deferred download (to be described below). If it is determined in block 326 that no bootable image is found in operating system/control program 201 , then the bootloader 300 immediately enters the hunt and download sequence of block 327 (to be described below with respect to FIG. 4 ). With respect to block 326 , the signature and CRC for the operating system/control program software is checked using the content of the signature area that is attached to the front of the bootable image.
If in block 326 the operating system control program software 201 checks operable, then in block 328 the control program is started and normal operation of the settop receiver 150 is released to the operating system control program software 201 . All of the above checks are performed once during the settop receiver 150 initialization. After handing over control of the settop receiver 150 to the operating system/control program software 201 , the bootloader 300 maintains periodic checks of the system operation through what is known as a “watchdog” service. In this manner, the operating system control program 201 periodically queries the bootloader 300 to enable the bootloader watchdog circuitry. This periodic call gives the bootloader 300 a chance to check for emergency messages being sent from the headend 101 on the QAM portion of the connection 102 . The watchdog service will be described in further detail below.
FIG. 4 is a flow chart 400 illustrating the frequency hunt procedure of the bootloader 300 of FIG. 2 . The image of the operating system/control program 201 is distributed in the in-band data stream on the QAM channels present on connection 102 ( FIG. 1 ). Data is embedded in the private section of the MPEG (motion picture experts group) packets embedded in that data stream. These packets are collected to the DRAM 250 into image collection buffer 256 and, after verification, are transferred to flash memory 200 as described above with respect to FIG. 2 to form the executable image of the operating system/control program software 201 . In accordance with an aspect of the invention, the method used to determine the final download frequency for the required executable image is based on reception of a code version table (CVT) that is sent from headend 101 via connection 102 to all settop receivers 150 in special messages on every QAM channel present over connection 102 . The CVT is sent on all digital frequencies present on connection 102 . The repetition rate of the CVT is preferably once per second. The CVT contains, among other information, the final download frequency to which the tuner 104 in settop receiver 150 will tune so that the settop receiver 150 can receive the operating system/control program download. After receiving the message containing the CVT and tuning to the final download frequency, the settop receiver 150 collects the executable image of the operating system/control program 201 in image collection buffer 256 of DRAM 250 ( FIG. 2 ). The format of the CVT table is illustrated below in Table 1.
TABLE 1
CVT format
Presented below is the format of the Code Version Table. Its hierarchical structure
supports flexible grouping of settops for the purpose of the download.
There are 3 levels of assignment in the CVT:
1.
CVT is divided into OEM (original equipment manufacturer) sub-tables that
are identified by 3 bytes of MAC (medium access control) address. In the
cable systems with mix of settops from many suppliers this provides the
method to download different versions of software depending on the
manufacturer.
2.
Within each OEM group operator may create logical groups (like the “new
software field test group”, “better flavor of OS for paying more”, “basic
software”, “Windows CE box” etc.). This is second level of table partitioning.
3.
Each CVT record in the set contains hardware ID range for which given
version of software is destined.
Placing zeros in ID field disables processing of each of these partitioning levels.
This is treated as global ID and means that each settop matches it.
Because CVT is sent to settop both on QAM and QPSK data streams, it has format
defined as independent from the transport used.
CVT format is defined as follows:
DNCS ID
2 bytes
CVT version
1 byte
# of OEM sub-tables
1 byte
{
OEM sub-table:
MAC range (manufacturer ID)
3 bytes
Number of sets (=nsets)
1 byte
If (nsets>128)
{
Addressed forced download set:
Number of sets (=naddr)
1 byte
for(i==0; i<naddr; i++)
{
MAC address lower bytes
3 bytes
}
alignment bytes
0 . . . 3 bytes
}
for(i==0; i<mod128(nsets); i++)
{
Group download set:
group ID
2 bytes
Number of records (=nrec)
2 byte
for(k== 0; k<nrec; k++)
{
CVT record:
settop hardware ID - start
2 bytes
settop hardware ID - end
2 bytes
frequency vector
2 bytes
carousel Prog#
2 bytes
image ID
2 bytes
download command/# of blocks
2 bytes (3 bits/13 bits)
}
}
}
where:
DNCS ID
this is 2 byte identifier of the DNCS that controls this segment
of network.
CVT version
version ID that is incremented every time CVT is updated.
Together with DNCS ID forces settop to recheck CVT every time it is
changed.
These 3 bytes are saved to NVM non-volatile memory) every
time forced download (based on MAC address) is performed.
This prevents forced downloads to happen repeatedly on every
box restart.
# of sub-tables
1 byte value indicating number of OEM specific subtables in
this CVT
MAC range
there are 3 OEM specific bytes defining range of MAC address.
This field supports specifying different software version for
boxes from various manufacturers.
If value is set to all zeros, it means global (matches every box).
# of sets
number of following group download sets in this OEM sub-
table. If this number is higher than 128 (MS-bit of byte is set to
1) then there is set of addresses inserted before first group
download set; if not, this number is immediately followed by
first download set.
Number of actual download sets is always coded on lower 7-
bits of this byte.
# of addresses
number of 3 byte address groups. These are lower 3 bytes of
MAC address, which together with MAC range (above) which
provides upper 3 bytes from full MAC address for the box that
is to be forced to download. This is one-shot, brute force
method to recover particular box.
alignment
these are bytes added after the last MAC address group to align
forced download set to 32-bit word boundary. Number of bytes
varies depending on number of addresses in the set.
Group ID
2 byte for logical grouping of boxes.
Group ID 0x0000 is global (forces acceptance with box group ignored)
# of records
number of CVT records for this group set (2 bytes - for word
alignment reasons)
hardware ID
start ID and stop ID (inclusive) identify hardware ID range for
which this record should be applied.
If stop ID is zero, this forces acceptance regardless of box ID
(default).
Freq vector
16-bit value encoding the frequency of the download carousel.
Frequency is coded as the number of 0.25 MHz intervals (as an
example: for 573.25 MHz vector is 573*4+1=2293).
It is assumed that download stream will be broadcasted on the
channel positioned on frequency which is multiply of 0.25
MHz (this is current resolution of SA hardware).
Carousel Prog#this is program number of the steam which is containing this
software version. Bootloader parses PAT (program allocation
table) and PMT (program map table) to find PID (packet ID)
for download.
image ID
This is 16-bit number identifying the download image in the
data stream specified by above PID. It is unique for every code
image (fixed in OS signature area).
Download command/#of blocks
download command is coded on 3 upper bits of this 16-bit
integer. Code 0 (zero) is interpreted as emergency download
request. Box starts download immediately, without any
consideration for proper shutdown. Remaining 7 codes (1 . . . 7)
are intended for graceful upgrade - OS is notified that new
software exists and should perform appropriate action as
assigned to code (user notification, interaction, waiting for OFF
etc.). Value of the lower 13 bits encodes the number of blocks
in the download image; it is used for efficient buffering on the
settop side.
Packaging
CVT transmitted on the QAM stream is sent in the Private Section blocks
following the generic syntax. Values for header fields are as follows:
table_id
0x77
section_syntax_indicator
set to 1 (full format compliance)
private_indicator
set to 0
private_section_length
as specified in standard (12 bits, value
<4093)
table_id_extension
set to 0xA753
version_number,
section_number,
last_section_number
set to 0, unused
CVT is transmitted on the pre-assigned PID = 0x1FF8.
Parsing
Code version table parsing rules:
CVT table is scanned from the beginning in search of proper section
(OEM and logical group match).
The records in the section are scanned for first match. When hardware
ID falls into range of one of the records, this record is selected and
parameters from it are used for download.
As mentioned before, setting one of the selection fields to zero disables
parsing based on it. This should be used as the protective stop in the last
element of the set and the entire table.
Zero in the hardware ID range field is used only to create one general group
for all the settops which do not fall into any of the specific ranges in preceding
CVT records. If there is only one version of software, this could be the only
record.
Zero in group ID defines group which could be either the only one in the
system where download groups are not implemented, or protective group in
full system. In the latter case, this download set assures recovery of the “lost
settops”, boxes which have group number corrupted or not assigned yet.
Software in this group should provide basic recovery capability (establish
QPSK link, get proper parameters).
Zero in OEM range could be defined in single OEM systems or as general
group in systems in which boxes from different OEM use the same software.
This will, however, create a problem with addressed forced download. If
mentioned functionality is used in the system, CVT must not have this field set
to zero.
If CVT contains forced download address set, settops that match that address
will start immediate emergency download even if OS seems to be operable
(OS ID in CVT record matches one in box). This functionality allows to
addressably “poke”, or prod, the settop having the problem and force
reloading of the code. It must be implemented in the system as the single-shot
operation, to avoid repeated downloads.
Returning now to FIG. 4 , in block 401 the startup sequence described above with respect to FIG. 3 has been initiated and the sequence has progressed to block 327 in FIG. 3 . In block 402 the bootloader 300 will attempt a number of different techniques to obtain a frequency to which tuner 104 will tune so that the CVT carried on the digital channel can be received. First, the bootloader 300 will attempt to use the last frequency known to include a digital channel. The last frequency known to include a digital channel is typically saved and stored in NVRAM 126 by the operating system/control program 201 before a code download begins. In this manner, the bootloader 300 may easily find the frequency over which the CVT can be received. Next, in block 404 , if tuning to the last known good frequency resulted in finding a digital channel, and therefore resulted in the ability to receive the CVT, then in block 409 the CVT is received and processed (see FIG. 5 ).
In block 404 , if tuning to the last known good frequency does not succeed in finding a digital channel over which the CVT can be received, then the bootloader 300 , in block 406 , will cause the tuner 104 to tune to a number of recommended frequencies stored by settop receiver 150 . These frequencies are recommended to cable television operators for the placement of the download channel over which the CVT can be received by the settop receiver 150 . Next, in block 408 , it is determined whether the tuner 104 has synchronized to a digital channel over which the CVT can be received. If, in block 408 , synchronization with a digital channel over which the CVT can be received is not achieved, then in block 407 it is determined whether there are any additional frequencies in the recommended frequency list. If there are additional frequencies in the recommended frequency list, then, in block 406 the bootloader 300 will cause the tuner 104 to tune to the next channel in the recommended list. In block 408 it is again determined whether the next recommended channel is a digital channel to which the settop receiver 150 can synchronize. If yes, then the process proceeds to block 409 for the reception and processing of the CVT (see FIG. 5 ). If in block 408 synchronization is not obtained, then it is again determined, in block 407 , whether there is another channel to tune to in the recommended list. If yes, then the process returns to block 406 . If it is determined in block 407 that there are no additional frequencies in the recommended frequency list then in block 411 the bootloader 300 will initiate a full hunt sequence. In accordance with this aspect of the invention, the bootloader 300 will cause tuner 104 to hunt for a QAM channel (on connection 102 of FIG. 1 ) over which the CVT can be received. In accordance with this aspect of the invention, the entire bandwidth (57 MHz–855 MHz) is scanned in 6 MHz increments to check for the presence of a frequency having a digital channel over which the CVT can be received. After proceeding through the entire spectrum in 6 MHz increments, and if a digital channel is not found, the hunt will be repeated on frequencies shifted by 1 MHz. This will occur up to a total of five times until the frequencies again overlap. Then, the entire sequence is repeated three times with a shift of 250 KHz. In this manner, the entire 57 MHz–855 MHz frequency range will be covered in 24 passes. In this manner, if there is a frequency having a digital channel anywhere in the available spectrum over which the bootloader 300 can receive the CVT, it will be found.
After tuning to each available carrier within the frequency spectrum between and including 57 MHz and 855 MHz, the bootloader 300 will execute a QAM acquisition script for both QAM 64 and QAM 256 channels. The total time for this operation is approximately 250 milliseconds (msec) per channel, which gives a hunt speed of approximately four channels per second. When the QAM channel is detected in any stage of the hunt, the bootloader 300 sets the settop receiver 150 for reception of the CVT. If the CVT is not received within one second, the hunt sequence will continue. If the hunt was started as a result of a checkup failure, the hunt will continue until complete. If a download was requested (either via operating system/control program request or manual override) the hunt will terminate after one full sequence and will then try to start the existing operating system/control program code 201 .
Therefore, the operation described above and illustrated in block 411 of FIG. 4 is repeated until it is determined in block 412 that the tuner 104 has synchronized to a frequency having a digital channel over which the CVT can be downloaded and processed, as illustrated in block 409 and to be described with respect to FIG. 5 .
FIG. 5 is a flow chart 500 illustrating the process of obtaining download information and executing the download sequence of the operating system/control program 201 . Prior to discussing the download sequence, the download initialization process will first be described. The settop receiver 150 will enter the download sequence from the startup procedure (see FIG. 3 ) when the bootloader 300 detects either an incorrect operating system/control program 201 or is forced into the download sequence by user input to the front panel keyboard 124 . An incorrect image of the operating system/control program 201 could be the result of corruption of the flash memory 200 , a failed operating system upgrade, or in the case where the settop receiver 150 has never had an operating system/control program 201 loaded. In addition to the above scenarios, manual override is provided to force the download of a new operating system/control program 201 . This can be achieved through auxiliary bootloader functionality, controlled from the front panel keyboard 124 . The settop receiver 150 may also initiate a download sequence as the result of reception of a system wide emergency download request. This request is received through a dedicated QAM data stream checked periodically by the above-mentioned watchdog service of the bootloader 300 .
Download initialization from the operating system/control program 201 is usually performed through a call to the “loader service.” Pass parameters give the download channel frequency and command for immediate or deferred download. The bootloader 300 is periodically called by the operating system/control program 201 . This is the watchdog mode. The bootloader 300 determines whether there are any CVT packets in memory. If there is CVT information, the bootloader will then determine whether a code download should be performed. If a download is to be performed, the bootloader will return from this call (from the operating system/control program 201 ), and provide the download code to the operating system/control program 201 . A code of a logic “1” indicates that an immediate download is to be performed. In such a case, the bootloader 300 will cause the settop receiver 150 to shut down, and initiate a download. A code of logic “0” indicates that a deferred download is to be performed. In such a case, at an appropriate time so as to cause as little disruption to the subscriber, a deferred download will be initiated.
For an emergency download, the download is started instantaneously without returning control to the caller. In the case of a deferred download, the call does not start any action but only records, in NVRAM 126 , the correct download frequency and the deferred download request. The operating system/control program 201 also records the deferred download request and calls the loader service as soon as conditions for an upgrade to the settop receiver 150 operating system/control program software 201 are favorable. This is, when the settop receiver 150 is turned off. The request for download recorded by the bootloader 300 is used only if the settop receiver 150 loses power before getting the immediate request. The startup sequence following this event detects deferred requests and begins the download sequence as will be described in FIG. 5 .
Referring again to FIG. 5 , in block 409 (see FIG. 4 ) the CVT is received and parsed for proper download definition. In accordance with an aspect of the invention, the received CVT is parsed according to the rules set forth above in Table 1. In this manner, the information contained in the CVT provides the final channel access vector (i.e. the channel to which tuner 104 should tune to receive the new operating system/control program 201 ) over which the operating system/control program 201 will be sent to settop receiver 150 . In this manner, the settop receiver 150 tunes to this channel and collects the data for the selected image of the operating system/control program 201 . This image is placed in image collection buffer 256 ( FIG. 2 ). After the collection is finished, in block 502 , the image is checked for the correct identification and CRC. In block 504 , if the test fails, the image is discarded and in block 507 the collection is repeated until successful. In block 506 , if the image passes the ID and CRC check, it is programmed from the image collection buffer 256 of DRAM 250 into flash memory 200 to reside as the current operating system/control program 201 . The operating system/control program 201 is loaded into the first available section of flash memory 200 above sector 0 , which is the location of bootloader 300 . When the programming is finished, the system is reset in block 507 , which once more forces checkup of the new flash content (i.e. the newly downloaded operating system/control program 201 ) during the main startup sequence (see FIG. 3 ).
Code images for download will be sent formatted into messages following the standard recommendation for DSMCC (digital storage media command & control) download data block, as shown in Table 2 below.
TABLE 2
Download packet format.
Code images for download will be sent formatted into messages
following standard recommendation for DSM CC Download Data
Block.
Format of the received data block is as follows:
DownloadDataBlock() {
DsmccDownloadDataHeader() {
protocolDiscriminator
1
dsmcc Type
1
messageID
2
downloadId
4
reserved
1
adaptationLength
1
messageLength
2
for(i=0;i<adaptationLength;i++)
dsmccAdaptationHeader Bytes
}
}
moduleId
2
moduleVersion
1
reserved
1
blockNumber
2
for(i=0;i<blockSize;i++)
blockDataBytes
}
(compiled from the table 7-1 “DownloadDataHeader” and 7-6
“downloadDataBlock” in DSM-CC specification).
In the above block header following fields are to be defined to hold values
as expected:
protocolDiscriminator
- 0x11
(identifies MPEG-2 DSM-CC
message)
dsmccType
- 0x03
(download message)
messageID
- 0x1003
(Download Data Block)
downloadID
- 0x????
−> ignored by download
reserved
- 0xFF
standard requirement
adaptationLength
- 0xXX
used to skip adaptation header,
word aligned
messageLength
- 0xLLLL
total length in bytes of the rest of
message
moduleID
- 0xYYYY
−> image ID from CVT
Data block is encapsulated in the standard Private Section framing, with
full syntax header (8 bytes) and CRC32 appended. Following the standard,
table ID in header is set to 0x3C.
Download data blocks should be kept as large as possible to minimize
burden of formatting overhead on the download efficiency.
Selection of the CVT record for download is performed in the bootloader 300 . The operating system/control program 201 receives the CVT record encapsulated in a QPSK message and passes it to the bootloader 300 . The bootloader 300 processes the information (CVT), which is kept in sync by a DNCS (digital network control system) located at headend 101 . In accordance with another aspect of the invention, the operating system/control program 201 receives the CVT over one of the bi-directional QPSK channels existing on connection 102 as a broadcast message. This message is either broadcast to all settop receivers 150 or individually addressed to individual settop receivers. If done as a broadcast message, the message provides a method for globally upgrading all boxes connected in the network without requiring the hunt sequence of FIG. 4 . An individually addressed message will force the addressed settop receiver box 150 to perform an upgrade. The message contains a CVT, which is parsed to determine whether the current version of the operating system/control program should be upgraded. This CVT includes entries that tie specific hardware versions of the settop receiver 150 to the required operating system/control program code version. The entry also contains download channel vectors and control fields used to select forced or delayed download.
The download request message is cycled continuously with the predetermined frequency. Each time the operating system/control program code receives this message it passes it to the bootloader 300 , which parses the CVT, as mentioned above, to find the relevant entry. When the relevant entry is found, the version of the operating system/control program from the request is compared to the current version of the operating system/control program. If these two versions are different, the bootloader 300 informs the operating system/control program 201 to perform the necessary action to start an immediate or a delayed download of new operating system/control program code 201 in accordance with that described above. The type of download depends on the control field in the entry. The operating system/control program will initiate the download sequence in the bootloader 300 . The bootloader 300 will use the CVT to determine the proper image of the operating system/control program for download. The CVT is received in the dedicated message, repeated frequently on every QAM channel for hunt speed improvement. The bootloader 300 will scan the list for appropriate entry and retrieve the required code ID and download channel vector. These two values are subsequently used for download of the executable image of the operating system/control program.
Bootloader 300 performs parsing of the CVT list according to the following rules. The list is always parsed in linear order. The first match stops parsing. Two components forming the settop receiver 150 hardware/bootloader code 300 configuration and stored in the bootloader 300 are defined to never have a value of zero. If any of these parameters in the received list entry is set to zero, it means that “all the settop receivers 150 with this hardware level” or “all with this boot code version.” Finally, if both hardware configuration components are zero it means “all settop receivers.” This should be the last list element to cover download to all remaining settop receivers not specified in the list.
The above parsing rules allow for both strict specification of the downloaded software version as well as for download processing for broad classes of settop receivers 150 . In this manner, classes or groups of settop receivers 150 can be isolated and independently upgraded with new operating system/control program code.
System Support for Download
The system support required for the download process described above is as follows. The image of the operating system/control program to be downloaded is broadcast on a dedicated data carrousel associated with headend 101 . The code is broken into even length packets and framed to form the download stream. The CVT is created and maintained in the DNCS. The CVT contains all versions of the control code for the settop receivers in the system (i.e. the correct operating system/control program images). This table is broadcast continually (once per minute) on the QPSK channel over connection 102 to ensure that all settop receivers in the system have the appropriate operating system/control program version. This broadcast message could also be sent individually to any settop receiver in the system. The CVT is also broadcast on every digital QAM channel in the system at the frequency of approximately once per second. This message is received and recognized only by the bootloader 300 and used for background version check and for the frequency hunt as described above. The emergency download request is inserted as an addressable field in the CVT that is already broadcast every second on the QAM channel and every minute on the QPSK channel.
Auxiliary Functions Processing
The auxiliary functions mentioned above, as part of the startup sequence code, include determining the state of the keys in the front panel keyboard 124 . If any of the keys is depressed, the bootloader 300 compares the detected state of the keys against the set of predefined key combinations, which will invoke specific auxiliary functions. Any key combinations that are not recognized and processed within the bootloader 300 are passed to the operating system/control program 201 . The auxiliary functions that can be invoked from the keyboard 124 are: manual request to start a code download, request to load through the serial port (NVRAM contents, bootloader module upgrade, executable to flash or RAM), or a request to load from a smart card.
It will be apparent to those skilled in the art that many modifications and variations may be made to the preferred embodiments of the present invention, as set forth above, without departing substantially from the principles of the present invention. For example, the present invention can be used to download operating system/control program code under a variety of conditions. Furthermore, the frequency hunt sequence aspect of the invention is useful in any situation in which it is desirable to find a particular frequency within a spectrum. All such modifications and variations are intended to be included herein within the scope of the present invention, as defined in the claims that follow. | A cable television settop receiver and method includes a software component and a frequency acquisition method for determining the ability of the operating system/control program in the settop receiver to operate the settop receiver. The software component, referred to as a “bootloader”, executes on the processor contained in the settop receiver and determines the capability and version of the settop receiver operating system/control program. If the bootloader determines that the operating system/control program should be updated, the bootloader initiates a download sequence, the performance of which allows the proper operating system/control program to be downloaded to the settop receiver. The download occurs after receipt, by the settop receiver, of a code version table (CVT). The CVT includes information that the settop receiver uses to determine which frequency to tune to receive the replacement operating system/control program. In accordance with another aspect of the invention, the bootloader initiates a frequency hunt sequence to determine the proper frequency to which to tune to receive the CVT. The frequency hunt sequence covers the entire spectrum of possible frequencies over which to receive the CVT. | 6 |
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/866,365, filed Nov. 17, 2006, the entire disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a method and apparatus for forming a window or door opening in a concrete wall.
BACKGROUND OF THE INVENTION
[0003] Pre-cast concrete wall panels or cast-in-place concrete walls often require window and door openings. One way to form a window or door opening is to cut and remove a section from the finished, cured wall which is costly and which can damage other portions of the wall. Alternatively, it is known to incorporate a void, i.e., a “buck”, into a concrete wall form to define the required opening in the wall panel. Bucks are usually transported to, or fabricated at, a construction site, in the case of a cast-in-place wall or, in the case of prefabricated wall panel construction, assembled at a factory. One drawback of bucks used today is that they are difficult to locate, are heavy, are size specific, are generally not insulated, and often wasteful. Further, bucks found in the art are often constructed of vinyl or non-eco-friendly wood products that include chemical additives to prevent wood degradation attributed to wood/concrete contact. Thus there is a long felt need in the field of concrete wall construction to provide a buck system that is easy to employ, is less wasteful, more ecological, and can be quickly and accurately formed and assembled on the construction site.
SUMMARY OF THE INVENTION
[0004] It is one aspect of the present invention to provide a customizable window and/or door buck. More specifically, embodiments of the present invention are constructed of members that are composed of wood and insulation that interconnect to form the window or door buck. In addition, the individual members of the window or door buck may be cut to any desired size thereby reducing waste and increasing design flexibility. More specifically, in the case of cast-in-place wall panel construction, often chemically treated wood, usually larger that what is required to form the members of a buck, are cut at the job site and assembled to form bucks wherein any excess wood is discarded. One advantage of embodiments of the present invention is that the individual buck members, as described in greater detail below, are assembled off-site using materials of dimensions that generally coincide with the desired window, door, or other opening shape wherein scrap at the jobsite is reduced or eliminated. More specifically, in the United States, timber is generally cut in the forest in 24 foot lengths. At the mill the timber is cut into three 8 foot lengths, an 8 foot and a 16 foot length, a 10 foot and a 14 foot length or two 12 foot lengths. These standard lengths must be modified at the job site to yield the desired opening wherein the excess is discarded. Conversely, the buck material of a customized length may be delivered to the job site and cut into separate buck members wherein the excess is significantly reduced. Embodiments of the present invention employ 47% less wood than bucks constructed of dimensional lumber. Furthermore, the buck members retain the advantages of wood, thereby facilitating sawing, drilling and general workability while being less expensive than wood alone or vinyl. The buck members are also eco-friendly because they eliminate the need for chemically treated wood products as the wood incorporated into the buck members does not contact the concrete. Another advantage of the buck members as described herein is that less heat transfer occurs because the buck material includes insulation as opposed to a wood/concrete interface. The present buck system is typically less costly, including material and labor costs, than buck systems of the prior art and provides greater design options.
[0005] It is another aspect of the present invention to provide bucks that may be employed in various concrete wall construction schemes, such as cast-in-place walls, prefabricated tilt-up walls (which may include a low density insulated core), or concrete walls that employ interlocking insulated concrete forms, as described in detail below. In the case of a cast-in-place wall, after a first wall form and associated reinforcement are located, the window buck is placed and secured to the reinforcing members and a second wall form. Yet another advantage of this building method, in addition to reduction in waste and omission of shims, is that workers can help ensure concrete is sufficiently placed under the window buck. More specifically, an aperture, in some embodiments about 1.5 to 6 inches in diameter, can be integrated on-site into a lower member of a buck to allow for vibrational concrete manipulation that causes the concrete to fill in the area under the window buck. The aperture can then be plugged to prevent excess concrete from escaping and/or to restore the continuity of the lower buck member.
[0006] One skilled in the art will appreciate that embodiments of the present invention may be incorporated into prefabricated concrete wall panels. For example, prior to placing the concrete into a horizontally-oriented form, a window buck may be located to define the desired window opening. Further, some embodiments of the present invention are adapted to be used with insulated panels spaced by a web. These insulated concrete forms (“ICF”) are usually light and stackable, thereby allowing workers to easily construct a wall of substantial size without the aid of heavy machinery. Embodiments of the present invention additionally provide a novel way of including a rebar securing member within the space between the two adjacent parallel insulation panels that make up the ICF.
[0007] It is yet another aspect of the invention to provide an indication of buck member length. That is, embodiments of the invention include ruled markings to help workers to easily estimate or customize the length of individual buck members prior to buck assembly. The markings maybe spaced in any common unit of length, including every inch, centimeter, yard, foot, meter, etc. In addition, other markings or colors may be employed to indicate size, such as buck depth, or to designate compatibility with other building materials, or to enhance assembly. Trademarks may also be included.
[0008] 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 or alternative 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
[0009] 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.
[0010] FIG. 1 is a perspective view of a window buck of one embodiment of the present invention;
[0011] FIG. 2 is a front elevation view of a buck member;
[0012] FIG. 3 is a front elevation view of an alternate embodiment of the buck member shown in FIG. 2 ;
[0013] FIG. 4 is a front elevation view of an alternate embodiment of the buck member shown in FIG. 2 ;
[0014] FIG. 5 is a front elevation view of an alternate embodiment of the buck member shown in FIG. 2 ;
[0015] FIG. 6 is a front elevation view of an embodiment of an adjustable brace that may be used in conjunction with a window buck;
[0016] FIG. 7 is a perspective view of an insulated concrete form;
[0017] FIG. 8 is a front elevation view of the insulated concrete form shown in FIG. 7 ;
[0018] FIG. 9 is a top plan view of a strapping plate;
[0019] FIG. 10 is a front elevation view of the strapping plate of FIG. 9 ;
[0020] FIG. 11 is a perspective view of a rebar holder;
[0021] FIG. 12 is a front elevation view of a wall form comprising a plurality of insulated concrete forms around a window buck; and
[0022] FIG. 13 is a partial sectional view of the wall form shown in FIG. 12 .
[0023] 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]
Component
#
Window buck
2
Upper Buck Member
6
Lower Buck Member
10
Lateral Buck Member
14
Brace
18
Adjustable Brace
22
Panel
26
Beam
30
Insulation
34
Keyway
38
Insulated Concrete Form
42
Insulation panel
46
Spacer Web
50
Tooth
54
Engineered Buck Material
58
Round
62
Fillets
66
Wall
67
Floor
68
Arcuate Channel
70
Spacer Web Face
74
Cavity
78
Strapping Plate
82
Aperture
86
Tab
90
Strap
98
Rebar Holder
102
Arcuate bend
106
Leg
108
Rebar
110
Wall
114
Void
122
Weld
126
Clamp fixture
130
Bar
134
Coupling
138
Plate
142
Outer pipe
146
[0024] It should be understood that the drawings are not necessarily to scale. 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 or described herein.
DETAILED DESCRIPTION
[0025] Referring now to FIGS. 1-13 , a system for creating an opening in a concrete wall is provided. More specifically, a window buck 2 that is comprised of an upper buck member 6 , a lower buck member 10 and two lateral buck members 14 positioned therebetween is generally provided. The buck members are maintained approximately square during forming with a brace 18 . An adjustable brace 22 may also be employed to ensure that the lateral buck members 14 and/or the upper buck member 6 and the lower buck member 20 do not bow inward when concrete is placed into the form. The buck members are generally comprised of a panel 26 with beams 30 interconnected thereto via fasteners, adhesives, etc. However, the buck members may be formed from a unitary form or extruded. The space between the beams 30 contains an insulative material 34 that may include a keyway 38 . The completed window buck 2 is integrated into a cast-in-place wall form, prefabricated tilt-up wall form, or into a system of interlocking insulated concrete forms 42 . The insulated concrete forms 42 are generally comprised of two insulation panels 46 that are separated by a spacer web 50 . The insulated concrete forms 42 may include teeth 54 and cavities 78 thereby facilitating interconnection between two adjoining insulated concrete forms 42 .
[0026] Referring specifically now to FIG. 1 , a window buck 2 is provided that is comprised of the upper buck member 6 , the lower buck member 10 , and the lateral buck members 14 positioned therebetween. In one embodiment the upper buck member 6 is longer than the lower buck member 10 such that the lower buck member 10 is positioned between the left lateral buck member 14 L and the right lateral buck member 14 R. The brace 18 may be used to ensure that the upper buck member 6 is aligned approximately 90 degrees relative to the lateral buck members 14 . Once the buck members are placed in the correct orientation, i.e. “square”, the upper buck member 6 and lower buck member 10 are interconnected to the lateral buck members using screws, nails, glue, or any other fastening mechanism known in the art. The upper buck member 6 , the lower buck member 10 and lateral buck members 14 are customizable wherein the lengths thereof may be selectively altered to form an opening of any size. An adjustable brace 22 may additionally be employed between two buck members, either horizontally, vertically or both, to resist the force of the concrete when it is placed in the form as explained in further detail below.
[0027] Referring now to FIGS. 2-5 , front elevation views of engineered buck material 58 that comprise the upper buck member 6 , the lower buck member 10 and the lateral buck members 14 is shown. The engineered buck material 58 is generally an assembly of a panel 26 with parallelly spaced beams 30 . Insulation 34 is positioned between the beams 30 , which may or may not include a cut-out, or keyway 38 . The keyway may be a continuous cavity or a plurality of discreet openings positioned in the insulation. The keyway 38 eliminates the need for nails, bolts, or other members that are traditionally integrated into the window buck 2 to anchor the window buck 2 to the concrete. The keyway 38 allows concrete to extend into the window buck 2 and creates a sheer prevention mechanism. The keyway 38 of some embodiments of the present invention is generally rectangular, with rounds 62 or fillets 66 included therein or other shapes, as shown. Some panel insulation employed include a trapezoidal keyway 38 , as shown in FIG. 5 . The walls 67 of the keyway 38 are angled (θ) from about 90°-150°, and are preferably angled about 135°. One advantage of employing angled walls 67 oriented greater than about 90° from each other is that the probability of maintaining concrete within the entire keyway 38 is increased. Generally, in one embodiment, the keyway 38 is about 0.75 inches deep and is centered within the insulation wherein about a 1.5 inch span of insulation resides between each beam 30 and the keyway 38 . One skilled in the art, however, will appreciate that the size of the insulation 34 , and thus the keyway 38 , may be scaled to any size to accommodate any wall size and/or thickness. It is also contemplated that the insulation 34 be comprised of distinct components that are associated with the beams 30 , thereby exposing a portion of the panel 26 . Further, the insulation 34 may be a multi-pieced assemblage.
[0028] The beams 30 in various embodiments of the present invention are preferably Laminated Strand Lumber (LSL) or Laminated Veneer Lumber (LVL) that are about 1 9/16 inches thick and about 1.25 inches wide. The LSL of embodiments of the present invention is an engineered lumber product provided by TrusJoint Products of Columbus, Ohio and sold under the trade name TimberStrand. The LVL of embodiments of the present invention is also provided by TrusJoist Products under the trade name Microllam. The panel 26 in various embodiments of the present invention is generally about 7/16 inches thick and about 8 to 15 inches wide. In one embodiment the panels are about 11 ½ inches wide. Thus the entire thickness of the engineered buck material 58 is about 2 inches. The total length of the engineered material 58 is customizable wherein the required length of each member is cut prior to incorporating with other buck members to form the desired opening. In certain embodiments of the present invention the panel 26 may be oriented strand board (OSB), or plywood, wood-plastic composite, and/or metal materials, the insulation 34 is expanded polystyrene (EPS) and the beams 30 are engineered LSL. One skilled in the art will appreciate that even though embodiments of the present invention employ materials as described above, any suitable building material may be used, including, but not limited to steel, plastic, aluminum, concrete, wood, plywood, extruded polystyrene, urethane, wood-plastic composites and/or a compilation thereof.
[0029] Referring now to FIGS. 1 and 6 , an adjustable brace 22 of one embodiment of the present invention is shown. More specifically, the adjustable brace 22 , which is adapted to be positioned between a left lateral buck member 14 L and the right lateral buck member 14 R is generally comprised of a bar 134 that is slidingly engaged to an outer pipe 146 . Embodiments of the present also employ an adjustable brace 22 between the upper buck member 6 and the lower buck member 10 , such an adjustable brace 22 can be employed alone as well. On one end of the outer pipe 146 is interconnected to a coupling 138 that is welded 142 to a plate 142 L. The other end of the outer pipe 146 is welded 142 to a clamp fixture 130 . The clamp fixture 130 is adapted to adjustably secure the bar 136 . The other end of the bar is interconnected to a coupling 138 that is also welded 126 to a plate 142 R. The plates 142 are adapted to be interconnected to the panel portions of the lateral buck members 14 . Customization of the adjustable brace 22 is achieved by selectively engaging the bar 134 within the clamp fixture 130 to provide the length required. In embodiments of the present invention, the clamp fixture 130 is a Pony Style 52 clamp fixture for a half inch pipe sold by Jorgensen. The bar 134 is about ½ inch schedule 40 pipe having an about ⅞ inch outside diameter. The outer pipe 146 is one inch schedule 40 pipe having an about 1 ¼ outer diameter. The couplings 138 are either a one inch NPT coupling or a ½ inch NPT coupling depending on their interconnection to either the outer pipe 146 or the bar 134 . The plates 142 are approximately 3×3 inch ×⅛ inch thick and have one or more holes positioned therein that allow for interconnection to the lateral buck members with nails, screws, bolts, etc. The adjustable brace 22 of this embodiment of the present invention allows for selectively adjustability wherein the clamp fixture 130 is welded to the outer pipe 146 between a range of about 20 ½ inches to 44 ½ inches from the plate 142 L. The span from the end of the bar 134 to the end of the plate 142 R is about 22-46 inches. Thus expandability of about 20 ½ inches to an about 90 ½ inches is provided by one embodiment. It is contemplated that the adjustable brace 22 may be scaled to any size to accommodate any size of window or door desired. For example, it is well within the scope of the present invention to provide an adjustable brace 22 that spans about 14-16 feet that are needed to form openings associated with a garage door.
[0030] Referring now to FIGS. 7 and 8 , one embodiment of an insulated concrete form (ICF) 42 is provided that includes parallel oriented and spaced insulation panels 46 that are separated with a spacer web 50 . The spacer web 50 may provide a location for the securement of reinforcing bars, preferably within arcuate channels 70 . The spacer webs 50 include faces 74 that extend through the insulation panels 46 and are visible on the outside of the insulation panel 46 . In some instances the spacer web faces 74 are at least partially embedded into the insulation panels 46 . Insulation panels 46 of embodiments of the present invention include teeth 54 and cavities 78 that provide an interlocking interconnection between two stacked or adjacently located insulated concrete forms 42 . The figures presented herein show ICFs manufactured by Arxx Building Products, Inc. One skilled in the art will appreciate that the buck system of embodiments of the present invention may be incorporated into most any ICF such as those offered by Reward Wall Systems, Inc., Nudura Corporation, ECO-Block, LLC, Quad-Lock Building Systems, Ltd., American PolySteel, LLC. The Vertical ICF, Inc., and other manufacturers.
[0031] Referring now to FIGS. 9 and 10 , a strapping plate 82 utilized in one embodiment of the present invention is shown. More specifically, the strapping plate 82 includes an aperture 86 and a tab 90 . During form assembly, which will be described in further detail below, the aperture 86 receives a fastener and is interconnected to the spacer web face 74 , which in some instances is located within the thickness of the insulation panel 46 . A strap 98 is then interconnected to the tab 90 and to a strapping plate 82 that is interconnected similarly to the lateral buck member 14 . Tensioning of the strap 98 firmly secures the insulated concrete form 42 to the buck 2 . Alternatively, two straps can be employed or the strap could wrap around the inside of the buck and be attached to a strapping plate on the other side of the ICF.
[0032] Referring now specifically to FIG. 11 , a rebar holder 102 is shown that is employed in some embodiments of the present invention. More specifically, the rebar holder 102 is generally a wire with a plurality of arcuate bends 106 . In addition, the rebar holder includes generally straight legs 108 depending in a perpendicular direction from the portion shown. These legs 108 may include a sharp point for interconnection to the insulation panel material 46 . Once the rebar holder 102 is firmly integrated into adjacent parallel insulation panels 46 , the arcuate bends 106 are adapted to receive and secure a reinforcing member, i.e. “rebar” 110 . The rebar 110 site generally being employed by some embodiments of the invention have an Imperial bar size of #4, #5 or #6, having a nominal diameter of about 0.5 in., 0.625 in., and 0.75 in. respectively. However, one skilled in the art will appreciate that aspects of the invention presented herein are not limited to any one size wherein any size rebar, or any other type of reinforcing member for that matter, may be employed.
[0033] Referring now to FIGS. 12 and 13 , the integration of a window buck 2 into a wall form 114 is shown. More specifically, here, a wall form 114 is provided that includes a plurality of interlocked ICFs 42 . The window buck 2 is placed on the ICFs 42 and secured thereto by way of the strapping plates 82 and tensioned strap 98 . One skilled in the art will appreciate that if the window buck 2 employs untreated lumber, a moisture resistant barrier must be placed between the exposed (i.e. non-insulated) wood portions of the window buck 2 and the concrete in accordance with the 2003 International Residential Code (IRC), Section R319.1. The exposed wood portions of the window buck 2 may be protected from concrete exposure by employing Gorilla Tape® sold by the Gorilla Glue Company of Cincinnati, Ohio. One or more adjustable bracing members 22 may also be included to prevent bowing of the lateral window buck members 14 and/or the upper buck member 6 and the lower buck member 10 when concrete is placed. The brace 18 is also included to maintain the substantially square shape of the window buck 2 .
[0034] As shown, the strapping plates 82 are interconnected to the lateral window buck member 14 and a spacer web face 74 . When the strap 98 is tensioned, the insulated concrete panel 42 will be securely fastened to the window buck 2 . Concrete is subsequently placed into a void 122 between the two insulation panels 46 that make up the ICF 42 . The rebar holder 102 , which is positioned prior to introduction of concrete, is integrated by piercing the ends thereof into each insulation panel 46 . Rebar 110 is then situated within the arcuate bends 106 of the rebar holder 102 and fastened thereto. It is important to note that the spacer webs 50 provided may also accommodate rebar 110 in a horizontal fashion. Once all of the rebar 110 is placed, concrete can be placed into the ICFs to form a concrete wall with insulation on either side thereof, thus providing superior thermal performance. One skilled in the art will appreciate that a rebar holder may be directly integrated into the individual buck members.
[0035] Referring now to FIGS. 1-13 a method of creating an insulated concrete wall panel 114 is provided. Initially, ICFs 42 are assembled to a height equal to or greater than the elevation of the rough buck opening minus the thickness of the engineered buck material 58 , preferably about two inches. Next, the rough dimensions of the desired opening are obtained and the lateral buck members 14 are cut to a dimension of the rough opening height plus two inches. Since the thickness of the engineered buck material 58 is preferably about two inches, four inches is added to the dimension of the rough opening width and the engineered buck material that will become the upper buck member 6 is cut to that dimension. The lower buck member 10 is obtained from a length of the engineered buck material corresponding to the rough opening width. The top buck member 6 and bottom buck members 10 are then interconnected to the lateral buck members 14 to create a square or rectangular window buck 2 . Fasteners, such as screws or nails, are used to interconnect the top buck member 6 and bottom buck member 10 to the lateral buck members 14 , thereby creating a semi-rigid structure. If the wood portions of the window buck 2 are pressure treated, the fasteners must be hot-dipped, zinc-coated, galvanized steel, stainless steel, silicon bronze or copper to comply with the IRC. The window buck 2 may be maintained square by one or more corner braces 18 interconnected to a horizontal buck member 6 or 10 and a lateral buck member 14 . After the buck members are sufficiently aligned, it is set atop the ICFs 42 that were previously placed.
[0036] The buck members are preferably interconnected to the ICFs 42 that are located adjacent thereto. This is accomplished by interconnecting strapping plates 82 onto the lateral members 14 . The strapping plates 82 are, in one embodiment of the present invention, interconnected to the beams 30 of the engineered buck material 58 . Next, the strap 98 , preferably of woven polyester, is used to connect one strapping plate 82 , which is connected to the beam 30 of the engineered buck material 58 to another strapping plate 82 that is connected to the other beam 30 of the engineered buck material. The straps 98 are of sufficient length to allow the excess to reside on either side of the window buck 2 . That is, one strapping plate 82 will be required for both the inside and the outside of the buck 2 . The strapping plates 82 must be spaced vertically according to form manufacturer requirements. A tab 90 positioned on the strapping plate 82 is adapted to receive the strap 98 . The strapping plates 82 positioned on the lateral buck members also may help retain the ICFs generally in line with the front and back faces of the window buck and prevent bulging of the ICF when the concrete is placed. One skilled in the art will appreciate that this function may be provided by interconnected plates or brackets. Alternatively, such securing/aligning devices may be directly integrated into the buck members.
[0037] Next, an ICF 42 is placed adjacent to the lateral members 14 of the window buck 2 . Additional strapping plates 82 are interconnected, via a screw, preferably, to the web faces 74 of the spacer webs 50 of the newly placed ICFs 42 . Next, the excess strap that is located on either side of the buck is interconnected to the strapping plates 82 that are interconnected to the ICFs 42 , via a buckle, for example. The straps 98 are then tensioned to remove any slack and firmly secure the insulated concrete forms 42 to the window buck 2 . This step is repeated for the opposite side of the buck 2 thereby insuring that the insulated concrete form positioned on both sides of the buck 2 are securely interconnected thereto. Tensioning and strapping by hand has the benefit of centering the buck 2 in the width of the insulated concrete forms 42 , preventing bulging of the ICF 42 at the buck 2 , and providing lateral support of the lateral buck material 14 .
[0038] As one skilled in the art will appreciate, often reinforcing, i.e. rebar 110 , must be employed within the thickness of the concrete. Here, rebar 110 is cut to a length that meets the lapping requirements of the local building code or design specifications and placed within the void 122 between the two insulative panels 46 of the ICFs 42 . Tie wire is preferably used to interconnect the rebar 110 to the rebar holder 102 . One skilled in the art will appreciate that this process can be scaled as the wall is increased in width and in height. As the wall form increases in size, additional straps 98 /strapping plates 82 may be required to further brace the forms prior to the introduction of concrete.
[0039] Prior to concrete placement, the straps 98 are checked for proper tension, while the strapping plates 82 , corner bracing 18 and adjustable bracing 22 are also checked to ensure that the fasteners are secure. Next, concrete is placed into the void 122 between the insulative panels 46 of the ICFs 42 . Immediately after concrete placement, any concrete debris is cleaned and removed from the adjustable bracing 22 and corner braces 18 to ensure that any locking mechanism integrated into the adjustable brace 22 may be released and the adjustable bracing 22 can move freely. In addition, the corner braces 18 are inspected for damage and/or stressing. After the concrete is sufficiently cured, the adjustable brace 22 is unfastened, cleaned and stored. The corner brace 18 is removed and inspected for damage or stressing, the strapping plates 82 are removed and the strap 98 is cut, removed and discarded. A reinforced concrete wall is thus created having insulation on the interior and exterior thereof that provides an opening for a window, or a door.
[0040] While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. 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. | A method and apparatus for forming an opening in a concrete wall is provided. More specifically, interlocking concrete forms comprising parallel spaced insulation panels are provided for receipt of concrete. Any openings, i.e. such as for windows and doors, are accommodated within the insulated concrete forms by way of a customizable buck. The buck members utilize less material than those of the prior art, and are easily customized to yield a required opening size. The placement of concrete into the form yields a concrete wall with the desired window or door opening. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This nonprovisional application claims priority under 35 U.S.C. § 119(a) on European Patent Application No. 05100023.0, filed on Jan. 4, 2005, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is related to a printing device such as a printing or copying system employing print heads containing discharging elements, e.g. nozzles, for image-wise forming dots of a marking substance on an image-receiving member, where the marking substance is in fluid form when discharged. Examples of such printing devices are inkjet printers and toner-jet printers. Hereinafter reference will be made to inkjet printers.
[0004] 2. Description of Background Art
[0005] Print heads employed in inkjet printers and the like usually each contain a plurality of nozzles arranged in (an) array(s). The nozzles usually are placed substantially equidistant. The distance between two contiguous nozzles defines the nozzle pitch. In operation, the nozzles are controlled to image-wise discharge fluid droplets of a marking substance on an image-receiving member. When the printer is of the scanning type, the print heads are moveable in reciprocation across the image-receiving member, i.e. the main scanning direction. In such printers, the print heads are typically aligned in the sub scanning direction perpendicular to the main scanning direction. In a traverse of the print heads across the image-receiving member a matrix of image dots of a marking substance, corresponding to a part of an original image is formed on the image-receiving member by image-wise activating nozzles of the print heads. The printed matrix is generally referred to as a print swath, while the dimension of this matrix in the sub scanning direction is referred to as the swath width. After a first traverse, when a part of the image is completed, the image-receiving member is displaced relative to the print heads in the sub-scanning direction enabling printing of a subsequent part of the image. When this displacement step is chosen equal to a swath width, an image can be printed in multiple non-overlapping swaths. However, image quality may be improved by employing printing devices enabling the use of multiple printing stages, hence printed swaths are at least partially overlapping. In the background art, two main categories of such printing devices can be distinguished, i.e. so-called “interlace systems” and “multi-pass systems”.
[0006] In an interlace system, the print head contains N nozzles, which are arranged in (a) linear array(s) such that the nozzle pitch is an integer multiple of the printing pitch. Multiple printing stages, or so-called interlacing printing steps, are required to generate a complete image or image part. The print head and the image-receiving member are controlled such that in M printing stages, M being defined here as the nozzle pitch divided by the printing pitch, a complete image part is formed on the image-receiving member. After each printing stage, the image-receiving member is displaced over a distance of M times the printing pitch. Such a system is of particular interest because it achieves a higher print resolution with a limited nozzle resolution.
[0007] In a “multi-pass system”, the print head is controlled such that only the nozzles corresponding to selected pixels of the image to be reproduced are image-wise activated. As a result, an incomplete matrix of image dots is formed in a single printing stage or pass, i.e. one traverse of the print heads across the image-receiving member. Multiple passes are required to complete the matrix of image dots. The image-receiving member may be displaced in the sub scanning direction in-between two passes.
[0008] In practice the majority of print jobs is executed in such multiple printing stage mode on a scanning type bidirectional printing system, i.e. a printing system capable of printing on the image-receiving member in reciprocation in the main scanning direction.
[0009] Such systems, which may be “interlace systems” and “multi-pass systems” as well as combinations thereof, are known to be sensitive to gloss variations. Gloss variations can occur when at least a part of the image dots of a marking substance of the same or a different process color are deposited in multiple printing stages in superimposition or at least partially overlapping and when the drying time of the image dots printed on the image-receiving member interacts with the time period required to render all pixels of an image part, i.e. the time period required to complete a sequence of printing stages defined by the print mask. This is particularly the case when, while printing is in progress, a delay signal is generated which causes the printer to interrupt printing immediately or after completion of the printing stage in progress. In any case, printing of the subsequent printing stages is delayed until the cause of the delay is resolved and/or a resume signal is generated. This is observed to cause gloss banding on the print in progress.
SUMMARY OF THE INVENTION
[0010] Thus, it is an object of an embodiment of the invention to control a scanning type printing system when operating in a multiple printing stage mode such as to overcome or at least reduce gloss variations in a printed image when printing in progress is temporarily interrupted upon receipt of a delay signal.
[0011] It is a further object of an embodiment of the invention to control the print heads and the image-receiving member displacement device of a scanning type printing system such that, particularly when operating in a multiple printing stage mode, at each location on the image-receiving member in the sub-scanning direction, about the same time intervals are used between the time of deposition of the respective image dots, which when deposited are in superimposition or at least partially overlapping.
[0012] To meet these objects, a printing device for printing images on an image-receiving member in a sequence of printing stages includes a control that controls, in an operative state of the printer, responsive to said delay signal, the print head and the displacement device so that further printing is executed only during the stroke whereon printing is in progress until all printing stages of the sequence are completed for said stroke. Upon receipt of a delay signal, printing is continued on incompletely printed strokes until these are completed. Therefore, a huge time period between the remaining printing stages for such strokes whereon printing was in progress and the printing stages already executed during the strokes is avoided. The remaining printing stages are the printing stages not yet executed for these strokes. Hence, for these strokes, image dots deposited before receipt of the delay signal are completely dried when resuming printing and thus image dots associated with the remaining printing stages are deposited at least some of them in superimposition or at least partially overlapping with image dots already present on the image-receiving member. By completing the strokes upon which printing is in progress upon receipt of the delay signal, gloss banding caused by such delay is avoided.
[0013] The printing device may be provided with a device for generating a resume signal so that responsive to such resume signal printing may be resumed on a subsequent stroke of the image-receiving member contiguous to the printed strokes.
[0014] The printer may generate a delay or resume signal automatically. For instance, a delay signal may be generated because of a low ink level detection, or because a cleaning action of the print head is required, or another maintenance or service action is required. A resume signal may be generated after the requested intervention is completed. A delay signal or a resume signal may also be generated by user interaction. The image-receiving member may be an intermediate image carrying member or a print medium. The print medium can be in web or sheet form and may be composed of e.g. paper, cardboard, label stock, plastic or textile.
[0015] The so-called print mask contains the information about the number and sequence of printing stages and defines for each print head which discharging elements can be image-wise activated, or in other words contains the information defining for each printing stage which pixels will be rendered by which discharging elements such that when all printing stages are completed, all the pixels of the image concerned, or at least a part of such image, are rendered. A print mask is associated with a printing mode. Selecting a printing mode enables the user to exchange image quality for productivity and vice versa dependent on his requirements. By selecting a printing mode also the discharging elements on the print heads which may be effectively used for image-wise activation are determined as well as the displacement step in the sub scanning direction after each printing stage.
[0016] Gloss banding may even be further reduced by ensuring that the time intervals between the deposition of at least partially overlapping image dots, each associated with a particular printing stage, are about the same regardless of the position on the image-receiving member in the sub-scanning direction. Hence, in an embodiment of the present invention, the control means select for each said traverse of the print head in the main scanning direction an active portion of the plurality of discharging elements, each active portion of discharging elements being selected on the basis of the predetermined distance so that for substantially each position in the sub scanning direction on the part of the image-receiving member where the image is to be rendered, the traversing direction of the print head is the same for each first exposure to an active portion of the traversing print head. Each traverse of the print head in operative state results in a printed portion of an image on the image-receiving member formed by a pattern of image dots of marking substance. After each traverse the image-receiving member is displaced with respect to the print head in the sub scanning direction either by displacing the image-receiving member or by displacing the print head. When printing subsequent portions of an image, a repetitive sequence of printing stages and corresponding displacement steps is used, each displacement step being defined by the relative displacement between the print head and the image-receiving member over a predetermined distance between respective subsequent printing stages. In particular, each of the displacement steps may equal the same constant.
[0017] By selecting for each traverse of the print head an active portion thereof taking account of the displacement step between subsequent traverses, the present invention accomplishes that on substantially each position of the image-receiving member the traversing direction of the print head is the same for each first exposure to an active portion of the traversing print head. The advantage thereof is that in the sub-scanning direction there are no time interval differences between the time of deposition of image dots originating from different traverses even when printing is temporarily interrupted due to a delay signal. Hence no gloss variations will occur or they will be at least severely reduced. The selected active portion for a forward traverse may be different from the selected active portion for a backward traverse. In particular each active portion may selected such that the product of the number of discharging elements available in that active portion and the discharging element pitch is a non-zero integer multiple of the displacement distance.
[0018] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] 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 limitative of the present invention, and wherein:
[0020] FIG. 1 depicts an example of an inkjet printer according to an embodiment of the present invention;
[0021] FIG. 2 a depicts an example of a print mask defining two printing stages;
[0022] FIG. 2 b depicts, according to an embodiment of the present invention, image dot patterns generated by a single print head assuming a full coverage image using all 24 nozzles of the print head and using the print mask of FIG. 2 a;
[0023] FIG. 2 c depicts, according to an embodiment of the present invention, for respective traverses of the print head/printing stages used, which portion of the print head will be used and how the receipt of a delay signal is dealt with;
[0024] FIG. 3 a depicts an example of a print mask defining three printing stages;
[0025] FIG. 3 b depicts, according to an embodiment of the present invention, image dot patterns generated by a single print head assuming a full coverage image using in each traverse a selected active portion of the print head using the print mask of FIG. 3 a ; and
[0026] FIG. 3 c depicts, according to an embodiment of the present invention, for respective traverses of the print head/printing stages used, which portion of the print head will be used and how the receipt of a delay signal is dealt with.
DETAILED DESCRIPTION OF THE INVENTION
[0027] In relation to the appended drawings, the present invention is described in detail in the sequel. Several embodiments are disclosed. It is apparent however that a person skilled in the art can imagine several other equivalent embodiments or other ways of executing the present invention, the scope of the present invention being limited only by the terms of the appended claims.
[0028] The printing device of FIG. 1 is a scanning bi-directional inkjet printer comprising a roller ( 1 ) for supporting an image-receiving member ( 2 ) and moving it along four print heads ( 3 ), each of a different process color. The roller is rotatable about its axis as indicated by arrow A. A scanning carriage ( 4 ) carries the four print heads and can be moved in reciprocation in the main scanning direction, i.e. the direction indicated by the double arrow B, parallel to the roller ( 1 ), such as to enable scanning of the image-receiving member in the main scanning direction. The image-receiving member can be a medium in web or in sheet form and may be composed of, e.g. paper, cardboard, label stock, plastic or textile. Alternately, the image-receiving member can also be an intermediate member, endless or not. Examples of endless members, which can be moved cyclically, are a belt or a drum. The carriage ( 4 ) is guided on rods ( 5 ) ( 6 ) and is driven by suitable means (not shown). Each print head ( 3 ) comprises a number of discharging elements ( 7 ) arranged in a single linear array parallel to the sub scanning direction. Four discharging elements ( 7 ) per print head ( 3 ) are depicted in the figure, however obviously in a practical embodiment typically several hundreds of discharging elements are provided per print head. Each discharging element is connected via an ink duct to an ink reservoir of a corresponding color. Each ink duct is provided with a device for activating the ink duct and an associated electrical drive circuit. For instance the ink duct may be activated thermally and/or piezoelectrically. When the ink duct is activated, an ink drop is discharged from the discharge element in the direction of the roller ( 1 ) and forms a dot of ink on the image-receiving member ( 2 ). The printer further comprises a controller (not shown), which controls the drive of the carriage, the print heads, the image-receiving member advancement, the ink supply, etc. The printer is arranged to automatically detect a maintenance condition and to generate a delay signal, which delays printing according to an embodiment of the present invention. The printer is also arranged to automatically detect the completion of the required intervention and will generate a resume signal such that printing can be resumed.
[0029] To enable printing a digital image is first formed. There are numerous ways to generate a digital image. For instance, scanning an original using a scanner can be used to create a digital image. A camera or a video camera can also be used to create digital still images. Besides digital images generated by a scanner or a camera, which are usually in a bitmap format or a compressed bitmap format also artificially created, e.g. by a computer program, digital images or documents may be sent to the printing device. The latter images can be in a vector format. The latter images can also be in a structured format including but not limited to a page description language (PDL) format and an extensible markup language (XML) format. Examples of a PDL format are PDF (Adobe), PostScript (Adobe), and PCL (Hewlett-Packard). The image processing system typically converts a digital image with known techniques into a series of bitmaps in the process colors of the printing device. Each bitmap is a raster representation of a separation image of a process color specifying for each pixel (“picture element”) an image density value for said process color. An image composed of ink dots can be formed on the image-receiving member by image-wise activating the ink ducts in relation to the pattern(s) of image pixels.
EXAMPLE 1
[0030] A printing device as depicted in FIG. 1 is used to reproduce a digital image. Instead of using the print heads provided with four discharging elements each as in the figure, each print head is provided with 24 discharging elements, i.e. nozzles, arranged in a single linear array. The nozzles are positioned equidistant at a resolution of 300 npi (nozzles per inch). This means that the nozzle pitch or element pitch, being the distance between the centres of two adjacent nozzles, is about 85 μm.
[0031] Suppose the user selects a particular printing mode enabling reproduction of a digital image at a printing resolution of 300 dpi (dots per inch) in both the main scanning and the sub scanning directions, or in other words, the printing pitch, i.e. the distance between centers of two contiguous dots of ink both in the main scanning direction and in the sub scanning direction, is about 85 μm. In this printing mode, the print mask as depicted in FIG. 2 a is used. In case the image is a multicolor image, the same print mask is used for each of the process colors. The print mask as depicted in FIG. 2 a defines a “multi-pass” system with two printing stages. As depicted in FIG. 2 b , in the first printing stage, a first portion of the image is printed by image-wise activating selected nozzles of the active portion of the print head. The image pattern resulting when activating all selected nozzles is indicated in FIG. 2 b with black circles. In this case the active portion includes all 24 available nozzles. This first printing stage coincides with a forward traverse of the print heads across the image-receiving member, i.e. a traverse from the left to the right. Then, the image-receiving member is advanced over a predetermined constant distance of 12 times the printing pitch to enable printing of a second portion of the image by image-wise activating a different selection of nozzles of the same active portion. The image pattern resulting when activating all selected nozzles according to the second printing stage is indicated in FIG. 2 b . This second printing stage coincides with a backward traverse of the print heads across the image-receiving member, i.e. a traverse from the right to the left. In a normal operation mode, when the image is not yet completed, the image-receiving member is again advanced over the same constant distance being 12 times the nozzle pitch. Thereafter, the above-described sequence of printing stages and image-receiving member advancing is repeated until the last portion of the image is completed.
[0032] Suppose, however, that a delay signal is generated during execution of a second printing stage, i.e. during a backward traverse of the print head. As indicated in FIG. 2 b , a delay signal is generated at the time printing is in progress on a stroke ( 21 ) of the image-receiving member. It is clear from FIG. 2 b that even after finishing printing stage 2 this stroke is still printed incompletely. According to an embodiment of the present invention, upon receipt of the delay signal, printing on strokes of the image-receiving member on which printing is already started is progressed. However, printing on a subsequent stroke of the image-receiving member is not started. In this example, this means that printing on stroke ( 21 ) is progressed until all printing stages required to completely render the image portion associated with this stroke are completed. Thus, in order to complete the stroke ( 21 ), the print head is advanced over a distance of 12 times the printing pitch. Thereafter, printing stage 1 is executed using only the upper half of the nozzles. Further referring to FIG. 2 c , as stroke ( 21 ) is completed now, printing is delayed until the required intervention is completed. When resuming printing, the printing process is recovered with the strokes left blank during finishing of printing process. One option is, as depicted in FIG. 2 c , to advance the print head from the right to the left with all nozzles inactive. Thereafter, printing stage 1 is executed for the subsequent stroke using the complementary part of the print head, being the lower half of the nozzles. Thereafter, printing can proceed according to the print mask until the complete image is printed. Instead of advancing the print head from the right to the left with all nozzles inactive after the delay, another option (not shown) is immediately executing printing stage one for the subsequent stroke. In that case the print head is traversed from the right to the left using the complementary part of the print head, being the lower half of the nozzles. Thereafter printing can proceed according to the print mask until the complete image is printed
EXAMPLE 2
[0033] A printing device as depicted in FIG. 1 is used to reproduce a digital image. Instead of using the print heads provided with four discharging elements each as in the figure, each print head is provided with 12 discharging elements, i.e. nozzles, arranged in a single linear array. The nozzles are positioned equidistant at a resolution of 300 npi (nozzles per inch). This means that the nozzle pitch or element pitch, being the distance between the centres of two adjacent nozzles is about 85 μm.
[0034] Suppose the user selects a particular printing mode enabling reproduction of a digital image at a printing resolution of 900 dpi (dots per inch) in both directions, or in other words, the printing pitch, i.e. the distance between the centers of two contiguous dots of ink both in the main scanning direction and in the sub scanning direction, is about 31 μm. To enable rendering of an image with a resolution higher than the nozzle resolution, the print mask associated with the selected printing mode as in FIG. 3 a defines an interlacing system. The print mask defines a sequence of three printing stages required to completely render at least a part of the image. For each printing stage, i.e. for each traverse of a print head(s) in the main scanning direction, an active portion of the plurality of available discharging elements of the print head is selected. In particular, as also depicted in FIG. 3 c , when a printing stage coincides with a traverse of the print head from the left to the right, the active portion includes all 12 available nozzles. When a printing stage coincides with a traverse of the print head from the right to the left, the active portion includes the six nozzles located in the middle of the print head, while the upper three nozzles as well as the lower three nozzles are part of the inactive portion.
[0035] In this example, the active portion in each forward traverse and the active portion in each backward traverse are selected such that the swath width of each portion of an image printed in the forward traverse is twice the swath width of each portion of an image printed in the backward traverse. When executing a first printing stage using the print mask as depicted in FIG. 3 a , the resulting dot pattern when activating all selected nozzles is indicated in FIG. 3 b with black circles. For instruction purposes, only the dots generated by a single print head are shown and a full coverage image is assumed. In practice, however, it is clear that images can be formed in the same way multi-color images can be formed by adequately timing both the driving of the respective print heads and the image-wise activation of the associated nozzles. Each nozzle image-wise forms a complete line of image dots of ink in the main scanning direction. In the sub scanning direction, only every third pixel is printed during the first printing stage. After the first printing stage is executed, the image-receiving member is advanced over a distance of 8 times the printing pitch. After the displacement step, the second printing stage is executed. In this second printing stage, i.e. a traverse from the right to the left, the active portion includes the 6 nozzles located in the middle of the print head, while the inactive portion includes both the lower and upper three nozzles. A dot pattern as schematically depicted in FIG. 3 b is obtained. After the second printing stage is executed, the image-receiving member is again advanced over a distance of 8 times the printing pitch. In the third printing stage, in this case a traverse from left to right, under normal operating conditions, again the full print head is employed. Under normal operating conditions, when the image is not yet completed, the image-receiving member is advanced over a distance of 11 times the printing pitch. Thereafter, the above-described sequence of printing stages, being stages 1 , 2 and 3 , and corresponding image-receiving member advancement steps of 8, 8 and 11 printing pitches, is repeated until the image is completed.
[0036] As can be observed in FIG. 3 b , the selection of the active portions in the forward and backward traverses respectively takes account of the image-receiving member displacement step so that for each position in the sub scanning direction on the part of the image-receiving member where the image is to be rendered, the traversing direction of the print head is the same for each first exposure to an active portion of the traversing print head.
[0037] Suppose, however, that a delay signal is generated during execution of a third printing stage, in this example during a forward traverse of the print head. As indicated in FIG. 3 b , a delay signal is generated at the time printing is in progress on a stroke ( 31 ) of the image-receiving member. It is clear from FIG. 3 b that even after finishing printing stage 3 , this stroke is still printed incompletely. According to an embodiment of the present invention, upon receipt of the delay signal, printing on strokes of the image-receiving member on which printing is already started is progressed. However, printing on a subsequent stroke of the image-receiving member is not started. In this example, this means printing on stroke ( 31 ) is progressed until all printing stages required to completely render the image portion associated with this stroke are completed. Thus, in order to complete the stroke ( 31 ), the print head is advanced over a distance of 11 times the printing pitch. Then, with reference to FIG. 3 c , printing stage 1 is executed using, in this case a traverse from the right to the left, the center half of the nozzles as an active portion of the print head. Subsequently, the print head is advanced over a distance of 8 times the printing pitch. Thereafter, printing stage 2 is executed. Normally, in this case a traverse from the left to the right, the active portion of the print head includes all nozzles. However, as printing is to be limited to stroke ( 31 ) only, only the upper half of the nozzles is image-wise activated. As stroke ( 31 ) is completed now, printing is delayed until the required intervention is completed.
[0038] When resuming printing, the printing process is recovered with the strokes left blank during finishing of the printing process. In particular, the print head is advanced from the right to the left with all nozzles inactive. Thereafter, printing stage 1 is executed for the subsequent stroke using the complementary part of the print head, being the lower half of the nozzles. Thereafter printing can proceed according to the print mask until the complete image is printed.
[0039] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A scanning type printing device is capable of operating in a multiple printing stage mode. When operating in a multiple printing stage mode, this printing device is controlled such upon receipt of a delay signal, further printing is executed, but only during the stroke of the image-receiving member, whereon printing is in progress until the image portion associated with that stroke is completely printed. This is done in order to overcome or at least reduce gloss variations in a printed image when printing in progress is temporarily interrupted. | 1 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention relates to downhole drilling, and more particularly to apparatus and methods for transmitting data along a downhole drill string.
[0003] 2. Description of the Related Art
[0004] For half a century, the oil and gas industry has sought to develop downhole telemetry systems that enable high-definition formation evaluation and borehole navigation while drilling in real time. The ability to transmit large amounts of sub-surface data to the surface has the potential to significantly decrease drilling costs by enabling operators to more accurately direct the drill string to hydrocarbon deposits. Such information may also improve safety and reduce the environmental impacts of drilling. This technology may also be desirable to take advantage of numerous advances in the design of tools and techniques for oil and gas exploration, and may be used to provide real-time access to data such as temperature, pressure, inclination, salinity, and the like, while drilling.
[0005] In order to transmit data at high speeds along a drill string, various approaches have been attempted or suggested. One approach that is currently showing promise is to incorporate a “network” of data transmission cable and other communication equipment into the drill string. Due to the length of drill strings, which may exceed 20,000 feet, such a network may require placing network “nodes” at selected intervals along the drill string. These nodes may act as repeaters to amplify the data signal and provide points of data collection along the drill string. Communication elements, such as magnetic couplers, may be incorporated into the ends of downhole tools to transmit data across the tool joints. Transmission lines, such as electrical cables, may be incorporated into the downhole tools to transmit data therealong.
[0006] Unfortunately, unlike conventional above-ground networks, a downhole network is constrained by the physical limitations of the downhole drill string. In particular, a downhole drill string is a linear structure, making it very difficult to build redundancy (and thereby reliability) into the downhole network. As a result, any break or malfunction in the data transmission path along the drill string may cause communication to be lost between the surface and downhole components. Because the drill string may include many hundreds of downhole components (e.g., sections of drill pipe, drill collar, bottom-hole assembly components, etc.), a single break or malfunction in any downhole component can break the communication path and cause the network to lose much if not all of its functionality.
[0007] In view of the foregoing, what are needed are apparatus and methods to provide multiple redundant paths of communication in a downhole network. Such apparatus and methods may be used to significantly improve the reliability of downhole communication networks.
SUMMARY
[0008] The invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available downhole networks. Accordingly, the invention has been developed to provide systems and methods to build redundancy into downhole networks. The features and advantages of the invention will become more fully apparent from the following description and appended claims, or may be learned by practice of the invention as set forth hereinafter.
[0009] In one aspect of the invention, an annular coupler for transmitting data across a tool joint may include a first coupler segment spanning a first portion of the circumference of the annular coupler. The annular coupler may further include a second coupler segment, electrically insulated from the first coupler segment, which spans a second portion of the circumference of the annular coupler. In selected aspects, the first and second portions do not overlap one another along the circumference. In certain aspects, the first and second coupler segments each span about fifty percent of the circumference of the annular coupler. Thus, each coupler segment may make up roughly half of the annular coupler.
[0010] In another aspect, a downhole tool in accordance with the invention may include an annular coupler installed in an end thereof. The annular coupler may include a first coupler segment spanning a first portion of the circumference of the annular coupler and a second coupler segment, electrically insulated from the first coupler segment, spanning a second portion of the circumference of the annular coupler. The first coupler segment may be coupled to a first transmission line to transmit data along the downhole tool. The second coupler segment may be coupled to a second transmission line to transmit data along the downhole tool.
[0011] In yet another aspect of the invention, a method for transmitting data across a tool joint may include installing an annular coupler in one of a primary and secondary shoulder of a downhole tool. Installing the annular coupler may include installing a first coupler segment in the primary or secondary shoulder that spans a first portion of the circumference of the annular coupler. Installing the annular coupler may also include installing a second coupler segment in the primary or secondary shoulder that spans a second portion of the circumference of the annular coupler. The first coupler segment may be electrically isolated from the second coupler segment. In selected aspects, the first coupler segment makes up about fifty percent of the circumference of the annular coupler and the second coupler segment makes up about the other fifty percent of the circumference of the annular coupler.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific aspects illustrated in the appended drawings. Understanding that these drawings depict only typical aspects of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through use of the accompanying drawings, in which:
[0013] FIG. 1 is a cross-sectional perspective view showing two transmission lines and a split-coil annular coupler incorporated into the pin end of a downhole tool;
[0014] FIG. 2 is a perspective view of multiple annular couplers connected by transmission lines;
[0015] FIG. 3 is perspective view of one aspect of a split-coil annular coupler in accordance with the invention;
[0016] FIG. 4 is a perspective cutaway view of a split-coil annular coupler installed in a mating surface of a downhole tool;
[0017] FIG. 5 is a perspective cutaway view of the split-coil annular coupler of FIG. 4 ;
[0018] FIG. 6 is a schematic view showing coupler segments rotationally aligned with one another; and
[0019] FIG. 7 is a schematic view showing coupler segments rotationally misaligned with one another.
DETAILED DESCRIPTION
[0020] It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of aspects of apparatus and methods of the present invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of various selected aspects of the invention.
[0021] The illustrated aspects of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. Those of ordinary skill in the art will, of course, appreciate that various modifications to the apparatus and methods described herein may be easily made without departing from the essential characteristics of the invention, as described in connection with the Figures. Thus, the following description of the Figures is intended only by way of example, and simply illustrates certain selected aspects consistent with the invention as claimed herein.
[0022] FIG. 1 shows a pair of transmission lines 102 a, 102 b and a split-coil annular coupler 104 incorporated into the pin end 108 of a downhole tool 100 . In the illustrated aspect, the downhole tool 100 is a section of drill pipe 100 . However, the downhole tool 100 may also include other tubular components such as heavyweight drill pipe, drill collars, crossovers, mud motors, stabilizers, hole openers, sub-assemblies, under-reamers, drilling jars, drilling shock absorbers, network links, downhole measurement tools, or other downhole tools known to those of skill in the art.
[0023] The transmission lines 102 a, 102 b and annular coupler 104 provide multiple redundant paths of communication along the downhole tool 100 . Consequently, if communication is lost or interrupted on one transmission line 102 a, the other transmission line 102 b may still transmit data along the downhole tool 100 . Such a configuration may be used to provide multiple paths of communication in a downhole network, one example of which is disclosed in U.S. Pat. No. 7,041,908 to Hall et al. and entitled “Data Transmission System for a Downhole Component,” which is herein incorporated by reference in its entirety.
[0024] In the illustrated aspect of the invention, the annular coupler 104 is an inductive coupler 104 configured to transmit data across a tool joint as a magnetic signal. Two magnetically coupled annular couplers 104 (as would occur with two annular couplers 104 communicating across the tool joint) create a “transformer,” in this case an RF signal transformer. However, in other aspects, the annular coupler 104 may use other methods for transmitting data across the tool joint. For example, the annular coupler 104 may be an acoustic coupler, a fiber optic coupler, or an electrical coupler for communicating or transmitting a signal (i.e., an acoustic, optical, or electrical signal) across the tool joint.
[0025] In the illustrated aspect, the pin end 108 of the downhole tool 100 is shown. In this example, the pin end 108 is a double-shouldered design, which has been found to be particularly suitable for implementing an annular coupler 104 in accordance with the invention. One example of a double-shouldered downhole tool is described in U.S. Pat. No. 5,908,212 to Smith et al. and entitled “Ultra High Torque Double Shoulder Tool Joint.” Nevertheless, the annular coupler 104 is not limited to double-shouldered tool joints, but may be incorporated into tool joints having a wide variety of different configurations.
[0026] As shown, the annular coupler 104 is installed in a groove or recess formed in the secondary shoulder 106 of the pin end 108 of the downhole tool 100 . In other aspects, the annular coupler 104 may be installed in a primary shoulder or other mating surface of the downhole tool 100 . A corresponding annular coupler (not shown) may be installed in the box end of the downhole tool 100 . In selected aspects, the transmission lines 102 a, 102 b may be routed through holes (e.g., gun-drilled holes) formed in the pin end and box end respectively, since the wall thickness is these areas is typically greater. Where the wall thickness is thinner, such as along the length of the downhole tool 100 between the pin end and box end, the transmission lines 102 a, 102 b may be routed through the central bore 110 of the downhole tool 100 . In selected aspects, the transmission lines 102 a, 102 b may be held under tension to minimize movement of the transmission lines 102 a, 102 b within the central bore 110 , and to keep the transmission lines 102 a, 102 b against the wall of the central bore 110 .
[0027] Referring to FIG. 2 , a perspective view of multiple split-coil annular couplers 104 a - d, connected by transmission lines 102 a - d, is illustrated. A first set of annular couplers 104 a, 104 b and transmission lines 102 a, 102 b may be installed in a first downhole tool, and a second set of annular couplers 104 c, 104 d and transmission lines 102 c, 102 d may be installed in a second downhole tool physically coupled to (e.g., threaded into) the first downhole tool. A pair of annular couplers 104 b, 104 c may communicate with one another across the tool joint.
[0028] As shown, a pair of transmission lines 102 may communicate with each annular coupler 104 . Each transmission line 102 may communicate with a different electrically-isolated coupler segment 200 , as will be explained in more detail hereafter. For example, a first transmission line 102 c may communicate with a first coupler segment 200 a, and a second transmission line 102 d (which is electrically isolated from the first transmission line 102 c ) may communicate with a second coupler segment 200 b (which is electrically isolated from the first coupler segment 200 a ). In the event one of the couplers segments 200 a shorts out or ceases to function for some reason, the other coupler segment 200 b and transmission line 102 d may continue to function. In this way, redundancy may be built into the downhole network by providing multiple paths of communication through each downhole tool.
[0029] One significant advantage of the “split-coil” couplers 104 shown in FIG. 2 is that if a first coupler segment 200 a ceases to function, it is not likely to cause the second coupler segment 200 b to also cease to function. For example, if the coupler segments 200 a, 200 b were in close proximity to one another (such as two overlapping segments), a failure of one coupler segment 200 a could also cause the failure of the other 200 b. For example, a scrap of metal, pebble, or other material that interferes with and shorts out a first coupler segment 200 a would also likely short out the other coupler segment 200 b since it is in close physical proximity thereto. By dividing the annular coupler 104 into segments 200 a, 200 b, the segments 200 a, 200 b may be physically and electrically separated from one another to reduce the chance that a failure of one will cause the failure of the other.
[0030] Referring to FIG. 3 , one aspect of a split-coil annular coupler 104 in accordance with the invention is illustrated. In this aspect, the annular coupler 104 is divided into a pair of coupler segments 200 a, 200 b, although more coupler segments (and associated transmission lines) are also possible. In this aspect, each coupler segment 200 a, 200 b makes up about fifty percent of the circumference of the annular coupler 104 . Other ratios are possible and within the scope of the invention.
[0031] In the illustrated aspect, each coupler segment 200 a, 200 b includes half of a conductive coil 300 a, 300 b (i.e., together forming a “split coil”). Each coil 300 a, 300 b is partially surrounded by magnetically-conductive, electrically-insulating (MCEI) elements, which may be inserted into an annular housing 304 . The conductive coils 300 a, 300 b may be coupled to conductive straight portions 302 a, 302 b, which may be electrically coupled (by soldering, contact, or other means) to the transmission lines 102 . The other ends of the coils 300 a, 300 b maybe grounded. For example, an end 306 may be grounded by way of soldering, welding, or direct contact with the annular housing 304 (this makes a ½ turn coil that is a complete circuit). The annular housing 304 may be grounded by way of direct contact with the tool 100 . In certain aspects, the coils 300 a, 300 b and straight portions 302 a, 302 b may be pieces of wire that are bent or formed into the illustrated shapes. In certain aspects, the entire annular coupler 104 is preassembled before being installed in the downhole tool 100 .
[0032] Referring to FIG. 4 , a perspective, cross-sectional view of one aspect of a split-coil annular coupler 104 in accordance with the invention is illustrated. In selected aspects, the annular coupler 104 may include an annular housing 304 forming a trough. MCEI elements 400 may be placed within the trough. In certain aspects, the MCEI elements 400 are fabricated from a ferrite material or other material with similar electrical and magnetic properties. Similarly, the MCEI elements 400 may be formed in a U-shape that is sized and shaped to fit within the annular housing 304 . The annular housing 304 may provide a durable frame in which to house the relatively fragile MCEI elements 400 . The conductive coil 300 may be provided within the U-shaped MCEI elements 400 to carry electrical current. In selected aspects, the conductive coil 300 is coated with an electrically insulating material 402 . For example, the conductive coil 300 may be made of copper or silver-plated copper-clad steel, which may be insulated with varnish, enamel, or a polymer. In other aspects, the coil 300 is insulated with a tough, flexible polymer, such as high density polyethylene or polymerized tetrafluoroethane (PTFE).
[0033] As current flows through the coil 300 , a magnetic flux or field may be created around the coil 300 . The U-shaped MCEI elements 400 may contain the magnetic flux created by the coil 300 and prevent energy leakage into surrounding materials. The U-shape of the MCEI elements 400 may also serve to transfer magnetic current to a similarly shaped MCEI element 400 in an adjacent annular coupler 104 . Since materials such as ferrites may be quite brittle, the U-shaped MCEI elements 400 may be provided in segments 404 a, 404 b to prevent cracking or breaking that might occur using a monolithic piece of ferrite. In selected aspects, these segments 404 a, 404 b may be held together using a resilient material, such as an epoxy, a natural rubber, polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA), a fiberglass or carbon fiber composite, a polyurethane, or the like.
[0034] As was previously discussed, an annular recess 406 may be provided in a mating surface 408 of the downhole tool 100 , such as in the secondary shoulder 408 of the downhole tool 100 . The recess 406 may be positioned so as to lie substantially equidistant between the inner and outer diameter of the secondary shoulder or face. The annular coupler 104 may be inserted into and retained within the recess 406 . In selected aspects, the recess 406 may include a locking mechanism to enable the annular housing 304 to be retained within the recess 406 . For example, in one aspect, a locking mechanism may include a groove 410 or recess 410 formed within the larger recess 406 . A corresponding shoulder 412 may be formed along the annular housing 304 . This shoulder 412 may engage the groove 410 , thereby retaining the annular coupler 104 within the recess 406 .
[0035] In order to close any gaps between annular couplers 104 in the pin end and box end of downhole tools 100 making up a tool joint, an annular coupler 104 may be biased with respect to the mating surface 408 . That is, the annular coupler 104 may be urged in a direction 414 with respect to the mating surface 408 . In selected aspects, angled surfaces 416 , 418 of the recess 406 and the annular housing 304 , along with the diameters of the annular housing 304 and the recess 406 may provide a “spring force” in the direction 414 . This may be accomplished may making the diameter of the annular housing 304 slightly smaller than the diameter of the recess 406 and then pressing the annular housing 304 into the recess 406 until the shoulder 412 snaps into the groove 410 . The top surface of the annular coupler 104 may slit slightly above the mating surface 408 , but may travel downward into the recess 406 upon contacting a corresponding annular coupler 104 of an adjacent downhole tool 100 . The spring force may keep the annular couplers 104 in firm contact with one another, improving their ability to transmit a signal across the tool joint.
[0036] Referring to FIG. 5 , another cutaway view of the split-coil annular coupler 104 of FIG. 4 is illustrated. As shown, the annular coupler 104 includes an annular housing 304 , forming a trough, with multiple MCEI elements 400 residing in the trough. The MCEI elements 400 are U-shaped with a size and shape to fit within the annular housing 304 . A conductive coil 300 is routed through the U-shaped MCEI elements 400 . An electrically insulating material 402 is used to coat the conductive coil 300 . A shoulder 412 is formed along the inside diameter of the annular housing 304 to enable the shoulder 412 to engage a corresponding groove 410 in the annular recess of the downhole tool 100 .
[0037] Referring to FIGS. 6 and 7 , one advantage of the present invention is that communication may be maintained regardless of the “clocking” of the annular couplers 104 . For example, referring to FIG. 6 , where the annular couplers 104 a, 104 b are substantially aligned, a coupler segment 200 a of the annular coupler 104 a will be aligned with the coupler segment 200 c of the annular coupler 104 b. Similarly, a coupler segment 200 b of the annular coupler 104 a will be aligned with the coupler segment 200 d of the annular coupler 104 b. If one of the coupler segments 200 a, 200 c loses functionality, communication may nevertheless be maintained between the other coupler segments 200 b, 200 d. Similarly, if one of the coupler segment 200 b, 200 d loses functionality, communication may be maintained between the coupler segments 200 a, 200 c. In this scenario, most if not all of the signal power from the coupler segment 200 a will be transmitted to the coupler segment 200 c, and most if not all of the signal power from the coupler segment 200 b will be transmitted to the coupler segment 200 d.
[0038] On the other hand, where the annular couplers 104 a, 104 b are misaligned, the annular couplers 104 a, 104 b may still maintain communication. For example, referring to FIG. 7 , consider a case where a coupler segment 200 a of the annular coupler 104 a is misaligned with the coupler segment 200 c of the annular coupler 104 b, and a coupler segment 200 b of the annular coupler 104 a is misaligned with the coupler segment 200 d of the annular coupler 104 b. If a coupler segment 200 a loses functionality, communication may nevertheless be maintained between the coupler segments 200 b, 200 d. Communication may also exist between the coupler segment 200 b and the coupler segment 200 a of the annular coupler 104 b. The difference between this scenario and that illustrated in FIG. 6 is that power transmitted from the coupler segment 200 b will be split in some proportion between the coupler segments 200 a, 200 d. Thus, the annular couplers 104 a, 104 b may maintain communication regardless of the “clocking” between the annular couplers 104 a, 104 b. In either case ( FIG. 6 or 7 ), a drop in signal power (that would not prevent the network from functioning correctly) could be used as a warning that a tool joint has a failure in one of the two communication paths.
[0039] The present invention may be embodied in other specific forms without departing from its essential characteristics. The described aspects are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | An annular coupler for transmitting data across a tool joint may include a first coupler segment spanning a first portion of the circumference of the annular coupler. The annular coupler may further include a second coupler segment, electrically insulated from the first coupler segment, which spans a second portion of the circumference of the annular coupler. In selected aspects, the first and second portions do not overlap one another along the circumference. In certain aspects, the first and second coupler segments each span about fifty percent of the circumference of the annular coupler. Thus, each coupler segment may make up roughly half of the annular coupler. | 4 |
CLAIM TO PRIORITY AND CROSS REFERENCE
[0001] This application claims the benefit of U.S. provisional application No. 60/702,933, filed on Jul. 27, 2005 and entitled One-Step Process for Rapid Structure Repair, the contents of which are hereby incorporated into this application.
TECHNICAL FIELD
[0002] This invention relates to a one-step process for rapidly repairing structures. The process uses a binder comprising a polyisocyanate-terminated pre-polymer containing a divalent metal catalyst, an acid chloride retarder, and preferably a tertiary amine catalyst, which cures in the presence of moisture.
BACKGROUND
[0003] The Air Force and other services have critical needs for technology for the rapid construction, repair, and safe operation of airbases. One of the problems involved in carrying out such activities is the presence of moisture in or around the structure to be repaired.
[0004] Typically, solvent-based binders, usually as two-component binders, are used in bonding aggregates. These binders are typically based on phenolic-urethane chemistry. Most commonly, such binders contain a large amount of solvents, usually 40, to 50 weight percent. The solvents are usually aromatic hydrocarbons, such as toluene, xylene, and others. For instance, see U.S. Pat. Nos. 6,130,268 and 5,872,203, and DE 29,920,721.
[0005] Another requirement needed for such applications is sufficient work time, so that setting of binder/aggregate mixture does not result before the structure to be filled is completely filled with the binder/aggregate mixture. Not only is an adequate work time needed to adequately fill the structure, but very short work time causes the moisture-cured binder/aggregate to rapidly setup in the mixing equipment. A work time of 15 to 30 minutes is typically required to fill large holes (about 5 feet deep and 10 feet wide).
[0006] All citations referred to in this application are expressly incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows that effect of using MPCP on work time.
[0008] FIG. 2 shows the effect of using MPCP on work time on core hardness.
SUMMARY
[0009] This invention relates to a one-step process for rapidly repairing structures. The process uses a binder comprising a polyisocyanate-terminated pre-polymer containing a divalent metal catalyst, an acid chloride retarder, and preferably a tertiary amine catalyst, which cures in the presence of moisture.
[0010] The process is particularly useful for rapid construction and repair, e.g. airfield damage repair applications, crater repair, pothole repair, bridge repair, road repair, and ramp repair. Although the binders used in the process can be used neat, they are typically mixed with aggregate or indigenous materials available at the site where the repair is needed. The binders used in the process have good shelf stability and excellent bonding strength to aggregates in presence of moisture.
[0011] The structures formed by carrying out the process have excellent water resistance, flexural strength, and compressive strength. These binders used in the one-step process cure rapidly in presence of moisture, e.g. water, atmospheric moisture. Additionally, the binder used is preferably solvent-free. And because the process only involves one step, the process can be carried out with simplicity and minimal labor cost.
[0012] The binders used in the process provide advantages over other polyurethane binders because they cure in the presence of high levels of water without degradation of strength properties. It is known that most polyurethane systems tend to lose mechanical performance in presence of moisture.
[0013] The addition of the acid chloride retarder increases the work time of the binder, so that setting of binder/aggregate mixture does not occur before the structure to be filled is completely filled with the binder/aggregate mixture, and so that binder/aggregate mixture does not setup in the mixing equipment. A work time of 15 to 30 minutes is typically required to fill large holes (about 5 feet deep and 10 feet wide).
DETAILED DESCRIPTION
[0014] The polyisocyanate pre-polymers used in the process are the reaction products of an excess of organic polyisocyanate and an active hydrogen-containing compound. Although primary and secondary amines can be used as the active hydrogen-containing compound to prepare the pre-polymer, preferably the active hydrogen-containing compound is a compound having hydroxyl group with a functionality of at least 2.0. The pre-polymers are prepared by methods well known to those of ordinary skill in the art. The amount of free isocyanate in the polyisocyanate pre-polymer typically ranges from 1 to 30, preferably from 9 to 18, and most preferably from 12 to 14 percent free NCO content. A tertiary amine catalyst is preferably added to the pre-polymers to promote their reaction with moisture.
[0015] The polyisocyanate pre-polymer is prepared by reacting the organic polyisocyanate with typically from 1 to 50 weight percent, preferably from 35 to 48 weight percent, of a compound having active hydrogen-containing groups, preferably free hydroxyl groups, where said weight percent is based upon the weight percent of the organic polyisocyanate. Typical compounds having free hydroxyl groups include polyhydric alcohols (e.g. glycols), phenolic resole resins, polyolefin polyols, polycarbonate polyols, polyester polyols, polyether polyols, and mixtures thereof.
[0016] The general procedure for preparing the polyisocyanate pre-polymer involves heating the hydroxyl-containing compound in the presence of the organic polyisocyanate until all of the active hydrogen-containing groups have reacted in the presence of a divalent metal catalyst. Examples of divalent metal catalysts include compounds having a divalent metal ion such as zinc, lead, manganese, copper, tin, magnesium, cobalt, calcium, or barium. Specific examples include dibutyltindilaurate stannous octoate, dibutyltin diacetate, and stannous oleate. Particularly useful is dibutyltindilaurate. The divalent metal catalyst is typically added to the pre-polymer in an amount of from 0.01% to 1.0% by weight of the pre-polymer, preferably about in a range between 0.01 to 0.5%. The mixture is typically heated to a temperature of about 50° C. for about two hours. The divalent metal catalyst remains in the formed pre-polymer.
[0017] The acid chloride retarder used is selected from the group consisting of acid chlorides and mixtures thereof. Examples of such retarders include benzoyl chloride, benzene phosphorus oxydichloride, phosphorus oxychloride, phthaloyl chloride, and monophenyldichlorophosphate. The amount of acid chloride retarder used in the process is typically from 0.01 to 1.0 weight percent based upon the weight of the binder, preferably from 0.01 to 0.5 weight percent, and most preferably from 0.01 to 0.3 weight percent.
[0018] The tertiary amine catalysts are liquid tertiary amines. Examples include 4-alkyl pyridines wherein the alkyl group has from one to four carbon atoms, isoquinoline, arylpyridines such as phenyl pyridine, pyridine, acridine, 2-methoxypyridine, pyridazine, 3-chloro pyridine, quinoline, N-methyl imidazole, N-ethyl imidazole, 4,4′-dipyridine, 4-phenylpropylpyridine, 1-methylbenzimidazole, and 1,4-thiazine. Preferably used as the liquid tertiary amine catalyst is an aliphatic tertiary amine, particularly [tris (3-dimethylamino) propylamine]. Preferably used as the tertiary amine are 2,2′-dimorpholinodiethylether and N,N′-dimethylpiperazine.
[0019] The amount of tertiary amine catalyst used is typically from 0.01 to 1.0 parts by weight, preferably from 0.01 to 0.5 parts by weight, most preferably from 0.1 to 0.25 parts by weight.
[0020] The organic polyisocyanate used to prepare the organic polyisocyanate pre-polymer is an organic polyisocyanate having a functionality of two or more, preferably 2 to 5. It may be aliphatic, cycloaliphatic, aromatic, or a hybrid polyisocyanate. Mixtures of such polyisocyanates may be used. Representative examples of organic polyisocyanates are aliphatic polyisocyanates such as hexamethylene diisocyanate, alicyclic polyisocyanates such as 4,4′-dicyclohexylmethane diisocyanate, and aromatic polyisocyanates such as 2,4-diphenylmethane diisocyanate and 2,6-toluene diisocyanate, and dimethyl derivatives thereof. Other examples of suitable organic polyisocyanates are 1,5-naphthalene diisocyanate, triphenylmethane triisocyanate, xylylene diisocyanate, and the methyl derivatives thereof, polymethylenepolyphenyl isocyanates, chlorophenylene-2,4-diisocyanate, and the like. The organic polyisocyanate is used in a liquid form. Solid or viscous polyisocyanates must be used in the form of organic solvent solutions, the solvent generally being present in a range of up to 80 percent by weight of the solution.
[0021] It may be useful in some cases to blend the pre-polymer with an organic polyisocyanate. If an organic polyisocyanate is blended with the organic polyisocyanate pre-polymer, the amount of organic polyisocyanate blended is from 1 to about 10 percent by weight, based upon the weight of the organic polyisocyanate pre-polymer.
[0022] Typical compounds having free hydroxyl groups include polyhydric alcohols (e.g. glycols), phenolic resole resins, polyolefin polyols, polycarbonate polyols, polyester polyols, polyether polyols, and mixtures thereof.
[0023] Polyhydric alcohols include ethylene glycol, propylene glycol, diethylene glycol, 1,4-butanediol, neopentyl glycol, 1,6-hexanediol, cyclohexane dimethanol, glycerol, trimethylolpropane, and pentaerythritol.
[0024] The polyether polyols are liquid polyether polyols generally having hydroxyl numbers from about 200 to about 1,000, more preferably from 300 to 800, and most preferably from 300 to 600 milligrams of KOH based upon one gram of polyether polyol. The viscosity of the polyether polyol is from 100 to 1,000 centipoise, preferably from 200 to 700 centipoise, most preferably 300 to 500 centipoise. The hydroxyl groups of the polyether polyols are preferably primary and/or secondary hydroxyl groups.
[0025] The polyether polyols are prepared by reacting an alkylene oxide with a polyhydric alcohol in the presence of an appropriate catalyst such as sodium methoxide according to methods well known in the art. Representative examples of alkylene oxide include ethylene oxide, propylene oxide, butylene oxide, amylene oxide, styrene oxide, or mixture thereof. The polyhydric alcohols typically used to prepare the polyether polyols generally have a functionality greater than 2.0, preferably from 2.5 to 5.0, most preferably from 2.5 to 4.5. Examples include ethylene glycol, diethylene glycol, propylene glycol, trimethylol propane, glycerin, and pentaerythritol.
[0026] Phenolic resins, which can be used as the polyol, include phenolic resole resins, preferably polybenzylic ether phenolic resins. The phenolic resole resin is prepared by reacting an excess of aldehyde with a phenol in the presence of either an alkaline catalyst or a divalent metal catalyst according to methods well known in the art. Solvents, as specified, are also used in the phenolic resin component along with various optional ingredients. The polybenzylic ether phenolic resin is prepared by reacting an excess of aldehyde with a phenol in the presence of a divalent metal catalyst according to methods well known in the art. They preferably contain a preponderance of bridges joining the phenolic nuclei of the polymer which are ortho-ortho benzylic ether bridges. They are prepared by reacting an aldehyde and a phenol in a mole ratio of aldehyde to phenol of at least 1:1, generally from 1.1:1.0 to 3.0:1.0 and preferably from 1.1:1.0 to 2.0:1.0, in the presence of a metal ion catalyst, preferably a divalent metal ion such as zinc, lead, manganese, copper, tin, magnesium, cobalt, calcium, or barium.
[0027] Preferably used as the hydroxyl-containing compound to prepare the polyisocyanate pre-polymers are liquid polyester polyols having a hydroxyl number from about 500 to 2,000, preferably from 700 to 1200, and most preferably from 250 to 600; a functionality equal to or greater than 2.0, preferably from 2 to 4; and a viscosity of 500 to 50,000 centipoise at 25° C., preferably 1,000 to 35,000, and most preferably 2,000 to 25,000 centipoise. They are typically prepared by ester interchange of ester and alcohols or glycols by an acidic catalyst. The amount of the polyester polyol in the polyol component is from 2 to 50 weight percent, preferably from 10 to 35 weight percent, most preferably from 10 to 25 weight percent based upon the polyol component.
[0028] Preferably used as the polyester polyol are aromatic polyester polyols. These are prepared by the ester interchange of an aromatic polyester such as phthalic anhydride based polyester and polyethylene terephthalate with a polyhydric alcohol such as ethylene glycol, diethylene glycol, triethylene glycol, 1,3,-propanediol, 1,4-butanediol, dipropylene glycol, tripropylene glycol, tetraethylene glycol, glycerin, and mixtures thereof. Examples of commercial available aromatic polyester polyols are Lexorez 1102-60, Lexorez-1640-150, Lexorez Resins manufactured by Inolex Corp.
[0029] Conventional defoamers, such as D-1400 (from Dow Corning), may also be added to the binder to promote homogeneous mix and faster reaction during the preparation of the binder.
[0030] Any aggregate can be used in connection with the binder. The aggregate may be an aggregate shipped to the site where the space is to be filled or some indigenous material found at the site. Examples of aggregate include sand, zircon, alumina-silicate sand, chromite sand, fly ash, pea gravel, grit, particles of stone, sandstone, clay, crushed concrete, etc. The aggregate is typically used in amounts of 5 to 95 weight percent based upon the total weight of the binder and aggregate.
[0031] The process is most simply carried out by adding the neat binder to the space to be filled in an amount to sufficiently fill the space and make it useful for its normal purpose. In some situations, it may be advantageous to add aggregate to the space to be filled and/or the binder before adding the binder to the space to be filled, and in another instance, the aggregate is mixed with the binder and both binder/aggregate are added to fill the space.
[0032] The amount of the binder can vary over wide ranges depending upon the specific application. Typically the level of binder ranges from about 5 parts by weight to about 50 parts by weight, preferably from about 25 parts by weight to about 35 parts by weight, where said parts by weight are based upon the parts by weight of the aggregate if an aggregate is used.
[0033] Abbreviations
MPCP monophenyldichlorophosphate, a retarder. PLIODECK® PVC a polyisocyanate pre-polymer, sold commercially by Ashland Specialty Chemical Company, a division of Ashland Inc., having a free NCO content of about 10 to 15 weight percent prepared by reacting an aromatic polyester polyol with MDI, which also contains from about 0.1 to about 1.0 weight percent of a tertiary amine catalyst, which was a mixture comprising a major amount of 2,2′-dimorpholinodiethylether (DMDEE) and a minor amount of N,N′-dimethylpiperazine (DMP), based upon the weight of the polyisocyanate pre-polymer. ST the time interval between filling the structure to be filled with the binder, or binder/aggregate mixture, and the time when the binder, or binder aggregate mixture, reaches a level of 90 on the Green Hardness “B” Scale Gauge sold by Harry W. Dietert Co., Detroit, Mich.
[0037] Work time the time interval after bringing the binder, or the binder/aggregate mixture, into contact with moisture, and the time when the binder, or binder aggregate mixture, reaches a level of 60 on the Green Hardness “B” Scale Gauge sold by Harry W. Dietert Co., Detroit, Mich.
EXAMPLES
[0038] The following examples will illustrate some specific ways to carry out this invention. These examples are merely illustrative and not intended to be exhaustive of all embodiments within the scope of the claims. In the examples, all units are in the metric system and all amounts and percentages are by weight, unless otherwise expressly indicated.
Example 1
[0039] MPCP in increasing amounts was added to 30 grams of PLIODECK® PVC (30 grams), mixed under high shear, and then added to sixty-nine grams of wet Tyndall silica sand having a moisture content ranging from 1 to 2 weight percent. The Tyndall sand was pre-dried in an oven at 100° C. for 24 hours. To the pre-dried Tyndall sand was added 1 gram of water, which was then mixed for 1 minute. Then the binder containing the increased level of MPCP was added to the wet Tyndall aggregate, and further mixed for 2 to 4 minutes. The resulting mixture was added to a 2 inch height by 4 inch diameter cup, which had a silicone release liner, and work time (open time) was determined via a gel tester. After 24 hours, the specimen was removed from the cup.
[0040] FIG. 1 graphically depicts the relationship between the addition of MPCP to the binder/aggregate mix and the work time observed. FIG. 1 shows that work time increases as the amount of MPCP increases.
Example 2
[0041] Example 1 was repeated along with a control that did not contain MPCP. Both the work time and strip time were measured.
[0042] FIG. 2 graphically depicts the relationship between the addition of MPCP to the binder/aggregate mix and the work time observed. FIG. 2 shows that work time increases as the amount of MPCP increases and how long it takes before the shape becomes so hard that it cannot be removed from the pattern, i.e. when the green hardness reaches 90. | This invention relates to a one-step process for rapidly repairing structures. The process uses a binder comprising a polyisocyanate-terminated pre-polymer containing a divalent metal catalyst, an acid chloride retarder, and preferably a tertiary amine catalyst, which cures in the presence of moisture. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Stage application under 35 U.S.C. §371 of International Application No. PCT/EP2013/064263, filed on Jul. 5, 2013, and claims benefit to British Patent Application No. 1211926.9, filed on Jul. 5, 2012. The International Application was published in English on Jan. 9, 2014, as WO 2014/006185 A1 under PCT Article 21(2).
FIELD
[0002] The present invention relates to a hydraulic lash adjuster for use in an engine valve train assembly.
BACKGROUND
[0003] A typical hydraulic lash adjuster (HLA) comprises a first oil chamber defined between an outer body and a plunger assembly slidably mounted within the outer body, and a spring biased to enlarge the first oil chamber by pushing the plunger assembly outwardly from the outer body to extend the HLA. Typically, the HLA has a second oil chamber, defined by the plunger assembly and which is in fluid communication with the engine's oil supply. The first oil chamber and the second oil chamber are separated by a one way valve and oil flows from the second chamber into the first chamber through the one way valve when the HLA extends (and hence the first chamber enlarges) because the oil pressure in the second chamber becomes higher than that in the first chamber. Whereas oil can flow into the first pressure chamber via the one way valve, it can only escape the first pressure chamber very slowly, for example, via closely spaced leak down surfaces. Accordingly, a HLA can extend to accommodate any slack in a valve train assembly, such as between the cam and the roller but after it is extended, the incompressible oil in the first chamber provides sufficient rigid support for the HLA to open the valve when a rocker arm pivots (i.e. the incompressible oil prevents the plunger assembly being pushed back inwardly of the outer body so that the HLA acts as a solid body).
[0004] Compression engine brakes are typically used as auxiliary brakes, in addition to wheel brakes, on relatively large vehicles, for example trucks, powered by heavy or medium duty diesel engines. A compression engine braking system is arranged, when activated, to provide an additional opening of an engine cylinder's exhaust valve when the piston in that cylinder is close to the top-dead-center position of its compression stroke so that compressed air is released through the exhaust valve. This causes the engine to function as a power consuming air compressor which slows the vehicle.
[0005] In a typical valve train assembly used with a compression engine brake, the exhaust valve is actuated by a rocker arm to provide an additional compression brake exhaust valve lift in addition to the main exhaust valve lift. The rocker arm rocks in response to a cam on a rotating cam shaft and acts on the exhaust valve, either directly, or indirectly (for example, by means of a valve bridge) to open it. Lost motion variable valve actuation systems may be used to inhibit the additional compression brake exhaust valve lift when the engine is in normal engine combustion mode.
[0006] A hydraulic lash adjuster may also be provided in the valve train assembly to remove any lash (i.e. gap) that develops between components in the valve train assembly.
[0007] U.S. Pat. No. 7,156,062 describes a valve actuation system that comprises a lost motion system and a separate, distinct automatic lash adjuster. The system is complicated and has a large number of distinct components.
[0008] U.S. Pat. No. 7,484,483 describes a variable valve actuation system that comprises a manual lash adjuster. Manual lash adjusters have the disadvantage of not providing automatic lash adjustment. Instead, a mechanic must adjust a manual lash adjuster during engine servicing.
SUMMARY
[0009] An aspect of the invention provides a hydraulic lash adjuster for an engine valve train, the adjuster comprising: a hydraulic lash adjusting arrangement configured to automatically compensate for lash in an engine valve train; and a lost motion arrangement configured to inhibit motion, induced in the valve train in response to a lift profile of a rotating cam, from being transferred to an engine valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. All features described and/or illustrated herein can be used alone or combined in different combinations in embodiments of the invention. The features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:
[0011] FIG. 1 is a schematic side view of a valve train assembly;
[0012] FIG. 2 is a schematic cross sectional side view of a HLA;
[0013] FIG. 3 a is a schematic cross sectional side view of a HLA with its components in a first configuration;
[0014] FIG. 3 b is a schematic cross sectional side view of the HLA of FIG. 3 a with its components in a first configuration;
[0015] FIG. 4 is a schematic side view of a valve train assembly;
[0016] FIG. 5 schematic side view of a valve train assembly;
[0017] FIG. 5 is a perspective view of a clip component;
[0018] FIG. 6 a is a is a schematic cross sectional side view of a HLA;
[0019] FIG. 6 b is a schematic cross sectional side view of a HLA;
[0020] FIG. 7 is a schematic side view of a valve train assembly;
[0021] FIG. 8 shows a component of an actuator;
[0022] FIG. 8 shows a plot of valve lift against cam angle;
[0023] FIG. 9 b shows the actuator and the engine brake capsule in a second configuration;
[0024] FIGS. 9 a , 9 b and 9 c each show schematic cross sectional side views of alternative HLAs.
DETAILED DESCRIPTION
[0025] An aspect of the invention provides a hydraulic lash adjuster for use in an engine valve train assembly, particularly, a hydraulic lash adjuster that provides a lost motion stroke variable valve actuation (VVA) capability.
[0026] Incorporating a lost motion arrangement into a HLA provides a system that is simpler has fewer components than known systems in which HLAs and lost motion systems are separate and distinct. This simplifies manufacturing and reduces costs.
[0027] An aspect of the invention provides a valve train including such an HLA.
[0028] FIG. 1 schematically illustrates a valve train assembly 1 comprising an exhaust rocker arm 3 , mounted for pivotal movement about a rocker shaft 5 . The exhaust rocker arm 3 comprises, at a first end 7 , a rotatably mounted roller 9 for engaging an exhaust cam 11 which is mounted or formed on a rotatable cam shaft 13 . The exhaust cam 11 comprises a base circle 11 a, a main exhaust lift profile 11 b and an additional exhaust lift profile 11 c.
[0029] As shown in FIG. 1 , the exhaust rocker arm 3 comprises, at a second end 15 , a cavity 17 in which is supported a Hydraulic Lash Adjuster (HLA) 19 . The HLA 19 is for contacting an exhaust valve 20 of an engine cylinder 21 .
[0030] Referring to FIG. 2 the HLA 19 comprises a hollow outer body 21 supported within the cavity 17 by means of a first retaining clip 23 . The hollow outer body 21 comprises a first closed end 25 which protrudes from the cavity 17 and defines a spigot 27 which is received in a socket 29 defined by an E-foot 31 . The E-foot 31 comprises a flat base end 33 for contacting a stem 35 of the exhaust valve 20 . The spigot 27 is retained within the socket 29 by means of a second retaining clip 37 .
[0031] The HLA 19 comprises a first plunger 39 slidably mounted within the hollow outer body 21 and which extends above a second open end 26 of the hollow outer body 21 . In this example, the first plunger 39 is a hollow two part component comprising a first hollow body 39 a and a second hollow body 39 b. The second body 39 b rests co-axially within the first body 39 a, for example, on a first annular lip 41 defined by the first hollow body 39 a. A first biasing means 40 , for example a compression spring, located at the first closed end 25 of the outer body 21 biases the first plunger 39 outwardly away from the outer body 21 such that a first open end 45 of the first plunger 39 , defined by respective ends of the first 39 a and second 39 b hollow bodies, presses against an upper inner surface 47 of the cavity 17 .
[0032] The HLA 19 further comprises a second plunger 49 slidably mounted within the first hollow body 39 a of the first plunger 39 . The second plunger 49 is coaxial with and opposes the second hollow body 39 b. In the position shown in FIG. 2 , the second plunger 49 rests upon a second annular lip 50 defined by the first hollow body 39 a. The second plunger 49 defines a first aperture 51 for connecting a first chamber 52 , defined by the hollow outer body 21 , the first hollow body 39 a and the second plunger 49 , and a second chamber 54 defined by the first hollow body 39 a the second plunger 49 and the second hollow body 39 b.
[0033] The second oil chamber 54 contains a second biasing means 53 , for example a compression spring, which biases the second plunger 49 away from the second hollow body 39 b.
[0034] The HLA 19 is further provided with a check ball valve 56 which comprises a ball 58 captured by a cage 60 supported in the first chamber 52 by the second plunger 49 and is biased by a third biasing means 62 , for example a small compression spring, to a position closing the first aperture 51 .
[0035] In use, if a lash (i.e. a gap) develops between any of the components in the valve train assembly 1 , the first biasing means 40 can expand the overall effective length of the HLA 19 by pushing the first plunger 39 away from the hollow outer body 21 so as to take up the slack in the valve train assembly 1 . During the course of this motion, the ball valve 58 allows oil to flow from the second chamber 54 to the first chamber 52 through the first aperture 51 so that the first chamber 52 is maintained full of pressurised oil. The oil is prevented from flowing back from the first chamber 52 to the second chamber 54 by the ball valve 60 . The HLA 19 therefore provides for automatic hydraulic lash adjustment.
[0036] The second hollow body 39 b and the upper inner surface 47 of the rocker arm 3 define a third chamber 68 located above the second chamber 54 . The second hollow body 39 b defines a second aperture 64 that connects the third chamber 68 and the second chamber 54 .
[0037] Oil is supplied to the third chamber 68 from the engine's oil supply via an oil supply conduit 65 formed through the rocker shaft 5 and exhaust rocker arm 3 into the HLA 19 . Oil is supplied from the third chamber 68 into the second chamber 54 when the relief valve 70 is open. In effect, the second chamber 54 and the third chamber 54 act as an oil reservoir for supplying the first chamber 52 when the HLA 19 extends and for replenishing oil that escapes from the first chamber 52 via leak down surfaces (illustrated by vertical dashed lines), for example, when the HLA is under load during a valve lift event.
[0038] In this example, the relief valve 70 is a poppet valve comprising an elongate stem 72 that extends along the longitudinal axis of the third chamber 68 and terminates at a first end in a valve head 74 that forms a seal with the second hollow member 39 b when the relief valve 70 closes the second aperture 64 . Many other types of valve may instead be used. A second end 78 of the stem 72 extends through an upper wall 80 of the HLA 19 where it is contactable by an actuator 82 which is operable to push the relief valve 70 from a first position in which the second aperture 64 is closed, to a second position in which the second aperture 64 is open. A fourth biasing means 84 is located in the third chamber 68 and is arranged to bias the relief valve 70 to the position in which the second aperture 64 is closed.
[0039] In this example, the actuator 82 comprises a lever 84 having a contact head 86 . When the relief valve 70 is in the first position in which it closes the second aperture 72 , the lever 84 is in a position in which the contact head 86 is above and not in contact with the second end 78 of the valve stem 72 . The lever 84 is moveable from this position into contact with the second end 78 of the valve stem 72 so as to push the relief valve 70 against the bias of the fourth biasing means 84 to open the second aperture 64 . The lever 84 may be moved for example by an electro-magnetic system 87 controlled by an engine control system. Other types of actuators may be used to actuate the relief valve 70 , for example, hydraulic actuators.
[0040] The HLA 19 is configurable by means of the actuator 82 to be in either a ‘combustion mode’ in which the relief valve 70 is open, or a ‘braking mode’ in which the relief valve 70 is closed. The ‘combustion mode’ corresponds to normal engine operation in which the engine cylinders provide power strokes. In contrast, the ‘braking mode’ corresponds to engine operation mode in which combustion is inhibited and de-compression engine braking is implemented.
[0041] In the braking mode, pivoting of the exhaust rocker arm 3 in response to the additional exhaust lift cam profile 11 c engaging the roller 11 causes an additional valve lift of the exhaust valve 20 , once per engine cycle, to provide a de-compression engine brake event. In contrast, in the combustion mode, the pivoting of the exhaust rocker arm 3 in response to the additional exhaust lift cam profile 11 c engaging the roller 11 is absorbed by a variable valve actuation ‘lost motion stroke’ of the HLA 19 and so the additional valve lift of the exhaust valve 20 is inhibited.
[0042] Referring now to FIGS. 1 , 3 a , 3 b and 4 , the combustion mode of operation will be explained. As illustrated in FIG. 1 , the cam shaft 13 is rotating clockwise in the sense of the page and the actuator 82 has configured the HLA 19 in combustion mode by pushing the relief valve 70 to open the second aperture 72 . FIG. 1 shows the valve train assembly 1 when the roller 9 is engaged with the base circle 11 a of the cam 11 and the exhaust valve 21 is closed, momentarily before the roller 9 begins to engage with the additional exhaust lift profile 11 c.
[0043] FIG. 3 a is an enlarged view of the HLA 19 as it is in FIG. 1 and shows the second plunger 49 resting upon the annular lip 50 formed around the bottom of the first hollow body 39 a and that there is a gap between the second plunger 49 and the second hollow body 39 b.
[0044] As the roller 9 starts to engage the leading rising slope of the additional exhaust lift profile 11 c, the exhaust rocker arm 3 starts to pivot clockwise in the sense of the page. As the exhaust rocker arm 3 pivots, the upper inner surface 66 of the exhaust rocker arm 3 pushes the first plunger 39 inwardly of the hollow outer body 21 in the direction of the bottom of the first chamber 52 . As the relief valve 70 is open, the movement of the first plunger 39 is able to displace oil in the first chamber 52 and the resultant pressure difference between the first chamber 52 and the second oil chamber 54 causes the second plunger 49 to move upwards towards the second hollow body 39 b.
[0045] When the first plunger 39 and the second plunger 49 are moving in this way, the outer body 21 remains substantially stationary and no force sufficient to open the exhaust valve 20 is transmitted to it, despite the clockwise pivoting of the exhaust rocker arm 3 . This could continue until the second plunger 49 hits the second hollow body 39 b, at which point, the HLA 19 would begin to act as a solid body that would transmit an opening force to the exhaust valve 21 , but in this example, even at the point at which the roller 9 engages the peak of exhaust lift profile 11 c, as shown in FIG. 4 , the second plunger 49 remains marginally out of contact with the second hollow body 39 b, as shown in FIG. 3B , and so the exhaust valve 20 remains closed. In effect, the movement of the second plunger 49 provides for a so called ‘lost motion stroke’, in which the exhaust rocker arm 3 performs a pivoting stroke but the exhaust valve 20 remains closed.
[0046] When the roller 9 engages the rising slope of the main exhaust lift profile 11 b, the exhaust rocker arm 3 pivots clockwise to a greater extent than when the roller 9 engages the rising slope of the additional exhaust lift profile 11 c. This motion is sufficient for the second plunger 49 to hit the second hollow body 39 b which acts as a stopper, at which point, the HLA 19 acts as a solid body due to the incompressible oil in the first chamber 52 and transmits an opening force to the exhaust valve 20 for the exhaust valve to open for the exhaust stroke of the engine cycle.
[0047] The maximum valve lift of the exhaust valve 20 occurs when the roller 9 engages the peak of the main exhaust lift profile 11 b. As the roller 9 passes out of engagement with the peak of the main exhaust lift profile 11 b, the exhaust rocker arm 3 starts to pivot anti-clockwise in the sense of the page and the exhaust valve 21 begins to close under the action of a valve return spring. When the roller 9 again becomes engaged with the base circle 11 a the exhaust valve 21 is closed. Furthermore, the first plunger 39 returns under the bias of the first biasing means 40 from its position shown in FIG. 3 b to its position shown in FIG. 3 a and, the second plunger 49 returns under the bias of the second biasing means 53 from its position shown in FIG. 3 b to its position shown in FIG. 3 a.
[0048] Referring to FIGS. 5 , 6 a , 6 b and 7 , the de-compression braking mode of operation will be explained. In this mode, the actuator 82 remains out of contact with the relief valve 70 , which under the bias of the fourth biasing means 84 keeps the second aperture 72 closed. FIG. 5 shows the valve train assembly 1 when the roller 9 is engaged with the base circle 11 a of the cam 11 and the exhaust valve 20 is closed, momentarily before the roller 9 commences to engage with the additional exhaust lift profile 11 c.
[0049] FIG. 6 a is an enlarged view of the HLA 19 as it is in FIG. 5 and shows that the second plunger 49 rests upon the annular lip 50 formed around the bottom of the first hollow body 39 a.
[0050] As the roller 9 starts to engage the leading rising slope of the additional exhaust lift profile 11 c, the exhaust rocker arm 3 starts to pivot clockwise in the sense of the page. In this mode of operation, because the relief valve 70 is closed, as the exhaust rocker arm 3 pivots, the oil pressure exerted by the oil in the second chamber 54 on the second plunger 49 and oil pressure exerted by the oil in the first chamber 52 on the second plunger 49 remain balanced so that the first plunger 39 cannot move inwardly of the hollow outer body 21 and the second plunger 49 cannot move upwards towards the second hollow body 39 b. Instead, the HLA 19 acts immediately as a solid body, due to the incompressibility of the oil in the first oil chamber 52 , and pushes down on the valve stem to open the exhaust valve 20 . The timing of the opening of the exhaust valve 20 is such that it opens by the end of the compression stroke of the engine cylinder so that compressed air is charged from the cylinder to provide de-compression engine braking. The maximum valve lift X (e.g. 1.9 mm) of this additional valve event occurs when the roller 9 engages the peak of the additional exhaust lift profile 11 c, see FIG. 7 . FIG. 6 b is an enlarged view of the HLA 19 as it is in FIG. 7 and line have been drawn across FIGS. 6 a and 6 b to illustrate the valve lift X.
[0051] When the roller 9 engages the rising slope of the main exhaust lift profile 11 b, the exhaust rocker arm 3 pivots clockwise to a greater extent than when the roller 9 engages the rising slope of the additional exhaust lift profile 11 c, and the HLA 19 acts on the exhaust valve 20 to fully open it for the exhaust stroke of the engine cycle. The maximum valve lift of the exhaust valve 21 occurs when the roller 9 engages the peak of the main exhaust lift profile 11 b. As in combustion mode, as the roller 9 passes out of engagement with the peak of the main exhaust lift profile 11 b the exhaust valve 21 begins to close under the action of a valve return spring and is fully closed when the roller 9 returns into engagement with the base circle 11 a.
[0052] FIG. 8 shows a plot of valve lift against cam rotation angle. The curve 101 is for the exhaust valve 20 and the curve 102 is for a corresponding intake valve for the engine cylinder, which is acted on by a intake rocker arm in response to an intake cam . The lost motion stroke absorbed by the HLA 19 in the combustion mode is illustrated by the double headed arrow 100 . In the combustion mode, the exhaust valve 20 remains shut during the ‘lost motion stroke’ and the exhaust valve opens at the point marked ‘EVO’ and closes at the point marked ‘EVC’. In the brake mode, the exhaust valve 21 begins opening at the point ExBr VO for the additional valve event by the end of the cylinder's compression stroke, to enable compressed air to be discharged from the cylinder. It closes at the point ExBbVc after the main exhaust lift. It will be appreciated that the exact movement of the valve during the additional valve lift will be dictated by the shape of the additional cam lift profile 11 c.
[0053] FIGS. 9 a to 9 c illustrate alternative HLAs 19 that may be used in embodiments of the invention. In these Figures, like reference numerals refer to like features previously described.
[0054] In each of FIGS. 9 a to 9 c the first hollow plunger 39 ′ is a single piece component rather than a two piece component as described above. The plunger 39 ′ has an annular region 200 that defines the second aperture 64 and provides a contact surface for stopping the second plunger 49 .
[0055] In FIG. 9 b , the relief valve 70 ′ is a two piece component comprising a first part 70 a′ which extends from the HLA 19 and which is contactable by the actuator 82 , and a second part 70 b′ which is acted upon by the first part 70 a′ to open the second aperture 62 .
[0056] In FIG. 9 c , the relief valve 70 ″ comprises a valve needle 70 a″ which extends from the HLA 19 and which is movable by the actuator 82 , to act upon a check ball valve 201 to open the second aperture 62 . The check ball valve 201 has a similar function and components to the check ball valve 60 that closes the first aperture 51 .
[0057] The above embodiments are to be understood as an illustrative example of the invention only. Further embodiments of the invention are envisaged. For example, although in the above described embodiment the HLA is supported in a rocker arm, this need not be the case, and the HLA may be supported in a different location or in a different component in a valve train. Although in the above embodiment the HLA acts directly on an engine valve this need not be the case. Although in the above embodiment the HLA acts on a single valve it may act on multiple valves, for example, by acting on a valve bridge or other such component that carries multiple valves. Although in the above described embodiment the HLA is used in conjunction with an engine de-compression braking operation, uses in conjunction with other operations, for example, Exhaust Gas Recirculation are envisaged. Although in the above described embodiment the lost motion arrangement of the HLA is used to entirely inhibit the additional exhaust valve lift when in combustion mode (i.e. the additional lift does not occur at all), it may be used to partially inhibit valve events (e.g. a valve does lift but not to the extent that it otherwise would have done). Further equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.
[0058] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. It will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different embodiments described above and below. Additionally, statements made herein characterizing the invention refer to an embodiment of the invention and not necessarily all embodiments.
[0059] The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article “a” or “the” in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of “or” should be interpreted as being inclusive, such that the recitation of “A or B” is not exclusive of “A and B,” unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of “at least one of A, B, and C” should be interpreted as one or more of a group of elements consisting of A, B, and C, and should not be interpreted as requiring at least one of each of the listed elements A, B, and C, regardless of whether A, B, and C are related as categories or otherwise. Moreover, the recitation of “A, B, and/or C” or “at least one of A, B, or C” should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B, and C. | A hydraulic lash adjuster for an engine valve train has a hydraulic lash adjusting arrangement for automatically compensating for lash in an engine valve train, and a lost motion arrangement for inhibiting motion induced in the valve train in response to a lift profile of a rotating cam from being transferred to an engine valve. | 5 |
This is a continuation-in-part of application Ser. No. 10/039,472, filed Jan. 4, 2002, now U.S. Pat. No. 6,634,685.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to door locking devices and, more particularly, to electromagnetically controlled door locks that are actuatable from remote locations throughout a building. Such locks, known generally as “electric strikes”; are commonly used to prevent the opening of an associated access obstructing member, such as a door, in hotels, offices, apartment buildings, storage cabinets and appliances. In a preferred embodiment the electric strike of the present invention employs a guard clip for deterring picking of the locking mechanism, a springless solenoid designed to prevent the build-up of residual magnetism which otherwise impairs a solenoid's ability upon activation to release the locking mechanism, and a one piece face plate for mounting in a doorjamb which serves to house the electric strike and guide the latch bolt associated with an access obstructing member into engagement with the latch bolt keeper of the electric strike. The present invention is also directed to a method of mounting the one piece face plate and its associated electric strike onto an aluminum doorframe in a manner which requires significantly less cutting of the doorframe by the installation technician than by other methods known in the art.
2. Description of the Related Art
Electronically-operable door strikes installed in a doorjamb to secure a door against opening are known in the art. Electric strikes typically provide a latch bolt keeper mounted on a pivot. The ability of the keeper to rotate on the pivot is electronically controlled. When the keeper is free to rotate to a latch bolt releasing position, the latch bolt associated with the access obstructing member is not retained in the door jamb and the access obstructing member can be opened. When the keeper is not free to rotate, that is, it is in its latch bolt securing position, the latch bolt is retained by the latch bolt keeper, thus securing the door.
Fundamentally, the function of an electric door strike is based on the fact that a retractable stop lever engages the latch bolt keeper and holds it in its latch bolt securing position. That is, the stop lever prevents the latch bolt keeper from rotating. The stop lever is sometimes held in its engaging position with the latch bolt keeper by a lock lever spring-urged into interlocking relationship with the stop lever. To permit the latch bolt keeper to rotate to its latch bolt releasing position, a solenoid is often employed. The solenoid is electronically energized, normally by means of a circuit completing switch remote from the door strike, and the lock lever is moved out of its locking engagement with the stop lever by the action of the solenoid plunger either pulling or pushing the lock lever. The stop lever, no longer being engaged by and being held in position by the lock lever, is incapable of resisting pivoting of the latch bolt keeper when force is applied to the keeper. The keeper is therefore able to be rotated and the door thus able to be opened.
One drawback of some of the electric strikes heretofore available is the ease with which they can be picked open and defeated by the insertion of a tool for unauthorized movement of the latch bolt keeper to a latch bolt releasing position. U.S. Pat. No. 3,638,984 to Davidson and U.S. Pat. No. 3,861,727 to Froerup et al. disclose a latch bolt keeper provided with a lateral edge projection arranged to occupy an overlapping position with respect to an edge of the strike plate and thus close the space between this edge and the adjacent face of the latch bolt keeper so as to provide against the insertion of a picking tool. U.S. Pat. No. 4,026,589 to Hanchett, Jr. also discloses a latch guard which precludes insertion of a tool. Finally, U.S. Pat. No. 4,056,277 to Gamus et al. discloses a plurality of pin-like protrusions positioned to form a barrier to prevent access by a tool to the ball and socket arrangement which serves to hold the latch keeper of that invention in place. Unlike the prior art electric strikes heretofore disclosed, the present invention utilizes a unique guard clip designed to prevent a tool from gaining access to the lock lever and further, by means of its fish hook-like configuration, to redirect any tool which is inserted into the electric strike away from the lock lever and the stop lever.
Another disadvantage of the electric strikes heretofore available is the undesirable build-up of residual magnetism within the solenoid or on the solenoid plunger. It is essential for proper operation of a solenoid that it lose its magnetic force once input electrical power to the solenoid is removed, thus allowing the solenoid plunger to return to its original position. Any magnetic field which remains when electrical power is removed is termed residual magnetism. The residual magnetism present in prior art electric strikes is occasioned by the frequent contact between two ferrous metal surfaces such as a ferrous metal solenoid plunger striking a ferrous metal lock lever during repeated energization and de-energization of the solenoid. Build-up of residual magnetism during repeated cycling of the solenoid results in the eventual failure of the solenoid's ability to remotely disengage the lock lever and the stop lever so as to permit the latch bolt keeper to be rotated and the access obstructing member opened. In some electric strikes termed “fail-safe” or “power to lock” by those of skill in the art, the plunger is pulled into the solenoid body when energized. This action of the plunger pulls the spring-resistive lock lever into engagement with the stop lever, thus preventing the latch bolt keeper from pivoting from its latch bolt securing position to its lockset latch bolt releasing position. When the solenoid is de-energized, the spring-urged lock lever returns to its original position where it is disengaged from the stop lever, thus allowing the latch bolt keeper to be pivoted to its lockset latch bolt releasing position. Upon the build-up of residual magnetism along the plunger or solenoid body, however, the plunger can remain in contact with the lock lever or not fully exit the body of the solenoid, thus compromising the ability of the lock lever to disengage from the stop lever. In the operation of other electric strikes, termed “fail-secure” by those of skill in the art, the plunger is pulled from its starting position into the body of the solenoid upon energization and this action releases the stop lever, thus permitting the latch bolt keeper to rotate. Upon de-energization the plunger exits the solenoid body by means of a spring and is returned to its starting position. Again, however, upon the build-up of residual magnetism along the plunger, the plunger may not be able to be completely returned to its starting position by the spring mechanism, thus compromising the solenoid's ability to return the stop lever or lock lever to a position where the latch bolt keeper is prevented from rotating.
Yet an additional drawback of prior art electric strikes is the large amount of cutting into a steel door jamb which is necessary to install the strike and its associated face plate. The American National Standards Institute (“ANSI”) standard face plate measures 4⅞ inches in length by 1¼ inches in width. Typically, electric strike face plates also utilize an auxiliary ramp which measures 3⅜ inches in length, thus necessitating that a corresponding length of the door jamb be removed at a depth of about one-half inch or more to properly seat the face plate and auxiliary ramp into the jamb. This large amount of cutting requires more time and money to install than otherwise would be necessary with an electric strike and face plate arrangement that reduces the amount of door jamb cutting required for installation.
This problem exists not only in the steel door industry but also in the aluminum/glass door industry which does not follow the ANSI standards. The aluminum/glass door industry manufactures what is commonly known in the trade as “storefronts”. A storefront is a door consisting of a glass panel surrounded and supported by an aluminum frame which is hung from a hollow aluminum doorjamb by means of hinges. A storefront-type entryway is common in many retail establishments such as those found in a strip mall. Architects, designers, and owners of these retail establishments commonly determine the specifications for the storefront including the door jamb. The door jambs are typically pre-fabricated and include a “cut-out” portion to accommodate the dimensions of the doorframe hardware specified by the architect/designer or owner, usually that of the largest selling U.S. manufacturer of such hardware for aluminum/glass doors. The dimensions of the cut-out are therefore commonly either 4⅝ inches in height by 1 9/16 inches in width or 2⅝ inches in height by 1 9/16 inches in width. When the decision is later made by the owner of the retail establishment to install or retrofit a prior art electric strike and associated faceplate into the cut-out portion of the aluminum door jamb, a significant amount of cutting of the door jamb is required, thereby requiring an extended amount of time for the installer and a corresponding high cost.
A still further drawback of prior art electric strike face plates occurs in those installations where the electric strike is required to be installed in door jambs which measure 4 inches or wider and the door is to be center hung. In those instances the auxiliary ramp and face plate comprise two or more pieces, thus again requiring more time for installation than if a one-piece face plate and auxiliary ramp were provided.
SUMMARY OF THE INVENTION
For the foregoing reasons, there is a need for an electric strike which overcomes the hereto before described problem of residual magnetism associated with a frequently cycled or continuous duty solenoid plunger. There is a further need for an electric strike in which a tool cannot be used to pry away the lock lever from the stop lever permitting the latch bolt keeper to be rotated and the access obstructing member opened by a tampering intruder. There is yet a still further need for an electric strike and face plate which reduces the amount of door jamb cutting necessary for its installation.
It is thus an object of the present invention to provide an electronically-operable door strike which utilizes a solenoid which avoids the build-up of residual magnetism along the solenoid body or plunger which otherwise would render the electric strike inoperable.
It is a further object of the present invention to provide an electronically-operable door strike which embodies an improved guard to the insertion of a picking tool and which redirects a picking tool away from contacting the lock lever or the stop lever.
It is a still further object of the present invention to provide an electronically-operable door strike and one piece face plate with fill lip and auxiliary ramp arrangement which reduces the amount of door jamb material which must be removed for installation of the face plate.
It is yet a still further object of the present invention to provide an electronically-operable door strike and associated one piece face plate that can be uniquely retrofitted into an existing aluminum door jamb cut-out of the dimensions previously noted thereby reducing the amount of cutting of the door jamb required to install the electric strike and its face plate, thus realizing a cost savings for the installation.
In accordance with the foregoing objects, an electronically-operable door strike which employs a guard clip for deterring picking of the locking mechanism, a springless solenoid designed to avoid the build-up of residual magnetism and a face plate which reduces the amount of door jamb cutting required for installation of the electric strike and face plate arrangement is disclosed. Briefly stated, the invention is practiced by utilizing a guard clip which protects the lock lever and the stop lever from tampering by a tool inserted into the door strike along an edge of the latch bolt keeper and which by virtue of its “fish hook” configuration redirects the tool away from the lock lever. In addition, to avoid the build-up of residual magnetism, a solenoid comprising a ferrous metal shell and front cap, a rear cap of non-ferrous material such as non-ferrous metal, and a ferrous metal plunger with a non-ferrous metal protuberance is provided. An air gap is maintained between the front cap and the plunger body during movement of the plunger to avoid the build-up of residual magnetism between the front cap and the plunger body. An additional air gap is provided between the plunger and a spool within which the plunger moves and around which a wire coil is wrapped inside of the solenoid shell. This additional air gap aids in the dissipation of heat generated when the wire coil of the solenoid is electronically-activated and the plunger is repeatedly cycled. Finally, the face plate associated with the electric strike is designed with a fill lip and flange tongue arrangement which reduces the amount of the door jamb which must be removed for the installation of the electric strike and face plate in comparison with heretofore known electric strike and face plate arrangements.
Further objects, features, aspects and advantages will be readily apparent to those skilled in the art and a better understanding of the present invention may be had by reference to the following detailed description taken in connection with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front plan view of the electric strike of the present invention with the cover removed and showing the lock lever in its position engaged with and immobilizing the stop lever such that the latch bolt keeper is maintained in its latch bolt securing position;
FIG. 2 is an exploded perspective view of the electric strike of the present invention;
FIG. 3 is a front plan view similar to FIG. 1 showing the solenoid plunger striking the lock lever and the lock lever moved to its position allowing the stop lever to be pivoted and the latch bolt keeper rotated to its latch bolt releasing position;
FIG. 4 is a front plan view similar to FIG. 3 showing the latch bolt keeper rotated to its latch bolt releasing position;
FIG. 5 is a side view of the electric strike of the present invention with the cover removed and showing the solenoid in its non-activated position and the lock lever in its engaged position with the stop lever;
FIG. 6 is a side view similar to FIG. 5 but showing the solenoid in its activated position and the lock lever in its disengaged position with the stop lever;
FIG. 7 is a cross-sectional view along line 7 — 7 of FIG. 1 ;
FIG. 8 is a cross-sectional view along line 8 — 8 of FIG. 4 showing the relationship between the stop lever and the rotated latch keeper;
FIG. 9 is a perspective view of the guard clip;
FIG. 10 is a cross-sectional view of the solenoid along line 10 — 10 of FIG. 5 when the latch bolt keeper is in its latch bolt securing position;
FIG. 11 is a cross-sectional view of the solenoid along line 11 — 11 of FIG. 6 when the solenoid is energized and the latch bolt keeper is in its latch bolt releasing position; and
FIG. 12 is an exploded perspective view of the solenoid.
FIG. 13 is a front plan view of the face plate and electric strike of the present invention installed within a door jamb.
FIG. 14 is a cross-sectional view along line 14 — 14 of FIG. 13 .
FIG. 15 is a side view of the face plate of the present invention installed within a door jamb.
FIG. 16 is a front plan view of a further embodiment of the face plate with the electric strike installed within a door jamb.
FIG. 17 is an exploded rear perspective view of the face plate of the present invention with a dust shield and electric strike.
FIG. 18 is an exploded perspective view of a common prior art face plate and an aluminum door jamb depicting an existing cut-out portion in the prefabricated door jamb.
FIG. 19 is an exploded perspective view of a common prior art face plate and its associated electric strike depicting the amount of an aluminum door jamb which must be removed to retrofit the strike and face plate into an existing cut-out portion in the prefabricated door jamb.
FIG. 20 is an exploded perspective view of the electric strike and its associated face plate of the present invention depicting the amount of an aluminum door jamb which must be removed to retrofit the strike and its face plate into an existing cut-out portion in the prefabricated door jamb.
FIG. 21 is an exploded perspective view of another common prior art face plate and an aluminum door jamb depicting an existing cut-out portion in the prefabricated door jamb.
FIG. 22 is an exploded perspective view of a common prior art face plate and its associated electric strike depicting the amount of an aluminum door jamb which must be removed to retrofit the strike and face plate into an existing cut-out portion of the prefabricated door jamb.
FIG. 23 is an exploded perspective view of the electric strike of the present invention and another embodiment of its associated face plate depicting the amount of an aluminum door jamb which must be removed to retrofit the strike and its face plate into an existing cut-out portion in the prefabricated door jamb.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings there is shown in FIG. 1 an electrically-operable door strike as generally indicated by the numeral 10 . The electric strike is comprised of a base 12 having a front edge 12 a and a rear edge 12 b . To base 12 are fixedly secured a pair of spaced-apart support blocks 14 a and 14 b each provided with threaded openings 11 (see FIG. 2 ) for receiving screws to fixedly hold a pair of end panels 13 a and 13 b and a cover 13 c . Support blocks 14 a and 14 b also carry a shaft pin 16 (see FIG. 2 ) for rotatably supporting a latch bolt keeper 18 . The cross-sectional configuration of the latch bolt keeper may best be observed in FIG. 7 . Mounted circumferentially around shaft pin 16 is a cylindrical turning spring 15 which urges the latch bolt keeper 18 into its latch bolt securing position wherein the front edge portion 17 of latch bolt keeper 18 protrudes beyond front edge 12 a of base 12 (as best seen in FIG. 1 ), through face plate 31 ( FIG. 2 ) and engages the latch bolt of an adjacent door (not shown).
Referring to FIG. 1 , the stop lever 20 , which extends substantially along the entire length of base 12 , is pivotally secured at one end by means of a pivot pin 21 extending normal to base 12 . The free end of stop lever 20 contains shoulder 34 (see FIG. 3 ) from which tooth 27 protrudes for engagement with angled notch 29 located on the free end of lock lever 22 . The shape of tooth 27 can be angular, curved or have a hook-like appearance. The shape of the angled notch 29 similarly can be angular, curved, or have a hook-like appearance. Lock lever 22 is itself pivotally secured at its opposite end by means of pivot pin 24 extending normal to base 12 . The stop lever 20 is urged into its locking position whereby it prevents latch bolt keeper 18 from pivoting around shaft pin 16 by means of a torsion spring 26 (see FIG. 5 ) which, with one leg, engages the wall of support block 14 a (see FIG. 1 ) and with its other leg fits into depression 28 of stop lever 20 . The lock lever 22 is urged into its interlocking position with the stop lever by means of a torsion spring 30 (see FIG. 2 ) which engages either both lock lever 22 and pivot pin 24 or both lock lever 22 and support block 14 b . In this interlocking position, tooth 27 of shoulder 34 of stop lever 20 hooks into angled notch 29 on the free end of the lock lever 22 . When lock lever 22 is moved from its locking position shown in FIG. 1 into its releasing position shown in FIG. 3 against torsion spring 30 by action of plunger 44 (see FIG. 12 ) in a manner to be described, it permits retraction of the stop lever 20 . Stop lever 20 , however, is initially maintained in its position in which it contacts latch bolt keeper 18 by torsion spring 26 . Due to the pivotal motion of the latch bolt keeper 18 by the latch bolt during the opening of the door, the rear edge portion 19 of the latch bolt keeper 18 pushes the stop lever 20 which then pivots and retracts into its open, latch bolt releasing position shown in FIG. 4 . After the latch bolt has been released by the latch bolt keeper 18 and the door has been opened, the cylindrical turning spring 15 returns the latch bolt keeper 18 into the latch bolt securing position shown in FIG. 1 . In this position, under the action of torsion spring 26 , the stop lever 20 snaps with its shoulder 34 behind the free end of the lock lever 22 which is returned to its locking position by spring 30 , thus maintaining the latch bolt keeper 18 in its latch bolt securing position.
When tooth 27 and notch 29 are engaged in an interlocking relationship, pressure exerted on latch bolt keeper 18 in an attempt to rotate latch bolt keeper 18 about shaft pin 16 to its latch bolt releasing position serves to more firmly engage tooth 27 and notch 29 and hence stop lever 20 and lock lever 22 , thus increasing the locking force or holding integrity of those two levers as they hold the latch bolt keeper 18 in its latch bolt securing position. If both tooth 27 and notch 29 are angled at 90 degrees so that they perpendicularly intersect each other, vibrations applied to the electric strike 10 through the door or door jamb can cause stop lever 20 to vibrate and walk out of its contact with lock lever 22 , thus allowing latch bolt keeper 18 to be rotated to its latch bolt releasing position. Therefore, both tooth 27 and notch 29 are preferably angled at less than 90 degrees. With the arrangement of tooth 27 and notch 29 heretofore described, it is observed that a load or force applied to latch bolt keeper 18 in an attempt to rotate latch bolt keeper 18 into its latch bolt releasing position will not disengage stop lever 20 from lock lever 22 ; however, the slightest amount of force applied directly to lock lever 22 pivots lock lever 22 on pivot pin 24 resulting in the disengagement of the stop lever 20 from the lock lever 22 .
Rear edge portion 19 of latch bolt keeper 18 is beveled at an angle of approximately 35 degrees as best illustrated in FIG. 7 . Front edge portion 23 of stop lever 20 is also beveled at an angle of about 35 degrees. Thus when latch bolt keeper 18 is pivoted about shaft pin 16 (as shown on FIG. 8 ), rear edge portion 19 of the keeper contacts the front edge portion 23 of stop lever 20 and rotates stop lever 20 on pivot pin 22 . Rear edge portion 19 of keeper 18 is permitted to slid behind stop lever 20 by virtue of beveled front edge portion 23 of stop lever 20 and beveled rear edge portion 19 of latch bolt keeper 18 . The pivoting motion of latch bolt keeper 18 to its latch bolt releasing position is stopped by shell 42 (see FIG. 5 ) of solenoid 35 . In this manner neither the rear edge portion 25 of stop lever 20 (see FIG. 4 ) nor the beveled rear edge portion 19 of latch bolt keeper 18 extends beyond rear edge 12 b of base 12 when latch bolt keeper 18 is pivoted to its latch bolt releasing position. The effect is that the electric strike of the present invention is compact and small in dimension and can be used particularly in those applications where space in the door jamb is limited. The electric strike of the present invention has a height (H) of about 1 11/16 inches or of about 1 13/16 inches and a width (W) of about 1 1/32 inches (see FIG. 5 ). Further with respect to size, electric strike 10 has a back set (the depth an electric strike requires to fit into a doorframe) of only about one (1) inch. This feature is important as it allows electric strike 10 to fit into more applications such as doorframes, storage cabinets and appliances with less restrictions due to size.
As best illustrated in FIGS. 1 and 9 , guard clip 54 is a separate element, not an integral part of base 12 , which is disposed between support block 14 b and latch bolt keeper 18 to minimize the ability of a potential intruder to insert a tool into electric strike 10 along latch bolt keeper 18 for purposes of contacting lock lever 22 and disengaging it from stop lever 20 . In those instances where a tool is successfully inserted into electric strike 10 , guard clip 54 is also intended to preclude access by the tool to lock lever 22 which, otherwise, could be contacted by the tool and disengaged from stop lever 20 . Arm 56 of guard clip 54 is comprised of three portions. First portion 56 a is of sufficient length to extend perpendicularly from front edge 12 a of base 12 to at least pivot pin 24 of lock lever 22 . Second portion or tab 56 b of arm 56 is angled away from latch bolt keeper 18 toward lock lever 22 until third portion or flange 56 c of arm 56 is again angled toward shoulder 34 of stop lever 20 . Because of the shape and dimensions of arm 56 of guard clip 54 , arm 56 prevents access to lock lever 22 by a tool inserted into electric strike 10 between guard clip 54 and latch bolt keeper 18 . Furthermore, any tool, such as an unfurled paperclip or wire, which is inserted into electric strike 10 in this manner will be directed away from lock lever 22 by means of the “fish hook” configuration of arm 56 . A guard clip which is not angled in the manner heretofore described will not redirect an inserted tool away from lock lever 22 .
For moving the lock lever 22 against the force of torsion spring 30 there serves a springless solenoid 35 having an axis that extends in the longitudinal direction of base 12 . The solenoid 35 , which takes up a substantial portion of the length of the base 12 , comprises wire coil 37 wound on a spool 36 made of a thermoplastic polyester resin, such as polyethylene terephthalate polyester resin, high temperature plastic, or other synthetic material. With the solenoid 35 there is associated a front cap 38 , a rear cap 40 , a cylindrical shell 42 and a plunger 44 which is movable within the spool 36 . Plunger 44 is comprised of a plunger body 46 and a protuberance or plunger tip 48 as best seen in FIGS. 10-12 . Plunger body 46 is cylindrical in shape and constructed of 1018 soft steel or other ferrous metal. Plunger tip 48 is also cylindrical in shape having a smaller diameter than that of plunger body 46 . Plunger tip 48 is constructed of stainless steel or other non-ferrous metal. This choice of materials for plunger tip 48 aids in avoiding the build-up of residual magnetism between front cap 38 and the plunger tip 48 through repeated travel of the plunger tip through the front cap 38 , as will be described, in response to repeated cycling of energizing and de-energizing the solenoid 35 . Front cap 38 has a hole 39 centrally disposed therein through which plunger tip 48 is movable when solenoid 35 is energized. Front cap 38 is constructed of 1018 soft steel or other ferrous metal which acts as a magnet to pull plunger 44 toward it when solenoid 35 is energized. To direct plunger 44 toward front cap 38 when solenoid 35 is energized, rear cap 40 also has a hole 41 centrally disposed therein through which plunger body 46 is moveable when solenoid 35 is energized. Rear cap 40 is constructed of aluminum, stainless steel, other non-ferrous metal, or other non-ferrous material which will not become magnetized when solenoid 35 is energized. Shell 42 is constructed of steel or other ferrous metal. The shell 42 functions not only as an enclosure for wire coil 37 , spool 36 and plunger 44 but also as a stop for latch bolt keeper 18 when it is pivoted about shaft pin 16 into its latch bolt releasing position. Plunger body 46 and plunger tip 48 are supported during the travel of plunger 44 by holes 39 and 41 in front cap 38 and rear cap 40 , respectively. Plunger body 46 and plunger tip 48 do not contact spool 36 . Thus, a first air gap 47 (see FIGS. 10 and 11 ) is created between the outer surface of plunger 44 and the inner surface of spool 36 . First air gap 47 helps to avoid the build-up of residual magnetism along plunger 44 and further aids in dissipating the build-up of heat in solenoid 35 when the solenoid is energized. This has several advantages. First, air gap 47 helps to avoid expansion of spool 36 , and a resulting shrinkage of the inside diameter of spool 36 , which otherwise would cause friction or binding between plunger 44 and spool 36 during travel of the plunger towards front cap 38 when solenoid 35 is energized. Second, solenoid 35 is able to be operated at a lower voltage than if no air gap were present because heat does not build-up inside of solenoid 35 . Heat build-up would otherwise increase the resistance of wire coil 37 thus requiring more voltage to operate solenoid 35 .
When solenoid 35 is energized, plunger body 46 is, by the resulting magnetic attracting forces, moved toward front cap 38 (see FIG. 11 ). During its motion caused by magnetic attraction, the plunger tip 48 exits the front cap 38 through hole 39 and strikes an aluminum or other non-ferrous metal actuator pin 50 which extends laterally from the underside of the lock lever 22 and which is disposed in the path of travel of the plunger tip 48 . As a result of the collision between the plunger tip 48 and the actuator pin 50 , the lock lever 22 is pivotally moved about pivot pin 24 into its releasing position against the force of spring 30 . The pivotal motion of lock lever 22 and its underlying actuator pin 50 is stopped by end panel 13 b . As a result, a second air gap 52 is maintained between plunger body 46 and front cap 38 , as best illustrated in FIG. 11 . This second air gap 52 further resists the build-up of residual magnetism between plunger 44 and front cap 38 which might otherwise result from the repeated striking of plunger 44 against front cap 38 during repeated energization/de-energization cycling of the solenoid. The pivotal motion of lock lever 22 into its releasing position in turn releases stop lever 20 from its engagement with lock lever 22 , thereby permitting stop lever 20 to pivot away from latch bolt keeper 18 thus allowing latch bolt keeper 18 to pivot to its latch bolt releasing position upon shaft pin 16 . Once the door or other access obstructing member has been opened and latch bolt keeper 18 returned to its latch bolt securing position by the urging of turning spring 15 , stop lever 20 is again urged to its closed position by torsion spring 26 , spring 30 also urges lock lever 22 into its closed position engaging stop lever 20 . When the lock lever 22 returns to its closed position, the actuator pin 50 underlying lock lever 22 strikes plunger tip 48 and returns a portion of the plunger tip 48 and the associated plunger 44 to the confines of the solenoid shell 42 , with end panel 13 a serving as a stop for the travel of the plunger 44 through hole 41 of rear cap 40 . In the manner heretofore described, plunger 44 moves from a starting position within non-energized solenoid 35 to a stop lever striking position when solenoid 35 is energized, and returns to the starting position when the solenoid is de-energized, all without the urging of any springs within solenoid 35 .
Also provided for housing and mounting the electric strike 10 of the present invention within a doorjamb is face plate 60 (see FIGS. 13 - 16 ). Face plate 60 is constructed of flat stock steel and is of one piece construction. Face plate 60 comprises lip 62 which is convex and overlaps edge 64 of door jamb 66 when face plate 60 is secured to door jamb 66 by screws or other attaching means inserted through holes 68 within face plate 60 . Face plate 60 further comprises flange tongue 70 which is displaced a distance apart from the outer edge 72 of face plate 60 (see FIG. 14 ) and the inner edges 74 of face plate 60 (see FIG. 13 ) thereby forming a channel 76 (see FIG. 15 ) which serves as a guide for the latch bolt associated with an access obstructing member to engage with the latch bolt keeper 18 and place the latch bolt keeper into its latch bolt securing position.
The arrangement of the face plate 60 and electric strike 10 within a standard width (e.g., 1⅜ inches or 1¾ inches) door jamb is depicted in FIGS. 13 and 14 . In those instances where the door jamb is wider (such as 4 inches or greater) and the access obstructing member is center hung, thus necessitating the location of the electric strike on or about the centerline 72 of door jamb 66 , the embodiment of face plate 60 depicted in FIG. 16 would be utilized. Therein, face plate 60 is of one piece construction and the width of lip 62 and flange tongue 70 are extended from the electric strike 10 to edge 64 of door jamb 66 .
Installation of face plate 60 within door jamb 66 requires less cutting and removal of door jamb material (typically metal such as steel or aluminum) than installation of prior art electric strike face plates. Prior art electric strike face plates utilize an auxiliary ramp which requires that a length (l) of door jamb measuring 3⅜ inches at a minimum depth (d) of ½ inch be removed to seat the face plate and ramp into the door jamb. In the present invention much less door jamb material is required to be removed to install the face plate because lip 62 wraps around door jamb 66 (see FIG. 14 ) thereby requiring only nominal cutting of the edge 64 of door jamb 66 to accommodate the width of narrow notch 76 (about 1⅛ inches) and the depth 80 (about 7/16 inch) of narrow notch 76 below the about ⅛ inch cut-out 82 which is precut into standard prefabricated steel door jambs. Prior art face plates associated with electric strikes typically require a wider (3⅜ inches) notch 76 and/or a greater depth cut 80 (about ½ inch or more) within the door jamb to effect proper installation. A further advantage of face plate 60 is that lip 62 acts as a trim skirt to cover and hide from view that portion of the edge 64 of door jamb 66 which must be cut to accommodate installation of face plate 60 . This is of particular advantage in those instances where installation of face plate 60 is performed by a technician in a door jamb which has already been installed in a doorway and hence precise cutting of the door jamb, such as is possible in a factory, is unlikely to occur.
The installation advantages of face plate 60 and electric strike 10 of the present invention are further illustrated in FIGS. 18 to 20 which depict the retrofitting of face plate 60 and electric strike 10 into a door jamb 66 constructed of aluminum.
Referring to FIG. 18 , there is depicted an aluminum door jamb 66 and existing door jamb cut-out portion 102 sized to receive prior art face plate 100 . The dimensions of cut-out portion 102 are sized by the aluminum door jamb manufacturer to accommodate the dimensions of the doorframe hardware specified by the architect/designer or the owner of, for example, a retail establishment. The dimensions of the cut-out portion 102 are most commonly either 4⅝ inches in height (h) by 1 9/16 inches in width (w) (as shown in FIG. 18 ) or 2⅝ inches in height (h) by 1 9/16 inches in width (w) (as shown in FIG. 21 ) because these are the dimensions of the doorframe hardware of the largest selling U.S. manufacturer of such hardware for aluminum/glass doors. In either instance the cut-out depth (d) is generally 3/32-inches into sidewall 106 of door jamb 66 .
Oftentimes there is a need to increase the security of an access obstructing member, such as a door in a building. In such an instance, it becomes desirable to retrofit an electric strike and its associated face plate into the existing cut-out portion 102 of an aluminum door jamb. Although there are many different sizes which are available, two common sizes of face plates manufactured by the electric strike industry for use in aluminum frames are: (a) a face plate measuring 6⅞ inches in height (Y) by 1⅝ inches in width (X) which is designed for use in conjunction with an electric strike having a height (H) of 4⅝ inches; and (b) a face plate measuring 4⅞ inches in height (Y) by 1¼ inches in width (X) which is designed for use in conjunction with an electric strike having a height (H) of 2⅝ inches. Therefore, using these two common sizes as examples, to retrofit a 4⅝ inch electric strike required also retrofitting an electric strike face plate 104 having a height (Y) of 6⅞ inches (see FIG. 19 ) into an existing aluminum door jamb cut-out portion 102 having a height (h) of 4⅝ inches. This required significant cutting of the door jamb 66 and associated door jamb sidewall 106 by the installation technician. As a consequence, the time and cost for the installation increased. Further, as can be observed in FIGS. 18 and 19 , retrofitting an aluminum door jamb to accommodate a prior art face plate 104 having a height (Y) of 6⅞ inches and a width (X) of 1⅝ inches, along with its associated 4⅝ inch (H) electric strike requires that the height (h) of the prefabricated cut-out portion 102 be expanded from 4⅝ inches to 6⅞ inches. Additionally, the width (w) of the cut-out portion 102 needs to be expanded from 1 9/16 inches to 1⅝ inches and the depth (d) of the cut-out portion 102 needs to be increased from 3/32-inches to ⅞-inches along a length (l) of 3⅜ inches. In addition, either one or both of mounting tabs 108 for face plate 104 must be replaced and relocated and one or both of holes 110 for securing mounting tabs 108 to door jamb 66 must be redrilled.
By employing the electric strike 10 and face plate 60 of the present invention (see FIG. 20 ), the amount of cutting of door jamb 66 and door jamb sidewall 106 during retrofitting is significantly less. This is in part because face plate 60 of the present invention having a height (Y) of 4⅝ inches is designed to be installed into an aluminum door jamb with an electric strike 10 of the present invention having a height (H) of about 1 11/16 inches or of about 1 13/16 inches. Furthermore, face plate 260 of the present invention having a height (Y) of 2⅝ inches (see FIG. 23 ) is designed to be installed into an aluminum door jamb with electric strike 10 of the present invention having a height (H) of about 1 11/16 inches or of about 1 13/16 inches.
Referring to FIG. 20 , there is shown electric strike 10 and face plate 60 of the present invention. Face plate 60 has a height (Y) of 4⅝ inches. Retrofitting face plate 60 into an existing aluminum door jamb cut-out portion 102 having a height (h) of 4⅝ inches requires only nominal cutting of door jamb 66 . Neither the height (h) of the cut-out portion nor the width (w) of the cut-out portion needs to be expanded. Only the depth (d) of the cut-out portion needs to increased from 3/32-inches to ½-inch along a length (l) of 2 1/16 inches along sidewall 106 . Therefore, when utilizing the electric strike 10 and face plate 60 of the present invention, a savings of time and money for a retrofitting installation is realized when compared to the prior art.
The installation advantages of a further embodiment of face plate 260 , and electric strike 10 , of the present invention are additionally illustrated in FIGS. 21 to 23 which depict the retrofitting of a further embodiment of face plate 260 and electric strike 10 into a door jamb 66 constructed of aluminum.
Referring to FIG. 21 , there is depicted an aluminum door jamb 66 and existing door jamb cut-out portion 202 sized to receive prior art face plate 200 . The dimensions of cut-out portion 202 are sized by the aluminum door jamb manufacturer to accommodate the dimension of the doorframe hardware specified by the architect/designer. The dimensions of the cut-out portion 202 are about 2⅝ inches in height (h) by about 1 9/16 inches in width (w). The cut-out depth (d) is about 3/32 inches into sidewall 106 of door jamb 66 .
As can be observed in FIGS. 21 and 22 , retrofitting an aluminum door jamb to accommodate a prior art face plate 204 having a height (Y) of 4⅞ inches and a width (X) of 1¼ inches, along with its asociated 2⅝ inch (H) electric strike requires that the height (h) of the prefabricated cut-out portion 202 be expanded from 2⅝ inches to 4⅞ inches. Additionally, the depth (d) of the cut-out portion 202 , needs to be increased from 3/32-inches to ⅞ inches along a length (l) of 3⅜ inches. In addition, either one or both of mounting tabs 108 for face plate 204 must be replaced and relocated and one or both holes 10 for securing mounting tabs 108 to doorjamb 66 must be redrilled.
By employing the electric strike 10 and face plate 260 of the present invention (see FIG. 23 ), the amount of cutting of door jamb 66 and door jamb sidewall 106 during retrofitting is significantly less. This is in part because face plate 260 of the present invention having a height (Y) of 2⅝ inches is designed to be installed into an aluminum door jamb with an electric strike 10 of the present invention having a height (H) of about 1 11/16 inches or of about 1 13/16 inches.
Referring to FIG. 23 , there is shown electric strike 10 and face plate 260 of the present invention. Face plate 260 has a height (Y) of 2⅝ inches. Retrofitting face plate 260 into an aluminum door jamb cut-out portion 202 having a height (h) of 2⅝ inches requires only nominal cutting of door jamb 66 . Neither the height (h) of the cut-out portion nor the width (w) of the cut-out portion needs to be expanded. Only the depth (d) of the cut-out portion needs to be increased from 3/32-inches to ⅝-inches along a length (l) of 2⅝ inches along sidewall 106 . Therefore, when utilizing the electric strike 10 and face plate 260 of the present invention, a savings of time and money for retrofitting installation is realized when compared to the prior art.
Referring to FIG. 17 , the face plate may optionally include dust shield 84 . The dust shield serves to prevent door jamb filler (typically cement, concrete, wood chips and the like) from entering the face plate channel 76 after installation of the face plate and electric strike into a door jamb and subsequently obstructing the travel of the latch bolt of an adjacent door (not shown) to the latch bolt keeper 18 . Dust shield 84 is constructed of aluminum, steel, or other metal and is connected to face plate 60 and the electric strike by screws or other connecting means.
An electronically-operable door strike and face plate is provided which readily avoids the problems and shortcomings associated with the prior art. The preferred embodiment has been illustrated and described. Further modifications and improvements may be made thereto as may occur to those skilled in the art and all such changes as fall within the true spirit and scope of this invention are to be included within the scope of the claims to follow. | An electronically-operable door strike employing a guard clip for deterring picking of the locking mechanism therein, a springless solenoid designed to avoid the undesirable build-up of residual magnetism and which incorporates air gaps for dissipating heat, thus prolonging the useful life of the solenoid, and a face plate for mounting the strike into a door jamb. | 4 |
RELATED PATENT DOCUMENTS
[0001] This patent document is a continuation of U.S. patent application Ser. No. 12/140,346 filed on Jun. 17, 2008, entitled “Transaction Card System and Approach,” now U.S. Pat. No. ______, which is a continuation of U.S. patent application Ser. No. 11/019,651 filed on Dec. 21, 2004, and now U.S. Pat. No. 7,398,919; which is a continuation-in-part of U.S. patent application Ser. No. 09/614,270 filed on Jul. 12, 2000 and entitled “Debit Card Billing System;” each of these patent documents is fully incorporated herein by reference and for subject matter common thereto, priority is claimed to the earliest of these patent documents under 35 U.S.C. § 120.
FIELD OF THE INVENTION
[0002] The present invention relates to a system and approach for debit-card transaction purchases with deferred billing.
BACKGROUND OF THE INVENTION
[0003] Modern consumers have become accustomed to the safety and convenience of making purchase transactions at remote points of sale using credit cards instead of cash. Credit cards allow a consumer to make purchases on credit accounts in which a credit card issuing institution records purchases to a consumer's account and then sends a monthly billing statement to the consumer. If the consumer elects not to pay off the entire balance of the account at the end of the billing cycle, then the credit card issuing institution typically collects interest on the outstanding balance on the account.
[0004] In response to the success of credit cards, banking institutions such as—banks and credit unions have developed debit cards which can be used just like credit cards to make purchases. However, unlike credit cards, the purchases are immediately posted to the consumer's checking account as if the consumer had written a check. Therefore, the consumer is not required to pay a monthly statement because the funds to cover the purchase are taken immediately and directly from the consumer's checking account.
[0005] Debit card accounts have drawbacks when compared to normal credit card accounts. There may be more than one cardholder drawing on an account such as in a joint checking account. With present debit account systems, using two debit cards for one account can result in overdrafts when both users unknowingly make debit transactions during the same time period. Because both cards draw upon the same account just like checks, two users may inadvertently draw upon the same funds resulting in an overdraft.
[0006] In addition, the typical debit account user loses interest compared to a credit card user. Because debit card transactions are posted to the checking account in the same way as checks, a user can expect the checking account to be drawn upon within a few days of the debit transaction. Credit card accounts, on the other hand, allow the user to keep funds in an interest bearing account until the end of a billing cycle before they are needed to pay the credit card bill. By waiting until the end of the month to pay a credit card bill, the credit card user receives interest on the funds for the remaining period of the billing cycle. Current debit card systems employed by banks, however, immediately debit the checking account just like a check would be debited. Therefore, a current debit card user does not receive the added interest he might have gained by keeping the funds in the interest bearing account for the remainder of a billing period.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to overcoming the above-mentioned challenges and others, including those related to the types of applications discussed above. These and other aspects of the present invention are exemplified in a number of illustrated implementations and applications, some of which are shown in the figures and characterized in the claims that follow.
[0008] An example embodiment of the present invention is directed to a method and system for managing an account for use by a banking institution which provides checking or savings account services. An account user is provided with a debit card which can be used to make debit transactions, each transaction being recorded by the bank but not billed to the account until after a billing cycle elapses and after the account user has been issued a billing cycle statement showing all credit transactions. The system automatically debits the account for all debit transactions made during the billing cycle after a payment period elapses following issuance of the statement.
[0009] The system has a number of embodiments and applications suitable for use in various billing systems. First, the system combines into one card the ability to make automated banking transactions on an account with the ability to make debit purchases against the account. The present system actually defers the time of payment as a credit card account would, but combines this ability with the convenience of a banking card tied to a particular financial account.
[0010] Various embodiments also address a problem associated with joint accounts. All debit transactions made with the transaction cards issued on the financial account are stored in the system until the end of a billing cycle without being debited against the account. At the end of the billing cycle, all the debit transactions for the billing cycle are reported to the debit card account holders. The debit card account holders are able to review the debit transactions and have the opportunity to supply additional funds or alternative sources of payment other than a direct debit to the account. In this way, joint checking account holders can avoid inadvertent overdrafts.
[0011] In addition, through the present system, the debit card account holder receives the advantage of accruing interest on funds which remain in the account during the time that elapses between the debit transaction and the actual debiting of the account for the transaction. Because the system defers debiting the account for the debit transactions until after the billing cycle and after a payment period following the billing cycle, the debit card account holder is able to capture the interest earned on funds which remain in the account during the deferred period.
[0012] The above summary is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures, detailed description and claims that follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention may be more completely understood in consideration of the detailed description of various embodiments of the invention that follows in connection with the accompanying drawings, in which:
[0014] FIG. 1 is a schematic flow chart of a debit transaction authorization process in accordance with an example an embodiment of the present invention.
[0015] FIG. 2 is a schematic flow chart of a debit transaction settlement process in accordance with another example embodiment of the present invention.
[0016] FIG. 3 is a schematic flow chart of the statement and debit process in accordance with another example embodiment of the present invention.
[0017] FIG. 4 is a schematic diagram of the components of a computer system, according to another example of the present invention.
[0018] FIG. 5 is a schematic diagram of a networked computer managing system, according to another example of the present invention.
[0019] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described.
DETAILED DESCRIPTION
[0020] The present invention is believed to be applicable to a variety of different types of devices, processes and approaches, and has been found to be particularly suited for financial transactions involving a consideration-bearing banking account.
[0021] According to an example embodiment, a system for managing a financial institution account, such as a checking or savings account, combines the monthly billing schedule of a credit card account with the automatic debiting of a debit account to provide an account holder with greater flexibility and control over cash management. The system includes a transaction card which the account holder can use to make automated banking transactions as well as debit transactions. Greater flexibility as well as convenience is afforded the debit card account holder by the system in that debit transaction information is accumulated and stored for a billing cycle period without being posted against the funds in the account. At the end of the billing cycle a report or statement of debit transactions is produced for the debit card account holder's review. After a predetermined payment period elapses after producing the statement is the account automatically debited for all debit transactions of the billing cycle.
[0022] FIGS. 1 and 2 show a debit transaction authorization process and a debit transaction settlement process respectively. In a typical debit transaction, there are a number of parties involved. The transaction involves a consumer or debit card account holder with a debit card 2 , a merchant with a point of sale processor 4 , a debit card issuing financial institution 10 which issued the debit card for use with the consumer's account, a credit institution 6 such as VISA or MASTERCARD, and often an intermediary clearinghouse or debit processing service 8 . The debit card issuing financial institution 10 may be any bank, credit union or similar institution at which the consumer or account holder has opened a checking, savings, or other financial account.
[0023] A debit transaction occurs in two phases or steps. Typically, the first phase is an authorization phase. The authorization process is shown in FIG. 1 . In the authorization phase the merchant 4 obtains verification and authorization from the debit card issuing financial institution 10 that the debit card 2 is valid and that the user has not exhausted a deferred purchase periodic limit. The authorization phase occurs before the merchant 4 allows the consumer to make the purchase. The second phase is typically a settlement phase. The settlement phase is shown in FIG. 2 . In the settlement phase funds are eventually transferred from the consumer's account at the financial institution to the merchant.
[0024] In the authorization phase of the present system, the debit card user first presents a debit card 2 to the merchant 4 in order to make a purchase. The merchant swipes the card through a point of sale processor which reads account information encoded on card 2 and combines it with information such as the date and the amount of the purchase and merchant identification. The point of sale system transmits the debit transaction information to the credit institution 6 identified by the card 2 such as VISA.
[0025] The credit institution 6 then identifies the card issuing financial institution 10 and transmits the debit transaction information to the card issuing financial institution 10 either directly or through a debit processing service 8 . The information is received by the card issuing financial institution 10 by a managing computer system 50 as shown in FIG. 4 . The information may be received by the computer system via a receiver system 40 which typically employs high speed dedicated communication lines. After identifying an account corresponding to the debit card 2 being used, the managing computer system 50 runs verifications against the identified account to determine whether the debit transaction should be authorized. The account status is verified 12 as a valid, open account that has not been put on hold. The amount of the purchase is checked against a deferred debit purchase monthly spending limit 14 . The deferred debit purchase spending limit is the amount in debit purchases the debit card account holder is permitted to make each month and may be, for example, between $1,000 and $20,000.
[0026] Upon approval by the card issuing financial institution 10 , an authorization record is stored 16 in the managing computer system's memory system 44 , noting the debit transaction information. An authorization signal is then sent back from the card issuing financial institution 10 through the credit institution 6 to the merchant's point of sale processor 4 where the debit transaction is authorized.
[0027] The settlement phase begins when the merchant 4 or the merchant's bank 20 requests payment from the credit institution 6 to cover the debit transactions authorized by the card issuing financial institution 10 . Typically, at the end of a business day a merchant 4 will total the debit transactions performed and request payment from the credit institution 6 . The credit institution 6 pays the merchant 4 and demands payment from the card issuing financial institution 10 by issuing a schedule or posting file 22 of all the transactions authorized by the card issuing financial institution 10 . When the card issuing financial institution 10 receives the posting file, the financial institution's managing computer system 50 verifies each debit transaction listed against the authorization records stored when the authorization was given 24 . Upon verification, the card issuing institution 10 makes payment to the credit institution 6 . Shortly thereafter, in prior art systems, and typically through on-line or batch processing, the managing computer system debits the consumer's checking account for the amount of the transaction and eliminates the authorization record, thereby completing the debit transaction.
[0028] The card issuing financial institution's managing computer system 50 is configured so that, during the settlement phase, after the receipt of the posting file 22 , and after the card issuing financial institution 10 makes payment to the credit institution 6 , the managing computer system 50 makes a deferred transaction billing record or history 26 without debiting the amount of the transaction against the consumer's account. The spending limit balance available is then updated 28 to reflect the purchase made.
[0029] A managing computer system 50 configured according to an embodiment the present invention, to accumulate a billing record of all debit transactions for a billing cycle, typically one month, without debiting the consumer's account. The debiting of the account is deferred. In this manner a deferred transaction history is maintained for each account. As shown in FIG. 3 , at the end of the billing cycle, the managing computer system 50 recalls the billing history and issues a statement which includes a notice itemizing and totaling the deferred debit transaction history for the consumer's account. The statement shows an accrued debit balance for the billing cycle. Once the statement is issued to the debit card account holder 30 , the billing cycle spending limit is reset 32 , allowing the debit card account holder to make additional deferred purchases for a new billing cycle. The statement may be made either through conventional hard copy reports or through electronic means. For example, the statement may be made available to the consumer by electronically posting the statement information at a secure site such as an internet site accessible by the account holder's personal computer 56 , or through an automated telephone service.
[0030] The managing computer system 50 includes a memory system 44 . FIG. 5 shows how the memory system 44 may be divided into databases that may include an account database 60 , a deferred history database 62 , and an authorization record database 64 . A record of authorization is made in the authorization record database 64 during the authorization phase as described above. The record may then be recalled from the authorization record database 64 and a new record made in the deferred history database 62 during the settlement phase.
[0031] After providing a statement to the debit card account holder, the managing computer system initiates a payment period countdown 34 . During the payment period countdown the debit card account holder has the opportunity to designate or provide sources of payment to cover the debit transactions by supplementing the funds of the account itself or by designating another account. The account holder may transfer funds from a credit line or from funds outside the debit card issuing financial institution. The transfer may be accomplished by phone or even electronically. Any payments made during the payment period are deducted from the accrued debit balance 36 which may be recorded in a deferred history database. When the payment period expires, the managing computer system automatically debits the debit card account or another designated account for the accrued debit balance 38 . In one preferred embodiment the payment period is a period of fifteen days. The debiting may be accomplished by recalling the deferred debit balance 38 from the deferred history database 62 and debiting an account database 60 as shown in FIG. 5 .
[0032] The system may also be configured so that the debit cards may be used in automated teller machines 54 to make automated banking transactions such as deposits and withdrawals. The managing computer system 50 according to the present invention may be configured to distinguish automated banking transactions from debit transactions wherein only the debiting of the debit transactions is deferred during the payment period. Accordingly, depending upon system configurations, automated banking transactions either may be posted to the account during on-line or batch processing, or they may be deferred according to the present invention.
[0033] By combining debit card purchasing and deferred billing utilizing a single transaction card to accomplish both debit transactions as well as automated banking, a debit card account holder can reduce the number of cards needed to perform all of these functions. Reducing the number of cards is not only more convenient for the debit card account holder but also decreases the risk of having multiple cards lost or stolen.
[0034] In summary, the present invention is directed to a deferred billing debit card system and method for managing an account at a financial institution. The system and method can be used in conjunction with a transaction card 2 which is encoded with computer-readable information identifying the financial institution 10 and the account at the financial institution 10 . An account holder uses the transaction card 2 to make debit purchases and transactions. The system includes a receiver system 40 which may include high speed dedicated phone or communication lines for receiving electronically transmitted debit transaction information generated by the account holder's use of the transaction card 2 in making a debit transaction. The debit transaction information is stored in a computer-readable memory system 44 . A computer processor system 42 recalls the debit transaction information from the memory system 44 and aggregates the debit transaction information in a statement showing an accrued debit balance 30 for a billing cycle. The computer processor system 42 automatically debits the account for the accrued debit balance 38 but not until after the end of the billing cycle and after the account holder is given an opportunity during a payment period 34 to provide a source of payment to cover all or part of the accrued debit balance.
[0035] The present invention may be configured to include an output system 46 by which the billing system makes the statement available to the account holder. The output system 46 may include a printer system for generating hard copy statements to be sent by mail to the account holder or the statement may be made available by electronic means via electronic mail or posting on a secure internet site.
[0036] The present invention may also be configured to work in conjunction with a transaction card that has also been encoded to be capable of use in automated banking transactions.
[0037] The present invention is to be limited only in accordance with the scope of the appended claims, since persons skilled in the art may devise other embodiments still within the limits of the claims. For example, the features described in the present application are not limited to a bank but apply to other financial institutions such as a credit union, a trust company, a savings and loan association, or a savings association. Furthermore, the present systems and methods may be applied to financial institution accounts beyond checking accounts, such as by designating payment of accumulated debit transactions against a savings account. | A system and method for managing a financial institution account with a transaction card used as a deferred-debit transaction card and as an automated banking card wherein debit transactions are stored by a managing computer system for a billing cycle without being automatically debited against the account until after debit transaction activity. In certain instances, this is not until after the activity for the billing cycle is reported to the holder of the account. Also, a limited time period is provided relative to the billing cycle, for the user to provide funds as consideration for payment against the transaction card purchases without an automatic debiting of available funds as full consideration for payment against the deferred-debit purchases. Before the limited time period lapsing, the available amount useful for additional purchases can be increased. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to the drawing and heat setting of extruded synthetic continuous textile filaments and, more particularly, to textile draw-warping systems wherein filament drawing and heat setting is combined in the same operation with the preparation of a textile warp beam.
Since the development of extruding systems for producing continuous filaments of synthetic polymeric materials suitable for use as textile yarns, it has been recognized that the physical properties of a continuous filament may be selectively controlled by subjecting the filament to a stretching process while applying heat above the glass transition temperature of the filament to effect alignment and ordering of the molecular and crystalline structure of the filament to a desired degree, commonly referred to as drawing. Conventionally, drawing has been carried out in the past as a separate process following spinning of the filament. However, it has been discovered that the molecular structure of filaments becomes increasingly oriented with the elevation of spinning speeds enabling achievement of a sufficient drawing effect in certain cases to enable the elimination of a separate drawing step, various applications of this technique being referred to as draw-spinning or spindrawing. Nevertheless, this technique suffers the disadvantages of being relatively expensive and, in some cases, producing less than optimal draw results. Since a significant proportion of drawn filamentary yarns are utilized in the textile industry in warp knitting and weaving processes, considerable attention has been devoted more recently to combining the drawing process with the winding of filamentary yarns onto a warp beam preparatory to knitting or weaving, which has come to be known as draw-warping. The draw-warping technique has thus far proved to provide two significant advantages. First, unusually high quality fabric may be produced using this combined drawing and warp preparation process in that all of the filaments formed into a fabric are drawn under essentially identical mechanical and thermal conditions. Further, draw-warping enables improved efficiency with lower capital investment costs enabling higher profit margins to be achieved.
Perhaps the most widely utilized and known machinery for draw-warping is the Model DSST equipment manufactured by Karl Mayer of Obertshausen, West Germany. Basically, draw-warping is carried out with this equipment by feeding a sheet of parallel warp yarns through a drawing unit consisting of a sequence of rollers in advance of a warp beaming machine whereat the warp sheet is wound onto a warp beam. The rollers in the drawing unit essentially consist of a group of several parallel side-by-side feed rollers and a group of several parallel side-by-side delivery rollers spaced along the path of travel of the warp sheet. Intermediate the feed and delivery rollers, the warp sheet travels about a deflection pin along an essentially V-shaped path. Inclined heating plates are respectively disposed alongside the two sections of the V-shaped path between the feed rollers and the deflection pin and between the deflection pin and the delivery rollers. The relative speeds of the feed and delivery rollers are controlled to achieve a desired degree of drawing therebetween, with the first heater plate being adapted to elevate the temperature of the filaments in the warp sheet to a desirable drawing temperature while the subsequent heater plate functions to heat set the filaments.
As will be understood, one problem unique to draw-warping is the accommodation of the periodic necessity of interrupting the normally continuous draw-warping operation, for example, when any one of the filaments in the warp sheet breaks or for other reasons experiences a significant loss in tension activating a stop motion arrangement of the draw-warping equipment. With the traveling movement of the warp sheet stopped under such circumstances, the application of heat thereto must be altered in order to prevent excessive localized heating of the warp sheet which can produce filament damage and even breakage and may result in unevenness in the dye uptake of the subsequently produced fabric causing so-called stop marks across the dyed fabric. To avoid this problem when the draw-warping process is interrupted, it is necessary to decrease the heating of the warp sheet to a temperature below the glass transition temperature of the filaments while at the same time maintaining constant filament tension in the draw region so as not to change the draw point along each filament, i.e. the point at which the filament is first subjected to a lengthwise stretching force.
In the Mayer DSST draw-warping machine, the foregoing considerations are addressed during stoppages and restarts of the draw-warping process by arranging the heater plates for movement during machine stoppages away from the warp sheet at a rate proportional to the decreasing travel speed of the warp sheet while simultaneously turning the deflection pin 180 degrees to expose its cooler side to the warp sheet, with the heater plates and the deflection pin being correspondingly returned to their respective former positions upon machine restart.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a improved drawing apparatus for use in a textile draw warping system utilizing one or more heated godet rolls in order to achieve superior control of the drawing process. It is a further object to provide a suitable means for removing the warp filaments from and reapplying them to the heated godet roll upon stoppages and restarts of the draw-warping system.
Briefly summarized, the drawing apparatus of the present invention utilizes one or more rotatable feed rolls, at least one heated rotatable godet roll and one or more rotatable take-up rolls respectively arranged for training of the filaments of the warp sheet to travel in peripheral engagement sequentially therewith. A suitable drive arrangement is provided for driving the godet and take-up roll at respective relative speeds to achieve a desired degree of drawing of the filaments during their travel between the godet and take-up rolls. Another arrangement is provided to be operative upon stoppage of the drawing apparatus for removing the filaments from engagement with the godet roll to prevent continued application of heat to the filaments while simultaneously engaging the filaments intermediate the feed roll and the godet roll to maintain substantially constant tension along their respective extents between the location of their last contact with the godet roll and the take-up roll and also to maintain a substantially constant length of the filaments between the feed and take-up rolls. This arrangement is further operative upon restart of the drawing apparatus for reengaging the filaments with the godet roll at the same location as the previous contact between the filaments and the godet roll. In this manner, degradation of the filaments during stopping and restarting of the drawings apparatus is prevented.
According to the preferred embodiment of the present invention, a second rotatable godet roll is arranged immediately upstream of the first-mentioned heated godet roll in relation to the path of filament travel. Additionally, a rotatable swing roll is provided for engaging the filaments intermediate the feed roll and the second godet roll. According to the present invention, the second godet roll and the swing roll are displaceable with respect to the filaments to effect filament removal from the godet roll during stoppages of the drawing apparatus and filament reengagement with the godet rolls upon restarts of the drawing apparatus. Preferably, the second godet roll and the swing roll are arranged for displacement along respective arcuate paths which are mutually convex with respect to one another with the displacement path of the second godet roll extending from one circumferential side of the first godet roll to the opposite circumferential side thereof. It is further preferred that the swing roll and the godet rolls be driven by a common drive adapted to permit rotation of the swing and godet rolls during displacement of the swing and second godet rolls.
Further, a heated platen is disposed alongside the path of filament travel between the heated godet roll and the take-up roll for heat setting purposes, the platen being movable away from the filaments upon stopping of the drawing apparatus in advance of displacement of the godet and swing rolls and being movable toward the filaments upon restart of the drawing apparatus after displacement of the swing and godet rolls.
The drawing apparatus includes a frame which supports each of the rolls with its opposite ends extending in cantilevered relation respectively from opposite sides of the frame to facilitate operator access thereto for filament thread-up and like operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a draw-warping system incorporating the preferred embodiment of the drawing apparatus of the present invention;
FIG. 2 is a perspective view of the drawing apparatus in the drawwarping system of FIG. 1, in its normal operating mode;
FIG. 3 is a side elevational view of the drawing apparatus in the drawwarping system of FIG. 1, also showing the drawing apparatus in its normal operating mode;
FIG. 4 is another side elevational view similar to FIG. 3, showing the drawing apparatus in its non-operating mode;
FIG. 5 is a vertical cross-sectional view through the drawing apparatus in its operating mode of FIG. 3;
FIG. 6 is another vertical cross-sectional view similar to FIG. 5 showing the drawing the drawing apparatus in its non-operating mode of FIG. 4; and
FIG. 7 is a side elevational view similar to FIG. 3 showing an alternate embodiment of the drawing apparatus of the present invention, in its normal operating mode.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings and initially to FIG. 1, a drawing apparatus according to the preferred embodiment of the present invention is shown generally at 10 as preferably embodied in a draw-warping system wherein a creel, representatively indicated at 12, supports a plurality of individual packages of partially oriented synthetic continuous filaments, such as polyester or nylon, which are fed as represented at F generally in side-by-side relation through an eyeboard 14 to the drawing apparatus 10 and travel therefrom through a filament inspecting device 16, a dancer assembly 18 and an oiling device 20, to a warp beaming machine 22, commonly referred to as a warper. For purposes of illustration, the particular embodiment of the present drawing apparatus herein disclosed is adapted for the draw warping of polyester filaments, but those persons skilled in the art will readily recognize that the present drawing apparatus is equally well adapted for the draw warping of nylon and other synthetic filaments.
As best seen in FIGS. 2 3, and 4, the drawing apparatus 10 has an upstanding central frame 24 by which a series of draw rollers, including a feed roller 28, a swing roller 30, a pair of godet rollers 32,34 and three take-up rollers 36,38,40, are rotatably supported to extend outwardly in cantilevered fashion from each opposite side of the frame 24 for training of the partially oriented filaments in sequence peripherally about the rollers, as shown. This construction facilitates operator access to the filaments F for ease of the filament thread-up and like operations. Within the interior of the frame 24, the feed rollers 28, the swing roller 30 and the godet rollers 32,34 are synchronously driven in common by an endless drive belt 42 trained in series about the interiorly mounted portions of such rollers as well as about an idler pulley 44 and a drive pulley 46 which, in turn, is driven through another drive belt 48 from a drive motor 50, as shown in FIGS. 5 and 6. Similarly, the take-up rollers 36,38,40 are synchronously driven in common by a drive belt 52 trained peripherally about each thereof and about an idler pulley 54 and a drive pulley 56 which, in turn, is driven by a drive motor 58 through another drive belt 60.
The godet roller 34 has a hollow cylindrical outer shell which is heated by a conventional electromagnetic induction heating system utilizing an electrical coil (not shown) mounted within the godet roller 34 to produce a magnetic flux field causing the outer shell to become sufficiently heated as it rotates through the flux field for heating the filaments F slightly above their glass transition temperature as they travel through the drawing apparatus 10. As necessary or desirable, the godet roller 32 may similarly be provided with a like heating means. A heated platen 62 is positioned for contact with the filaments F along the extent of their travel from the godet roller 34 to the first take-up roller 36 for heating the filaments F to a more elevated temperature sufficient to achieve crystalization of the filaments. The respective drive systems for the feed, swing and godet rollers 28,30,32,34 and for the take-up rollers 36,38,40 are adjustable to enable selective control of the relative speeds of each set of rollers to achieve a predetermined speed differential therebetween. In this manner, the heated filaments are caused to be drawn longitudinally to a predetermined desired degree from the point at which the filaments leave contact with the godet roller 34 to the first take-up roller 36, the platen 62 being operative in this area to crystalize, or heat set, the filaments.
To accommodate the occasional necessity of stopping the drawing apparatus during its above-described normal operation, the swing roller 30 and the godet roller 32 are individually mounted for arcuate movement and the heated platen 62 is similarly mounted for arcuate movement to remove the filaments from contact with the godet rollers 32,34 and the platen 62 in the event of a stoppage of the draw warping system. For this purpose, the godet roller 32 is rotatably supported at the free end of a generally L-shaped crank arm 64 pivotably supported at its opposite end within the frame 24 at a pivot location 63 substantially opposite the godet roller 34 from the normal operating position of the godet roller 32. Pivotal movement of the crank arm 64 is actuated by a drive arm 66 pivoted within the frame 24 at one end thereof at a pivot location 67 and connected at the opposite end thereof with the crank arm 64 through a drive link 68, the opposite ends of which are pivoted respectively to the crank arm 64 and the drive arm 66. Pivotal actuating movement of the drive arm 66 is controlled through a hydraulic piston and cylinder assembly 70 mounted within the frame 24 with the extensible piston 72 thereof pivotably connected to the drive arm 66 centrally along its length. Through this mechanism, the godet roller 32 is thereby movable through an approximately 180 degree arcuate path from its operating position shown in FIGS. 2, 3 and 5 to a non-operative position shown in FIGS. 4 and 6 at the opposite circumferential side of the godet roller 34, as defined by a slot 65 formed in each upright side wall of the frame 24.
The swing roller 30 is rotatably supported at one end of a pivot arm 74, the opposite end of which is pivotably mounted within the frame 24. Pivotal movement of the pivot arm 74 is controlled by another hydraulically-operated piston and cylinder assembly 76, the piston 78 of which is pivotably attached to the pivot arm 74 adjacent its pivot location. Thus, through this mechanism, the swing roller 30 may be moved through an approximately 90 degree range of arcuate movement extending oppositely to that of the godet roller 32 from the normal operating position of the swing roller 30 adjacent the feed roller 28 as seen in FIGS. 2, 3 and 5 to an inoperative position spaced therefrom as seen in FIGS. 4 and 6, as defined by a slot 75 in each upright side wall of the frame 24.
For the same purpose, the heated platen 62 is similarly mounted to the free end of a pivot arm 80 pivotably supported within the frame 24 at 85 and attached to the piston 82 of another piston and cylinder assembly 84 also supported within the frame 24. In this manner, the platen 62 is pivotable toward and away from the path of filament travel through the drawing apparatus 10 between an operative position shown in FIGS. 2, 3 and 5 wherein the platen 62 is in surface contact with the extent of filament travel between the godet roller 34 and the takeup roller 36 and an inoperative position shown in FIGS. 4 and 6 wherein the platen 62 is pivoted away from such path of filament travel.
The hydraulic piston and cylinder assembly 76 for the swing roller 30 is continuously actuated for withdrawal of its piston 78 to apply a predetermined biasing force urging the roller 30 into tensioning engagement with the drive belt 42 to maintain a predetermined tension in the drive belt 42. Operation of the hydraulic piston and cylinder assemblies 70 and 84 for actuating movement of the godet roller 32 and the platen 62 is controlled by a microprocessor or other suitable controller, representatively indicated at 86, to which each stop motion and the start/stop controls of the draw warping system are operatively input, as collectively indicated representatively at 88.
In normal operation, each piston and cylinder assembly 70,84 is activated to extend its respective piston 72,82 to position the godet roller 32 and the platen 62 in their respective operative dispositions of FIGS. 2, 3 and 5. As a result, the swing roller 30 assumes its operative disposition wherein the piston 78 of the associated piston and cylinder assembly 76 is also substantially extended, to maintain desired tension in the drive belt 42. Thus, as the filaments F travel through the drawing apparatus 10 along the path of travel shown in FIGS. 2, 3 and 5, the filaments F are heated by contact with the periphery of the godet roller 34 (and also the godet roller 32, if heated) to an elevated temperature slightly above the glass transition temperature of the particular filaments F to cause the filaments to be drawn, i.e. stretched lengthwise, at the point of leaving contact with the godet roller 34, as a result of the differential speeds between the godet roller 34 and the first takeup roller 36. The filaments F then travel in contact across the heated facing surface of the platen 62 at a more elevated temperature which serves to heat set, i.e. crystalize, the filaments F in their thusly drawn state.
In the event of any stoppage of filament travel through the drawing system, such as for example when a stop motion device 88 on the creel or elsewhere in the system is activated by a filament breakage or other substantial loss of filament tension, the microprocessor 86 recognizes the system stoppage and automatically deactuates the electric drive motors 50,58 and actuates suitable braking devices, shown only representatively at B, to control the slowing and stoppage of the draw rollers 28,30,32,34,36,38,40. Simultaneously, the microprocessor 86 actuates retraction of the piston 82 of the piston and cylinder assembly 84 to pivot the heated platen 62 away from the filaments F into the non-operative disposition of the platen 62 shown in FIGS. 4 and 6, the pivotal movement being precisely controlled in synchronism with the braking of the rollers and the corresponding slowing of the speed of filament travel to reduce the heat application to the filaments F in direct proportion to the slowing filament speed, thereby insuring a constant heat application to the filaments F. Immediately upon stoppage of the rollers and filament travel, the microprocessor 86 then actuates retraction of the piston 72 of the piston and cylinder assembly 70 to cause the godet roller 323 to move through its respective arcuate path into its nonoperating disposition of FIGS. 4 and 6. The hydraulic biasing force applied to the piston and cylinder assembly 76 causes its piston 78 to withdraw simultaneously for synchronous movement of the swing roller 30 through its respective arcuate path into its respective non-operating disposition of FIGS. 4 and 6, to thereby continuously maintain constant tension in the drive belt 42.
As a result of such movements of the heated platen 62 and the swing and godet rollers 30,32, the filaments F are removed entirely from contact with both godet rollers 32,34 and the platen 62, the filaments F extending in a substantially linear path from their point of leaving contact with the swing roller 30 in its nonoperating disposition to the first take-up roller 36. During the arcuate movements of the swing and godet rollers 30,32, the braking devices B associated with the feed and godet rollers 28,34 remain activated to hold the drive belt 48, the drive pulley 46 and the drive belt 42 fixed against further movement, while the braking device B associated with the swing and godet rollers 30,32 are released to permit such rollers to rotate essentially as idler rollers. Thus, since the path of filament travel and the path of travel of the drive belt 42 are identical between the swing and godet rollers 30,32, as will be seen in FIGS. 3-6, the swing and godet rollers 30,32 are constrained to rotate during their respective arcuate movements to substantially precisely the degree of rotation necessary to avoid the application of a pulling force on the filaments F.
As aforementioned, the arcuate movement of the swing roller 30 is synchronized with the arcuate movement of the godet roller 32 by the hydraulic biasing force applied to the swing roller 30 by its associated piston and cylinder assembly 76 to insure that the swing roller 30 serves to immediately take up the loss of filament tension which otherwise would result from the arcuate movement of the godet roller 32 out of contact with the filaments F and thereby serves to maintain substantially constant both the overall length of each filament F between the feed roller 28 and the first take-up roller 36 and the tension in each filament F along such extent of its length. By thus maintaining substantially constant tension in the filaments F along their respective lengths between the location of their last contact with the godet roller 34 and the first take-up roller 36, the so-called draw point of each filament F, i.e. the point at which each filament F was last in contact with the godet roller 34 whereat each filament F was last subjected to a drawing force, is likewise maintained.
For restart of the draw warping system, the microprocessor 86 first actuates the piston and cylinder assembly 70 to return the godet roller 32 to its respective operative disposition with the swing roller 30 returning synchronously to its operative disposition against the biasing force of the associated piston and cylinder assembly 76 to reengage the filaments F at the identical points of previous contact with the filaments F while continuing to maintain constant filament tension throughout such return movement. Then, the draw warping system is restarted to resume filament travel, the piston and cylinder assembly 84 being activated simultaneously with the drive motors 50,58 with the microprocessor controlling the return pivotal movement of the platen 62 toward its operating disposition in direct proportion to the increasing speed of filament travel to insure uniform heat application. As a result, degradation of the filaments from overheating, over-tensioning or the like is prevented during stopping and restarting of the drawing apparatus 10.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. For example, an additional heated feed roller 29 may be provided and separately driven intermediate the feed roller 28 and the swing roller 30 to establish an additional draw zone for adapting the drawing apparatus for the draw warping of nylon filaments 3 as shown in FIG. 7. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | A drawing apparatus for a textile draw warping system includes rotatable feed, swing, godet and take-up rolls about which a plurality of synthetic continuous filaments travel in sequential peripheral engagement. The godet and take-up rolls are driven at different relative speeds with the godet roll being heated above the glass transition temperature of the filaments to cause drawing of the filaments between the godet and take-up rolls. A heated contacts the filaments between the godet and take-up rolls to crystalize the drawn filaments. The godet and swing rolls are mounted for movement in respective arcuate paths which are mutually convex to one another for disengaging the filaments from the godet roll upon stoppage of the drawing system while maintaining constant filament tension to prevent overheating and degradation of the filaments. The platen is also movable away from the filament path upon system stoppages in coordinated relation to the decreasing speed of filament travel. | 3 |
This is a continuation of application Ser. No. 159,764, filed June 16, 1980, now abandoned.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to the field of jacks.
Particularly the present invention relates to the field of vibration jacks which are controlled and driven by servo-valves. These jacks have a characteristic frequency which is essentially a function of the volume of the chamber or chambers, of the force developed, and of the moving mass.
(2) Description of the Prior Art
As stated above, the characteristic frequency of a jack is dependent upon thechamber volume, force developed and the moving mass. As an illustration of this dependency for a given jack, the larger the moving mass, the lower the hydraulic characteristic frequency. This hydraulic characteristic frequency dependency on chamber volume, force development and mass has disadvantages. One disadvantage is that a loss of operational control over the jack occurs with an overpressurization of the chamber or chambers. The overpressurization of the chamber is difficult to overcome, particularly at low frequencies. This difficulty is related to the hydraulic characteristic frequency dependency upon chamber volume, developed force and mass. As this frequency is lowered it develops greater energy or force. This increase in force or energy hampers the elimination of overpressurization because greater pressure is required to overcome the force.
The prior art discloses various attempts to eliminate this overpressurization. These attempts have mainly involved the increasing of the working section of the chambers. This is accomplished by putting the volumes of the chamber, which are separated by the piston, into communication with each other. While this reduces overpressurization it necessarily involves sacrificing part of the efficiency.
Accordingly, the present invention has as one of its objects the ability to reduce the overpressurization without reducing the efficiency.
Another object of the present invention is the reduction of overpressurization by absorbing the increase of energy at lower frequencies.
SUMMARY OF THE PRESENT INVENTION
The present invention overcomes the above-discussed disadvantages and other deficiencies of the prior art by providing a novel hydraulic vibration jack.
A novel hydraulic vibration jack in accordance with the present invention includes a means for absorbing the increased energy as the characteristic frequency becomes lower.
This means for absorbing the increased energy is a fluid filled chamber. The chamber is positioned so that an extension of the jack's working rod, or similar mechanism, can move co-axially within the chamber. This extension, by moving in and out of the chamber displaces fluid which is maintained at a constant pressure. The fluid is maintained at this constant pressure by either adding or removing an appropriate volume of fluid.
Any increase of energy is transmitted to the fluid of this chamber by means of the working rod extension. By maintaining the fluid in this chamber pressurized, any excess energy is absorbed before overpressurization occurs in the jack.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood and its numerous advantages and objects will become apparent to those skilled in the art by reference to the accompanying drawing wherein:
FIG. 1 is a schematic cross-sectional side elevation view of a preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a first embodiment of the present invention is indicated generally at 10. As a way of illustrating the present invention, FIG. 1 depicts a servo-controlled linear vibration jack. It will become apparent to those skilled in the art that the present invention may be used with other types of vibration jacks.
Servo-controlled vibration jacks are generally driven according to the principals of a sine law. According to these principals the coordinates related to the motions of velocity and acceleration are out-of-phase. The result is that when velocity is at its maximum, acceleration is zero and vice-versa.
When translated into terms corresponding to a vibration jack, when the velocity coordinate is at a maximum, the force developed by the jack tends toward zero. The inverse also being true. As will be discussed below this following of the law of sine is related to the functioning of the present invention.
As seen in FIG. 1 the vibration jack has a housing 10. Due inherently to the way they are driven two piston rods are required, working rod 1 and guide rod 2. Both rods 1 and 2 are attached to piston 3, which is contained within chamber 16 of housing 10. The driving mechanism of the jack servo-valve distributor 4. Servo-valve distributors of the type suitable for driving vibration jacks are well known in the art. Furthermore, distributor 4 is not part of the present invention and no further discussion of distributor 4 is believed to be required.
Piston 3 has a diameter slightly smaller than the diameter of chamber 16. This allows piston 3 to reciprocate co-axially within chamber 16. Servo-valve distributor 4 delivers fluid under pressure to chamber 16 through lines 5 and 5'. Distributor 4, in conjunction with lines 5 and 5', also evacuates pressurized fluid from chamber 16. This ensures the reciprocating action of the piston 3 within chamber 16. The lines 6 and 6' are conventional elements which isolate the high pressure section from the low pressure section. Lines 6 and 5' also collect leaking fluid.
The above discussion defines a conventional linear vibration jack. The present invention involves the addition of an energy absorption means to the conventional jack.
This energy absorption means encompasses energy absorption chamber 7, rod 8 and fluid supply line 12 and fluid discharge line 15. While chamber 7 is shown as an integral piece with the casing 10 it is not essential for the present invention. This also applies for rod 8, which may or may not be a co-axial extension of rod 2.
A constant fluid pressure is maintained within chamber 7 by lines 12 and 15. The chamber 7 is supplied independently via the supply line 12. The fluid flow through line 12 is controlled by the check valve 13. Check valve 13 prevents backup of the fluid.
The volume which is delivered and maintained within chamber 7 is controlled by a throttle 14. Throttle 14 may also be adjustable nozzle mounted on the discharge line 15 to the tank. Throttle 14 controls the fluid discharge from chamber 7 through line 15. This throttle 14 only allows the flow of fluid after the fluid has obtained a desired pressure.
The present invention functions by filling and evacuating fluid from chamber 7. As rod 8 withdraws from chamber 7 fluid fills chamber 7, through rod 12 and valve 13, to maintain a pressure. As rod 8 extends into chamber 7 fluid is discharged through throttle value 14 and line 15. Excess pressure which might develop in chamber 16 of the jack is transmitted to rod 8 and is absorbed by the fluid within chamber 7. By setting throttle 14 for a specific pressure the excess pressure absorbed the fluid in chamber 7 causes fluid to be discharged through throttle 14.
As stated above the motions of velocity and acceleration are out of phase due to the fact that servo-controlled vibration jacks operate in accordance with a sine law. Fluid which is discharged through throttle 14 due to excess pressure within chamber 7, also follows a sine law. This discharge is in phase with the velocity of the jack, but is out of phase by the factor of π with respect to the force developed by the jack. It has been shown that thecharacteristic frequency is not generated instantaneously but only over two or three alternating cycles. Thus a single-action energy absorber, operating every half-cycle, is sufficient.
While a preferred embodiment has been described and illustrated, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. | An improved vibration jack is presented wherein the excess energy which might develop from overpressurizations and cause loss of control, is absorbed. This excess energy is transmitted to fluid within a chamber by means of an extension of the jack piston rod. Maintaining the fluid in the chamber at a constant pressure, and allowing discharge of fluid when this pressure is exceeded allows the fluid to absorb any excess energy. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/436,882 filed on May 13, 2003, which issued as U.S. Pat. No. 7,060,930 on Jun. 13, 2006, which claims the benefit of German Patent Application DE 10223147.8, filed May 16, 2002. The disclosure of the above application is incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to a joining system head for attachment to a movable frame, in particular to a robot, having
a holding means for an element to be joined to a part, and a joining drive means to move the holding means along a joining direction for joining.
The present invention relates further to a joining system having a robot movable on at least two coordinate axes and a joining system head attached to the robot. Lastly, the present invention relates to a method of feeding elements from a stationary unit to a movable joining system head and joining said elements to parts by means of the joining system head.
Such a joining system head, such a joining system and such a method of feeding and joining elements by means of a joining system head are generally known. The term ‘joining’ in the present context is intended to refer to all ways of connecting elements to parts, in particular connections of metal elements to metal parts, for example by bonding, forming, as for example riveting, or by union of matter, as for example welding, including short-time arc welding. Short-time arc welding is often referred to as bolt welding, even though it is not exclusively bolts that are welded. A current system of bolt welding in industrial use, in combination with a robot, is known in the brochure “Neue TUCKER Technologie. BolzenschweiBen mit System!,” Emhart TUCKER, September 1999.
Bolt welding finds application chiefly, but not exclusively, in vehicular technology. Here, metal elements such as metal bolts, with or without threads, eyes, nuts etc., are welded onto the sheet metal of the bodywork. The metal elements then serve as anchors, or fastening elements, to fix for example interior fittings, lines and the like to the sheet metal of the body. At the joining system head, disclosed in the above-mentioned Emhart TUCKER publication, the joining drive means is configured either as a linear electric motor or as a combination of a lift magnet and a spring.
The holding means is constituted by a one-piece tongs elastically expandable in radial direction. The elements are as a rule welding bolts comprising a head having a somewhat larger diameter than the shank of the bolt. In the known system, the bolts are fed to the welding head by way of suitable feeding conduits by means of compressed air. The bolts are thus fed ‘head first’ into the tongs from behind. Ordinarily the bolt will strike the tongs from the inside, but without passing through it. A loading pin provided coaxial with the tongs is then actuated to propel the bolt thus fed through the tongs. The tongs are elastically expanded radially when the head of the bolt passes through. Then the tongs snap closed elastically around the shank of the bolt and hold it fast in the position determined by the travel of the pin.
The joining drive means in the form of a linear motor (or lift magnet/spring combination) has a travel of a few millimeters. Also, the welding head is fixed at the end of an arm of the robot, usually by way of a pneumatic or hydraulic carriage. That is, the entire welding head is movable in a direction parallel to the welding axis by means of the carriage, which has a considerably greater travel than the linear motor. The welding head further comprises a control means to control the linear motor and the loading pin, provided spatially separate from the welding head, more specifically in a stationary feeder.
To perform a welding operation, first the robot is programmed so that it travels into a predetermined position in which the carriage and linear motor axes are perpendicular to the sheet metal onto which the bolt is to be welded. The bolt is prestressed so that it protrudes vis-à-vis a supporting foot. Then the carriage is actuated until the foot meets the sheet metal. The bolt held in the holding means then rests in contact with the sheet metal. Next comes a determination of the zero line of the holding means with respect to the sheet metal. Alternatively, however, there are methods of zero line determination that dispense with the supporting foot.
Then, in the case of welding with supporting foot, an electric pre-current is switched on, passing through the bolt and the part. The bolt is then lifted relative to the part by means of the linear motor (lifting means). An electric arc is set up. Then a switch is made to the welding current. By the high welding current, the opposed faces of bolt and part begin to be fused. The bolt is then lowered onto the part again, so that the respective melts will mingle. Upon attainment of the part and the short circuit of the arc, or just before, the welding current is switched off. The entire melt solidifies and the welded connection is complete.
Now the welding head is drawn off from the welded-on bolt, using the carriage. The carriage is necessary because, among other reasons, the drawing-off motion must take place exactly on the centerline of the welded-on bolt. Otherwise, owing to the one-piece tongs, there would be danger of damage to the bolt and/or the tongs. The robot arm alone is not capable of such a precise linear motion in an arbitrary direction of space. For owing to the superposition of the simultaneous regulation of several components of robot arm motion, as required for this purpose, such linear motions can be executed by the robot with a certain amount of undulation only. The known welding head comprises a comparatively great axial extent. Since moreover the welding head must be drawn off from the bolt in axial direction, use of the welding head in places of difficult access is possible only within limits.
Then there are developments for employing robot technology to feed the bolt. Here a separate pick-up takes pre-sorted bolts and brings them to the welding location. This is disclosed in “BolzenschweiBen. Grundlagen und Anwendung” by Trillmich, Welz, Fachbuchreihe SchweiBtechnik, DVS Verlag, 1997, Chapter 9.3. It is there explained that this technology lends itself especially to headed bolts that, because of their size and shape, cannot be blown through hoses. This type is referred to as the “pick-up system.”
Further, a welding head by the firm of Nelson has been disclosed, in which a lift device moves a carrier projecting laterally arm-like up and down. At the terminal portion of the carrier, a holding means with tongs is rigidly mounted. The bolts are fed, as in the case of the TUCKER welding head described above, to the tongs from behind, by means of a compressed air hose extending through the carrier. The end portion of the carrier with holding device fixed thereto is more readily positioned at inaccessible locations. The lift device to move the projecting arm and the pertinent control means are arranged in the initial portion of the carrier.
Against this background, the object of the invention consists in specifying an improved joining system head, an improved joining system and an improved method of feeding and joining fed elements. This object is accomplished, in the case of the joining system head initially mentioned, in that the holding means is mounted rotatable at the joining system head about an axis extending transverse to the joining direction.
The joining system head according to the invention represents a completely novel concept. For joining, in particular for bolt welding, the joining operation of the prior art always takes place in a linear motion. In the prior art, consequently, it was the practice to mount the holding means slidable at least along a linear axis. For example, it is known that the joining system head may be mounted bodily on a carriage which in turn is fixed to the robot.
Owing to the rotatable mounting of the holding means on the joining system head, it is now possible to move the holding means along a circular or circular arc path. This creates the prerequisite for a number of fundamental changes in past concepts of joining system heads. The rotatability of the holding means is comparatively simple to realize as a matter of design. In particular, it is possible by means of the robot to turn the holding means on the circular path in order to reach various welding positions quickly and without extensive motion routines, for example a welding position for welding in vertical direction downward and then an overhead welding operation. The turnability as an additional degree of freedom at the joining system head is sufficient for many applications. Considering that also the carrier itself is rotatable about its longitudinal axis by means of the robot as a rule, and positionable at will in space, joining operations can be performed at very inaccessible locations indeed. The interference edge profile of the joining tool is here determined by the required radius of swing. In the joining system according to the invention, the above object is accomplished in that a joining system head according to the invention is attached to the robot.
The method according to the invention for feeding elements from a stationary unit to a movable joining system head and for joining said elements to parts by means of the joining system head, said joining system head comprising a holding means for an element, mounted rotatable about an axis extending transverse to the joining direction, includes the steps of feeding an element from the stationary unit to the transfer station at the joining system head, rotating the holding means towards the transfer station, taking over an element from the transfer station into the holding means, and joining the element taken over to the part. In the method of the invention, accordingly, there is a fundamental departure from the idea of feeding elements from the stationary unit directly to the holding means. Instead, the elements are fed to a transfer station at the joining system head, and the holding means is rotated towards the transfer station, to pick up the elements. The holding means thus ‘fetches’ the elements from the transfer station in each instance. As a result, there is an uncoupling between the feeding means comprised by the transfer station and the holding means. This is a prerequisite for a number of advantages about to be illustrated in detail. The object, then, has been wholly accomplished.
It is of especial advantage if the holding means and the joining drive means are mounted rotatable about the axis as a joining tool. In this embodiment, the holding means and the joining drive means form a rotatable unit of small dimensions. This is true especially if a control means to control the joining drive means is mounted at the welding head, but spatially separate from the joining tool. The joining tool can consequently be made with small dimensions and little relevant edge interference.
Here it is especially preferred if the joining tool is mounted rotatable about the axis at an end portion of a projecting elongated carrier. Owing to the arrangement of a joining tool of small dimensions at the end portion of an elongated carrier, it is possible to bring the joining tool to places difficult of access. Here no transmission of a lifting motion over long distances (no boom or the like) is required. Therefore the positioning and the actual joining or welding operation itself can be performed locally with high precision. At the same time, it is especially advantageous if the control means is provided in an initial portion of the carrier. The joining tool of small dimensions can then be brought to inaccessible locations through openings.
In an especially preferred embodiment, the elongated carrier comprises two arms running parallel, between which the joining tool is rotatably mounted. This embodiment has the advantage, firstly, that the mounting of the joining tool can be accomplished with high spatial precision. Besides, the space remaining between the arms of the carrier can be utilized for other functional units. These units as well as the joining tool are moreover protected between the arms of the carrier.
It is of especial advantage also if the axis of rotation is oriented transverse to the longitudinal axis of the carrier. In this embodiment, it is advantageously brought about that the circular path of the holding means can extend beyond the foremost ends of the carrier. Consequently, the carrier can be of comparatively short configuration. Secondly, it is brought about that the holding means can be swung as far as a midportion of the carrier, and can therefore be brought all the way to other functional units.
Over all, then, it is of advantage firstly if the joining system head comprises a feeding means with transfer station for the feeding of elements and if a loading drive means is designed to rotate the holding means and/or the joining tool all the way to the transfer station. Thus the elements are not fed, as in the prior art, all the way to the holding means. Rather, the feeding of the elements at first takes place only as far as the transfer station. Hence this step of the feed can take place while the joining-welding head itself is joining an already fed element to a part. This parallel processing serves to permit shorter periods over all. It is especially preferred if the transfer station is fixed to the carrier. Provided the transfer station is arranged on the elongated carrier, a fixed relative position of the transfer station can be achieved in relation to the holding means or the joining tool. Besides, it is advantageous that the cross section of the carrier is smaller as a rule than the cross section of the joining tool or the holding means, so that space is available for the transfer station.
According to one embodiment, the loading drive means comprises a rotary motor arranged at the end portion of the carrier. In this embodiment, a precise control of the joining tool can be achieved, with good response behavior.
In an alternative embodiment, the loading drive means comprises a rotary motor arranged in the initial portion of the holder and a gear to transmit the motions of the motor to the holding means. In this embodiment, an improved interference edge clearance results, since the interference-relevant end portion of the carrier has no motor of its own to move the holding means and/or the joining tool. Rather, the comparatively bulky motor is arranged in the initial portion of the carrier and transmits its motions to the holding means and/or the joining tool by way of a transmission. Also, a rotary motor will serve to execute motions with precision and high responsiveness.
It is especially preferred if the transmission is a transmission with tension means. The transmission with tension means will permit comparatively long distances between the initial portion of the carrier on the one hand and the final portion of the carrier on the other hand by comparatively simple design means.
In general, in a preferred embodiment, provision is made for the loading drive means and the joining drive means to consist of a single rotary drive means. In this embodiment, the rotatability of the holding means is used not only to swing the holding means all the way to a transfer station to ‘fetch’ an element. Rather, the holding means is moved to join a held element, not in a direction perpendicular to the axis of rotation, but along a circle around the axis of rotation. This embodiment has the special advantage that an axially prolonged linear drive in the region of the holding means, in particular the end region of the elongated carrier, is not required. Rather, the rotary drive means constituting the loading drive means and the joining drive means may be provided for example in the initial portion of the carrier, and their motions can be transmitted to the holding means in the end portion of the carrier by way of a transmission with tension means. In this embodiment, a sort of ‘reduced’ joining tool is formed at the anterior end portion of the carrier, consisting basically of the holding means alone. In this embodiment, consequently, an especially low interference edge relevance results, and hence the possibility of performing joining operations even in especially inaccessible locations.
In an alternative embodiment, the joining drive means comprises a linear drive means instead. In this embodiment, the holding means is consequently set in rectilinear motion for joining in conventional manner. The rotatability of the holding means about the axis of rotation is then preferably employed by means of development of the loading drive means to rotate the holding means or the joining tool into any welding position and/or ‘fetch’ elements from a transfer station of the feeding means.
Provided the linear drive means comprises a linear electric motor, only comparatively few lines are required for control. The holding means may then be regulated in either lift direction. In this embodiment, it is of especial advantage if the longitudinal axis of the joining drive means and the longitudinal axis of the holding means are spaced apart parallel to each other. Here it is possible to position the holding means so that even welding positions close to edges are attainable. The distance of the longitudinal axes may be within the range of a few centimeters, just enough to shift the holding means out of the joining drive direction projected into the joining direction.
In general, provision is made, in a preferred embodiment, for the holding means to comprise a plurality of jaws arranged distributed around the longitudinal axis of the holding means and movable away from each other so as to hold or release one element in each instance. It is especially preferred if the holding means comprises two jaws. The term ‘jaws’ is to be understood broadly in the present context. The jaws may for example refer to elongated fingers. With two jaws, rotationally symmetrical or approximately rotationally symmetrical parts in particular can be picked up conveniently and held securely. It is preferred for the jaws to be movable away from each other far enough so that the holding means can release the element by being drawn off from the element obliquely to the joining direction.
This embodiment makes it possible to accomplish the process of ‘running’ the joining system head away from the element joined to the part, by means of the robot alone. Then no carriage is required to establish a completely rectilinear reverse motion. Thus this embodiment also contributes to a small axial extent of the welding head.
However, it is especially preferred if the jaws are movable away from each other far enough so that the holding means can release the element by being swung away from the element about the axis of rotation. In this embodiment, the jaws can be moved far enough away from each other so that the joining tool need not be run away in the joining direction. Rather, it is possible to run the joining tool and/or the holding means away after the joining operation transversely, in particular perpendicular to the joining direction, the element passing between the jaws of the holding means. In this embodiment, therefore, no axial motion is required. In this way it is possible to pass the carrier with joining tool and/or holding means arranged at the anterior end portion through even extremely small means, and execute joining operations inside of cavities. The carrier, after the joining position has been reached, can remain positioned almost without change. After the joining operation, the joining tool is swung away transversely to the joining direction, and then the carrier can be run out of the cavity again along its longitudinal axis.
Also, this embodiment makes it possible for the elements to be picked up especially simply from the transfer station. The joining tool in this embodiment is swung in one step so that the holding means is oriented with an element at the transfer station with jaws released. Then the element can be grasped by the jaws and taken out of the transfer station by an ensuing swinging motion. In general, it is here preferred for a jaw actuator to be provided, actively opening and/or closing the jaws. In this embodiment, the jaws are usually configured as rigid fingers. The jaw actuator ensures that the jaws are either actively opened, to release an element, or else actively closed to hold the element.
Alternatively, it is possible for the jaws to be elastically configured or elastically mounted, in such manner that they are passively movable towards and/or away from each other. Here the jaws may either be made of an elastic material, in which case other elastic means may as a rule be dispensed with, or alternatively the jaws may be configured as rigid elements and elastically mounted. It is also possible within the scope of this embodiment for the jaws to be elastically pre-stressed in holding or in releasing direction. In that case, as a rule an actuator is provided that moves the jaws actively in the respective other direction.
In the joining system according to the invention, it is of advantage if a stationary individualizing means conveys individual elements to the feeding means of the joining-welding head. This embodiment serves generally to enhance the degree of automation. Such stationary individualizing and feeding means are known per se in the prior art. They convey individual elements in one step, however, all the way to the holding means, whereas in the joining system according to the invention, a conveyance occurs only as far as the feeding means (transfer station). Thence the holding means ‘fetches’ an element conveyed thither. It will be understood that the features named above and the features yet to be illustrated below may be employed not only in the combination given in each instance, but also in other combinations or by themselves, without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are represented in the drawing by way of example and will be illustrated in more detail in the description to follow. In the drawing,
FIG. 1 shows a schematic view of a joining system according to the invention;
FIG. 2 shows an alternative conformation of a joining system according to the invention;
FIG. 3 shows a longitudinal section of an embodiment of a holding means;
FIG. 4 shows a cross-section at the line IV-IV in FIG. 3 ;
FIG. 5 shows the end portion of a joining system head according to the invention, with an alternative conformation of a joining tool;
FIG. 6 shows a view of the end portion of the joining system head of FIG. 5 from below;
FIG. 7 shows another alternative embodiment of a joining tool of a joining system head according to the invention;
FIG. 8 shows a schematic representation of a transfer station of a joining system head according to the invention;
FIG. 9 shows a schematic representation of an alternative transfer station of a joining system head according to the invention;
FIG. 10 shows a schematic representation of still another alternative embodiment of a transfer station of a joining system head according to the invention;
FIG. 11 shows a schematic sectional view at the line XI-XI in FIG. 10 ; and,
FIG. 12 shows a schematic side view of an alternative embodiment of a joining system head according to the invention.
DETAILED DESCRIPTION
In FIG. 1 , a joining system according to the invention is generally designated 10 . The joining system 10 comprises a robot 12 . The robot 12 contains a stationary base 14 from which two arms 16 , 18 extend, articulately connected to each other. At the end of the arm 18 , a flange 20 is provided.
To the flange 20 , a joining system head is attached, generally designated 22 in FIG. 1 . The joining system head 22 comprises a baseplate 24 attached to the flange. From the baseplate 24 , an elongated carrier 26 extends. The elongated carrier 26 comprises a first short carrying segment 28 and an adjoining second elongated carrying segment 30 . The second carrying segment 30 is bent off from the first carrying segment 28 by an angle α of 120°. The angle α is preferably between 60° and 80° or between 100° and 120°. In general, however, it is also conceivable that the first carrying segment 28 and the second carrying segment 30 may be oriented on an axis with each other. The axis of the second carrying segment 30 is designated 27 in FIG. 1 .
At the end of the second carrying segment 30 , a joining tool 32 is mounted rotatable about an axis 34 . The axis of rotation 34 extends perpendicular to the axis 27 of the second carrying segment 30 and, in the embodiment shown, is oriented about parallel to the baseplate 24 .
The joining tool 32 serves to weld an element, in particular a welding bolt 36 , to a part, in particular a metal sheet 38 . Although the joining system may be employed for numerous kinds of joining as a matter of design, a conformation of the joining system as a bolt-welding system, or short-time arc-welding system with lift ignition, is especially preferred. In the following, therefore, without loss of generality, the joining system will be referred to as a bolt welding system and the joining system head 22 as a bolt welding head. The joining tool 32 will be referred to as a welding tool 32 . The welding tool 32 welds the bolts 36 to the part 38 in a linear motion (joining direction 40 ).
The welding head 22 further comprises a control means 42 . The control means 42 is provided at the initial portion of the elongated carrier 26 and, in the embodiment shown, is mounted on the first carrying segment 28 , to wit next to the baseplate 24 . The control means 42 serves to drive the joining tool 32 and as intersection with superordinate control devices.
The welding head 22 further comprises a feeding means 44 . The feeding means 44 serves to pick up bolts by the shank in advance from a feed hose and place them in readiness at a transfer station 46 . The feed means 44 is consequently configured essentially as a tube or hose and extends along the elongated carrier 26 . The transfer station 46 is located in a mid-portion of the second carrying segment 30 . In it, one element at a time is placed in readiness for transfer to the welding tool 32 . This element is designated 36 ″ in FIG. 1 .
The welding system 10 further comprises a stationary base station 50 . The base station 50 serves to furnish energy for welding to the welding head 22 and serves as superordinate control device. The base station 50 is connected to an individualizing device 52 . The individualizing device 52 serves to individualize bolts, as a rule supplied in bulk, and convey them to the feeding means 44 individually by way of a hose 54 . For this purpose, the individualizing device 52 as a rule comprises a compressed air unit to convey the elements 36 pneumatically.
Further, FIG. 1 shows a line 56 connecting the base station 50 to the welding head 22 . The line 56 is generally embodied as a system of lines, and includes lines to carry the welding current, control lines etc. Further, FIG. 1 shows a line 58 connecting the welding head 22 to the base 14 of the robot 12 . The line 58 is optionally provided and contains one or more control lines. By means of the control lines 58 , the motions of the robot 12 can be matched with those of the welding tool 32 .
Alternatively or additionally, the base 14 of the robot 12 is connected to the base station 50 by way of a line 60 . Hence it is possible also for the matching to take place between robot 12 and welding head 22 by way of lines 60 , 56 . The lines 56 , 58 are passed to the control means 42 , whence some are looped to the welding tool 32 (for energy supply to unit there), others are utilized directly.
The welding tool 32 comprises a housing 62 rotatably mounted on the axis 34 . At the housing 62 , a joining drive means 64 is provided in the form of a linear motor 64 . The linear motor 64 serves to move a holding means 66 projecting from the housing 62 perpendicular to the axis of rotation 34 for holding one bolt 36 at a time. The linear motor 64 therefore constitutes a lifting means for executing lift and dip motions in the course of a bolt welding operation, as described in the introduction.
Further, at the end portion of the second carrying segment 30 , a rotary drive 68 is provided, serving to rotate the welding tool 32 under control into any angular positions in relation to the second carrying segment 30 . The rotational range is typically at least 270°, commonly 360°. The rotary drive 68 serves firstly to rotate the welding tool 32 into a suitable welding position in each instance, one of which welding positions is shown in solid lines in FIG. 1 . An alternative welding position is indicated by dot-dash lines at 32 ′. In the further welding position, the welding tool 32 ′ is employed along a welding direction 40 ′ to weld a bolt 36 ′ to a part not explicitly shown.
Further, the rotary drive 68 serves as loading drive means. For this purpose, the welding tool 32 is turned into a position shown dotted in FIG. 1 . In this position, the holding means 66 ″ is oriented flush with the transfer station 46 , and is able in that position to grasp a bolt 36 ″ there held in readiness and take it over for a subsequent welding operation.
Although, in the embodiment represented, the loading drive means is constituted by the rotary drive 68 alone, for example an electric motor, modifications of this are conceivable. Thus the loading drive means may for example be constituted in that the—non-rotatable—welding tool 32 is shifted in lengthwise direction on the carrier 26 , to mention one example. It will be understood that then the transfer station 46 would have to be arranged correspondingly in a different place.
It is easily seen that the welding tool 32 may be configured with very small dimensions. In the first place, the welding tool 32 is spatially separated from the control means 42 . In the second place, the welding tool 32 is decoupled from the pneumatic bolt-feeding means. So no pneumatic or hydraulic lines need be flanged to the welding tool 32 . The supply of electricity to the linear motor 64 and/or the rotary drive 68 is comparatively easy to arrange. The same applies to the actuation of the holding means 66 , insofar as it is actively actuated electrically.
Since the bolts 36 are put into the holding means 66 , not from behind but from in front, no loading pin is required as in the prior art. Therefore the welding tool 32 can be compact in axial direction. It will be understood that instead of a linear motor as joining drive means 64 , alternatively a combination of a spring and a solenoid may be provided. Further, it will be understood that the rotary drive 68 may be configured as an electric step motor having a precision of <1°, better yet 0.5°.
The parameters assigned to the rotary motion relate firstly to a welding program and secondly to a program of robot motion. Each welding position has its own welding program and its own robot motion program. By referring the parametric data to the several welding and robot motion programs, it is ensured that firstly the bolt 36 will always be perpendicular to the surface of the part 38 , and secondly the welding tool 32 will be in a position in the robot motion affording the robot maximal freedom of motion on the way to the welding position. The control of the rotary motion of the welding tool 32 may be effected by way of the base station 50 and/or by way of the base 14 of the robot 12 .
The oblique angling of the second carrying segment 30 with respect to the first carrying segment 28 offers, firstly, an improved interference edge clearance. Secondly, the feeding means 44 is easier to construct, since the bolts, as shown, are held at the transfer station 46 by gravity and/or blown air.
FIG. 1 further shows that the part 38 has the conformation of an angle part having a relatively small aperture 70 . Viewed from the robot 12 , the desired welding position is located inside of a cavity 72 . It is easily seen that the bolt welding system 10 according to the invention is quite especially well-suited to accomplish this object. To introduce the second carrying segment 30 through the opening 70 , the welding tool 32 can be turned into a position in which it is largely flush with the second carrying segment 30 , for example the position 32 ″ in FIG. 1 .
After introduction into the cavity 72 , the welding tool 32 is turned into the welding position indicated by solid lines. Before that, a bolt 36 is picked up from the transfer station 46 , so that it is located in the holding means 66 . Then, in per se conventional manner, a bolt welding operation is carried out, as explained in the introduction.
As remains to be set forth in detail below, the holding means 66 is preferably of such configuration that it can release the welded-on bolt 36 in a direction transverse to the welding direction 40 . Consequently, it is possible to turn the joining tool 32 immediately after welding back into the flush position 32 ″, with no need for the second carrying segment 30 to execute a motion in the welding direction 40 . As soon as the flush position 32 ″ has been reached, the second carrying segment 30 can be withdrawn again through the opening 70 . The robot 12 then carries the welding head 22 to the next welding position. The axis of rotation 34 constitutes an additional axis of rotation for the robot 12 . Hence the positioning in a welding position can be accomplished in simpler manner. This the more so as the additional axis of rotation is located near the welding position.
Another advantage of the welding system 10 according to the invention results as follows. In the prior art, the welding head as a whole was interference-edge relevant. In the prior art, therefore, no pneumatic valves were provided on the welding head. But this occasioned very complicated cabling between the base station 50 and the welding head 22 .
Owing to the spatial separation of the control means 42 from the welding tool 32 at the welding head 22 , the control means 42 itself is not interference-edge relevant. Consequently valves can be integrated into the control means 42 at the welding head 22 , so that the number and complexity of the supply lines can be reduced. Since the control means 42 is provided at the welding head 22 , no great outlay of electric cabling is needed between welding head 22 and base station 50 . For example, it is possible for the supply lines 56 in a hose pack to contain only a welding cable, two auxiliary voltage supplies for the linear motor and a 24-volt supply for the control means, two light guides for serial transmission of measurement and control data and the feed hose 54 . In an enlarged version, the hose pack might be supplemented by a protective gas supply line and/or a jet-suction line, for example for color marking. Hence the hose pack can be lighter in weight, torsionally less rigid and therefore more secure.
Besides, the uncoupling of supply means 44 and welding tool 32 makes it possible for the bolts 36 to be fed to the transfer station 46 parallel with the bolt welding operation. In the prior art, bolt feeding and bolt welding are strictly serial. Therefore cycle periods of <1 second are attainable only with great difficulty and under special boundary conditions.
According to the invention, immediately after removal of a bolt from the transfer station 46 to initiate a bolt welding operation, another bolt can be conveyed from the individualizing device 52 by way of hose 54 and feed means 44 , to the transfer station 46 . This can be accomplished while the welding tool 32 is performing a bolt welding operation.
Also, as the carrier 26 moves from one welding position to the next, the welding tool 32 can be swung to the transfer station 46 and then swung into the right setting for the new welding position. This parallelism also generally ensures that welding cycle periods of definitely less than 1 second are attainable. Although the elements to be welded may basically be of any shape, yet elements feedable by means of compressed air, in particular rotationally symmetrical elements, are especially suitable for processing by the joining system according to the invention. The further welding position 32 ′ may for example be an overhead position, like the position 32 ′ shown. This can be attained without need to rotate the carrier 26 . This avoids overstraining the supply cable and hoses.
In the following description and details and modifications of the joining system shown in FIG. 1 , like or similar elements are designated by the same reference numerals. Identical designation generally implies like or similar mode of operation, unless expressly otherwise noted below. Where individual elements of the joining system are discussed, it may be assumed that the function is otherwise identical or similar to the function of the joining system 10 of FIG. 1 . Further, it will be understood that subsequent references to welding systems, heads or tools are intended to refer generally to such elements for joining, including for example riveting or bonding processes.
FIG. 2 shows an alternative embodiment of a welding head 22 . In contradistinction to the welding head 22 of FIG. 1 , a rotary drive 68 ′ is provided to rotate the welding tool 32 , not in the end portion of the second carrying segment 30 , but in the region of the control means 42 . The rotary motions of the rotary drive 68 ′ are transmitted to the welding tool 32 by means of a belt drive 80 . The belt drive 80 runs along the elongated carrier 26 . The elongated carrier 26 is formed in the representation of FIG. 2 by two parallel arms, between whose end portions the welding tool 32 is rotatably mounted.
FIGS. 3 and 4 represent an embodiment of a holding means 66 . The holding means 66 comprises a housing 84 , in turn comprising an opening 86 facing downward in the joining direction. The holding means 66 comprises two jaws 88 A, 88 B mounted with limited swingability on the housing 84 and made of an essentially inelastic material. The jaws 88 A, 88 B form a tongs, an element 36 being grasped between the ends of the jaws 88 A, 88 B with a predetermined force.
The jaws 88 A, 88 B are each connected in one piece with a lever segment 92 A, 92 B. With respect to axes 90 A, 90 B on which the jaws 88 A, 88 B are mounted, the lever segments 92 A, 92 B extend in the respective other direction. The lever segments 92 A, 92 B are here bent off relative to the joining direction 40 , so that they overlap. By pressure on the lever segments 92 A, 92 B from above (in the representation of FIG. 3 ), the jaws 88 A, 88 B are consequently moved away from each other, releasing the bolt 36 . This is shown for the jaw 88 A in FIG. 3 . It may be seen that the jaw 88 A releases the bolt 36 completely in the direction transverse to the joining direction 40 (that is, in FIG. 3 , out of the plane of the paper). Consequently the holding means 66 with opened jaws 88 A, 88 B can be moved transverse to the joining direction 40 and perpendicular to the plane of the jaws 88 A, 88 B without touching the bolt 36 . The direction of motion of the jaws 88 A, 88 B in this operation is designated 93 in FIG. 4 .
To actuate the lever segments 92 A, 92 B, an actuator 94 is provided, preferably triggered electrically. The actuator 94 opens and closes the jaws 88 A, 88 B actively in each instance. It will be understood that for this purpose the actuator 94 must be configured as a two-directional drive.
Active actuation of the jaws 88 A, 88 B has the advantage that the bolt 36 can be held with a defined force (for example 20 newtons). The derivation of the holding force from the elasticity of the several fingers of the tongs, as in the prior art, is dispensed with. Consequently a definitely longer service life can be attained. The direction of actuation of the actuator 94 is shown at 96 in FIG. 3 . At their ends, the jaws 88 A, 88 B are of such conformation that they can securely grasp the bolt 36 in question. For this purpose, it may be appropriate to place suitable adapters on the jaws 88 A, 88 B, in order to fit different bolts 36 .
From the under side of the housing 94 , as shown in FIG. 3 , a positioning pin 98 extends. The positioning or contact pin 98 is rigidly connected to the housing 84 . It serves, when a bolt 36 is picked up from the transfer station 46 , to ensure that the bolt 36 will occupy a defined position in relation to the holding means 66 , and as a stop to assume the axial forces in welding.
The two-directional active actuator can consist of a pneumatic or hydraulic drive. Preferably, however, it consists of a combination of two electromagnets, or of an unregulated linear motor on the ‘moving coil’ or ‘moving permanent magnet’ principle. Further, it is possible to configure the actuator 94 as semi-active. Then the opening of the jaws 88 A, 88 B is effected for example by an electromagnet. When this is switched on, suitably arranged springs serve to ensure that a bolt 36 will be grasped by the jaws 88 A, 88 B with a defined force.
For welding, the jaws 88 A and/or 88 B are supplied with welding current, conducted to the bolt 36 . The defined force provides for a secure, low-wear passage of current. For this reason, it will be understood that the jaws 88 A, 88 B will be made of a conductive metal. The positioning pin 98 , however, should be non-conductive, or insulated from the housing 84 .
Alternatively to an active or semi-active holding means 66 , it is possible also to provide jaws of elastic configuration, permitting a lateral introduction of the bolt 36 between them (in the direction 93 ) and releasing them without substantial exertion of force upon motion transverse to a welded-on bolt 36 . In FIG. 3 , the longitudinal axis of the holding means 66 is designated 100 .
In FIGS. 5 and 6 , an additional alternative embodiment of a welding tool 32 is shown. The welding tool 32 comprises a tool housing 102 to which a linear motor 104 of a joining drive means 64 is fixed. The axis or centerline of the linear motor 104 is shown at 105 . It is represented that the axis 100 of the holding means 66 and the axis 105 of the linear motor 104 are spaced at a distance d from each other. In this way the holding means 66 is shifted out of the projection of the linear motor 104 in joining direction. This makes it possible to position the holding means 66 , and therefore a held bolt 36 , closer to an interfering wall or edge. Upon the whole, this enhances the flexibility of the welding head 22 .
The linear motor 104 comprises an armature segment 106 connected to a guide plate 108 extending transverse to the joining direction. From the guide plate 108 , two guide rods 110 , 112 extend, arranged diagonally in relation to the linear motor 104 . The guide rods 110 , 112 ensure that the guide plate 108 is guided free from tilt. From the under side of the guide plate 108 , the holding means 66 extends. An actuator to actuate the hold means 66 may for example be configured on top of the guide plate 108 or integrated therein.
In FIG. 6 , it is shown that the carrier 26 is made up of a comparatively massive carrying arm 116 and a less massive tension arm 118 extending parallel thereto. The welding tool 32 is mounted between the arms 116 , 118 along the axis of rotation 34 . In FIG. 6 , current cables 120 A, 120 B to supply current to the jaws 88 A, 88 B are also indicated.
Another alternative conformation of a joining tool 32 is shown in FIG. 7 . The welding tool 32 comprises a linear motor housing 122 . At the tops of the guide rods 110 , 112 , flanges 123 are provided in each instance. Between the flanges 123 and the linear motor housing 122 , compression springs 124 are arranged, configured around the guide rods 110 , 112 . The linear motor 104 is consequently so pre-stressed by the compression springs 124 that the guide plate 108 moved thereby is located in the retracted, to wit not extended, position. In addition to the compression springs 124 or alternatively thereto, an additional compression spring 126 may be provided inside of the linear motor housing 122 .
Further, it is shown that on top of the guide plate 108 , a hinged magnet 128 is articulated to an axis 130 . The magnet 128 serves to press the lever segments 92 A, 92 B downward to open the jaws 88 . In general, however, the lever segments 92 are pre-stressed towards the closed position of the jaws 88 by means of a tension spring 132 .
FIG. 8 shows a first embodiment of a transfer station 46 of the feeding means 44 . At the transfer station 46 , two opposed sensors 136 (for example a light barrier) are provided, detecting whether there is a bolt 36 in the transfer station 46 or not.
The feeding means 44 consists essentially of a tube or hose 138 , bent off inward in the region of the transfer station 46 . The bolts 36 are fed shank first from the individualizing device 52 through the feeding means 44 . Consequently the head of the bolt 36 will strike the rolled edge of the tube 138 and remain so in the transfer station 46 . Thus the shank of the bolt 36 protrudes from the tube 138 .
The holding means 66 can now be run with opened jaws 88 A, 88 B all the way to the bolt 36 and grasp it. Then the holding means 66 is swung back again, out of the plane of the paper in the representation of FIG. 8 . It will be understood that at the transfer station 46 , a suitable lateral recess must be provided in the tube 138 , though not explicitly shown in FIG. 8 .
An alternative embodiment of a transfer station 46 ′ is shown in FIG. 9 . In this embodiment a tube 138 ′ of the feeding means 44 ′ is open towards the end. At a transfer housing 140 , two clamping jaws 142 A, 142 B are rotatably mounted. The jaws 142 are pre-stressed by means of two springs 144 into a position where their inner sides block the exit of a bolt 36 from the tube 138 ′. The bolt 36 is braked thereby upon being fed. Here a positioning lever 146 is swung laterally out of the representation shown in FIG. 9 to let the bolt 36 through. Then the positioning lever 146 is swung, as indicated at 147 . Thus the bolt 36 presses the jaws 142 A, 142 B apart and is shifted away from the tube 138 ′ until the head of the bolt 36 snaps into an annular recess 148 . The annular recess 148 is formed by the inner sides of the jaws 142 A, 142 B. In this position, the bolt 36 is definitely held with a certain force. The holding means 66 may, as in FIG. 8 , grasp the shank of the bolt 36 and pull it laterally out of the annular recess 148 .
Over the embodiment of FIG. 8 , this embodiment has the advantage that the bolt 36 is in a defined position in the transfer position 46 ′, and is held with a defined force, so that a secure hold on the bolt 36 by the holding means 66 is ensured. It will be understood that at the transfer station 46 ′ also, suitable sensors may be provided to detect a bolt 36 in the transfer position.
A third embodiment of a transfer station 46 ″ is shown in FIGS. 10 and 11 . In this embodiment, the bolts 36 are conveyed by way of a tube 138 ″ into a bolt receptacle 154 of a swingable rotational segment 152 . The segment 152 is rotatable about a transfer housing 140 ″ about an axis 153 oriented transverse to the axis of the tube 138 ″ and transverse to the orientation of the bolt 36 in the transfer position.
In FIGS. 10 and 11 , the segment 152 is in a transfer position. In this position, a pneumatic cylinder 156 serves to push the bolt 36 by means of a plunger 158 between two tension jaws 160 , between which the bolt 36 is then held in a defined manner. Then the segment 152 is turned back about transfer housing 140 ″ 0 to pick up another bolt 36 in the receiving position shown dotted, flush with the tube 138 ″. This embodiment has the advantage that the bolts 36 can be conveyed at high speed through the tube 138 ″. Hence short cycle periods can be achieved.
Another embodiment of a welding head according to the invention is generally designated 170 in FIG. 12 . The welding head 170 comprises, at the anterior end of the carrier 26 , a welding tool 171 comprising only a housing rotatably mounted on the carrier 26 and a holding means 172 fixed thereto. The welding tool 171 is not provided with a welding drive motor, in particular not a linear motor.
The holding means 172 comprises two jaws 174 between which a bolt 36 is so held that it is oriented tangential to a circumference around the axis of rotation 34 . In other words, a joining operation does not occur along a rectilinear motion, but along a circular path. The corresponding direction of guidance is indicated in FIG. 12 as a partial circle 176 .
In this embodiment, a rotary drive 175 serves as joining drive means, arranged in the region of the control means 42 . Rotary motions of the drive 175 are transmitted by a belt drive 80 to the welding tool 171 . It will be understood that the rotary drive 175 is preferably an electric precision step motor with which the difficult movements of the bolt 36 can be executed during a bolt welding operation. The rotary drive 175 thus serves simultaneously also as loading drive, being swung so as to pick up one new bolt 36 at a time from a transfer station 180 of a feeding means 178 .
In the feeding means 178 , the bolts 36 are not fed successively but side by side, in such manner that the holding means 172 can grasp the bolts 36 transverse to their own extent. It will be understood that the feeding means 178 may either comprise suitable means of converting the lengthwise motion out of the individualizing device 52 into the transverse orientation shown in FIG. 12 , or alternatively it is possible to feed the bolts 36 out of the individualizing device 52 already in transverse position.
Further, in FIG. 12 schematically a magazine 186 provided on the carrier 26 is provided. The magazine 186 may serve as supply magazine for a plurality of bolts 36 , then to be transferred by means of a suitable integrated individualizing device to the feeding means 178 , or to the transfer station 180 . It will be understood that such a magazine may also be employed in the embodiments of FIGS. 1 to 11 instead of a stationary individualizing device 52 or in addition thereto. | A joining system head is provided for fixation to a movable frame, in particular to a robot having a holder for an element to be joined to a part. A joining drive moves the holder along a joining direction for joining. The holder is mounted on the joining system head and is rotatable about an axis running transverse to a joining direction. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to devices for attaching drilling equipment to vehicles. In particular, the present invention relates to an auger holder used in conjunction with an all-terrain vehicle (ATV) to support an auger used to drill holes in ice for the sport of ice fishing. More particularly, the present invention is adapted to be easily mounted on an ATV and operated therefrom without obstructing the normal use of the ATV.
2. Description of the Prior Art
Ice fishing is a popular activity in the colder regions of the world. Ice fishing requires that a hole be drilled through varying thicknesses of ice, which ice may be over several feet thick. The earliest devices for penetrating the ice included using picks, axes, or hand-driven ice augers. More modern devices include various types of powered augers that more easily penetrate the ice. Some of these inventions include hand-held, motor-driven augers. Problems associated with hand-held, power augers include the ease with which they can bind up while drilling through thick ice, leading to the risk of injury, resulting from the auger's maximum torque being applied to its operator. In addition, such a device requires the application of a considerable amount of power by its operator in order to stabilize the auger while it is drilling the hole. Since in cold weather, it is desirable to minimize physical exertions so that the body can focus on keeping warm, it is particularly disadvantageous to have to expend so much energy early in the fishing day just trying to get the hole drilled.
Another problem associated with these hand-held, power augers is that they are fairly large and hence for movement from one location to another requires a person of considerable strength, or two people. This limits the number of people able to take advantage of these powered devices. In particular, people of limited strength cannot use such devices and therefore cannot maximize their fishing time and pleasure.
As the use of power augers has grown, platforms have been created to help stabilize the auger and facilitate moving the auger up and down while drilling through thick ice. This simplifies some aspects of ice fishing, but also adds more problems. Ice fishing often takes place in secluded areas not allow easy access to larger vehicles because of the weight of the vehicle or the difficult terrain in getting to the location. The auger and platform used therewith must therefore be transported by a smaller vehicle, such as an ATV or a snowmobile. Most ATVs and snowmobiles have cargo racks for storing equipment during transportation. Upon arriving at the fishing site, the equipment must be unloaded and assembled in order to drill the hole. It is often desirable to relocate to another area in order to find more fish. Each time a new fishing hole is to be drilled, the equipment must be disassembled, loaded onto the vehicle, and then unloaded and reassembled in order to drill the new hole. This problem is not exclusive to ice fishing. For example, if such a device were used on land for drilling post-holes, the process of unloading, assembling, and stabilizing the auger would waste the time and energy of the operator.
U.S. Pat. No. 3,602,321 (1971, Kortschaga) teaches the use of an auger powered by the clutch pulley of a snowmobile. U.S. Pat. No. 3,731,751 (1973, Rusco) teaches the use of an auger powered by the track of a snowmobile. These devices require added assembly time and energy and can often be dangerous to use due to the open moving parts associated with the assembly and operation of the apparatus. Since ice fishing only takes place in cold climates, thick clothing and gloves are usually needed to keep the individual warm. Such bulky clothing and gloves can get caught in the open moving parts. It is also difficult for someone wearing such clothing to set up devices requiring the manipulation of small parts or to operate a device that requires precise movements. Another problem associated with these devices is that they take up space in the cargo rack and/or they must be secured to the user's vehicle during transportation. This requires time and the expenditure of energy, thus detracting from the safety and enjoyment of ice fishing.
U.S. Pat. No. 2,723,835 (1954, Reese) teaches a frame for supporting a motor-driven ice hole cutter. The frame of the Reese device rests on the top surface of the ice. The frame has prongs that are inserted into the ice in order to further secure the frame while operating the ice cutter. The motor of the cutter is secured to a platform carried by the frame for vertical movement. The Reese device also has a windlass journalled in the frame and has a hoisting rope secured to the platform for raising the platform and the parts associated therewith after the ice hole has been cut.
The Reese device fails to address many of the problems associated with the stabilization, transportation and operation of the auger. While the Reese device may provide more stability than a hand-held auger, the device may still twist or loosen, depending on the vibration and torque exerted when drilling through the ice. The Reese device must be assembled and disassembled each time a new hole is drilled. The device takes up space on the vehicle and likely must be secured during transportation. The operation of the Reese device becomes more difficult because of the setup time required to secure the pins in the ice and the rope-pulley means for retracting the auger from the hole.
Therefore what is needed is an augerholder that can be secured to, transported by, and operated from various types of vehicles, including ATVs and snowmobiles, without the need to disassemble the device at any point. What is further needed is an augerholder that permits full use of the vehicle's cargo rack. What is still further needed is a device that allows an individual to easily raise and lower the auger when drilling a hole. What is still further needed is an auger-holder that is relatively easy to install and operate. Finally, what is needed is an auger-holder that is adjustable to fit various types of vehicles and to be used on various types of terrain.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an auger-holder that can be secured to and transported by a vehicle. It is another object of the present invention to provide an auger-mounting device that permits the auger to be operated while secured to a vehicle. Yet another object of the present invention is to provide an auger-holder that can be transported by a vehicle without limiting the normal use of the vehicle's cargo rack or requiring supplemental means for securing the device. Another object of the present invention is to provide an auger-holder that will allow a single person to easily retract the auger from the hole after drilling. Yet another object of the present invention is to provide an auger-holder that is relatively easy to install and operate while wearing thick clothing and gloves. Finally, it is an object of the present invention to provide an auger-holder that is adjustable for use with various types of augers on various types of terrain.
The auger-holder of the present invention includes a primary frame, a secondary frame, a locking means for securing the secondary frame in a fixed vertical position relative to the primary frame, and an attachment means for securing the primary frame to the vehicle. The secondary frame includes a means for securing an auger and is connected to the primary frame in a way that permits the auger to be moved up and down in relation to the stationary primary frame. The secondary frame may be secured at various positions on the primary frame. The primary frame includes vertical and horizontal supports and is detachably connected to a vehicle. The primary frame may further include a means for adjusting the angle of the primary frame in relation to the terrain. The mounting device may be used to secure any sort of hole-forming equipment, including, but not limited to, post-hole drills. For that type of auger, the mounting device of the present invention can be adjustable with respect to the terrain so as to accommodate the pitch of a hill in order to align the post holes vertically. Since ice is relatively flat, the adjustable primary frame would not generally be necessary for the ice auger to drill a hole perpendicular to the plane of the ice, but the distinguishing feature may occasionally be useful when pressure ridges cause the ice to become uneven and non-flat.
An obvious advantage of the present invention, especially in cold weather, is the ability to secure the auger to the rear of a vehicle and to drive to any location where a hole is to be drilled and then to drill the hole without any installation of the mounting device or the auger. Another advantage arises because the auger is capable of being operated while attached to the vehicle. No further stabilization of the auger is required, because the vibrational and torque-related forces are countered by the weight of the vehicle. The present invention allows one to secure, transport, and operate an auger using the existing cargo rack for support with little, if any, restriction on rack storage capacity. A further advantage of the present invention is the facility of drilling the hole and retracting the auger from the hole after it has been drilled. This may be accomplished by using assistive means including, but not limited to, a spring-, hydraulic-, gear-, or motor-type mechanism mounted on the primary or secondary frame. Finally, a further advantage is that the present invention may be used with various types of augers and vehicles on various types of terrain. These and other advantages of the present invention will become apparent upon review of the drawings, detailed description of the device, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the present invention attached to the rear cargo rack of an ATV with an auger mounted thereon.
FIG. 2 is a front view of the present invention with an auger mounted thereon.
FIG. 3 is a top view of the present invention with an auger mounted thereon.
FIG. 4 is a front view of an alternative design including a motor mounted on the primary frame for retracting the auger from the hole and showing horizontal adjustment features.
FIG. 5 is an expanded view of an alternative design including a hinged connector for securing the primary frame at an angle with respect to the ATV.
FIG. 5a is a three-dimensional view showing an alternative attachment means for securing the primary frame at an angle with respect to the ATV.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is illustrated in FIGS. 1-5a. As shown in FIGS. 1-2, an auger-holder 1 includes a primary frame 10, a secondary frame 20 for securing an auger 3, a locking means 30, and an attachment means 40 for securing primary frame 10 to a rack 4 of an all-terrain vehicle (ATV) 2. It is to be understood that the device 1 may be mounted to any vehicle. In the preferred embodiment of the present invention, the auger-holder 1 is formed of aluminum. However, it is to be understood that all or portions of the device 1 may be made from materials such as other metals, plastics (including fiberglass), or the like, having sufficient strength to support the auger 3 and the vibration associated with its use.
The primary frame 10 includes a left rear vertical support 11, a left front vertical support 12, a right front vertical support 14, an upper horizontal support 15, a middle horizontal support 16, and a lower horizontal support 17. It is to be understood that a right rear vertical support is symmetrically positioned in cubical alignment with the left rear vertical support 11 and the right front vertical support 14. The secondary frame 20 includes a left auger arm support 21, a right auger arm support 22, an upper horizontal member 23, a lower horizontal member 24, a left sliding means 25, a right sliding means 26, a left diagonal support 27, and a fastening means 28. It is understood that a right diagonal support is positioned similarly to left diagonal support 27. The locking means 30 preferably includes an engaging means 31, such as a hook, and a lever 32. In the preferred embodiment of the invention, the left sliding means 25 is a section of tubular iron and its crosssection is slightly larger than the cross-section of the vertical support 12 in order to allow the vertical support 12 to easily pass therethrough. The right sliding means 26 is similarly designed. The locking means 30 may be designed in a variety of ways. It may include any of a number of forms of catch-and-release mechanisms such as a releasable ratchet, a locking pin, or the like.
As illustrated in FIGS. 2-3, the auger 3 is secured to the secondary frame 20 by the left auger arm support 21 and the right auger arm support 22. The left auger arm support 21 and the right auger arm support 22 are formed to receive and secure handle 5 of the auger 3. The fastening means 28 stops handle 5 from sliding out of the right auger arm support 22. The fastening means 28 may be one of a variety of securing devices, including, but not limited to, a threaded bolt, a selflocking pin, and the like. The upper horizontal member 23 is fixed to the left auger arm support 21 and to the right auger arm support 22. The right auger arm support 22 is designed to receive the fastening means 28 by inserting the fastening means 28 through the end thereof. The upper horizontal member 23 and the lower horizontal member 24 may be adjustable in order to accommodate various shapes and sizes of handles. As shown in Fig. 4, a first section 23a and a second section 23b of upper horizontal member 23 are movable with respect to one another so as to permit width adjustment of the secondary frame 20. Similary, lower horizontal member 24 includes first section 24a and second section 24b that are movable with respect to one another for such adjustment. Pins extending through sections 23a, 24a, and 23b, 24b, lock the adjusted secondary frame 20 in place for receiving augers of virtually any handle dimensions. The upper horizontal member 23 and the lower horizontal member 24 may be channelled, angled, or tubular members. An engaging means 31 is angled or hookshaped and secures the upper horizontal member 23 in close proximity to the upper horizontal support 15. The engaging means 31 is welded or bolted to a lever 32. The lever 32 is hingedly fixed to the upper horizontal support 15 and extends to within reach of the operator of the auger 3. The upper horizontal member 23 is fixed to the upper end of the left sliding means 25 and the upper end of the right sliding means 26. The lower horizontal member 24 is fixed to the lower end of the left sliding means 25 and the lower end of right sliding means 26. The cross-sections of the left sliding means 25 and the right sliding means 26 are tubular, allowing the left front vertical support 12 and the right front vertical support 14, respectively, to pass therethrough. The left diagonal support 27 is welded to the lower horizontal member 24 and to the left auger arm support. It is to be understood that a right diagonal support is positioned similarly to the left diagonal support 27.
As shown in FIGS. 1-3, the upper horizontal support 15, the middle horizontal support 16, and the lower horizontal support 17 are adjustable in width, corresponding with adjustments to the secondary frame 20 in order to accommodate various sizes of augers. Sets of paired holes 18 allow width adjustment of the primary frame 10. The upper horizontal support 15 and the lower horizontal support 17 may be channelled members or flat strips. The vertical supports are attachable to the upper horizontal support 15 and the lower horizontal support 17. The left rear vertical support 11, the left front vertical support 12, the right front vertical support 14, and the right rear vertical support are tubular. Each includes a bolt or pin fixed within the uppermost and lowermost portions thereof which are inserted through the sets of paired holes 18 to secure the primary frame 10.
In an alternative embodiment illustrated in FIG. 4, the horizontal supports 16, 23, and 24, are adjustable to fit various sizes of vehicles and augers. Each support includes an outer portion, such as 16a, and an inner portion, such as 16b. The outer portion 16a has a cross-section sufficiently larger than the cross section of its corresponding inner portion 16b to allow the inner portion to be inserted therein. The adjustable portions are secured together by a bolt, pin, or the like. It is also possible to make the vertical supports adjustable in a similar manner.
The secondary frame 20 is adjustably engaged with the left front vertical support 12 and the right front vertical support 14. The middle horizontal support 16 is fixedly attachable to the left rear vertical support 11 by a left rear sliding means 19a and to the right rear vertical support by a right rear sliding means 19b. The means for securing the rear sliding means 19a and 19b may be a pin, bolt or the like. The middle horizontal support 16 may be channelled or L-shaped. The middle horizontal support 16 clamps down on the rack 4 to secure the auger-holder 1 to the ATV 2. It is to be understood that various types of vehicle racks or mounts exist and that the middle horizontal support 16 may be adapted to secure the primary frame 10 to such racks or mounts. The auger-holder 1 is further secured to the ATV 2 by the hitch mount 40. The hitch mount 40 is adjustably secured to the lower horizontal support 17 and includes a pin 6 for inserting into the hitch of the ATV 2. The auger-holder 1 may include an assistive means 45 for moving the secondary frame 20 in vertical relation to the primary frame 10. It is to be understood that the assistive means 45 may be mounted on the primary frame 10 or the secondary frame 20 and may include, but is not limited to a spring, motor, hydraulic, gear, pulley, or the like. The assistive means 45 is simply affixed to the primary frame 10 or to the secondary frame 20 such that by its operation, the secondary frame 20 moves with respect to the primary frame 10. That is, as is well known to those skilled in the art, since the secondary frame 20 is slidable on the primary frame 10 as has been described creating a mechanical link between the two frames by way of the assistive means 45 and actuating the assistive means 45 will result in movement of the secondary frame 20 with respect to the primary frame 10 in a manner suitable for bringing the auger in contact with the underlying surface.
As shown in FIGS. 5 and 5a, the hitch mount 40 may further include a hinge 41 to allow the auger-holder 1 to be angularly mounted in relation to the underlying terrain. Alternatively, the hitch mount 40 may be two pieces of metal 42 and 43 with sets of holes to make the hitch mount 40 adjustable in length in order to accommodate for the angular mounting. The two pieces may be secured together by a bolt, pin, or the like.
The preferred embodiment of the present invention has been described herein. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims. | An auger-holder designed for transporting, stabilizing, and operating an auger from a vehicle, preferably an all-terrain vehicle (ATV). The auger-holder includes a primary frame, a secondary frame, an attachment device for attaching the primary frame to a vehicle, and a locking mechanism for securing the secondary frame to the primary frame when the auger is not in use. The primary frame includes a structure of vertical and horizontal support members. The secondary frame is adjustably connected to the primary frame for stability and operability of the auger. The auger-holder optionally includes a hinge apparatus for aligning the auger at a range of angles relative to the plane of underlying terrain. | 4 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/805,477 (attorney docket no. 91904/4), filed on May 22, 2007, which in turn is a continuation-in-part of U.S. patent application Ser. No. 11/805,271 (attorney docket no. 91904/3), filed on May 21, 2007, both of which are entitled System and Method For Removing Carbon Dioxide From An Atmosphere and Global Thermostat Using The Same, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to systems and methods for removing greenhouse gases from an atmosphere, and in particular to systems and methods for removing carbon dioxide from an atmosphere.
BACKGROUND OF THE INVENTION
[0003] There is much attention currently focused on trying to achieve three energy related and somewhat conflicting energy related objectives: 1) provide affordable energy for economic development; 2) achieve energy security; and 3) avoid the destructive climate change caused by global warming. Many different approaches are being considered to address climate change, including increasing the use of clean, non polluting renewable energy sources such as biofuels, solar, wind and nuclear, attempting to capture and sequester the carbon dioxide emissions from fossil fuel plants, as well as increased conservation efforts. Some of these approaches, such as solar power, have had their large scale implementation blocked due to their current high costs as compared to the cost of fossil based electricity, and other approaches, such as nuclear, are restrained by their environmental and security risks. In fact, the infrastructure and supply for renewable energy is so underdeveloped (e.g., only about 0.01% of our energy is provided by solar) that there is no feasible way to avoid using fossil fuels during the rest of this century if we are to have the energy needed for economic prosperity and avoid energy shortfalls that could lead to conflict.
[0004] The climate change threat caused by global warming and the more general recognition of our need to use renewable resources that do not harm our planet has grown steadily since the first Earth Day in 1972. It is mostly undisputed that an increase in the amount of so-called greenhouse gases like carbon dioxide (methane and water vapor are the other major greenhouse gases) will increase the temperature of the planet. These greenhouse gases help reduce the amount of heat that escapes from our planet into the atmosphere. The higher the concentrations of greenhouse gases in the atmosphere the warmer the planet will be. There are complicated feedbacks that cause the amount of carbon dioxide and other greenhouse gases to change naturally even in the absence of human impact. Climate change throughout geological history has caused many extinctions. The concern about the threat of human induced climate change (i.e., global warming) resulted in the Kyoto Protocol that has been approved by over 165 countries and is an international agreement that commits the developed countries to reduce their carbon emissions.
[0005] One reason global warming is thought by the Intergovernmental Panel on Climate Change (IPCC) to be a threat is because of the sea level rise resulting from the melting of glaciers and the expansion of the ocean as our planet becomes hotter. Hundreds of millions of people who live just above sea level on islands or on the coasts are threatened by destructive flooding requiring relocation or the building of sea walls if the sea level rises even a meter. There is also a threat to other species from climate change which will destroy ecosystems that cannot adjust to the fast rate of human caused climate change. Additional threats include increased infectious diseases and more extreme weather as well as direct threats from extreme heat.
[0006] The challenge of dealing with global warming can be demonstrated by using a simple model. Let C CA (Y N ) represent the carbon dioxide added to the atmosphere in year Y N in gigatonnes per year. Similarly, let C EX (Y N ) equal the amount extracted, G EM (Y N ) the amount emitted by humans and C N (Y N ) be the amount either added or removed due to natural variations in the carbon cycle. Today, the land stores each year approximately 1.8 gigatonnes (10 9 tonnes) of carbon dioxide and the ocean approximately 10.5 gigatonnes (note carbon dioxide is 3.66 times heavier than carbon), while the amount humans add by emissions is about 24 gigatonnes of carbon dioxide. More generally, we have:
[0000] C CA (Y N )=−C EX (Y N )+C EM (Y N )+C N (Y N ) (1)
[0000] C A (Y N+1 )=C A (Y N )+C CA (Y N ) (2)
[0000] where C A (Y N ) is the amount of carbon in the atmosphere in year Y N , 2780 gigatonnes of carbon dioxide today. Other forms of carbon contribute to global warming, most notably methane, although by weight they represent a small component
[0007] If C EX (Y N ) is set to zero than the only way one could possibly stop adding carbon dioxide to the atmosphere would be to reduce our emissions to be equal to the natural uptake. However, C N (Y N ) itself varies greatly and can be a net addition to the atmosphere from the much larger natural carbon cycle which adds and subtracts carbon at about 750 gigatonnes of carbon per year. It is the shifts in this natural balance that has caused climate change before our species existed and will also continue to do so in the future. Thus, it is clear that there is no solution that only reduces human contributions to carbon dioxide emissions that can remove the risk of climate change. With air extraction and the capability to increase or decrease the amount of carbon dioxide in the atmosphere one can in principle compensate for other greenhouse gases like methane that can change their concentrations and cause climate change.
[0008] Further, although there are known processes for removing some of the carbon dioxide from the flue gas of a fossil fuel plant, such processes are internal to the fossil fuel plant itself, so that there is no effect on the reduction of carbon dioxide already present in the atmosphere.
[0009] Accordingly, there is a broadly recognized need for a system and method for reducing the amount of carbon dioxide in the atmosphere created by burning of fossil fuels and for providing a low cost, non-polluting renewable energy source as a substitute for fossil fuels.
SUMMARY OF THE INVENTION
[0010] A system for removing carbon dioxide from an atmosphere to reduce global warming according to an exemplary embodiment of the present invention comprises: an air extraction system that collects carbon dioxide from the atmosphere through a medium and removes carbon dioxide from the medium; a sequestration system that isolates the removed carbon dioxide to a location for at least one of storage and generation of a renewable carbon fuel; and one or more power supplying units that supply heat to the air extraction system to remove the carbon dioxide from the medium, at least one of the one or more power supplying units being a fossil fuel plant.
[0011] In at least one embodiment, the air extraction system comprises an air contactor that includes the medium to absorb carbon dioxide from the atmosphere.
[0012] In at least one embodiment, the air contactor is selected from the group of air contactors consisting of: convection towers, absorption pools and packed scrubbing towers.
[0013] In at least one embodiment, the medium is selected from the group of mediums consisting of: a liquid, a porous solid, a gas and mixtures thereof.
[0014] In at least one embodiment, the medium is an NaOH solution.
[0015] In at least one embodiment, the medium comprises an amine.
[0016] In at least one embodiment, the air extraction system collects carbon dioxide and the sequestration system isolates the removed carbon dioxide using the heat supplied by the one or more power supplying units.
[0017] In at least one embodiment, the location of the isolated carbon dioxide is underground.
[0018] In at least one embodiment, the location is at a remote site upwind from one or more other components of the system.
[0019] A method for removing carbon dioxide from an atmosphere to reduce global warming according to an exemplary embodiment of the present invention comprises the steps of: collecting air from the atmosphere; removing carbon dioxide from the collected air; and isolating the removed carbon dioxide to a location for at least one of storage and generation of a renewable carbon fuel, wherein at least one of the collecting, removing and isolating steps is performed using process heat generated by a fossil fuel plant.
[0020] A global thermostat for controlling average temperature of a planet's atmosphere according to an exemplary embodiment of the present invention comprises: one or more first systems for extracting greenhouse gases from the atmosphere at a rate slower than the greenhouse gases are increasing in the atmosphere and at least one of storing the greenhouse gases and generating a renewable carbon fuel using the greenhouse gases; one or more second systems for extracting greenhouse gases from the atmosphere at a rate faster than the greenhouse gases are increasing in the atmosphere and at least one of storing the greenhouse gases and generating a renewable carbon fuel using the greenhouse gases; one or more third systems for extracting greenhouse gases from the atmosphere at the same rate as the greenhouse gases are increasing or decreasing in the atmosphere and at least one of storing the greenhouse gases and generating a renewable carbon fuel using the greenhouse gases; and a fossil fuel plant for providing heat to at least one of the first, second and third systems.
[0021] These and other features of this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Various exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein:
[0023] FIG. 1 is a generalized block diagram of a system for removing carbon dioxide from an atmosphere according to an exemplary embodiment of the present invention;
[0024] FIG. 2 is a block diagram of a system for removing carbon dioxide from an atmosphere according to an exemplary embodiment of the present invention;
[0025] FIG. 3 is a block diagram of an air extraction system according to an exemplary embodiment of the present invention; and
[0026] FIG. 4 is a map illustrating a global thermostat according to an exemplary embodiment of the present invention;
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] FIG. 1 is a generalized block diagram of a system, generally designated by reference number 1 , for removing carbon dioxide from an atmosphere according to an exemplary embodiment of the present invention. The system 1 includes an air extraction system 40 and a sequestration system 50 . The air extraction system 40 preferably incorporates any known or later-discovered CO 2 extraction method, including methods which use a medium to absorb and/or bind CO 2 from the atmospheric air by exposing the medium to chemical, electrical and/or physical interaction with the CO 2 in the captured air. The medium may be liquid, gaseous or solid, or a combination of liquid, gaseous and solid substances, where in the case of solids, the substance is preferably porous. The medium is preferably recyclable so that after the CO 2 is captured by the medium and separated from the medium for sequestration, the medium can be reused for absorption/binding of additional CO 2 . However, in other embodiments the medium may be sequestered along with the captured CO 2 . As shown in FIG. 1 , the separation of the CO 2 from the medium, as well as other processes such as the absorption/binding of CO 2 and the sequestration of the CO 2 performed by the sequestration system 50 , may be made more efficient by the addition of heat to the air extraction system 40 . In the present invention, the heat is process heat generated by a fossil fuel power plant, to be described in further detail below. The term “process heat” as used herein refers to the lower temperature heat remaining after the higher temperature heat has been used to generate electricity. More generally, the term “process heat” refers to any low temperature heat remaining after a primary process or that is added by the process itself, such as, for example, exothermic carbonation reactions in which carbon dioxide is stored as a mineral.
[0028] FIG. 2 is a block diagram of a system, generally designated by reference number 2 , for removing carbon dioxide from an atmosphere according to an exemplary embodiment of the present invention. The system 2 includes a fossil fuel power plant 30 , an air extraction system 42 and a sequestration system 50 . Each of these components of the system 2 are explained in detail below.
[0029] The fossil fuel power plant 30 may be any known or later discovered facility that relies on the burning of fossil fuels, such as, for example, coal, fuel oil, natural gas and oil shale, for the generation of electricity. The thermal energy produced by the fossil fuel power plant 30 is used to produce electricity and the residual thermal energy (i.e., process heat) may be used to drive the air extraction system 42 and/or the sequestration system 50 . For example, the process heat from the fossil fuel power plant 30 may be used to improve the efficiency of chemical and/or physical reactions used in the air extraction system 42 to absorb CO 2 from the air and/or to drive off the CO 2 from the medium.
[0030] The residual heat provided by the fossil fuel power plant 30 may be supplemented by energy generated by a supplemental energy source. For example, the supplemental energy source may be a waste incineration plant or a renewable energy source, such as, for example, solar, nuclear, biomass, and geothermal energy sources, which provides additional thermal energy to drive the air extraction system 42 and/or the sequestration system 50 . Process heat from the supplemental energy source may also be used to drive the air extraction system 42 and/or the sequestration system 50 .
[0031] FIG. 3 is a block diagram of the air extractor system 42 useable with the system 2 according to an exemplary embodiment of the present invention. The air extractor system 42 includes an air contactor 41 , a causticizer 43 , a slaker 45 , a calciner 47 and a capture unit 49 . The air contactor 41 may use a sorbent material to selectively capture CO 2 from the air, and may be composed of any known or later-discovered contactor structures, such as, for example, large convection towers, open, stagnant pools, and packed scrubbing towers. In the present embodiment, the sorbent material may be sodium hydroxide (NaOH), which readily absorbs CO 2 from the air. It should be appreciated that other known or future-discovered capture methods may be used, such as, for example, chemical absorption, physical and chemical adsorption, low-temperature distillation, gas-separation membranes, mineralization/biomineralization and vegetation. As a further example, as known in the art, aqueous amine solutions or amine enriched solid sorbents may be used to absorb CO 2 . Preferably, the sorbent material is regenerated and the capture method requires less than about 100-120° C. heat to regenerate the sorbent material.
[0032] In this embodiment, at the air contactor 41 , CO 2 may be absorbed into an NaOH solution forming sodium carbonate (Na 2 CO 3 ). Of course, other known or future-developed absorbers may also be used as an alternative or in addition to an NaOH solution. The generated Na 2 CO 3 is then sent to the causticizer 43 , where the NaOH is regenerated by addition of lime (CaO) in a batch process. The resulting CaCO 3 solid is sent to the calciner 47 where it is heated in a kiln to regenerate the CaO, driving off the CO 2 in a process known as calcination. The regenerated CaO is then sent through the slaker 45 , which produces slaked lime Ca(OH) 2 for use in the causticizer 43 .
[0033] The capture unit 49 captures the CO 2 driven off at the calciner 47 using any know or later-discovered CO 2 capturing method that is effective in the low concentrations in which CO 2 is present in the atmosphere and that needs only low temperature heat for regeneration. For example, the capture unit 49 may use an amine based capture system, such as the system described in U.S. Pat. No. 6,547,854, incorporated herein by reference. The capture unit 49 may also compress the captured CO 2 to liquid form so that the CO 2 may be more easily sequestered.
[0034] The sequestration system 50 may use any known or future-discovered carbon storing technique, such as, for example, injection into geologic formations or mineral sequestration. In the case of injection, the captured CO 2 may be sequestered in geologic formations such as, for example, oil and gas reservoirs, unmineable coal seams and deep saline reservoirs. In this regard, in many cases, injection of CO 2 into a geologic formation may enhance the recovery of hydrocarbons, providing the value-added byproducts that can offset the cost of CO 2 capture and sequestration. For example, injection of CO 2 into an oil or natural gas reservoir pushes out the product in a process known as enhanced oil recovery. The captured CO 2 may be sequestered underground, and according to at least one embodiment of the invention at a remote site upwind from the other components of the system 2 so that any leakage from the site is re-captured by the system 2 .
[0035] In regards to mineral sequestration, CO 2 may be sequestered by a carbonation reaction with calcium and magnesium silicates, which occur naturally as mineral deposits. For example, as shown in reactions (1) and (2) below, CO 2 may be reacted with forsterite and serpentine, which produces solid calcium and magnesium carbonates in an exothermic reaction.
[0000] ½Mg 2 SiO 4 +CO 2 =MgCO 3 +½SiO 2 +95 kJ/mole (1)
[0000] ⅓Mg 3 Si 2 O 5 (OH) 4 +CO 2 =MgCO 3 +⅔SiO 2 +⅔H 2 O+64 kJ/mole (2)
[0036] Both of these reactions are favored at low temperatures. In this regard, both the air capture and air sequestration processes described herein may use electricity and/or thermal energy generated by the fossil fuel power plant 30 to drive the necessary reactions and power the appropriate system components. In an exemplary embodiment of the present invention, a high temperature carrier may be heated up to a temperature in a range of about 400° C. to about 500° C. to generate steam to run a generator for electricity, and the lower temperature steam that exits from the electrical generating turbines can be used to drive off the CO 2 and regenerate the sorbent (e.g., NaOH). The temperature of the high temperature heat, the generated electricity and the temperature of the lower temperature process heat remaining after electricity production can be adjusted to produce the mix of electricity production and CO 2 removal that is considered optimal for a given application. In addition, in exemplary embodiments, still lower temperature process heat that emerges out of the capture and sequestration steps may be used to cool equipment used in these steps.
[0037] One or more systems for removing carbon dioxide from an atmosphere may be used as part of a global thermostat according to an exemplary embodiment of the present invention. By regulating the amount of carbon dioxide in the atmosphere and hence the greenhouse effect caused by carbon dioxide and other gas emissions, the system described herein may be used to alter the global average temperature. According to at least one exemplary embodiment of the present invention, several carbon dioxide capture and sequestration systems may be located at different locations across the globe so that operation of the multiple systems may be used to alter the CO 2 concentration in the atmosphere and thus change the greenhouse gas heating of the planet. Locations may be chosen so as to have the most effect on areas such as large industrial centers and highly populated cities, or natural point sources of CO 2 each of which could create locally higher concentrations of CO 2 that would enable more cost efficient capture. For example, as shown in FIG. 4 , multiple systems 1 may be scattered across the globe, and international cooperation, including, for example, international funding and agreements, may be used to regulate the construction and control of the systems 1 . In this regard, greenhouse gases concentration can be changed to alter the average global temperature of the planet to avoid cooling and warming periods, which can be destructive to human and ecological systems. During the past history of our planet, for example, there have been many periods of glaciation and rapid temperature swings that have caused destruction and even mass extinctions. Such temperature swings in the future could be a direct cause of massive damage and destabilization of human society from conflicts resulting from potential diminished resources. The global thermostat described herein may be the key to preventing such disasters in the decades to come.
[0038] Preferably, the air extraction system 42 and the sequestration system 50 are located at a facility that is separate from the fossil fuel power plant 30 . Thus, the overall system 2 functions to remove from the atmosphere carbon dioxide produced by sources other than the fossil fuel power plant 30 . It should also be appreciated that in an embodiment of the invention, the air extraction system 42 and the sequestration system 50 may be used to remove the equivalent amount of CO 2 generated by the fossil fuel power plant, so that the entire facility may be considered “carbon neutral”. Also, removing CO 2 from the atmosphere, rather than directly from the flue gases, is advantageous in that it avoids the pollutants in the flue gases that would poison the adsorbent and otherwise negatively effect costs and operations.
[0039] While this invention has been described in conjunction with the exemplary embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. | A system for removing carbon dioxide from an atmosphere to reduce global warming including an air extraction system that collects carbon dioxide from the atmosphere through a medium and removes carbon dioxide from the medium; a sequestration system that isolates the removed carbon dioxide to a location for at least one of storage and generation of a renewable carbon fuel; and one or more power supplying units that supply heat to the air extraction system to remove the carbon dioxide from the medium, at least one of the one or more power supplying units being a fossil fuel plant. | 8 |
This application is the U.S. national phase of International Application No. PCT/EP2013/054189, filed on 1 Mar. 2013, which designated the U.S. and claims priority EP Application No. 12157761.3, filed on 1 Mar. 2012, the entire contents of each of which are hereby incorporated by reference.
The invention relates to a method for impregnating a rope with a liquid material. The invention further relates to a device for carrying out the same.
BACKGROUND OF THE INVENTION
It has been the universal commercial practice to pass a rope slowly through a bath of liquid material to permit the material to penetrate the voids or interstices of the rope. Such a method and a device for carrying out the method are known from U.S. Pat. No. 3,960,050 wherein the rope is placed in a basket which is immersed in an impregnation tank containing the liquid material to be impregnated in the rope. Alternatively, the rope may be passed through an impregnation bath containing said liquid. U.S. Pat. No. 3,960,050 also describes a device for carrying out the method disclosed therein. Further methods for impregnating a rope and devices for carrying out said methods are known from U.S. Pat. No. 4,197,695 wherein an impregnation bath or an impregnation closing die are used; U.S. Pat. No. 4,490,969 wherein an impregnation bath or a spraying device are used; U.S. Pat. No. 5,098,493 wherein injection needles are used; and U.S. Pat. No. 4,635,432 wherein an injection die is used.
Another device for impregnation is disclosed for example in U.S. Pat. No. 1,587,652 which is used to saturate a fibrous material in particular a felt sheet with e.g. asphalt. The device disclosed therein contains a pressure saturating chamber which uses high pressure, i.e. pressure higher than the atmospheric pressure, to cause the asphalt to penetrate the sheet. After saturating or impregnating the sheet using high pressure, the device may subsequently use vacuum to extract any moisture or air trapped therein; and then the sheet may be again subjected to saturation under great pressure. Vacuum however is not used during the saturation step.
CA 768356 also discloses a device for impregnating a textile, the device comprising an impregnation bath containing an impregnant and a vacuumed column located within the impregnant such that the impregnant acts as a seal for the bottom of the column. Just as in U.S. Pat. No. 1,587,652, vacuum is used to extract any air which may be retained within the impregnated textile. A device similar to the one of CA 768356 is disclosed by JP 48-41094.
Another disclosure of a device for impregnating a wire rope is given by JP 2005 264358. The device disclosed therein operates in a batch-like fashion wherein a portion of a length of the wire rope is placed in a vacuumed tube and a molten resin is injected under pressure in said tube, to impregnate said portion. After impregnation, the vacuum is released, the impregnated portion of the rope is removed from the tube and a portion of the adjacent non-impregnated part of the rope is placed in the tube. The operation is repeated to impregnate the complete length of the rope.
Moreover, although impregnating a rope and coating a rope are in principle two different processes with different characteristics, in some instances is arguable that the methods for coating a rope may also achieve some low degree of impregnation. A method for coating a rope is described for example in JP 5 510 2457, wherein the rope is coated with grease by injecting the grease into a chamber while the chamber moves along the length of the rope. The thickness of coated grease is controlled by the size of the gap between the outer periphery of the rope and the internal periphery of the outlet of the chamber which discharges the rope. Further methods for coating ropes wherein some degree of impregnation may be achieved are known from U.S. Pat. No. 4,067,211 wherein a spraying method is used for coating the rope; and U.S. Pat. No. 8,105,657 wherein a coating chamber is used.
It was however noticed that the results obtained with the known impregnation or coating methods may depend on the modus operandi, or in other words, to the skills of the operator, i.e. the person carrying out the method. The rather poor reproducibility of such methods typically implies that the quality of the impregnation may vary with the skills of the operator and in turn, impregnated ropes forming for example a rope batch may have inconsistent properties. Also due to the employment of complicated machinery and/or heavy hardware, the known methods may be cumbersome to use and even pose safety risks.
It was also noticed that the above mentioned methods have difficulties in achieving an optimum degree of impregnation; in particular since the liquid material does not always optimally penetrate inside the rope. Moreover, achieving sizeable rope lengths which are optimally impregnated with the liquid material along a significant, preferably entire, length thereof is hardly possible. Especially for thick ropes, e.g. ropes having an effective diameter of more than 10 mm and even more than 20 mm, it was observed that the liquid material hardly penetrates fully the rope reaching the core of the rope also. Such an uneven distribution of the liquid material inside the rope may in turn cause a reduced life time thereof and even variations in rope strength along its length during its use.
To partly solve the above drawbacks and in particular the inhomogeneous penetration, methods were devised where ropes were assembled from previously coated fibers or coated strands containing fibers. Such a method is for example disclosed in DE 749 220. Therein, before constructing a rope, the individual elements of the rope, e.g. fibers, yarns of strands, are coated or impregnated by passing several filaments through an impregnation bath and thereafter combining them in an elongated nozzle tube. However, processes such as the one of DE 749 220 are very complicated and extremely polluting. Also, it came as a surprise for such methods that in spite of distributing a liquid material on each fiber or strand of the rope, the exterior of the rope assembled from said fibers and/or strands contained less liquid material than the core of the rope. Hence, even for such methods the degree of rope impregnation can be optimized.
Accordingly, the object of the present invention may be to provide a method for coating a rope which shows the above mentioned disadvantages to a lesser extent. In particular, the present invention aims to provide a method for more uniformly impregnating a rope with a liquid material and a device for carrying out said method.
SUMMARY OF THE INVENTION
The invention proposes a method for impregnating a liquid material into a rope comprising a plurality of fibers and interstices between said fibers, said method comprising the steps of:
a. Providing a liquid material in a tank, said liquid material defining a level of liquid in said tank; b. Providing an impregnation unit containing a chamber at least partially immersed in said liquid material, said chamber comprising:
i. a rope-inlet for tightly receiving the rope, wherein said rope-inlet is positioned below the level of liquid; ii. a rope-outlet for tightly discharging said rope; iii. a vacuum-outlet; and
c. Providing a vacuum-device operatively connected to said vacuum-outlet for lowering the pressure in said chamber below the atmospheric pressure; d. Passing the rope through the liquid material in the tank and then inside and outside said chamber via the rope-inlet and rope-outlet, while maintaining the pressure inside said chamber below the atmospheric pressure to force the liquid material to fill at least part of said interstices between the fibers of the rope by penetrating between said fibers.
It was observed that the method of the invention has an increased safety factor and offers good reproducibility as well as a high level of ergonomics. Ropes with a uniform distribution of the liquid material, as observed on a cross-section of the rope, may be produced. The method of the invention also seems less sensitive to the type of the liquid material used for impregnation or to the characteristics of the rope to be impregnated, e.g. the construction, diameter or material thereof. In particular it was observed that with the method of the invention the efficiency of the impregnation was optimized, e.g. the liquid material reached the core of the rope, which in turn led to a larger quantity of liquid material present inside said rope than it was obtained heretofore. Another important advantage of the method of the invention is that said method can be applied continuously.
The invention also relates to a device for carrying out the method of the invention, which comprises:
a. A tank comprising a liquid material, said liquid material defining a level of liquid in said tank; b. An impregnation unit containing a chamber at least partially immersed in said liquid material, said chamber comprising:
i. a rope-inlet for tightly receiving the rope, wherein said rope-inlet is positioned below the level of the liquid material in the tank; ii. a rope-outlet for tightly discharging said rope; iii. a vacuum-outlet; and
c. A vacuum-device operationally connected to said vacuum-outlet for lowering the pressure in said chamber below the atmospheric pressure.
The device of the present invention makes use of vacuum to force the liquid material from the tank inside the rope, between the fibers forming the rope, such that said liquid material fills voids, pores and interstices present in the rope and effectively coats the individual fibers of which the rope is composed. In other words, in order to force the liquid material to penetrate inside the rope and in-between the fibers of the rope to fill out said voids, pores and interstices, a pressure difference is created in respect with the atmospheric pressure with the lower pressure being in the chamber. This pressure difference forces the liquid material to flow inside the chamber between the fibers of the rope and thus filling out said voids, pores and interstices. Therewith in order for the device to operate properly, a pressure difference Δ, wherein Δ=P atm −P chamber , needs to be maintained throughout the impregnation process, with a pressure in the chamber (P chamber ) that is lower than the pressure outside the chamber. Typically, the pressure outside the chamber is the atmospheric pressure, hereinafter denoted as P atm . Preferably Δ is maintained at a constant level to ensure for a uniform impregnation of the rope. Δ can vary widely depending on e.g. the rope characteristics, e.g. rope tightness, diameter and materials used; but also time needed for impregnation and characteristics of the liquid material, e.g. viscosity. For example, the higher the diameter of the rope or the tightness of the rope, applying a higher Δ can be considered. On the other hand when dealing with a rope having a specific construction, applying a higher Δ may imply that more liquid material impregnates the rope. In one embodiment, it is preferred that Δ is at least 0.05 bar, more preferably at least 0.1 bar, most preferably at least 0.5 bar. For example, a Δ of 0.05 bar when the P atm is 1 bar would correspond to a P chamber of 0.95 bar. Although not limited for upper values, for practical reasons, preferably Δ is at most 10 bar, most preferably at most 5 bar, most preferably at most 3 bar.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further illustrated by the following drawings:
FIG. 1 is a schematic representation of the device for carrying out the method of the invention.
FIG. 2 is a picture showing the difference between a rope impregnated with known methods and a rope impregnated using the device of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention proposes a method for impregnating a liquid material into a rope comprising a plurality of fibers and interstices between said fibers. With reference to FIG. 1-1 , the device ( 100 ) for carrying out the method of the invention comprises a supplying device (not shown) such as a bobbin or an unwinder from which the rope ( 101 ) to be impregnated is supplied through rollers ( 102 ) to the impregnation unit ( 103 ). The impregnation unit ( 103 ) is immersed into a tank ( 104 ) comprising a liquid material ( 105 ) to be impregnated into the rope ( 101 ).
The impregnation unit ( 103 ) comprises chamber ( 106 ), the chamber having preferably an inversed T shape and containing a rope-inlet ( 107 ) for receiving rope ( 101 ); a rope-outlet for discharging rope ( 101 ) and a vacuum-outlet ( 109 ). A vacuum device (not shown) such as for example a vacuum pump is operatively connected to the vacuum-outlet ( 109 ) via a system of pipes for example and is used to reduce the pressure inside the chamber ( 106 ) below the atmospheric pressure. The reduced pressure inside the chamber ( 106 ) will cause a flow of the liquid material ( 105 ) from the tank ( 104 ) into the chamber ( 106 ) between the fibers of the rope ( 101 ). During the method of the invention, the liquid material ( 105 ) is continuously transported from the tank ( 104 ) into the chamber ( 106 ) and may also accidentally enter the vacuum outlet causing a pollution of the vacuum device. To prevent such pollution, a buffer vessel (not shown) may be provided preferably between the vacuum outlet and the vacuum device. Also a feedback system (not shown) may be utilized where the liquid material from the buffer vessel is fed back to the tank ( 104 ) to replenish the amount of the liquid material ( 105 ).
The liquid material ( 105 ) has a defined liquid level ( 105 - 1 ) inside the tank ( 104 ) which is preferably maintained constant during the impregnation process. This can be carried out by using for example the feedback mechanism described hereinabove provided with a liquid-feeding system (not shown) and a liquid level detector which triggers a replenishing mechanism when the level ( 105 - 1 ) drops below a set point.
The rope-inlet ( 107 ) and the rope-outlet ( 108 ) tightly receive and discharge the rope ( 101 ), respectively. This may be carried out by using sealing means ( 110 ) or any other type of valves (not shown in figures), e.g. pneumatic diaphragm valves, of suitable character so that the pressure in the chamber ( 106 ) may be lowered and maintained at the desired level.
As shown in FIG. 1-1 , the rope ( 101 ) having an outer-surface ( 101 - 1 ) is received by the rope-inlet ( 107 ) of the chamber ( 106 ), said rope-inlet having an inner wall ( 107 - 1 ). The sealing means ( 110 ) is positioned between the rope outer-surface ( 101 - 1 ) and the inner wall ( 107 - 1 ) of the rope-inlet ( 107 ) to provide a tightly sealing thereof.
A preferred sealing means is a tapered sealing device having for example a shape of a frustum of a cone ( FIG. 1-2A ). Such a shape of the tapered sealing device may ease its installment while being less sensitive to the size of the rope used or to the dimensions of the rope-inlet or of the rope-outlet contained by the impregnation unit. Moreover, such a device usually has good sealing properties. With reference to FIG. 1-2A , the tapered sealing device contains an admission inlet ( 110 - 1 ) with lateral dimensions, e.g. diameter, adjusted to accommodate the rope such that a tight fit between said device and the rope is achieved. The tapered region ( 110 - 2 ) also has dimensions adjusted to accommodate the rope-inlet ( 107 ) or the rope-outlet ( 108 ), respectively, such that a tight fit between said device and the respective inlet or outlet is achieved. The skilled person can routinely determine the necessary dimensions of said admission inlet ( 110 - 1 ) and of said tapered region ( 110 - 2 ) with due regard to the size of the rope to be impregnates as well as of the rope-inlet and of the rope-outlet of the impregnation unit such that an optimum tight fit is achieved.
A second preferred embodiment of a sealing means is a sealing device having essentially a cylindrical shape ( FIGS. 1-2B ) and containing an admission inlet ( 110 - 1 ) for receiving the rope, wherein said device has an inner surface ( 110 - 11 ) and a outer surface ( 110 - 2 ) wherein said inner surface and/or said outer surface are provided with a plurality of protrusions ( 110 - 12 ) and ( 110 - 21 ), respectively, said protrusions preferably having a cross-section defined by a height ( 110 - 6 ) and a width ( 110 - 7 ). Although referred to as essentially cylindrical shape, is it understood that the shape of the sealing device may vary in order to tightly engage the rope and the inner wall of the rope-inlet and of the rope-outlet, e.g. said sealing device may have two, preferably parallel, bases connected to each other by at least one lateral face, wherein said parallel bases may be polygons or may have a rounded shape, e.g. elliptic or circular. The protrusions of the inner surface, hereinafter referred to as the inner protrusions, define an effective inner diameter ( 110 - 3 ) which is the smallest distance between the tips of two opposite inner protrusions. The protrusions of the outer surface, hereinafter referred to as the outer protrusions, define an effective outer diameter ( 110 - 4 ) which is the largest distance between the tips of two opposite outer protrusions. The sizes of the inner and/or outer protrusions are adjusted to provide a tight fit with the outer surface of the rope and with the inner wall of the rope-inlet and/or of the rope-outlet.
Is to be understood that the above-mentioned embodiments of the sealing means are only representative, without imposing any limitation on the shape or size of the sealing means. Any sealing means, such as gaskets, rubber sealing and the like, which ensures for a tight fitting between the rope outer surface and the inner wall of the rope-inlet and of the rope-outlet may be used. Moreover, the described embodiments should not be understood as being limited to the shapes and the sizes mentioned thereto. It is to be understood that the profiles of the rope-inlet and of the rope-outlet, as well as when applicable the profiles of the admission inlets of the sealing means, are determined by the profile of the rope to be impregnated. The skilled person can routinely determine such profiles.
By tightly receiving or discharging the rope it here understood that the liquid material ( 105 ) for impregnating the rope ( 101 ) which is stored in the tank ( 104 ) mainly flows from said tank ( 104 ) into the chamber ( 106 ) through the rope ( 101 ) between the fibers of said rope. The sealing means ( 110 ) preferably prevent the liquid material ( 105 ) to flow into the chamber ( 106 ) through an eventual opening between the sealing means and the inner wall of the rope-inlet or rope-outlet, respectively. By the term “mainly flows” is herein understood that leakages are acceptable wherein the liquid material can flow, percolate or exude through an eventual space between the sealing means and the surface of the rope. It was observed that such embodiment may enable the manufacturing of a rope which not only is well impregnated but also optimally coated.
In one embodiment, the sealing means are adapted such that the rope-inlet and the rope-outlet are hermetically receiving and hermetically discharging, respectively, the rope. By hermetically receiving or discharging the rope is herein understood that the flow of liquid material between the sealing means and the surface of the rope is prevented in order to force most of the liquid material to penetrate the rope. The advantage of such an embodiment is that an optimally impregnated rope may be obtained.
The skilled person knows how to obtain a tighter, e.g. hermetical, fitting or a looser fitting between the sealing means and the rope surface by for example utilizing various known embodiments of valves or sealing means but preferably those disclosed hereinabove.
It is further preferred that the sealing means does not deform the rope ( 101 ) to be impregnated, by for example exerting a compressing action on said rope ( 101 ), since such deformation may minimize or even close the interstices between the fibers forming the rope, impeding therefore the flow of the liquid material ( 105 ) inside the chamber ( 106 ) between the fibers of said rope. To avoid such deformation, the sealing means may be constructed out of a resilient material, however, flexible enough to ensure for a minimized deformation of the rope passing thereto. Example of suitable materials for constructing said sealing means include widely known thermoplastic and thermosetting materials, most preferred being ones manufactured from rubber-based materials, i.e. having elastic properties. It was also observed that a suitable construction of the sealing means, such as the one of the second preferred embodiment presented hereinbefore, may minimize the deformation of the rope ( 101 ) passing through the sealing means. Avoidance of rope deformations may be achieved for example by adjusting the height ( 110 - 6 ) of the inner protrusions ( 110 - 12 ) and/or their width ( 110 - 7 ) to ensure for enough flexibility thereof.
Preferably, the sealing means are halved, i.e. they contain two, preferably symmetrical, parts ( 110 - 51 ) and ( 110 - 52 ) which engage each other in a tight fit such that an eventual gap ( 110 - 5 ) between the parts is minimized. Such a construction allows for an optimum installation thereof.
According to the invention, the rope-inlet is positioned below the level ( 105 - 1 ) of the liquid material ( 105 ). Although this ensures an optimum flow of the liquid material ( 105 ) between the fibers of the rope ( 101 ), it is also envisaged that in case the rope ( 101 ) needs to be impregnated only partially, the rope-inlet may be at least partially immersed in said liquid material. Furthermore, although the rope-outlet is shown in FIG. 1-1 as positioned below the level ( 105 - 1 ) of the liquid material ( 105 ), it is to be understood that said rope-outlet may be also positioned above said level of the liquid material. Such an embodiment offers several advantages, such as a cleaner impregnation process for example.
The rope ( 101 ) is passed through the liquid material ( 105 ), through the impregnation unit ( 103 ) and then out of the tank ( 104 ) via a system of driven and/or idle belts, e.g. caterpillars, rollers and/or winches. It is preferred that during the impregnation process, the rope ( 101 ) is kept under a tension Σ, wherein the tension Σ is sufficient enough to at least keep said rope taut. When the rope ( 101 ) is passed continuously through the liquid material and impregnation unit, the tension Σ should be high enough to ensure a preferably constant haul of said rope during the impregnation process. Preferably, said tension Σ is low enough not to deform the rope to the extent that the flow of liquid material ( 105 ) from the tank ( 104 ) into the chamber ( 106 ) between the fibers of the rope ( 101 ) is impeded.
Any liquid material suitable for rope impregnation can be used in accordance with the present invention. For example melts of polymeric materials such as those used typically in injection molding processes can be used for impregnation; suitable examples thermoplastics, thermosets and elastomers, more in particular polyolefins and polyolefin copolymers such as polypropylenes and polyethylenes, e.g. low density polyethylene (LDPE); liquid crystal polymers; acrylonitrile butadiene styrene copolymers (ABS); styrene-acrylonitrile copolymers (SAN); polyvinyl acetate (PVA) and ethyl-vinylk acetate (EVA) polyacrylates; polyamides; polybutadienes; epoxies; polyimides; silicon- and fluorosilicone-based rubbers and the like. Also materials such as pitch, tar, asphalt, or other hydrocarbon or bituminous compounds may be used. Also liquid formulation such as suspensions of various solids into a liquid medium may be used. Preferably the liquid medium is water. Suitable examples of solid materials suitable for manufacturing said suspensions, and in particular water based suspensions, include polyurethanes, epoxies, waxes, rubbers and silicone based materials.
The liquid material needs also to be able to flow under the pressure difference Δ between two locations, e.g. from the tank inside the rope, through a narrow passage, e.g. the passage dictated by the voids, pores and interstices of the rope. It is known that the extent to which a rope is impregnated depends upon at least three factors, namely the porosity of the rope, i.e. the amount and size of voids, pores and interstices thereof; the flow behavior of the liquid material; and the time allowed for impregnation, i.e. the speed with which the rope passes through the impregnation device. The flow behavior of a liquid material depends on its viscosity or in other words, the less viscous the liquid material is the easier it flows. The viscosity of the liquid materials used in accordance with the invention can vary between wide ranges, e.g. between water-like viscosities for diluted water based suspensions to melt-like viscosities for melts of polymeric materials. It is to be understood that the viscosity is not the limiting factor for carrying out the present invention as even higher viscosity liquid materials can be forced between the fibers of a rope by applying a larger pressure difference Δ between the atmospheric pressure and the pressure of chamber ( 106 ) and/or by using ropes having larges interstices between the fibers thereof.
By rope it is understood an elongated body having a length much larger than its lateral dimensions of for example width and thickness or diameter. The rope to be used in accordance with the invention may have a cross-section which is rounded or polygonal or combination thereof. Preferably, ropes having an oblong cross-section or a circular cross-section are used in the present invention as it is easier to provide a tight fitting into the impregnation unit for such ropes. By diameter of the rope is herein understood the largest distance between two opposite locations on the periphery of a cross-section of the rope. The diameter of the rope used in accordance with the invention can vary between large limits, e.g. from diameters specific to fishing lines of less than 1 mm, to diameters specific to off-shore mooring lines of more than 200 mm and even more than 500 mm. Although not a limiting factor, it was observed that good results were obtained when said diameter of said rope is at least 10 mm, more preferably at least 20 mm, most preferably at least 30 mm. Also good impregnation was achieved for larger diameter ropes, i.e. ropes having a diameter of at least 80 mm, preferably at least 100 mm which otherwise are difficult to be impregnated with the known methods or even manually.
The rope is preferably passed through the impregnating unit ( 103 ) with a speed that is adjusted with due regard to the diameter and construction of the rope, the pressure difference applied and the characteristic of the liquid material. The skilled person can easily adjust said speed to achieve an optimum impregnation.
Preferably, the rope used in accordance with the invention is a non-impregnated rope, i.e. a rope which has not yet been subjected to an impregnation step or steps; or a rope which was subjected to a light impregnation. In other words, the preferred rope utilized herein is a rope which contains less than 10 wt % based on the total weight of the rope of components other than the fibres, more preferably less than 5 wt %, most preferably less than 1 wt %. It was observed that using such a rope may lead to better impregnation.
The rope used in accordance with the invention comprises a plurality of fibers and interstices between said fibers. Preferably the fibers are grouped or bundled into yarns which preferably are subsequently grouped or bundled into strands. Preferably the ropes used in accordance with the present invention comprise a plurality of strands, said strands comprising a plurality of yarns containing said fibers. Preferred constructions of ropes which entail the presence of interstices between the fibers of the rope include braided ropes and laid ropes. The tightness of the rope also determines the size of the interstices between the fibers forming thereof; the tighter the rope is the smaller the interstices may be. The tightness of the rope may be related for a braided rope to the braiding period and for a laid rope to the twist factor; whereas the smaller said braiding period or the larger said twist factor, the tighter the rope.
The fibers contained by the rope used in the present invention may be natural or synthetic fibers, i.e. fibers produced out of a natural or a synthetic material. Natural materials may include metals but also cotton, hemp, abaca, bamboo, coir, flax (linen), jute, kapok, kenaf, pina, raffia, ramie, sisal, wood. Also animal fibers may be used to produce the rope to be impregnated in accordance with the present invention such as alpaca, angora, byssus, camel hair, cashmere, catgut, silk, wool, yak and the like.
Preferably, the ropes used in the present invention are synthetic ropes, i.e. ropes containing synthetic fibers. Said synthetic ropes preferably contain at least 50 wt %, based on the total weight of the rope, synthetic fibers, more preferably at least 70 wt %, even more preferably at least 90 wt %, most preferably all fibers contained by said synthetic ropes are synthetic fibers. It was observed that by using such rope, the best impregnation results were achieved. By synthetic fibers are herein understood fibers manufactured out of a synthetic material such as cellulose, e.g. acetate, triacetate, rayon, but also polymeric materials. Preferably the synthetic fibers are manufactured from a polymer chosen from the group consisting of polyamides and polyaramides, e.g. poly(p-phenylene terephthalamide) (known as Kevlar®); poly(tetrafluoroethylene) (PTFE); poly{2,6-diimidazo-[4,5b-4′,5′e]pyridinylene-1,4(2,5-dihydroxy)phenylene} (known as M5); poly(p-phenylene-2, 6-benzobisoxazole) (PBO) (known as Zylon®); liquid crystal polymers (LCP); poly(hexamethyleneadipamide) (known as nylon 6,6), poly(4-aminobutyric acid) (known as nylon 6); polyesters, e.g. poly(ethylene terephthalate), poly(butylene terephthalate), and poly(1,4 cyclohexylidene dimethylene terephthalate); polyvinyl alcohols; and also polyolefins e.g. homopolymers and copolymers of polyethylene and/or polypropylene. The preferred synthetic fibers are polyaramide fibers and high or ultra high molecular weight polyethylene (HMWPE or UHMWPE) fibers. Preferably the HMWPE fibers are melt spun and the UHMWPE are gel spun, e.g. fibers manufactured by DSM Dyneema, NL. An example of a melt spinning process for producing melt spun HMWPE fibers is disclosed in EP 1,350,868
In a preferred embodiment, the rope used in the present invention contains UHMWPE fibers, more preferably gel spun UHMWPE fibers. Preferably the UHMWPE used to manufacture the UHMWPE fibers has an intrinsic viscosity (IV) of at least 3 dl/g, more preferably at least 4 dl/g, most preferably at least 5 dl/g. Preferably said IV is at most 40 dl/g, more preferably at most 25 dl/g, more preferably at most 15 dl/g. The IV may be determined according to ASTM D1601(2004) at 135° C. in decalin, the dissolution time being 16 hours, with BHT (Butylated Hydroxy Toluene) as anti-oxidant in an amount of 2 g/l solution, by extrapolating the viscosity as measured at different concentrations to zero concentration. Examples of gel spinning processes for the manufacturing of UHMWPE fibers are described in numerous publications, including EP 0205960 A, EP 0213208 A1, U.S. Pat. No. 4,413,110, GB 2042414 A, GB-A-2051667, EP 0200547 B1, EP 0472114 B1, WO 01/73173 A1, EP 1,699,954 and in “ Advanced Fibre Spinning Technology ”, Ed. T. Nakajima, Woodhead Publ. Ltd (1994), ISBN 185573 182 7.
The fibers contained by the rope used in the present invention may be continuous fibers, also referred to in the art as filaments, or discontinuous fibers, also referred to in the art as staple fibers.
The method of the invention may also contain a drying step when a liquid material containing volatile mediums is used, or a solidifying step when a liquid material which is a melt is used. It was observed that the rope coated with the method of the invention contained an optimum distribution of solids, i.e. the materials left in the rope after drying or solidifying, and/or may even contain a higher amount of solids.
Furthermore, the present invention allows for a simplification of the entire method and of the device for impregnation as well as simplified technical service thereof.
The invention also relates to a 1-step impregnated rope obtainable by the method of the invention.
By 1-step impregnated rope is herein understood a rope which is impregnated as produced, i.e. directly after being constructed. For example a process wherein a rope containing a plurality of strands is firstly open, i.e. the individual strands are spread apart, then immersed or dipped into a liquid material for impregnation and then reassembled into its initial form, is not a 1-step process but at least a 2-steps process wherein the rope first is opened and subsequently impregnated. In contradistinction with such a process, the method of the invention allows for a 1-step impregnation process since the rope is not firstly opened but used as produced.
The rope of the invention can be utilized in a variety of applications such as tugging, mooring, hoisting/lifting, installation, offshore, commercial fishing, sailing and yachting, forestry, arborists, diving, rescue and safety, station keeping, dredging, climbing/rappelling and sailing.
The invention will be further explained with the help of the following example and comparative experiment.
EXAMPLE
A rope having an essentially circular cross-section with an effective diameter of about 21 mm was braided from 12 principal strands, each principal strand containing 7 laid secondary strands, each secondary strand containing a bundle of 15 yarns having 1760 dtex and comprising UHMWPE fibers. The yarns were sold by DSM Dyneema, NL, under the name of Dyneema® SK75. The primary strands were braided with a braiding period of 150 mm. The secondary strands were twisted to form a primary strand with a twist factor of 15 twists per m. The yarns were twisted to form a secondary strand with a twist factor of 13 twists per m.
The rope was unwound from a coil and pulled through a tank containing a liquid material. The liquid material was a water dispersion and contained a liquid phase and a solid phase and had a viscosity of about 90 mPa*s (Brookfield viscosity, cup 1, 50 rpm, 25° C.). The solid phase amounted to about 50 wt % of the total weight of said liquid material.
From the tank, the rope entered an impregnation unit, which was completely submerged into the liquid material, through a rope-inlet and then it exited said impregnation unit through a rope-outlet. A hermetical seal was ensured between the rope and the impregnation unit by sealing means such as the ones depicted in FIG. 1-2B . The height and the width of the inner protrusions was adjusted to ensure for enough flexibility of said protrusions in order to avoid the rope being compressed, though to ensure a hermetical fitting with the rope and prevent the liquid material from oozing between the sealing means and the surface of the rope.
The rope was pulled through the impregnation unit with a linear speed of about 3 m/min while a vacuum pump connected to the vacuum outlet reduced the pressure inside the chamber of the impregnation unit to between −0.1 bar and −0.7 bar.
To avoid potential damages to the vacuum pump due to the excess of the liquid material in the chamber of the impregnation unit a buffer vessel was used. About 60 cm of rope was impregnated with the liquid material and after impregnation the rope was dried by allowing the liquid phase contained by the liquid material to evaporate.
The results are presented in Table.
Comparative Experiment
The rope of example 1 was coated dipping the rope into the liquid material and allowing said liquid material to diffuse into the rope. The results are presented in Table.
TABLE
Weight of the solid material in
Weight impregnated
the impregnated rope after
Pressure
sample after drying
drying
Sample
(bar)
(g)
(g/m)
(wt %)
Ex. 1
−0.5
157
265
52
−0.68
161
271
56
C. Ex.
N/A
125
231
33 | Methods for impregnating a liquid material into a rope are provided whereby a liquid material is provided in a tank which defines the liquid level in the tank. An impregnation unit containing a chamber at least partially immersed in the liquid material includes a vacuum-device operatively connected to the vacuum-outlet of the chamber so as to lower the pressure in the chamber below atmospheric pressure. The rope may therefore be passed through the liquid material in the tank and then inside and outside the chamber via the rope-inlet and rope-outlet of the chamber, while maintaining the pressure inside the chamber below the atmospheric pressure to thereby force the liquid material to fill at least part of the interstices between the fibers of the rope by penetrating between the fibers. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a nonvolatile semiconductor memory device, and in particular to a nonvolatile semiconductor memory device provided with a floating gate for storing data based on the state of a charge accumulated in the floating gate.
2. Description of the Related Art
Briefly referring to FIG. 16, a conventional nonvolatile semiconductor memory device of the above-mentioned type will be described. In FIG. 16, symbol SA denotes a sensing amplifier, YD denotes a decoder in a y direction, MC denotes a nonvolatile memory cell, WL1 through WLn denote word lines, BL1 through BLm denote bit lines, and SO denotes a source line for a plurality of nonvolatile memory cell sections including two memory cells MC. The word lines WL1 through WLn are selected by a decoder in an x direction (not shown) perpendicular to the y direction.
FIG. 17 is a circuit diagram of an example of the sensing amplifier SA. An input IN receives the potential of a bit line BLi (i=1, 2, . . . , m) which is selected from the bit lines BL1 through BLm. Symbol V REF is a prescribed reference potential. Symbol SS denotes a control signal. While the signal SS is low, precharging is performed; and while the signal SS is high, sensing is performed to output a signal DOUT representing memory data.
In such a nonvolatile semiconductor memory device, data is read using the phenomenon that the threshold voltage of a transistor provided in the nonvolatile memory cell changes in accordance with the level of the charge accumulated in a floating gate. In more detail, the voltage on the bit line BL is set to an arbitrary voltage level while the source line SO is grounded. When the voltage level of the word line WL is raised, the charge accumulated in the bit line BL flows out to the source side of the transistor and thus decreases. The threshold voltage of the transistor is determined based on the reduction level in the charge. Thus, data "1" or "0" is read out.
In the above-described circuit, the source line of the transistor should be grounded for reading data. This process requires the transistor to have a source diffusion region and a contact area for supplying a potential to the source diffusion region in a memory cell array. This enlarges the area of the nonvolatile memory device. Further, if the memory cell is in an excessive erase state, the threshold voltage of the transistor becomes negative, and thus a transistor in a memory cell connected to an unselected word line is turned on when the bit line BL is precharged to a prescribed level before the reading operation. Accordingly, it may be impossible to precharge the bit line BL properly, or wrong data may possibly be read since the transistor of the memory cell connected to an unselected word line is "ON" although the transistor of the memory cell connected to a selected word line is "OFF".
The above-mentioned problem will be described in more detail with reference to FIG. 16. An operation by which electrons are injected into a floating gate FG is referred as to a "program operation". By contrast, an operation by which electrons accumulated in the floating gate FG are discharged is referred as to an "erase operation". In the erase operation, it is difficult to control the amount of discharge to be equal to the amount of the accumulated electrons. If the amount of discharge is larger than the amount of the accumulated electrons, holes are generated in the floating gate FG. As the result, the threshold voltage of the transistor of the memory cell MC becomes negative. This state of the memory cell MC is referred to as the "excessive erase state". As an example, the case where the threshold voltages of memory cells A and B in FIG. 16 are normally 5 V and 0.5 V, respectively and the excessive erasure occurs to the memory cell B which results in the threshold voltage of the memory cell B becoming -1 V, is described. Even if the voltage on the WL2, which is connected to a control gate CG of the transistor in the memory cell B is 0 V, the source S and the drain D of the transistor in the memory cell B is electrically connected. That is, the transistor of the memory cell B is in an ON-state even if the memory cell B is in an unselected state. As the result, the level of the voltage applied to BL1 for reading date in the memory cell A is affected by a current through the memory cell B. Accordingly, the data stored in the memory cell A cannot be read correctly.
In order to solve such problems, circuits shown in Japanese Patent Publication No. 5-86675 (Japanese Laid-Open Patent Publication No. 59-147461) have been proposed. In a circuit shown in FIG. 2 of the above publication, when data is read out, the data is changed by carriers, such as hot electrons, which are generated in a floating gate by zener or avalanche breakdown. Accordingly, refreshing of the data is necessary despite the use of the circuit in a nonvolatile memory device. In a circuit shown in FIG. 4 of the above-described publication, a bit line also acts as a control gate, and thus two or more memory cells cannot be arranged on one bit line. In such a structure, data cannot be decoded in the direction of the control gate as is conventionally done, and therefore the memory cell arrays cannot be highly integrated.
SUMMARY OF THE INVENTION
A nonvolatile semiconductor memory device according to the present invention includes a semiconductor substrate; an insulation layer located on the semiconductor substrate; a plurality of memory cells arranged on the semiconductor substrate in a matrix with the insulation layer therebetween, the memory cells each including a floating gate located on the semiconductor substrate with the insulation layer therebetween, a control gate for forming a capacitance with the floating gate with the insulation layer interposed therebetween, an impurity diffusion region located in the semiconductor substrate and having an opposite conductivity to that of the semiconductor substrate, and a bit line connected to the impurity diffusion region; an application member for applying a control voltage for reading data from the memory cell to the control gate; and a determination member for determining data to be read from a plurality of sets of data and outputting the data. The determination member determines the data to be read, based on the difference in voltages on the bit line which is caused by the difference in the capacitances between the floating gate and the semiconductor substrate. The difference in the capacitances is caused by the difference in charge levels in the floating gate when the control voltage is applied to the control gate.
Thus, the invention described herein makes possible the advantage of providing a nonvolatile semiconductor memory device which requires no source diffusion region nor does it change data written in a memory cell during data reading.
This and other advantages of the present invention will become apparent to those skilled in the art upon reading and understanding the following detailed description with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a memory cell of a nonvolatile semiconductor memory device according to the present invention in a program state;
FIG. 2 is an equivalent circuit of the memory cell of the nonvolatile semiconductor memory device shown in FIG. 1 in the program state;
FIG. 3 is a cross sectional view of the memory cell of the nonvolatile semiconductor memory device shown in FIG. 1 in an erase state;
FIG. 4 is an equivalent circuit of the memory cell of the nonvolatile semiconductor memory device shown in FIG. 1 in the erase state;
FIG. 5 is a graph illustrating voltages at a control gate and a bit line over time during the data reading operation of the nonvolatile semiconductor memory device shown in FIG. 1;
FIG. 6 is a cross sectional view of a nonvolatile semiconductor memory device according to the present invention having a different structure from that of the device shown in FIG. 1;
FIG. 7 is a block diagram of a nonvolatile semiconductor memory device in a first example according to the present invention;
FIG. 8 is an enlarged cross sectional view of a memory cell of the nonvolatile semiconductor memory device shown in FIG. 7;
FIG. 9 is a diagram of a circuit for setting a reference potential in the nonvolatile semiconductor memory device shown in FIG. 7;
FIG. 10 is a block diagram of a nonvolatile semiconductor memory device in a second example according to the present invention;
FIG. 11 is a graph illustrating voltages at a control gate and a bit line over time during the data reading operation of the nonvolatile semiconductor memory device shown in FIG. 10;
FIG. 12 is a circuit diagram of the nonvolatile semiconductor memory device in accordance with the second example and a circuit diagram of a nonvolatile semiconductor memory device provided with select gates;
FIG. 13 is a cross sectional view of a memory cell of the nonvolatile semiconductor memory device shown in FIG. 10;
FIG. 14 is a block diagram of a nonvolatile semiconductor memory device in a third example according to the present invention;
FIG. 15 is a diagram of a circuit for generating a reference potential in the nonvolatile semiconductor memory device shown in FIG. 14;
FIG. 16 is a block diagram of a conventional nonvolatile semiconductor memory device; and
FIG. 17 is a circuit diagram of a sensing amplifier in the conventional nonvolatile semiconductor memory device shown in FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be described by way of illustrative examples with reference to the accompanying drawings.
Referring to FIGS. 1 through 5, the principle of the present invention will be described. FIG. 1 is a cross sectional view of a memory cell of a nonvolatile semiconductor memory device according to the present invention in a program state. FIG. 2 is an equivalent circuit of the memory cell in the program state. FIG. 3 is a cross sectional view of the memory cell of the nonvolatile semiconductor memory device in an erase state. FIG. 4 is an equivalent circuit of the memory cell in the erase state. FIG. 5 is a graph illustrating voltages at a control gate and a bit line over time during the data reading operation.
In FIGS. 1 and 3, symbol BL denotes a bit line, CG denotes a control gate (word line), FG denotes a floating gate, DR denotes an n-type drain diffusion region, I denotes an isolation area formed of, for example, SiO 2 , SUB denotes a p-type substrate formed of silicon, and the hatched area is an insulation layer. CHN in FIG. 3 denotes a conductive channel formed in a channel region. In FIGS. 2 and 4, symbol C CG-FG denotes a capacitance between the control gate CG and floating gate FG, C FG-DR denotes a capacitance between the floating gate FG and the drain diffusion region DR, CF FG-CHN denotes a capacitance between the floating gate FG and the conductive channel CHN and C PR denotes a parasitic capacitance of the bit line BL.
In the case where electrons are injected into the floating gate FG of the memory cell as is shown in FIG. 1 (program state), the conductive channel CHN (inversion layer) is not generated in the channel region below the floating gate FG. As a result, the capacitance between the floating gate FG and the substrate SUB is equal to the capacitance C FG-DR . When the voltage in the control gate CG changes by ΔV CG , the voltage on the bit line V BL1 in the program state changes by ΔV BL1 expressed by Equation (1).
ΔV.sub.BL1 =ΔV.sub.CG /{1+(1/C.sub.CG-FG +1/C.sub.FG-DR)C.sub.PR }. . . (1)
In the case where no electron is injected to the floating gate FG of the memory cell as is shown in FIG. 3 (erase state), a conductive channel CHN (inversion layer) is formed by excited electrons in the channel region below the floating gate FG. As a result, the capacitance between the floating gate FG and the substrate SUB is C FG-DR +C FG-CHN . When the voltage in the control gate CG changes by Δ CG , the voltage in the bit line V BL2 in the erase state is changed by ΔV BL2 expressed by Equation (2).
ΔV.sub.BL2 =ΔV.sub.CG /[1+{1/C.sub.CG-FG +1/(C.sub.FG-DR +C.sub.FG-CHN)}C.sub.PR ]. . . (2)
By comparison-amplifying the difference between ΔV BL1 and ΔV BL2 with a prescribed reference potential V REF which is internally determined, data "1" or "0" written in the memory can be read. The concept of such operation is shown in FIG. 5.
The control gate CG and the floating gate FG are not necessarily arranged as is shown in FIGS. 1 and 3. For example, as is shown in FIG. 6, it is possible to provide the control gate CG on the isolation region and the floating gate FG so as to cover the control gate CG and partially cover the drain diffusion region DR with an insulation layer interposed therebetween. In the arrangement shown in FIG. 6, the area of the floating gate FG can be larger than that of the floating gate FG shown in FIG. 1. This leads to wider process margin.
Hereinafter, practical examples according to the present invention will be described.
EXAMPLE 1
FIG. 7 is a block diagram illustrating a structure for a nonvolatile semiconductor memory device 1 in a first example according to the present invention. As is shown in FIG. 7, the nonvolatile semiconductor memory device 1 includes a sensing amplifier SA, decoders YD in a y direction, word lines WL1 through WLn, bit lines BL1 through BLm, nonvolatile memory cells MC, a writing circuit WC, an erasing circuit EC, and a backgate BG. The word lines WL are selected by a decoder in an x direction (not shown for simplicity).
FIG. 8 is a view illustrating the structure of a memory cell section each including two memory cells MC. As is shown in FIG. 8, each memory cell MC includes a control gate CG connected to the corresponding word line WL (FIG. 7) and a drain diffusion region DR connected to the corresponding bit line BL. Each memory cell MC may include a source diffusion region which is not connected to any line although the source diffusion region need not be formed in the memory cell MC.
The sensing amplifier SA has the same structure as is shown in FIG. 17.
In the case where a great number of electrons are accumulated in the floating gate FG in the memory cell MC as is shown in FIG. 1 (program state), during the time the control gate CG is in the off state, the conductive channel CHN (inversion layer) is not formed in the channel region. This is because holes are excited in the channel region. Accordingly, the capacitance between the floating gate FG and the substrate SUB is C FG-DR as is shown in FIG. 2. As a result, the voltage V BL1 on the bit line BL in the program state increases by ΔV BL1 expressed by Equation (1) in accordance with an increase in the voltage by ΔV CG in the word line WL connected to the control gate CG, as is illustrated in FIG. 5.
By contrast, in the case where no electrons are accumulated in the floating gate FG as is shown in FIG. 3 (erase state), during the time the control gate CG is in the off state, the conductive channel CHN (inversion layer) is formed in the channel region. This is because electrons are excited in the channel region. Accordingly, the capacitance between the floating gate FG and the substrate SUB is C FG-DR +C FG-CHN . As a result, the voltage V BL2 on the bit line BL in the erased state increases by ΔV BL2 as is expressed by Equation (2) in accordance with an increase in the voltage by ΔV CG in the word line WL connected to the control gate CG, as is illustrated in FIG. 5.
Accordingly, the voltage in the bit line BL increases in accordance with an increase in the voltage in the control gate CG by a larger level in the erase state (V BL2 ) than in the program state (V BL1 ). Utilizing such a phenomenon, by setting a reference potential V REF of the sensing amplifier SA to be midway between the potential in the program state and the potential in the erase state by resistance division or the like and comparison-amplifying the voltage in the bit line BL and the reference potential V REF , data written in the memory cell MC can be read. It may also be possible to read the data in the memory cell by detecting ΔV BL1 and ΔV BL2 .
FIG. 9 is a diagram of a circuit for setting the reference potential V REF . Values of resistances R 1 and R 2 are set so as to allow the value of V REF to be the same as described above.
In the nonvolatile semiconductor memory device 1 in this example, since the potential at the drain diffusion region DR is up to approximately 1 V, carrier generation caused by the zener or avalanche breakdown as occurs in the case of Japanese Patent Publication No. 5-86675 does not occur. Accordingly, written data does not change.
The lowest possible voltage to be applied to the control gate CG for data reading is determined by the sensitivity of the sensing amplifier SA. The highest possible voltage is determined by a withstand voltage of the insulating layer below the control gate CG and the floating gate FG. An optimum voltage in the range between the highest and the lowest voltages is applied to the control gate CG. The capacitances C CG-FG and C FG-DR can be controlled by the thickness of the respective insulating layer and the area of the respective gate electrode.
Data programming in a memory cell MC is performed by setting the voltage on the word line WL to be higher than the voltage on the bit line BL. For example, data is programmed in a selected memory cell in the following manner utilizing hot electrons. A voltage equal to or higher than a supply voltage is applied to the bit line BL which is decoded by the decoder YD, in the state where the voltage on the word line WL is at least twice of the supply voltage and the writing circuit WC is active. The substrate SUB is grounded or supplied with a prescribed negative potential. The supply voltage is usually approximately 5 V. In general, when the supply voltage is 5 V, the voltage on the word line WL is approximately 10 to 15 V, and the voltage on the bit line BL is 5 to 8 V. Impurity implantation to the drain diffusion region DR is needed in order to rapidly change the potential in the vicinity of the interface between the drain diffusion region DR and the channel region when the voltage is applied, namely, in order to generate a strong electric field so as to facilitate the generation of the hot electrons. This method can provide a relatively fast writing speed.
Data programming in the selected memory cell MC may also be performed by injecting electrons to the floating gate FG using a tunnel current in the state where the supply voltage is 5 V, the voltage on the word line WL is approximately 21 V, and the drain voltage in the selected memory cell is 0 V. The drain voltage in unselected memory cells is approximately 10 V. This method can provide data programming with a relatively small current.
The data in the memory cell MC is electrically erased by, for example, a source erasure method, a source and gate erasure method, and a substrate erasure method. By the source erasure method, for example, a voltage of 0 V is applied to the gate, and a voltage of 12 V is applied to the source. By the source and gate erasure method, for example, a voltage of -10 V is applied to the gate, and a voltage of 5 V is applied to the source. By the substrate erasure method, for example, a voltage of -18 V is applied to the gate. If the source is not provided, the data in the memory cell MC may be erased by applying the above-mentioned voltage to the drain instead of the source. Alternatively, data erasure is performed by irradiating UV to the memory cell to excite the electrons in the floating gate FG, thereby allowing the electrons to go beyond the energy barrier of the insulation layer as in the case of an EPROM and the like.
EXAMPLE 2
FIG. 10 is a block diagram of a nonvolatile semiconductor memory device 2 in a second example according to the present invention. In this example, the prescribed reference potential V REF is set using a dummy cell. In FIG. 10, symbol DMC denotes a dummy nonvolatile memory cell, and DBL denotes a dummy bit line. The two dummy nonvolatile memory cells form a dummy memory section. The level of the charge accumulated in a floating gate FG in the dummy memory cell DMC is set to be lower than the level of the charge injected to the floating gate FG of the memory cell MC by an internal circuit. Such setting is performed in advance by using an external device such as a device tester.
In the case where a great number of electrons are accumulated in the floating gate FG of the memory cell MC as is shown in FIG. 1 (program state), during the time the control gate CG is in the off state, a conductive channel CHN (inversion layer) is not formed in the channel region of the transistor of the memory cell MC. This is because holes are excited in the channel region. Accordingly, the capacitance between the control gate CG and the substrate SUB is C FG-DR as is shown in FIG. 2. As a result, the voltage V BL2 on the bit line BL in the program state increases by ΔV BL1 expressed by Equation (1) in accordance with an increase in the voltage by ΔV CG in the word line WL connected to the control gate CG connected. By contrast, in the case where no electrons are accumulated in the floating gate FG as is shown in FIG. 3 (erase state), during the time the control gate CG is in the off state, a conductive channel CHN (inversion layer) is formed in the channel region. This is because electrons are excited in the channel region. Accordingly, the capacitance between the floating gate FG and the substrate SUB is C FG-DR +C FG-CHN as is shown in FIG. 4. As a result, the voltage V BL2 on the bit line BL in the erase state increases by ΔV BL2 expressed by Equation (2) in accordance with an increase in the voltage by ΔV CG on the word line WL connected to the control gate CG. The voltage on the bit line BL increases more in the erase state than in the program state as is appreciated from FIG. 11. The reference voltage V REF of the sensing amplifier SA is set to be equal to the reading voltage of the dummy memory cell DMC via the dummy bit line DBL as is illustrated in FIG. 10. The level of the reading voltage of the dummy memory cell DMC is a function of the level of the charge accumulated in the floating gate FG in the dummy memory cell DMC. As is mentioned above, the level of the charge accumulated in the floating gate FG in the dummy memory cell DMC is set to be lower than the level of the charge injected to the floating gate FG of the memory cell MC by the internal circuit. Due to such a setting, as is shown in FIG. 11, the reading voltage of the dummy memory cell DMC is midway between the voltage V BL1 on the bit line BL in the program state and the voltage V BL2 on the bit line BL in the erase state. By comparing the levels of the voltages V DBL on the dummy bit line DBL and the voltages V BL1 and V BL2 on the bit line BL, the data written in the memory cell MC can be read. That is, the data in the memory cell MC can be determined by the result of detecting which one of the potential on the data line (V BL1 or V BL2 ) and the reference potential (V DBL ) is higher. This comparison operation can be conducted by using a sensing amplifier SA having the same structure as is shown in FIG. 17.
In the above-described method, the reading voltage of the dummy memory cell DMC is used as a reference voltage. Accordingly, the reading margin can be larger than the reading margin obtained by the method of comparison-amplifying the prescribed reference voltage, which is constant with time, obtained by resistance division and the voltage in the bit line BL. As a result, reading can be performed at a higher speed.
As is shown in FIG. 5, when the prescribed reference voltage V REF obtained by resistance division or the like is used as the reference voltage for reading data, the voltage V BL2 on the bit line BL in the erase state is lower than V REF as is the voltage V BL1 in the program state in an initial stage of reading. Accordingly, in the case where data is read based on the comparison result of the levels of the reference voltage V REF and the voltages V BL1 and V BL2 , the voltage V BL2 may be incorrectly read as the voltage V BL1 during the initial stage. By-contrast, when the voltage V DBL on the dummy bit line DBL is used as the reference voltage, the voltage V BL2 is higher than the reference voltage V DBL , from the start of reading as is shown in FIG. 11. Accordingly, there is no possibility that the voltage V BL2 is incorrectly read as the voltage V BL1 even if the reading speed is raised. Needless to say, it is possible to comparison-amplify the difference between the voltages V DBL and, V BL1 and V BL2 and to read the data based on the difference.
Data may be programmed into and erased from the memory cell MC in the same manner as described above with reference to FIG. 7. UV irradiation should not be used because UV erases the data stored in the dummy memory cell DMC.
In the first and the second examples, a nonvolatile semiconductor memory having an array structure is described. In such a case, a capacitance between the drain diffusion region and the floating gate of a memory cell which shares the bit line with the selected memory cell should also be considered. Such a capacitance changes in accordance with whether the device is in the program state or in the erase state. As a result, different bit lines BL have different levels of reading voltages. Accordingly, when the number of memory cells connected to one bit line BL is increased, a select gate SG for selecting the memory cell MC is needed between the drain diffusion region and the bit line BL of each memory section as is shown in FIG. 12. FIG. 13 shows a cross sectional view of the device shown in FIG. 12. As is shown in FIG. 13, the select gate SG can share the gate with the control gate CG of the memory cell MC which is selected by the select gate SG. Thus, provision of the select gate SG does not enlarge the area of the device. The select gate SG may alternatively be provided separately from the control gate CG, in which case, the select gate SG may be formed of the same material as the floating gate FG, for example, polysilicon.
Further, the area required for one datum can be reduced by storing "polynary" data (for example, quarternary, quinary, or senary data) in each memory cell MC.
EXAMPLE 3
FIG. 14 is a block diagram illustrating a structure for a nonvolatile semiconductor memory device 3 in a third example according to the present invention. As is shown in FIG. 14, the nonvolatile semiconductor memory device 3 includes sensing amplifiers SA1 through SAg, decoders YD in a y direction, memory cell sections each including two memory cells MC, word lines WL1 through WLn, bit lines BL1 through BLm, dummy bit lines DBL1 through DBLg, and dummy memory cell sections each including two dummy memory cells DMC. The word lines WL are selected by a decoder in an x direction (not shown for simplicity). A data writing circuit WC and a data erasure circuit EC are also omitted from FIG. 14. Data in the number of g+1 can be stored in one memory cell MC.
Each memory cell MC includes a control gate CG connected to the corresponding word line WL and a drain diffusion region DR connected to the corresponding bit line BL. Each dummy memory cell DMC also includes a control gate CG connected to the corresponding word line WL and a drain diffusion region DR connected to the corresponding dummy bit line DBL. Each memory cell MC and each dummy memory cell DMC may include a source diffusion region which is not connected to any line although the source diffusion region need not be included in the memory cell MC or the dummy memory cell DMC.
The dummy memory cells DMC connected to the same dummy bit line DBL are set to have an identical level of charge accumulated in the floating gates FG thereof. The dummy memory cells DMC connected to the same word line WL are set to have different amounts of electrons injected thereto in advance by using an external device such as a device tester or the like, so that different levels of reading voltages will be supplied to different dummy bit lines DBL1 through DBLg.
For example, in the case that the reading voltage of the dummy cells DMC supplied to dummy bit lines DBL are V DBL1 <V DBL2 <. . . <V DBLg <V ER (the voltage in the erase state) for reading data of the memory cell MC, the voltage in the erase state (V ER ) is higher than the voltage supplied to any dummy bit line DBL. As a result, all the outputs DOUT1 through DOUTg from all the sensing amplifiers SA1 through SAg are "1". In the case when data are programmed in the memory cells MC so that V DB1 <V BL <V DBL2 may be realized, only the output DOUT1 from the sensing amplifier SA1 is "1" and the other outputs are all "0". The data stored in the memory cell MC is read in the form of the number of the "1" data supplied from the corresponding sensing amplifier SA in accordance with the level of the reading voltage. Thus, polynary data can be read. That is, the polynary data is read based on the result of detecting whether each reference potential (V DBL1 -V DBLg ) is higher than the potential on the bit line (V BL ) which corresponds to charge accumulated on the floating gate FG in the memory cell MC. By providing an encoder or the like for receiving the outputs DOUT1 through DOUTg, binary codes having a prescribed number of bits (for example, a 2-bit binary code for quarternary data) can be obtained.
Data may be programmed into and erased from the memory cell MC in the same manner as described above with reference to FIG. 7. UV irradiation should not be used because UV erases the data stored in the dummy memory cell DMC. For dealing with polynary data, a select gate SG is preferably provided as is illustrated in FIG. 12 for the array structure because the voltage for comparison amplification is extremely small.
In the third example, a plurality of reference voltages (in this case, reference voltages in the number of g) are set using dummy memory cells. Such setting may also be performed by resistance division. FIG. 15 shows a circuit diagram for setting a plurality of reference voltages by resistance division. In FIG. 15, a plurality of resistances R 1 , R 2 , . . . , R g+1 having different resistance values are connected in series. A plurality of reference voltages V REF1 , V REF2 , . . . , V REFg are set by resistance division.
In a nonvolatile semiconductor memory device according to the present invention, when the voltage on the control gate of the memory cell is changed, the level of the charge accumulated on the floating gate of the memory cell changes. Accordingly, the capacitance between the floating gate and the semiconductor substrate changes, which causes a change in the voltage on the bit line. The change in the voltage on the bit line corresponds to the capacitance between the floating gate and the channel region. The level of change in the voltage on the bit line and the reference voltage which is set internally are comparison-amplified for reading data. Due to such a structure, a source diffusion region of the transistor of the memory cell is not necessary, which reduces the area of the memory device.
Since the source diffusion region is not grounded or no source diffusion region is provided, there is no current flowing through the transistor of the memory cell for reading data. Accordingly, incorrect data reading is avoided even if the data in the memory cell is excessively erased.
By storing polynary data in the memory cell in the form of capacitances between the control gate and the channel region of the transistor and comparing the capacitances and voltages in the memory cell having different levels, polynary data in the memory cell can be read. In this manner, an area required for one datum is further reduced.
Various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be broadly construed. | Disclosed is a nonvolatile semiconductor memory device, including a semiconductor substrate; an insulation layer located on the semiconductor substrate; and a plurality of memory cells arranged on the semiconductor substrate in a matrix with the insulation layer therebetween. The memory cells each includes a floating gate located on the semiconductor substrate with the insulation layer therebetween, a control gate for forming a capacitance with the floating gate with the insulation layer interposed therebetween, an impurity diffusion region located in the semiconductor substrate and having an opposite conductivity to that of the semiconductor substrate, and a bit line connected to the impurity diffusion region. The nonvolatile semiconductor memory device further includes an application device for applying a control voltage for reading data from the memory cell to the control gate; and a determination device for determining data to be read from a plurality of sets of data and outputting the data. The determination device determines the data to be read, based on the difference in voltages on the bit line in two different states of the memory cell. The difference in the voltages on the bit line is caused by the difference in the capacitances between the floating gate and the semiconductor substrate in the two different states of the memory cell. The difference in the capacitances is caused by the difference in charge levels in the floating gate when the control voltage is applied to the control gate in the two different states of the memory cell. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
In general, the present invention relates to systems that filter out adverse characteristics that may be present in a power transmission from a power supply. More particularly, the present invention relates to the systems that provide voltage surge protection, EMI/RFI protection and/or in-rush current suppression to a power transmission.
2. Prior Art Statement
The prior art is replete with different types of devices and circuits that filter out undesired electrical characteristics from an incoming source of electricity. In the United States of America, most every home and business is supplied with power from a utility company. Typically, the power supplied from the utility company passes through a transformer and is supplied to a building with an alternation current of 120 volts and a nominal frequency of 60 Hz. Although the power at the utility company is generated at these voltages and frequency values, the actual power received at a particular home or business can vary widely depending upon both how the power is transmitted and how the power is used.
Power transmission lines emanating from utility companies are commonly exposed to the elements as they travel from the utility company to a home or business. As such, the power transmission lines are subject to lightning strikes, interference from sun flares, storm damage and the like. All of these occurrences can create abnormalities in the characteristics of the power being transmitted in the transmission line. For example, a lightning strike in a power transmission line can create a large voltage spike in the power being transmitted. If this voltage spike is received by a home or business, the voltage spike can cause damage to many electronic items that experience the voltage spike. Alternatively, power can be disrupted if the spike causes a circuit breaker to trip.
Similarly, power transmission lines can receive electromagnetic interference (EMI) and/or radio frequency interference (RFI) from natural and manmade sources. The resulting EMI/RFI signals cause noise in the characteristics of the power transmission that can disrupt sensitive electronic circuits that receive such power transmissions.
Power transmissions with undesirable characteristics can also be created by the way power is used in a home or business. Many electronic devices draw a higher current when they are first turned on. This is because the circuits in the electronic device are cold and the capacitors in the circuits are not charged. However, soon after the circuit is powered, the current drawn by that circuit can decrease dramatically. As a result, when an electronic device is first turned on, there is an inrush of current, thereby causing a current spike. If multiple electrical devices are all turned on at once, the inrush current spike can be quite large and either cause a circuit breaker to trip or cause damage to the electronic components of those devices that experience the current spike.
In the prior art, there are many different filtering devices that are used to eliminate adverse characteristics from a power supply. However, many of these filters are designed to filter out only one type of adverse characteristic. For example, there are many types of commercially available surge protector items that can eliminate voltage spikes caused by lightning. Such prior art surge protectors are exemplified U.S. Pat. No. 4,870,534 to Harford, entitled Power Line Surge Protector. However, such prior art surge protection devices do not protect from EMI/RFI signal interference or incidents of inrush current.
Similarly, devices exist in the prior art record that are designed to filter EMI/RFI signal interference from power supplies. Such prior art filters are exemplified by U.S. Pat. No. 5,530,396 to Vlatkovic, entitled EMI Input Filter Power Factor Correction Circuits. However, such prior art devices do not filter out voltage surges or inrush current surges.
Lastly, devices exist in the prior art that are designed to eliminate inrush current surges. Such prior art devices are exemplified by U.S. Pat. No. 4,573,113 to Bauman, entitled Surge Protection System For A D-C Power Supply During Power-up, and U.S. Pat. No. 5,930,130 to Katyl, entitled Inrush Protection Circuit. However, such prior art devices do not filter out EMI/RFI signal interference or voltage surges.
A need therefore exists for an improved filtering system that is capable of eliminating voltage surges, EMI/RFI signal interference and inrush current spikes from a power source. This need is met by the present invention as described and claimed below.
SUMMARY OF THE INVENTION
The present invention is a system and method for conditioning a power transmission, thereby eliminating adverse characteristics from the power transmission. The system includes a voltage surge protector, an EMI/RFI filter and at least one inrush current suppressor integrally formed into a single system. To condition an incoming power transmission, the power transmission is first passed through the voltage surge protector to eliminate any abnormal voltage spikes. The power transmission is then passed through an improved EMI/RFI filter having a dual output. The outputs of the EMI/RFI filter lead into a first inrush current suppressor. The inrush current suppressor limits the amperage of the power transmission for a predetermined period of time and then permits unrestricted current flow. The inrush current suppressor also can be used as an on/off switch to stop the power transmission. The on/off state of the inrush current suppressor is dependent upon the receipt of an external control signal by the inrush current suppressor.
Electronic equipment receives the power transmission through the circuitry of the inrush current suppressor. Multiple inrush current suppressors can be arranged in a cascading system to power many different collections of electronic equipment. As one inrush current suppressor is activated, it generates a time delayed control signal that can be used to activate a subsequent inrush current suppressor. In this manner, different collections of equipment can be turned on in a controlled sequence that does not surpass the amperage rating of the circuit breaker through which the power transmission is passed.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference is made to the following description of exemplary embodiments thereof, considered in conjunction with the accompanying drawings, in which:
FIG. 1 is schematic of an exemplary embodiment of a power conditioning system in accordance with the present invention;
FIG. 2 is a schematic of an exemplary embodiment of an EMI/RFI filtering circuit for use in the present invention power conditioning system; and
FIG. 3 is a schematic of an exemplary embodiment of an inrush current suppressor circuit containing control circuitry for use in producing an automatically cascading system.
DETAILED DESCRIPTION OF THE INVENTION
Although the present invention power conditioning system can be created as internal circuitry within many different types of electronic equipment, the present invention power conditioning system is particularly well suited for use as a self-contained unit. In this manner, the present invention power conditioning system can be used to condition incoming electrical power and any separate electronic device can then be connected to the power conditioning system to receive the conditioned power. Accordingly, in the exemplary embodiment of the invention that is shown, the present invention power conditioning system is shown as a self-contained unit that is separate from the electronic equipment that receives electrical power through the power conditioning system.
Referring to FIG. 1, a schematic of the present invention power conditioning system 10 is shown. In the embodiment, the power conditioning system 10 is connected to utility power lines 12 and receives power from the local utility company 14 . The power conditioning system 10 removes adverse characteristics that may be present in the incoming electrical power transmission and presents the conditioned power to at least one output port 20 . The output port 20 can be the circuit breaker box of a building, thereby providing filtered power to every receptacle in the building. Alternatively, the output port 20 can be a single receptacle that supplies filtered power to a single piece of electrical equipment 22 that is plugged into the power conditioning system 10 .
In the power conditioning system 10 there are three types of circuits that are used to condition the power transmission received from the utility company 14 . Each type of circuit filters a particular adverse electrical characteristic from the received power. The first of the circuits, is a voltage surge protector 24 . The voltage surge protector circuit 24 eliminates voltage spikes in the received power transmission that may be caused by lightning strikes, shorted transformers or the like. In the prior art, there exist many different types of voltage surge protector circuits that can eliminate voltage spikes. Many of these prior art circuits can be adapted for use in the present invention filtering system. However, the surge protector circuitry found in U.S. Pat. No. 4,870,528 to Harford, entitled Power Line Surge Protector is particularly advantageous and is preferred in the exemplary embodiment of the invention. Accordingly, the disclosure of U.S. Pat. No. 4,870,528 to Harford is therefore incorporated into this specification by reference.
The second type of power condition circuit, embodied by the present invention system, includes an EMI/RFI filter 26 . The output of the voltage surge protector 24 is received by an EMI/RFI filter 26 . Due to the presence of the voltage surge protector 24 , any voltage spikes in the received power signal have been removed. However, EMI and/or RFI signal noise can still be present in the power signal. The EMI/RFI filter 26 reduces noise present in the power signal transmission that can be categorized as either electromagnetic interference or radio frequency interference. In the prior art, there exist many types of EMI/RFI filters. Many of these prior art filters can be adapted for use as part of the present invention power condition system 10 . However, a specific EMI/RFI filter 26 is preferred in the exemplary embodiment. This circuit will later be described with reference to FIG. 2 .
The output of the EMI/RFI filter 26 is then received by at least one inrush current suppressor 28 . It is the inrush current suppressor 28 that is the third power conditioning circuit of the present invention system 10 . As such, by the time the power transmission is received by the inrush current suppressor 28 , the power transmission has already been filtered of voltage spikes and EMI/RFI noise. At least one inrush current suppressor is present in the power conditioning system 10 . However, as is shown in FIG. 1, any plurality of separate inrush current suppressors 28 can be used. As will later be explained, the various inrush current suppressors 28 can be arranged in a cascading array. As such, each of inrush current suppressors 28 is activated after the previous inrush current suppressor 28 has finished powering up. In this manner, separated groupings of electronic equipment 22 can be kept on the same circuit without surpassing the amperage rating for that circuit when the various groupings of equipment are first turned on.
As is shown in FIG. 1, each inrush current suppressor 28 supplies power to a separate grouping of electronic equipment 22 . The first of the inrush current suppressors 28 may also be optionally coupled to a remote activation unit 30 . As will later be explained, the remote activation unit 30 enables the first of the inrush current suppressors 28 to be selectively activated when needed and/or desired.
Accordingly, the present invention power conditioning system 10 takes the power transmission from the utility company, removes voltage spikes, EMI/RFI noise and inrush current spikes prior to that power being presented to an electronic device 22 .
Referring now to FIG. 2, an exemplary embodiment of an EMI/RFI filter 26 is shown that can be used in the present invention power conditioning system 10 . The EMI/RFI filter 26 receives a power transmission from the voltage surge suppressor 24 (FIG. 1 ). The EMI/RFI filter 26 contains a mutual inductor 32 , sometimes referred to as a common-mode choke. The mutual inductor 32 provides mode attenuation to EMI noise and RFI noise. Two ferrite beads 34 , 36 are used on the leads that leave the mutual inductor 32 . The presence of the ferrite beads 34 , 36 provides series impedance to the power signal, thereby attenuating EMI noise and RFI noise. The presence of the ferrite beads 34 also prevents the EMI/RFI filter 26 from ringing and helps control filter characteristics. The EMI/RFI filter 26 also contains three capacitors. The first capacitor 37 is for when the filter is operating in normal mode, wherein the capacitor 37 provides low impedance to EMI noise and RFI noise. The second and third capacitors 38 , 39 are arranged across the outputs of the filter 26 and provide low impedance to EMI noise and RFI noise when the filter operates in a common mode.
The EMI/RFI filter 26 shown in FIG. 2 has two outputs 40 . These outputs 40 are received by the inrush current suppressor 28 , which is shown in FIG. 3 . Referring to FIG. 3, it will be understood that the output of the EMI/RFI filter 26 is 120 volts AC. However, EMI/RFI noise has been removed and voltage spikes have been eliminated. The outputs 40 of the EMI/RFI filter 26 are supplied to the inrush current suppressor at two points. At the first point, the incoming power passes into a first relay 42 . At the second point, the incoming power passes into a second relay 44 . If either the first or second relay 42 , 44 is closed, the power passes through to an output port 46 . It is this output port 46 that is coupled to external electronic equipment 22 (FIG. 1 ).
The operation of the first and second relays 42 , 44 is dependent upon an integrated control circuit containing three transistors 47 , 48 , 49 . The integrated control circuit has two control signal input ports 43 , 52 that are used to trigger the operation of the circuit. The first control signal input port 43 is coupled directly to the common DC voltage 50 . A first resistor 45 is disposed within the connection pathway. The second control signal input port 52 is coupled to the base of the first transistor 47 . A second resistor 51 is disposed in this pathway.
The collector of the first transistor 47 and the emitters of the second and third transistors 48 , 49 are connected to a common DC voltage 50 . A third resistor 53 is present between the base of the first transistor 47 and ground. A fourth resistor 54 is present between the collector of the first transistor 47 and the common DC voltage 50 .
The base of the second transistor 48 is coupled to the collector of the first transistor 47 . However, a first capacitor 55 and a fifth resistor 56 are positioned in series between these two points. A sixth resistor 57 is positioned between the base of the second transistor 48 and the DC voltage source 50 , wherein the sixth resistor 57 is in series with both the fifth resistor 56 and the first capacitor 55 .
The base of the third transistor 49 is coupled to the collector of the first transistor 47 . However, a seventh resistor 58 and an eighth resistor 59 are positioned in series between these two points. A ninth resistor 60 is positioned between the base of the third transistor 49 and the common DC voltage 50 , wherein the ninth resistor 60 is in series with both the seventh resistor 58 and the eighth resistor 59 . A second capacitor 61 is placed in parallel with the eighth and ninth resistors 59 , 60 , respectively.
The operation of the various transistors 47 , 48 , 49 and thus the first and second relays 42 , 44 are controlled by the selective application of a control input voltage. The control input voltage is received at the control signal input port 52 and can be between 5 volts and 30 volts DC. Alternatively, the circuit can be controlled by a contact closure between the first control signal input port 43 and the second control signal input port 52 , wherein the second control signal input port is directly coupled to the common DC voltage 50 .
When a control input voltage is received that is over 5 volts DC, the first relay 42 is energized and the power supply signal is transmitted directly from the input ports 40 to the output port 46 through a high energy surge resistor 62 .
When an appropriate voltage is applied to the control signal input port 52 , the voltage is immediately experienced by the second resistor 51 and the first transistor 47 is switched on. Once the first transistor 47 is switched on, the voltage at the fourth resistor 54 and seventh resistor 58 are pulled low. The first capacitor 55 is initially uncharged. Accordingly, when the first transistor 47 is turned on, the voltage across the fifth resistor 56 is pulled down. This turns on the second transistor 48 . The activation of the second transistor 48 enables the first rely 42 to be energized, thereby enabling electricity to flow from the first of the input ports 40 to the output port 46 . However, the AC current flowing through the first relay 42 passes through the high energy surge resistor 62 that limits the inrush current to a maximum of 25 amps.
Simultaneously, as the first transistor 47 turns on and the seventh resistor 58 is pulled low, the second capacitor 61 charges. The second capacitor 61 is initially uncharged and therefore prevents the voltage on the eighth resistor 59 from being pulled low. As the voltage on the eighth resistor 59 rises, the third transistor 49 turns on. However, this takes about one half of a second to occur. This period of time can be selectively adjusted between 0.1 seconds and 1.0 second by varying the values associated with the eighth resistor 59 and second capacitor 61 . Once the third transistor 49 is turned on, the second relay 44 is energized. When the second relay 44 is energized, the high energy surge resistor 62 is bypassed and current flows directly to the output port 46 unrestricted.
As the first capacitor 55 continues to charge, the voltage on the fifth resistor 56 rises. After between a one second and a five second delay, the second transistor 48 turns off. This de-energizes the first relay 42 , thereby disconnecting the high energy surge resistor 62 from the load. This protects the high energy surge resistor 62 from overheating or burning out should the second relay 44 fail to energize.
An optional third relay 70 can also be used within the circuitry of the power conditioning system 10 . The third relay 70 has a coil that is wired in parallel to the coil of the second relay 44 . Accordingly, when the third transistor 49 is activated, both the second relay 44 and the third relay 70 are energized. When the third relay 70 is energized, at least one new circuit is closed. A control voltage can be sent through the circuit that is closed by the third relay 70 . This circuit can be interconnected to the control signal input ports of a second inrush current suppressor circuit that is identical to the one shown in FIG. 3 . As has been previously described, the third transistor 49 does not activate until approximately one half second after the activation of the first transistor 47 . Accordingly, since the third relay 70 is controlled by the third transistor 49 , the third relay 70 does not energize until approximately a one half second delay has occurred.
By interconnecting the contacts of the third relay 70 of one inrush current suppressor 28 to the control signal input ports of a subsequent inrush current suppressor, a cascading system can be created. In the cascading system, any number of inrush current suppressors can be activated one after another with an approximate one half second delay in activations.
Referring back to FIG. 1, multiple inrush current suppressors 28 are shown to illustrate that any number of inrush current suppressors 28 can be arranged in a cascading system. However, since the inrush current suppressors 28 can be used to directly activate electronic equipment 22 , the activation of the first inrush current suppressor is preferably selectively controlled. It is for this reason that a remote activation unit 30 can be provided. The remote activation unit 30 can be a wall switch, a control panel switch or any other manually or remotely activated switch that can be selectively thrown by a user. Alternatively, the remote activation unit 30 can be any source capable of providing a DC voltage to the second control signal input port 52 of between 5 volts and thirty volts. Once the remote activation unit 30 is activated, the first inrush current suppressor 28 is activated and the subsequent inrush current suppressors are automatically activated by the cascading effect.
Returning to FIG. 1, the power condition system 10 is shown having three major circuits, which are the voltage surge protector 24 , the EMI/RFI filter 26 and the inrush current suppressor 28 . The use of all three circuits in the stated order is merely exemplary. The present power condition system 10 may include any two of the circuits. Accordingly, the power condition system 10 may include a voltage surge protector 28 with either an EMI/RFI filter 26 or an inrush current suppressor 26 . Similarly, the power condition system 10 may include an EMI/RFI filter 26 with either a voltage surge protector 24 or an inrush current suppressor 26 .
Furthermore, the sequence in which the various circuits are used in the power conditioning system 10 can be selectively altered. In FIG. 1, the incoming power passes through the voltage purge protector 24 , EMI/RFI filter 26 and then the inrush current suppressor. This sequence can be selectively changed into any alternate order.
It will be understood that the embodiments of the present invention system described and illustrated are merely exemplary and a person skilled in the art can make many variations to the shown embodiment. For example, a circuit designer can create many circuits that perform the same functions as the circuits specifically illustrated. All such alternate embodiments and modifications are intended to be included within the scope of the present invention as defined below in the claims. | A system and method for conditioning a power transmission, thereby eliminating adverse characteristics from the power transmission. The system selectively includes a voltage surge protector, an EMI/RFI filter and at least one inrush current suppressor integrally formed into a single system. To condition an incoming power transmission, the power transmission is passed through the voltage surge protector to eliminate any abnormal voltage spikes. The power transmission is then passed through an improved EMI/RFI filter having a dual output. The outputs of the EMI/RFI filter lead into a first inrush current suppressor. The inrush current suppressor limits the amperage of the power transmission for a predetermined period of time and then permits unrestricted current flow. | 7 |
REFERENCE TO PRIOR APPLICAITONS
This application is a continuation-in-part of copending application Ser. No. 735,443 filed May 17, 1985, now U.S. Pat. No. 4,610,888 of co-inventors James Teng and John H. Dokos.
BACKGROUND OF THE INVENTION
The invention relates to the field of beer dispensing and beer dispensing apparatus and, in particular, relates to a faucet for stabilizing foam draft beer as it is dispensed.
In the art of making beer, it is very important that the appearance of the beer in the glass be attractive to the user. While flavor is the aspect most talked about in beer, appearance is the first thing noticed by the customer and that makes it important. The shade and depth of color, the clarity, beading, type of head foam, the foam retention, and the foam cling, all contribute to making the initial impression. It is desirable that the foam atop a glass of beer dispensed from a faucet be smooth, creamy, be relatively stable and have an attractive taste. The incorporation of air into beer as it is dispensed at the faucet spout gives a head of very fine bubbles with excellent stability and a creamy slightly sweet desirable taste.
In application Ser. No. 735,443, there is disclosed a process and apparatus for incorporating air into beer after it leaves a conventional faucet spout by passing the beer through a perforated plate with small openings which break up the beer into smaller high velocity streams which pull air into the beer streams utilizing a Venturi effect. The pressure drop across the perforated plate starts the foaming process and the mixed beer, CO 2 foam, and air is then passed through a screen to form small stable bubbles which result in the desired smooth, creamy and stable foam.
In Ser. No. 735,443 there is described the history of the efforts to dispense Irish stout and English beer with a desired head. These procedures were not totally successful, and some use nitrogen which result in additional expense. Several of the processes require the use of high pressure kegs, which, in turn, necessitates heavier duty installation in the pub.
Currently there are on the market so-called push back foam causing faucets, which work on the principle of restricting the beer at the valve seat, usually through on or two apertures on the shaft. These devices are believed to operate on the foaming caused by the pressure drop across the shaft wall and do not incorporate additional air or nitrogen into the foam.
These type devices, moreover, are not capable of producing a satisfactory type foam on the new light beers. The foam does not form a tight head and the foam "falls off", i.e., it goes flat quickly.
Accordingly, it is a principal object of this invention to provide a dispensing faucet which when in a first position will dispense flat beer and when in a second position will dispense a smooth, creamy and stable foam.
Furthermore, it is an object of this invention to provide a faucet which will dispense a stable, thick foam on a conventional "light-type" beer.
It is another important object of this invention to provide a beer dispensing faucet in which air is drawn into a stream of finely divided jets of beer, turbulence in the stream is created to mix the air into the beer, and a beer foam is dispensed which is comprised of bubbles of very small diameter, which foam is extremely stable over a period of time. This faucet is capable of creating this foam even with the light-type beers presently sold in this country. This faucet also is capable of dispensing flat beer so that the single faucet can dispense a glass of beer having a head of a smooth, creamy foam which is stable and long lasting.
These and other objects and advantages will become apparent in the drawings and description hereinafter set forth.
SUMMARY OF THE INVENTION
This invention comprises an apparatus for forming a stable, creamy foam from a malt beverage utilizing a unique dispensing faucet capable of dispensing flat beer and of incorporating air into the beer in the faucet prior to entering the receptacle from which it is to be drunk.
DESCRIPTION OF THE DRAWINGS
In the drawings where like numerals refer to like parts wherever they occur FIG. 1 is a vertical partly sectional view of the dispensing faucet of this invention at the shut-off position;
FIG. 2 is a view similar to FIG. 1 except that the valve is in full forward open position to dispense flat beer;
FIG. 3 is a view similar to FIGS. 1 and 2 except that the valve is in its full backward position to dispense a stable, creamy foam;
FIG. 4 is a plan view, partly in section of the faucet shaft of this invention; and
FIG. 5 is a sectional view taken along line 5--5 of FIG. 4.
DETAILED DESCRIPTION
It is the general practice and custom in the brewing industry to exclude all possible air from contact with beer because of the known oxidizing effect of air on beer. Oxygen, when in contact with beer for periods of time, tends to cause off flavors, etc. Accordingly, the incorporation of air into beer is contrary to present practices, but when added immediately prior to the beer entering the glass, the known deleterious effects are avoided.
CONSTRUCTION
FIG. 1 shows the beer dispensing faucet 10 of this invention in its "off" position. The faucet 10 consists of a body 11, an actuator handle 12 and a faucet shaft 13.
The body 11 includes an enlarged chamber 14 connected to a supply of pressurized malt beverage and terminating in an internal shoulder 15 which functions as a valve seal for the valve seat 16, which is made from an elastomeric material. Connected to the shoulder 15 is a reduced main passage 17 which includes a guide chamber 18 for a cylindrical end member 19 of the faucet shaft 13. A discharge port 20 intersects the main passage 17 at approximately a 60° angle and allows the malt beverage to flow from the faucet 10.
The faucet shaft 13 comprises a stem 25 (shown in FIGS. 4 and 5) which includes the cylindrical guide member 19 which fits loosely in the faucet chamber 18 and reciprocates back and forth therein and serves to align the shaft mechanism 13 in the body 11. A reduced shaft 26 connects the guide member 19 to a valve seat retaining flange 27 which is a critical and essential feature of this invention. The flange 27 reciprocates freely in the main passage 17 and is provided with a series of homogenizing passages 28 around its periphery. The openings 28 are from 0.010 to 0.040 inches in diameter.
Connected to the rear face 29 of the flange 27 is a tubular member 30 which has an internal passage 31 terminating in the flange rear face 29. The tubular member 30 has a reduced circumferential area 32 adjacent to the flange rear face 29 which contains two ports 33 connecting the reduced area 32 to the internal passage 31. An enlarged spring retainer bearing area 34 connects to the reduced portion and terminates in a threaded portion 35.
Referring back to FIG. 1, the faucet shaft 13 further includes the valve seat 16 which is mounted on a spring retainer 36. The spring retainer 36 is longitudinally slidably positioned on the valve stem bearing area 34 and has a circumferential flange 37 which separates a return spring 38 from the seat 16. An end cap 39 is threaded onto the faucet shaft threaded portion 35 and retains the spring 38 on the stem 25. The end cap 39 has a throughbore 40 which connects to the stem passage 31.
The handle 12 is loosely positioned in an elongated opening 45 in the body 11. An end 12a of the handle 12 is loosely positioned in a slot 46 in the faucet shaft cylindrical guide member 19. Longitudinal movement of the handle 12 moves the stem 25 through the positions of FIGS. 1, 2 and 3, i.e., from shut-off (FIG. 1) to flat beer dispensing (FIG. 2) to foam dispensing (FIG. 3) positions.
The body 11 also includes one or more vents 47 to admit air (along with the air which enters through the loose fit of the faucet shaft guide member 19 in the body chamber 18) to the body interior 17,20 where it is mixed with beer when the faucet shaft 13 is in the position of FIG. 3.
OPERATION
The faucet 10 is designed to dispense flat beer from the position of FIG. 2 and to dispense a thick, creamy foam which is stable (even when light-type beers are being dispensed) from the position of FIG. 3.
FIG. 1 shows the tap in its shut-off position. The handle 12 is in its vertical or neutral position with the valve seat 16 seated against the internal shoulder 15. This seals the main passage 17 from the enlarged chamber 14 which is connected to beer supply. Accordingly, no beer can pass the valve seat 16 and enter the dispensing port 20.
To dispense regular or flat beer, the handle 12 is pulled forward (toward the left in FIGS. 1, 2 and 3) to shift the faucet shaft 13 longitudinally toward the right to the position shown in FIG. 2. In this position, the valve seat 16 is moved away from the shoulder 15 to open a passageway 48 therebetween (FIG. 2). This allows beer to flow unimpededly from the beer source in the chamber 14, through the passage 48, along the main passage 17, and out the dispensing port 20. This flow is depicted by the arrow "A" in FIG. 2.
When it is desired to dispense foam, the handle 12 is moved backward to the position of FIG. 3, which shifts the stem 25 longitudinally to the left. This engages the valve seat 16 in sealing engagement with the shoulder 15. The end cap 39 compresses the return spring 38 against the spring retainer 36. The tubular member 30 moves longitudinally leftward to open a cylindrical chamber to the flow of beer through the internal 31 and the ports 33. The ports 33 have a size of from about 0.02 to about 0.06 inches in diameter. The beer in this chamber (designated by the numeral 50 in FIG. 3) has less pressure than the 12-15 p.s.i. of the beer in the storage receptacle because of the pressure drop across the ports 33. The beer in the chamber 50 is forced through the orifices 28 in the valve seat retaining flange 27 at increased velocity as the orifices 28 are smaller in diameter than the ports 33. From the orifices 28, the beer moves into the main passage 17 where it draws air through the vents 47 by a Venturi type effect. Air also enters the main passage 17 beside the loose fit of the faucet shaft guide 19 in the body chamber 18. When the beer is forced around the turn from the main passage 17 into the dispensing port 20, it is intimately mixed with the air and the foam is formed into small stable bubbles which deposit a smooth, creamy, stable head on a glass of flat beer. The beer flow is indicated diagrammatically by the arrows "B" in FIG. 3.
To stop the formation of foam, the valve mechanism, is returned to the positions of FIGS. 1 or 2.
Thus, it is seen that the present invention achieves all of the objectives and advantages sought theretofore. This application is intended to cover all changes and modifications and variations of the examples herein chosen for purposes of the disclosure which do not constitute departures from the spirit and scope of the invention. | A faucet for dispensing flat malt beverage and a smooth, creamy and stable foam having a shiftable faucet shaft which in one position dispenses flat beer and in a second position provides an alternate flow path through restricted orifices which increase the velocity of the malt beverage so that it draws air into the faucet housing through orifices therein and incorporates the air into the foam to dispense a stable, creamy foam from the faucet discharge port. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. non-provisional application Ser. No. 13/024,292, filed on Feb. 9, 2011, which claims priority to U.S. Ser. No. 61/374,213 filed on Aug. 16, 2010, U.S. Ser. No. 13/023,467 filed on Feb. 8, 2011 and Republic of China Patent Application No. 099104551 filed on Feb. 12, 2010, commonly assigned, and hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus and method for purifying materials. More particularly, the present invention relates to a method and system for purifying metallurgical silicon fields to produce raw materials suitable for manufacturing single crystal silicon ingots and poly crystal silicon ingots for solar cells at a lower cost. Although the above has been described in terms of purifying silicon, it can be applied to other applications.
Conventional polysilicon silicon material used for manufacturing solar cells is often produced by the so-called Siemens process. Such process is well established, stable, and produces silicon with certain quality for manufacturing solar cells. The Siemens process, however, has limitations. That is, the Siemens' process, due to the nature of its manufacturing process, is difficult to adjust and has failed to meet the dramatic increase in demand and the need for lower prices over the past few years. In addition, it involves use of poisonous raw materials such as HCl and SiHCl 3 during the manufacturing process and produces a poisonous by-product, SiCl 4 . These materials are also highly explosive. The Siemens process is also dangerous and not environmentally friendly.
Alternatively, silicon purification methods that use metallurgy have been proposed. Such purification methods, however, have limitations. That is, such methods have not been able to achieve production scale. Certain other efforts have been achieved using metallurgy techniques. Unfortunately, the ability to scale of the equipment for such techniques is enormous, and thus the production costs are still high. These and other limitations may be overcome by the present techniques described throughout the present specification and more particularly below.
From the above, it is seen that improved techniques for producing silicon are highly desired.
SUMMARY OF THE INVENTION
The present invention relates to an apparatus and method for purifying materials. More particularly, the present invention relates to a method and system for purifying metallurgical silicon fields to produce raw materials suitable for manufacturing single crystal silicon ingots and poly crystal silicon ingots for solar cells at a lower cost. Although the above has been described in terms of purifying silicon, it can be applied to other applications.
The manufacturing methods mentioned above produce silicon with quality high enough for solar cells. But with increasing demands for cleaner and more flexible production, lower cost, and mass production capability, the conventional method has limitations. Depending upon the embodiment, one or more of these limitations may be overcome.
In a specific embodiment, the present invention provides a system for forming high quality silicon material, e.g., polysilicon. In a specific embodiment, the melted material comprises a silicon material and an impurity, e.g., phosphorous species. The system includes a crucible having an interior region. In a specific embodiment, the crucible is made of a suitable material such as a quartz material or others. The quartz material is capable of withstanding a temperature of at least 1400 Degrees Celsius for processing silicon. In a specific embodiment, the crucible is configured in an upright position and has an open region to expose a melted material. In a specific embodiment, the present system has an energy source. Such energy source may be an arc heater or other suitable heating device, including multiple heating devices, which may be the same or different. The arc heater is configured above the open region and spaced by a gap between the exposed melted material and a muzzle region of the arc heater to cause formation of a determined temperature profile within a vicinity of a center region of the exposed melted material while maintaining outer regions of the melted material at a temperature below a melting point of the quartz material of the crucible. In a specific embodiment, the system produces a melted material comprising a resulting phosphorous species of 0.1 ppm and less, which is purified silicon.
In a specific embodiment, the present invention provides a method for forming high quality silicon material, e.g., polysilicon. The method includes transferring a raw silicon material in a crucible having an interior region. The crucible is made of a quartz or other suitable material, which is capable of withstanding a temperature of at least 1400 Degrees Celsius. The method includes subjecting the raw silicon material in the crucible to thermal energy to cause the raw silicon material to be melted into a liquid state to form a melted material at a temperature of less than about 1400 Degrees Celsius. Preferably, the melted material has an exposed region bounded by the interior region of the crucible. The method also includes subjecting an exposed inner region of the melted material to an energy source comprising an arc heater configured above the exposed region and spaced by a gap between the exposed region and a muzzle region of the arc heater to cause formation of determined temperature profile within a vicinity of an inner region of the exposed melted material while maintaining outer regions of the melted material at a temperature below a melting point of the quartz material of the crucible. Preferably, the method removes one or more impurities from the melted material to form a higher purity silicon material in the crucible.
In a specific embodiment, the arc heater is a plasma gun configured to emit an excited argon species to cause thermal transfer to a portion of the melted material. In a specific embodiment, the arc heater is configured to subject a selected portion of the exposed region of the melted material. The arc heater is configured with a thermal transfer device to cause cooling of the arc heater. In a specific embodiment, the arc heater is capable of being ignited by a source. Preferably, the arc heater comprises a power rating of 20 kWatt and greater and capable of being pulsed according to a duty cycle of about 30%˜50%, and others. For example: 30% duty cycle means 30% on, then 70% off, which is interpreted by one of ordinary skill in the art. In a specific embodiment, the muzzle region has a maximum dimension of about 0.5 centimeters to about 2 centimeters. Of course, there can be other variations, modifications, and alternatives.
In a specific embodiment, the temperature profile is determined to achieve a certain result. That is the temperature profile is a maximum temperature profile greater than about 3000 Degrees to cause removal of phosphorous entities from the melted material. In a preferred embodiment, such temperature has been important to remove any phosphorous impurities and/or entities from a silicon material melt. In a specific embodiment, the melted material within the crucible is characterized by a convective flow caused by a temperature gradient formed by at least the maximum temperature profile and lower temperatures within a vicinity of edges of the melted material. In a specific embodiment, the convective flow causes a mixing within the melted material. In a preferred embodiment, the flow is also turbulent to facilitate mixing within the melted material.
In a preferred embodiment, the system and method also have a nozzle region configured to output argon gas to cause a dimple region within a vicinity of the center region of the melted material. In one or more embodiments, the nozzle region is a plurality of nozzles or the like. In a specific embodiment, the dimple region provides an increased surface region for a plume to interact with the melted material; wherein the dimple region has a depth of at least one centimeter and greater. Preferably, the increased surface region is at least three times greater than a surface region without the dimple region or more preferably, the increased surface region is at least five times greater than a surface region without the dimple region. As an example of silicon, the melted material comprises a viscosity of 0.7 Pascal-second, which may be slightly more or less. In a preferred embodiment, the argon gas comprises a flow rate of 5 l/min to 20 l/min. In a specific embodiment, the gas impinging on the melted material forms the dimple region that is characterized by a plurality of recessed regions each of which is separated by an elevated region. In a specific embodiment, the nozzle region coupled to the argon gas source is made of a ceramic material. Preferably, the argon gas source is operable independent from operation of energy of the arc tube. In a preferred embodiment, the argon gas source is 99.99% purity and greater. In other embodiments, other suitable gases that are non-reactive may be used. Of course, there can be other variations, modifications, and alternatives.
In a preferred embodiment, the present system and method use a cover gas or pressing gas to enclose a substantial portion of the melted material within the crucible. That is, the crucible is subject to a cover gas to maintain the melted material within the crucible. In a preferred embodiment, the crucible is subject to an argon containing cover gas or other suitable inert gas or gases to maintain the melted material within the crucible. Preferably, the cover gas is suitable to maintain the melted material free from oxidation or other undesirable conditions. The cover gas is provided within a chamber and/or housing enclosing the crucible. Of course, there can be other variations, modifications, and alternatives.
In a preferred embodiment, the system and method also include a carrier gas configured to cause a portion of evaporated melted material to return to the melted material. In a specific embodiment, the carrier gas can be argon or other inert gas, which is suitable to return any evaporated melted material consisting of silicon entities back into the melted material. In a specific embodiment, the system includes a plurality of surface regions configured to cause a substantial portion of a phosphorus species to be exhausted while returning a substantial portion of silicon species into the melted material. Preferably, the surface regions comprise a plurality of fin regions configured to cause a substantial portion of a phosphorus species to be exhausted while returning a substantial portion of silicon species into the melted material. Of course, there can be other variations, modifications, and alternatives.
In other embodiments, the present invention includes an apparatus for purifying metallurgical silicon that overcomes limitations of conventional techniques. In a specific embodiment, the present method and system modify a conventional single crystal silicon puller apparatus, which usually includes a vessel, a crucible, a crucible support and a heater. By implementing at least one of the following means in the existing apparatus, purification of metallurgical silicon is performed using one, some or all of the devices simultaneously:
an independent injecting device provided above the crucible for providing plasma, gases and chemicals required for purifying in a high-speed jet flow to the surface of a silicon melt, and forming a dimple on the surface of the silicon melt by its supplying tubes, and in cooperation with a temperature profile across the silicon melt due to a temperature gradient, facilitating heat circulation and increasing the circulation inversion radius, as well as increasing the contact area between the purifying gases and chemicals and the silicon melt, thereby increasing purification efficiency;
a guiding element with fins thereon, provided above the silicon melt in the crucible at an appropriate location with respect to the crucible and the supplying tubes for supplying the purifying gases and chemicals, for guiding damped gas flow rising from the surface of the silicon melt as a result of heating of the silicon melt back to the surface of the silicon melt, so that the damped gases effectively contact the silicon melt, wherein the distance between the guiding element and the surface of the silicon melt, the distance between the fins and the silicon melt, and the distance between the interior circumference of the crucible and the fins are critical;
a manipulating device provided underneath the vessel for vertically and horizontally shifting and rotating the crucible with respect to the heater to adjust the solidus-liquidus interface to obtain one-directional cooling purification without the need for temperature segregation coefficient management of the concentration of remaining impurities in the silicon melt with respect to the solidus-liquidus line, therefore allowing effective backflow of the damped gases and controlling the form of the dimple created by the jet flow from the injecting device on the surface of the silicon melt by adjusting the distance between the crucible and the guiding element, wherein a set of valves capable of horizontal shifting is further provided in the manipulating device in order to reduce reactions of carbon parts with oxygen when the crucible is taken out or inserted into the vessel by opening/closing the vessel; and
a vacuum pump provided to regulate the pressure or degree of vacuum inside the vessel and to accommodate evaporating conditions for various impurities.
According to a specific embodiment, the present technique overcomes some or all of these limitations by adding simple structures such as an independent gas and chemical injecting device, a crucible shifting manipulating device, a gas flow guiding element, and a vacuum pump to regulate the pressure inside the vessel, so that with these small modifications, purification efficiency can be improved. Meanwhile, the apparatus is simple, is easy to maintain, is with small modifications to an existing single crystal silicon puller apparatus, and has a short building time; therefore, the cost can be reduced, and mass production is possible. In addition, the apparatus of the present technique does not use poisonous raw materials and produces no poisonous by-products, while ensuring the safety of the purification process.
According to a specific embodiment, the present invention provides an apparatus for purifying metallurgical silicon obtained by modifying an existing single crystal silicon puller apparatus including a vessel, a crucible, a crucible support and a heater. The apparatus includes one, some, or all of the following devices for the purification of metallurgical silicon: an independent injecting device above the crucible for providing plasma, gases and chemicals required for purifying in a high-speed jet flow to the surface of a silicon melt; a guiding element above the silicon melt in the crucible at an appropriate location for guiding gas coming from the surface of the silicon melt back to the surface of the silicon melt; a manipulating device underneath the vessel for vertically and horizontally shifting and rotating the crucible with respect to the heater and the guiding element to obtain optimum purification efficiency; and a vacuum pump to regulate the pressure or degree of vacuum inside the vessel and to accommodate evaporating conditions for various impurities.
Many benefits are achieved by way of the present invention over conventional techniques. For example, the present technique provides an easy to use process that relies upon conventional technology. In some embodiments, the method provides highly purified silicon material using a modular approach. In preferred embodiments, the present method and system uses one or more of (1) nozzle for gas in making dimple region(s) in the melted material; (2) cover gas or environment for maintaining the melted material; and (3) carrier gas or environment for returning vaporized melted material back into the melt. Additionally, the method provides a process and system that are compatible with conventional process technology without substantial modifications to conventional equipment and processes. Depending upon the embodiment, one or more of these benefits may be achieved. These and other benefits will be described in more throughout the present specification and more particularly below.
Various additional objects, features and advantages of the present invention can be more fully appreciated with reference to the detailed description and accompanying drawings that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more fully understood by reading the following detailed description of the preferred embodiments, with reference made to the accompanying drawings, wherein:
FIG. 1 is a cross-sectional diagram depicting a simplified traditional apparatus for growing single crystal silicon ingots.
FIG. 2 is a cross-sectional diagram depicting a first embodiment of a modified apparatus of the present invention.
FIG. 3 is a cross-sectional diagram depicting a second embodiment of a modified apparatus of the present invention for easy transportation of a crucible.
FIG. 4 is a cross-sectional diagram depicting inserting/removing the crucible into/from the vessel of FIG. 3 .
FIG. 5 is a cross-sectional diagram depicting the end of a tube for a purifying material supplying system of the present invention.
FIG. 6 is a cross-sectional diagram depicting a plurality of tubes for a purifying material supplying system of the present invention.
FIG. 7 is a cross-sectional diagram depicting a guiding element of the present invention.
FIG. 8 is a cross-sectional diagram depicting gas flow of a plasma arc heater in an apparatus of the present invention.
FIG. 9 is a schematic diagram illustrating a dimple and circulation of a silicon melt caused by a plasma arc heater and high-pressure gases of the present invention.
FIG. 10 is a schematic diagram illustrating the positional relationship of the injecting device and guiding element inside an apparatus of the present invention.
FIG. 11 is a schematic diagram illustrating arrangements of a plurality of arc heaters of the present invention.
FIG. 12 is a schematic diagram illustrating positions of a plurality of injecting device with respect to a crucible of the present invention.
FIG. 13 is a schematic diagram illustrating a dimple region on a center of the surface of a silicon melt caused by a plurality of plasma arc heaters of the present invention.
FIG. 14 is a simplified diagram of a pulling apparatus according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention relates to an apparatus and method for purifying materials. More particularly, the present invention relates to a method and system for purifying metallurgical silicon fields to produce raw materials suitable for manufacturing single crystal silicon ingots and poly crystal silicon ingots for solar cells at a lower cost. Although the above has been described in terms of purifying silicon, it can be applied to other applications.
The implementations of the present invention are described using the embodiments below.
FIG. 1 is a cross-sectional diagram depicting a simplified apparatus typical for growing single crystal silicon ingot. This diagram is merely an example, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize other variations, modifications, and alternatives. In the diagram, reference number 1 indicates a vessel, 2 a crucible support, 3 a crucible manipulating device, 4 a heater, and 5 a crucible. Quartz crucible 5 in vessel 1 is supported by crucible support 2 made of low-density thermo material to prevent cracking of crucible 5 due to thermal creep during the silicon purification process. Crucible 5 is placed inside heater 4 , which radiates heat and produces a thermal field in vessel 1 to melt the silicon raw material in crucible 5 , thereby producing silicon melt. The silicon melt absorbs the heat radiated from heater 4 and dissipates heat from its surface or propagates heat to a growing ingot (not shown) via the solidus-liquidus interface and dissipates heat from the ingot surface, producing a silicon growing phenomenon. Crucible manipulating device 3 shifts crucible 5 up or down to assist the growing of the silicon. This is because, during silicon growth, the ingot slowly rotates upwards while the silicon melt surface descends, in order to keep a constant level of the liquid surface as well as to maintain the heating of the silicon material at the solidus-liquidus interface; crucible 5 has to be slowly raised to ensure stability of the silicon growing process.
It should be noted that in order to avoid oxidation of silicon at high temperature, the vessel is usually operated in a inert argon (Ar) gas atmosphere, wherein Ar gas can be fed through the top of the vessel to facilitate purification through reaction of Ar damped gas and the silicon melt.
In a preferred embodiment, the present system and method use a cover gas or pressing gas to enclose a substantial portion of the melted material within the crucible. That is, the crucible is subject to a cover gas to maintain the melted material within the crucible. In a preferred embodiment, the crucible is subject to an argon containing cover gas or other suitable inert gas or gases to maintain the melted material within the crucible. Preferably, the cover gas is suitable to maintain the melted material free from oxidation or other undesirable conditions. The cover gas is provided within a chamber and/or housing enclosing the crucible. Of course, there can be other variations, modifications, and alternatives.
FIG. 2 is a diagram depicting a first embodiment of a metallurgical silicon purification apparatus modified from a conventional crystal puller. This diagram is merely an example, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize other variations, modifications, and alternatives. In the diagram, reference numeral 10 indicates a vessel, 10 a the upper portion of the vessel, 10 b the vessel body, 11 a heater, 12 a decompression tube, 15 an exhaustion passage controlling cap, 20 a crucible, 30 a crucible manipulating device, 61 a chemical and gas supply tube, 62 a high-pressure gas supplying tube, 70 a gas flow guiding element, and 100 a silicon melt.
Vessel 10 consists of upper portion 10 a and vessel body 10 b . Above the surface of silicon melt 100 is an independent injecting device consisting of a chemical and gas supply tube 61 and a high-pressure gas supply tube 62 . Through supply tube 61 , chemicals and gases required for purification, such as soluble compounds of calcium (Ca), silicon (Si) and magnesium (Mg), hydrogen (H 2 ) gas or oxygen (O 2 ) gas, are delivered to the surface of the silicon melt 100 . Meanwhile, through high-pressure gas supply tube 62 , high-pressure, damped gas mixtures, such as water steam (H 2 O) or Ar gas, are delivered to the center of the surface of the silicon melt 100 via the high-pressure jet flow, thereby forming a dimple 90 at the surface of silicon melt 100 (see FIG. 9 ), and in conjunction with a temperature gradient within silicon melt 100 in crucible 20 , heat circulation and/or mass convection can be achieved. The jet flow not only facilitates mixing of silicon melt 100 in crucible 20 , but also increases the contact areas between the chemicals/gases and silicon melt 100 , thus improving the efficiency of the purification process.
In addition, guiding element 70 is provided above silicon melt 100 in crucible 20 at an appropriate location and distance with respect to crucible 20 and supplying tubes 61 and 62 . Through guiding element 70 , hot gas rising from the surface of silicon melt 100 is guided back to the surface of silicon melt 100 , allowing effective contact of the damped gas with silicon melt 100 , thus increasing the efficiency of the purification process. Guiding element 70 is further discussed below.
In a preferred embodiment, the system includes guiding element along with a carrier gas configured to cause a portion of evaporated melted material to return to the melted material. In a specific embodiment, the carrier gas can be argon or other inert gas, which is suitable to return any evaporated melted material consisting of silicon entities back into the melted material. In a specific embodiment, the system includes a plurality of surface regions configured to cause a substantial portion of a phosphorus species to be exhausted while returning a substantial portion of silicon species into the melted material. Preferably, the surface regions comprise a plurality of fin regions configured to cause a substantial portion of a phosphorus species to be exhausted while returning a substantial portion of silicon species into the melted material. Of course, there can be other variations, modifications, and alternatives.
In addition, in order to prevent oxidation of the silicon at high temperature and superheating of the silicon melt, the degree of vacuum inside vessel 10 is changed to accommodate evaporating conditions for various impurities contained in the raw silicon, so as to ensure a safe metallurgical silicon purification process. Specifically, a vacuum pump (not shown) and a gas flow valve (not shown) can be used to control the gas and gas flow in vessel 10 , wherein the pump regulates pressure via decompression tube 12 , which avoids any danger caused by pressure rising due to a constant supply of water steam (purifying material), thereby providing safe and stable metallurgical silicon purification process conditions.
FIGS. 3 and 4 are diagrams depicting a second embodiment of the metallurgical silicon purification apparatus modified from the conventional puller. In the diagram, reference numeral 10 indicates a vessel, 11 a heater, 12 a decompression tube, 13 a set of valves and/or port or load locks, 14 a set of valve operating arms, 15 an exhaustion passage controlling cap, 20 a crucible, 30 a crucible manipulating device, 31 a crucible manipulating device base, 32 a crucible manipulating device shifting shaft, 33 a crucible manipulating device motor, 40 a crucible transporting device, 41 a crucible conveyer belt, 50 a plasma arc heater, 60 a purifying material supplying system, 61 a chemical and gas supply tube, 62 a high-pressure gas supply tube, 70 a gas flow guiding element, and 100 a silicon melt.
Above the surface of silicon melt 100 is an independent injecting device consisting of chemical and gas supply tube 61 and high-pressure gas supply tube 62 . Through supply tube 61 , chemicals and gases required for purification, such as soluble compounds of calcium (Ca), silicon (Si) and magnesium (Mg), hydrogen (H 2 ) gas or oxygen (O 2 ) gas, are provided to the surface of silicon melt 100 . Meanwhile, through high-pressure gas supplying tube 62 , high-pressure damped gas mixtures, such as water steam (H 2 O) or Ar gas, are provided to the center of the surface of silicon melt 100 via the high-pressure jet flow, thereby forming a dimple 90 at the surface of silicon melt 100 (see FIG. 9 ), which, in conjunction with the temperature gradient within silicon melt 100 in crucible 20 , allows heat circulation and/or convection to be achieved. The jet flow not only facilitates mixing of silicon melt 100 in crucible 20 , but also expands the contact areas between the chemicals/gases and silicon melt 100 , thus improving the efficiency of the purification process. In addition, plasma arc heater 50 is provided above silicon melt 100 . The plasma arc heater 50 , forming an independent injecting device in conjunction with purifying material supplying system 60 , intermittently and locally emits the plasma toward the surface of silicon melt 100 in crucible 20 . This creates a reproducible temperature profile across silicon melt 100 . Meanwhile, oxygen (O 2 ) gas from high-pressure gas supplying tube 62 is provided toward the burning hydrogen (H 2 ) supplied by plasma arc heater 50 and into the center of the surface of silicon melt 100 in crucible 20 , forming water steam (H 2 O) via hydrogen burning. The water steam is further propagated into silicon melt 100 through the force of the high-pressure oxygen jet flow, effectively providing water steam required for silicon purification to silicon melt 100 .
In addition, in the second embodiment, a crucible manipulating device 30 is provided underneath vessel 10 to provide for raising/lowering, rotating and horizontal shifting. Crucible manipulating device 30 includes crucible manipulating device base 31 , crucible manipulating device shifting shaft 32 , and crucible manipulating device motor 33 . Since the present invention does not need a seed ingot for silicon growth, during the purifying process, the surface level of silicon melt 100 in crucible 20 does not descend. Through crucible manipulating device 30 , not only can the vertical movements of crucible 20 inside vessel 10 be controlled in order to install or remove crucible 20 , but crucible 20 at the end of the silicon purification process can be transported in cooperation with crucible transporting device 40 and crucible conveyer belt 41 . Moreover, the vertical movements and the rotation of crucible 20 can be controlled by crucible manipulating device 30 , so as to adjust the solidus-liquidus interface of silicon melt 100 with respect to the location of heater 11 , so as to achieve one-directional cooling purification associated with Segregation Theory, without the need for temperature segregation coefficient management of the concentration of remaining impurities in silicon melt 100 with respect to the solidus-liquidus line. In addition to adjusting the solidus-liquidus interface of silicon melt 100 with respect to the location of heater 11 for silicon purification by crucible manipulating device 30 , the distance between crucible 20 and guiding element 70 can also be controlled by crucible manipulating device 30 , so that damped gases from the surface can be effectively directed back to silicon melt 100 to facilitate the supply of water for purification. Meanwhile, by controlling the distance, the form of dimple 90 (see FIG. 9 ) on the surface of silicon melt 100 caused by direct impact of the jet flow from the injecting device can be controlled. Furthermore, referring to FIGS. 3 and 4 , besides the crucible manipulating device 30 , a set of valves 13 that can be horizontally closed or opened, and which are controlled by a set of valve operating arms 14 capable of horizontal shifting, is provided beneath vessel 10 . When installing/removing crucible 20 into/from vessel 10 , the valve 13 is opened and closed horizontally to reduce the reaction of carbon products in the vessel with oxygen, which would affect the purification response of silicon melt 100 .
In addition, guiding element 70 is provided above silicon melt 100 in crucible 20 at an appropriate location with respect to crucible 20 and supply tubes 61 and 62 . Through guiding element 70 , hot air flow from the purifying gas flow provided to the surface of silicon melt 100 is guided back to the surface of silicon melt 100 , allowing effective contact of the damped gas with silicon melt 100 , thus increasing the efficiency of the purification process.
In addition, in order to prevent oxidation of the silicon at high temperature, vessel 10 has to be kept at a certain degree of vacuum. Specifically, a vacuum pump (not shown) and a gas flow valve (not shown) can be used to control the gas and gas flow in vessel 10 , wherein the pump regulates pressure via decompression tube 12 , which avoids any danger caused by pressure rising due to constant supply of water steam (purifying material), therefore providing safe and stable metallurgical silicon purification process conditions.
FIG. 5 is a schematic diagram depicting the tube end of purifying material supply system 60 of the present invention described in FIGS. 2 , 3 , and 4 . For the purpose of supplying high pressure damped gas mixtures so as to form a dimple 90 on the center of the surface of silicon melt 100 that expands the contact area and contact time of the purifying materials with silicon melt 100 , and enhancing the mixing of silicon melt 100 in crucible 20 for purification, the tube of purifying material supplying system 60 is designed to have a converging cone shape to increase the injecting pressure and flow rate. The material of this cone-shaped tube should be carefully selected to reduce loss when used for supplying chemicals and gases and as a heat source. To this end, the tube is preferably coated by a material such as quartz.
FIG. 6 is a schematic diagram depicting an implementation of independent purifying material supplying system 60 of the present invention consisting of chemical and gas supply tube 61 and high-pressure gas supply tube 62 described in FIGS. 2 , 3 , and 4 . FIG. 6 shows a design of concentric double tubes for providing different combinations of purifying materials (e.g., chemicals, gases, and soluble chemicals), including an outer tube a and an inner tube b. Reference letters/numerals a 0 and b 0 indicate the outlets of outer tube a and inner tube b, respectively. However, the present invention is not limited to these, but can have three or more tubes, as long as they provide different combinations of purifying materials to the surface of the silicon melt.
FIGS. 6(A) and 6(B) are cross-sectional diagrams depicting implementations of multi-tube designs for supplying purifying materials to the surface of silicon melt 100 . As shown in FIG. 6(A) , the inner tube protrudes from the outer tube, wherein outlet b 1 of the inner tube supplies high-pressure damped gases (e.g., Ar) and/or water, while outlet a 1 of the outer tube supplies Ar gas. Through such a design, the high-pressure damped gases and/or water may pass through the surface of the silicon melt via the center of dimple 90 (see FIG. 9 ), effectively delivering damped gases and/or water required for silicon purification into silicon melt 100 in crucible 20 . As shown in FIG. 6(B) , the inner tube is shorter than the outer tube, and outlet a 2 of the outer tube supplies H 2 gas for reacting with O 2 to form water, while outlet b 2 of the inner tube supplies O 2 necessary for forming water when reacting with the burning hydrogen gas. Since the inner tube is shorter than the outer tube, H 2 provided by outlet a 2 of the outer tube can reach the surface of silicon melt 100 through diffusion and burn due to high temperature, and if O 2 is provided from outlet b 2 of the inner tube b 2 towards the center of the burning H 2 , water steam is produced. This water steam and a portion of the non-reacted free oxygen are effectively brought to the surface of the silicon melt 100 for purification.
FIG. 7 is a schematic diagram depicting a design for gas flow guiding element 70 of the present invention. As described above, guiding element 70 is positioned at an appropriate distance and location with respect to silicon melt 100 in crucible 20 , taking into consideration plasma arc heater 50 and purifying material supplying system 60 . The guiding element 70 redirects rising hot air back to the surface of silicon melt 100 , allowing effective contact of the damped gas with silicon melt 100 , thus increasing the efficiency of the purification process. Guiding element 70 includes a body 74 and several fins 71 , 72 and 73 extending from the lower edge of body 74 .
FIG. 8 is a schematic diagram depicting the flow of the rising hot and damped gases. When plasma arc heater 50 irradiates silicon melt 100 in crucible 20 , the temperature of silicon melt 100 rises and generates a rising hot and damped gas flow (indicated by dashed lines), which diffuses above the surface of silicon melt 100 in crucible 20 .
Also, FIG. 10 shows the distances and locations of guiding element 70 with respect to crucible 20 and the surface of silicon melt 100 , and their relative relationship with the rising hot and damped gas flow. The following distances and locations are obtained from actual experiments performed by the inventors, which are not to be construed as limiting the present invention.
As shown in FIG. 10 , reference numeral 11 indicates a heater, 50 a plasma arc heater, 60 a purifying material supply system, 61 a chemical and gas supply tube, 62 a high-pressure gas supply tube, 70 a gas flow guiding element, 71 and 72 fins, 20 a crucible, 100 a silicon melt, h 1 the distance between the plasma arc heater outlet and the surface of the silicon melt, h 2 the distance between fin 71 of guiding element 70 and the surface of silicon melt 100 , h 3 the length of longest fin 71 , h 4 the distance from gas supplying tube 61 to the plasma arc heater 50 outlet, s 1 the distance between the bore of guiding element 70 to the plasma arc heater 50 , s 2 the distance from the plasma arc heater 50 to inner fin 72 , and s 3 the interval between fins 71 and 72 . Distance h 4 is dependent on the jet force of purifying material supplying system 60 and the supplied amount (V) of the gas flow through guiding element 70 .
Based on the experimental results, when the supplied amount (V) is 100˜800 L/hour, distance h 4 is 10 cm, which is the maximum value.
For distance h 1 , it can be understood from the experimental results that when distance h 1 reaches 5 cm, the results are best. A suitable range is from 1 cm to 18 cm.
For distance s 1 , it can be understood from the experimental results that this distance s 1 should be as short as possible to accelerate the rate at which the gas flows through. From the experimental results, in the case that the chemical and gas supplying tube 61 and the high-pressure gas supplying tube 62 are lowered to the level of the lower edge of guiding element 70 , distance s 1 is preferably between 1 cm and 6 cm.
Distance s 2 is dependent on the pressure of purifying material supplying system 60 and the supplied amount (V) of the gas, i.e., the flow rate of the gas going through that space. From the experimental results, in the case that the supplied amount (V) is 100˜800 L/hr, the results are optimum when distance s 2 is between 2 cm and 8 cm.
Distances s 2 and s 3 are also dependent on the number of fins 71 and 72 . From the experimental results, when the number of fins is two, the sum of distances s 2 and s 3 is preferably distance s 2 plus 5 mm to 30 mm.
For distance h 2 , it can be appreciated that, from theory, the smaller the distance, the better the result. But considering the effect of temperature and so on, the distance h 2 is preferably between 5 mm and 50 mm.
Distance h 3 is related to distance h 2 and the position of guiding element 70 . From the experimental results, distance h 3 is preferably between 5 mm and 30 mm.
For distance h 1 , in the case that the plasma arc heater 50 is used in the experiment, 5 cm is suitable. However, the use of plasma arc heater 50 is potentially dangerous, so a reasonably good result is obtainable if distance h 1 is between 1 cm and 18 cm.
Furthermore, FIG. 9 is a schematic diagram depicting dimple 90 formed by irradiation by the plasma arc heater 50 and/or circulation in silicon melt 100 induced by purifying material supplying system 60 . When plasma arc heater 50 emits plasma and purifying material supply system 60 supplies high-pressure and high-speed jet flow to the center of the surface of silicon melt 100 , a dimple 90 is formed thereon, and as plasma is irradiating the dimple 90 , the high-temperature area on the surface of silicon melt 100 is expanded. In conjunction with the temperature profile across silicon melt 100 in crucible 20 formed by the plasma arc heater 50 , a greater inversion radius of heat circulation in silicon melt 100 is produced. The heat circulation redistributes the impurities within silicon melt 100 more evenly. The jet flow facilitates mixing of silicon melt 100 in crucible 20 , and also expands the contact area between silicon melt 100 and the purifying materials (e.g., gases and chemicals), thereby increasing purification efficiency. In addition, the plasma from plasma arc heater 50 can be applied intermittently to prevent overheating of overall silicon melt 100 and to maintain an appropriate temperature profile across silicon melt 100 in crucible 20 .
FIGS. 11 , 12 , and 13 are schematic diagrams depicting the irradiation of the surface of silicon melt 100 in crucible 20 using various sets of plasma arc heaters 50 .
When a large amount of raw silicon has to be purified, a plurality of plasma arc heaters 50 can be used to generate irradiation of higher energy. However, when a plurality of plasma arc heaters 50 is used to irradiate the center of the surface of silicon melt 100 at the same time, it may overheat and damage the purifying apparatus, for example, overheat and damage the bottom of crucible 20 . In order to overcome such a problem, the present invention arranges a plurality of plasma arc heaters 50 around the center of the surface of silicon melt 100 at equal angular distances. For example, FIG. 11(A) is a schematic diagram depicting three plasma arc heaters 50 surrounding center a of the surface; FIG. 11(B) four plasma arc heaters 50 ; FIG. 11(C) five plasma arc heaters 50 ; and FIG. 11(D) six plasma arc heaters 50 . In the above combinations of plasma arc heaters 50 , the irradiation from the plurality of plasma arc heaters 50 is required to focus somewhere below the surface of silicon melt 100 to avoid overheating of crucible 20 , while ensuring good heat circulation of silicon melt 100 .
Referring to FIG. 12 , plasma arc heaters 50 are arranged at certain angles with respect to the surface of silicon melt 100 . Different angles produce different forms of dimple 90 . The angle should be smaller than or equal to 90° (≦90°). As shown in FIG. 12 , plasma arc heaters are arranged at angles α and β above the surface of silicon melt 100 , which determines the irradiation focus of the plasma. Normally, the deeper the irradiation, the greater the angles α and β. In addition, the temperature profile of silicon melt 100 in crucible 20 will also change in accordance with the change in angles of plasma arc heaters 50 . The dimples 90 that are formed will be different, which implies that varying the irradiation angles changes the evaporation rate of silicon melt 100 . As shown in FIGS. 13(A) and 13(B) , different dimples 90 are formed when plasma arc heaters 50 at different angles irradiate the surface of silicon melt 100 . Further, it should be noted that, by controlling the positions of plasma arc heaters 50 using crucible manipulating device 30 , various positions and temperatures of optimum plasma irradiation can be obtained, and the form of the dimples 90 depends on the irradiation angles α and β of plasma arc heaters 50 .
The preferred embodiments of the present invention are described in detail below with respect to the aforementioned drawings.
The present invention addresses the issue of how to efficiently mix purifying materials (e.g., chemicals and gases) into metallurgical silicon to be purified.
The melting temperature of metallurgical silicon is about 1425° C. There is the possibility that the purifying materials will be nebulized and exhausted due to circulation of radiation heat of the silicon melt before reaching the silicon melt.
In view of this, the following approach is proposed by conventional techniques.
Purifying materials are blown from the bottom of the crucible. This approach may work in theory, but in practice, the following problems occur. A pressure that is sufficient to overcome the viscosity of liquid silicon melt is required. In addition, in order to avoid backflow, blowing has to be done at a level higher than the surface of the silicon melt, which lengthens the blowing tube, therefore requiring an even higher pressure. In the case that the pressure is temporarily decreased, silicon melt backflows into the tube and solidifies at a low-temperature region, which may result in breaking of the tube due to increased mechanical pressure. Thus, the tube has to be maintained at a certain temperature.
This approach thus has the following problems:
a) Addition of impurities cannot be avoided, i.e., product has a low purity; b) Expensive apparatus; c) Safety issue.
Furthermore, although silicon melt can be mixed and stirred by device of mechanical stirring, considering the high-temperature and viscous environment, the material and mechanical strength requirements of the stirring shaft render no easy solution.
Another approach, the so-called weathering approach, is also used for purification.
This method of purification is commonly used in making iron and aluminum, and is proven to be effective.
This method removes impurities and additives (e.g., magnesium oxide and calcium) by vitrification.
The vitrified impurities float on the surface of the purified metal, and after cooling, they can be removed from the surface by mechanical device to obtain a purified product.
This approach has limitations in terms of the purity level of the final product. However, if this approach is simultaneously adopted with the apparatus of the present invention, the purity can be increased.
The present invention is related to the development of a purification apparatus that allows effective mixing of purifying materials into silicon melt.
It should be understood that the metallurgical silicon purifying apparatus proposed by the present invention can be obtained by modifying existing single crystal silicon puller apparatus. The existing apparatus usually includes a vessel, a crucible, a crucible support and a heater. By implementing at least one of the following device in the existing apparatus, purification of metallurgical silicon is performed using one, some or all of the device simultaneously:
an independent injecting device provided above the crucible for providing plasma, gases and chemicals required for purifying in a high-speed jet flow to the surface of a silicon melt, and forming a dimple on the surface of the silicon melt by its supply tubes, and in cooperation with a temperature profile across the silicon melt, facilitating heat circulation and increasing the circulation inversion radius, as well as increasing the contact area between the purifying gases and chemicals and the silicon melt, thereby increasing purification efficiency;
a guiding element with fins thereon provided above the silicon melt in the crucible, at an appropriate location with respect to the crucible and the supply tubes for the purifying gases and chemicals, for guiding damped gas flow rising from the surface of the silicon melt back to the surface of the silicon melt, so that the damped gases effectively contact the silicon melt, wherein the distance between the guiding element and the surface of the silicon melt, the distance between the fins and the silicon melt, and the distance between the interior circumference of the crucible and the fins are critical;
a manipulating device provided underneath the vessel for vertically and horizontally shifting and rotating the crucible with respect to the heater to adjust the solidus-liquidus interface to obtain one-directional cooling purification without the need for temperature segregation coefficient management of the concentration of remaining impurities in the silicon melt with respect to the solidus-liquidus line, and allowing effective backflow of the damped gases and controlling the form of the dimple created by the jet flow from the injecting device on the surface of the silicon melt by adjusting the distance between the crucible and the guiding element, wherein a set of valves capable of horizontal motion is further provided in the manipulating device in order to reduce reactions of carbon parts with oxygen when the crucible is taken out or inserted into the vessel by opening/closing the valves; and
a vacuum pump provided to regulate the pressure or degree of vacuum inside the vessel and to accommodate evaporating conditions for various impurities.
In summary, the present invention proposes an apparatus, obtained by modifying an existing apparatus, for purifying metallurgical silicon for use as raw silicon in manufacturing solar cells to replace the traditional Siemens method.
Depending upon embodiment, one or more of the following aspects are included.
1. An apparatus for purifying metallurgical silicon obtained by modifying an existing single crystal silicon puller apparatus including a vessel, a crucible, a crucible support and a heater, with the addition of one, some, or all of the following devices for the purification of metallurgical silicon:
an independent injecting device provided above the crucible for providing plasma, gases and chemicals required for purifying in a high-speed jet flow to the surface of a silicon melt, and forming a dimple on the surface of the silicon melt by its specially designed supplying tubes;
a guiding element with fins thereon provided above the silicon melt in the crucible at an appropriate location and distances (h 1 ) (h 2 ) (h 3 ) (h 4 ) (s 1 ) (s 2 ) (s 3 ) with respect to the crucible and the surface of the silicon melt for guiding damped gas flow rising from the surface of the silicon melt (as a result of heating at the surface of the silicon melt) back to the surface of the silicon melt, so that the damped gases effectively contact the silicon melt;
a manipulating device provided underneath the vessel for vertically and horizontally shifting and rotating the crucible with respect to the heater to adjust the solidus-liquidus interface to obtain purification and to further control the relative position of the crucible with respect to the guiding element and the injecting device above to obtain optimum purification efficiency; and
a vacuum pump provided to regulate the pressure or degree of vacuum inside the vessel and to accommodate evaporating conditions for various impurities.
2. The apparatus of claim 1 , wherein the injecting device includes an independent chemical and gas supply tube for supplying chemicals, gases and soluble gases to the center of the surface of the silicon melt for purification.
3. The apparatus of claim 1 , wherein the injecting device includes an independent high pressure gas supply tube for supplying a high-pressure damped gas mixture to the center of the surface of the silicon melt for purification.
4. The apparatus of claim 1 , wherein the injecting device includes an independent purifying material supply system including a chemical and gas supplying tube and a high-pressure gas supply tube for supplying chemicals, gases and soluble gases and a high-pressure damped gas mixture, respectively, to the center of the surface of the silicon melt for purification.
5. The apparatus of claim 4 , wherein the end of the tubes in the purifying material supply system have a converging cone shape for increasing jet pressure and flow rate.
6. The apparatus of claim 5 , wherein the material of the tubes includes quartz coating material thereon.
7. The apparatus of claim 4 , wherein the purifying material supply system has a concentric multi-tube design for supplying at least one of chemicals, gases, soluble chemicals, damped gases and water.
8. The apparatus of claim 7 , wherein the concentric multiple tubes include an inner tube longer than an outer tube.
9. The apparatus of claim 8 , wherein the outlet of the inner tube supplies at least one of a high-pressure damped gas and water, and the outlet of the outer tube supplies argon gas.
10. The apparatus of claim 7 , wherein the concentric multiple tubes include an inner tube shorter than an outer tube.
11. The apparatus of claim 10 , wherein the outlet of the outer tube supplies hydrogen gas for reacting with oxygen to form water, and the outlet of the inner tube supplies oxygen for reacting with burning hydrogen to form water.
12. The apparatus of claim 1 , wherein the injecting device include at least one plasma arc heater for irradiating the surface of the silicon melt and injecting chemicals and gases required for purification.
13. The apparatus of claim 12 , wherein plasma is irradiated intermittently and locally on the surface of the silicon melt to create a reproducible temperature gradient in the silicon melt.
14. The apparatus of claim 12 , wherein a plurality of plasma arc heaters are arranged around the center of the surface of the silicon melt at equal angular distances, and the plasma arc heaters are tilted at predetermined angles with respect to the plane of the silicon melt, so the irradiation is focused at a point below the silicon melt surface to form dimples of different forms on the surface of the silicon melt.
15. The apparatus of claim 14 , wherein the tilting angles of the plasma arc heaters with respect to the plane of the silicon melt are smaller than or equal to (90° (≦90°).
16. The apparatus of claim 1 , wherein the manipulating device includes a crucible manipulating device base, a crucible manipulating device shifting shaft, and a crucible manipulating device motor for controlling the vertical movements of the crucible inside the vessel in order to install or remove the crucible and for controlling the vertical movements and rotation of the crucible in order to move the crucible with respect to the heater, so as to adjust the solidus-liquidus interface for one-directional cooling purification, and in order to control the distance between the surface of the silicon melt and the guiding element above, so that damped gases generated from the surface can be effectively directed back to the silicon melt to facilitate the supply of water for purification, and also, by controlling this distance, to control the form of the dimple created on the surface of the silicon melt caused by direct impact of the jet flow from the injecting device.
17. The apparatus of claim 16 , wherein the manipulating device further includes a crucible transporting device and a crucible conveyer belt for transporting the crucible at the end of the purification process.
18. The apparatus of claim 1 , wherein the manipulating device further includes a set of valves provided beneath the vessel that can be horizontally closed or opened by a set of valve operating arms, so in the case of installing or removing the crucible into or from the vessel, the valves are opened and closed horizontally to reduce the reaction of carbon parts in the vessel with oxygen, which would affect the purification of the silicon melt.
19. The apparatus of claim 1 , wherein the guiding element includes a body and at least one fin extending from the lower edge of the body.
20. The apparatus of claim 1 , 2 , 3 , 12 or 19 , wherein in the case that the gas flow rate through the guiding element (V) is 100˜800 L/hour, the distance (h 4 ) from the gas supplying tube of the injecting device to the outlet of the plasma arc heater is 10 cm, which is the maximum value; the distance (h 1 ) from the outlet of the plasma arc heater to the surface of the silicon melt is in a range between 1 cm and 18 cm, with 5 cm being preferable; the distance (s 1 ) from the plasma arc heater to the bore of the guiding element, in the case that the chemical and gas supply tube and the high pressure gas supply tube are lowered to the level of the guiding element, is preferably between 1 cm and 6 cm; the distance (s 2 ) from the plasma arc heater to an inner fin of the guiding element, which is dependent on the pressure of the injecting device and the supplied amount (V) of the gas, i.e., the flow rate of the gas going through that space, in the case that the supplied amount (V) is 100˜800 L/hr, is preferably between 2 cm and 8 cm; the distance (s 2 ) and the distance between fins of the guiding element (s 3 ) are also dependent on the number of fins provided, so that when the number of fins is two, the sum of distances s 2 and s 3 is preferably distance (s 2 ) plus 5 mm to 30 mm; the distance (h 2 ) from a fin to the surface of the silicon melt is preferably between 5 mm and 50 mm; and the longest fin (h 3 ) in the guiding element is preferably between 5 mm and 30 mm.
21. The apparatus of claim 1 , wherein a vacuum pump and a gas flow valve are used to control the gas and gas flow rate in the vessel, with the pump regulating the pressure via a decompression tube to avoid any danger caused by the pressure rising due to constant supply of water steam, to accommodate evaporating conditions for various impurities contained in raw silicon, and to prevent superheating of the silicon melt, thereby ensuring a safe metallurgical silicon purification process.
It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.
Example
To prove the principle and operation of the present invention, we performed certain experiments. We performed the poly-Si purification experiments using several generations of modified conventional single crystal Si ingot pullers. Such pullers included a very small and conventional puller (about 20 Kg Si per charge) to a mid-size puller (about 80 Kg Si per charge). We maintained the crucible apparatus and controls, which were modified to operate in a manner consistent with the present pilot silicon purification apparatus configured for purifying metallurgical silicon. Upon introducing metallurgical silicon, processing such silicon, and purifying the silicon according to the present examples. We achieved purification result of 6N˜7N (e.g., 99.9999 to 99.99999 silicon purity), reaching the desired specification suitable for solar cell applications. The present pilot purifier in operation has been modified from a large size conventional puller (about 140 Kg Si per charge). See, for example, FIG. 14 . Of course, there can be other variations, modifications, and alternatives.
It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims. | A method includes transferring a raw silicon material in a crucible and subjecting the raw silicon material in the crucible to thermal energy to form a melted silicon material at a temperature of less than 1400 Degrees Celsius, the melted silicon material having an exposed region bounded by an interior region of the crucible, subjecting an exposed inner region of the melted silicon material to an energy source to include an arc heater configured above the exposed region and to be spaced by a gap between the exposed region and a muzzle region of the arc heater to form a determined temperature profile within a vicinity of an inner region of the exposed melted silicon material while maintaining outer regions of the melted silicon material at a temperature below a melting point of the crucible, and removing impurities from the melted silicon material to form higher purity silicon. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a continuation of U.S. patent application Ser. No. 13/021,135, filed Feb. 4, 2011, which is a continuation of U.S. patent application Ser. No. 10/568,262, filed Jun. 30, 2006, now U.S. Pat. No. 7,896,918, which is a National Phase Patent Application of International Application Number PCT/EP2004/008998 filed Aug. 11, 2004 which claims priority of DE 103 37 088.9 filed Aug. 12, 2003, the entire contents of which are incorporated herein by reference.
SUMMARY
The present invention concerns space holders according to the preamble of claim 1 .
Space holders, especially for vertebrae and intervertebral discs, which, for example, are used as replacements for a vertebra, have been known for some considerable time in medical technology, as is confirmed by DE 36 37 314 A1 or DE 43 23 034 C1. The space holders used initially (DE 36 37 314 A1) have also already undergone numerous further developments, as is shown by U.S. Pat. No. 5,972,031 or DE 43 23 034C1, to adjust the space holders to the individual needs or to facilitate use, especially for the operator.
Although good results are obtained with the space holders already known, there is at the same time a need to further improve the known space holders, and more especially with regard to more optimum adjustment to the individual requirements of the site of implantation to improve compatibility and usage possibilities for the patient in order to increase their quality of life as well as with regard to improved user-friendliness for the operator who implants the space holder.
An implant is known from DE 100 56 977 C2 that can be used as a replacement for vertebrae or intervertebral discs. These implants have plate-shaped supporting elements between which a pipe-like hollow space is formed by a bellows-like outer wall. Into the hollow space, which is formed by the non-extensible and thus rigid outer wall, the degree of flexibility of which derives only from the bellows-like structure, can be filled bone cement or a flowable or rubber-like elastic compound such that the supporting elements at the ends of the hollow space are given a slight degree of mobility. Although this already provides a certain degree of mobility for a patient fitted with these implants, this solution is unsatisfactory as regards manufacturing effort and functionality. Due to the combination of a rigid outer wall, which is flexible only by mechanical means (bellows-like structure) in conjunction with a soft core, defined setting of the necessary properties as regards mobility is not satisfactorily possible. Moreover, the differential movement between the bellows-like external wall and the flowable or rubber-elastic filling material creates problems at the interface between filling material and outer wall, a fact which also can lead to impairment of the implant's service life.
It is therefore the object of the present invention to create a space holder that is an improvement on the prior art, with said space holder adapting better to the individual requirements of the site of implantation and assuming more diverse functions, especially also with regard to accommodating load, transferring load and mobility. Especially, the purpose of the space holder is to ensure that the patient is burdened as little as possible by the implant and retains or regains as much of their original load-bearing capacity and mobility as possible.
Furthermore, the space holder of the invention is intended to simplify the work of the operator and lend itself overall to simple and inexpensive manufacture.
This object is solved by a space holder having the features of patent claim 1 . Advantageous embodiments are the subject of the dependent claims.
The basic idea of the invention is that greater variability of the space holder and optimisation of its property profile can be obtained by reshaping the base body usually employed in the form of a lattice-like or cylinder pipe for the space holder such that the functionality is increased and improved. Starting from this idea, the inventor has recognised that this can be achieved in such a way that, according to a first aspect, the rigid and stiff design of the cylinder pipe-like base body is eschewed in favour of an elastic and flexible design of the cylinder-like body and, according to a second aspect, the lattice-like cylinder pipe shape is transformed into a solid shape since, on one hand, the elastic and flexible design of the cylinder-like base body makes it possible for the patient to accommodate mechanical loads more bearably and especially since the mobility, i.e. the mobility of the body parts connected to each other by means of the space holder or the body parts adjacent to the space holder, is improved. Moreover, on the other hand, the solid form of the cylinder-shaped base body facilitates overall better distribution of load and especially a simple, elastic, flexible embodiment with a long service life.
By elastic shape here is especially meant that, with the loads that occur when the space holder is in use, i.e. especially at the site of implantation, elastic deformation of the cylinder-like base body occurs in an order of magnitude appropriate to service use. By solid cylinder is meant that especially no lattice-like or framework hollow structure such as a cylinder pipe is intended. However, surface structures, such as grooves, recesses and the like are also comprised in an otherwise solid body. By cylinder or cylinder-like is hereby also meant a shape derived from a circular cross-section, like a polygon, and oval shape or a pea shape that copies the vertebrae.
The provision of a completely elastic-flexible solid cylinder facilitates limited movement of the body parts joined by the space holder towards each other as well as flexible alignment of the space holder with individual adjacent body parts. This markedly increases the comfort of the patient receiving this implant since, unlike a rigid space holder, a flexible, elastic space holder with good load distribution not only increases mobility but also, for example in the case of vibration, reduces loads on the adjacent body parts and thereby increases wearing comfort.
The use of a solid cylinder as the main component of a space holder that does not impair the means by which the space holder attaches to or grows into the flesh at the site of implantation is made possible by the fact that appropriate provision is made at the ends of the cylinder-like body for connection with adjacent body parts. Especially, it has proven advantageous to make provision for corresponding rings or cylinder pipe-shaped elements whose shape approximately resembles the lattice-like cylinder pipe-like elements that have so far been used as the base body. Especially, these means for connecting the space holder to adjacent body parts have protrusions, such as serrations or teeth extending in axial longitudinal direction, for penetration into adjacent body parts, especially bones, cartilage and the like, as well as recesses, apertures and/or cavities for enabling body tissue to grow into the recesses, apertures and/or cavities. In this way, adequate immobilisation of the space holder in the tissue of the implantation site is ensured.
Since, however, the means for connecting the space holders to adjacent body parts preferentially only take up a short section at the ends of the cylinder-shaped base body, it has proved advantageous to make corresponding adjustments to the shape of the cylinder pipe-like rings or pipes relative to the known shapes of the lattice-like, cylinder-pipe-shaped base bodies.
For example, it has proven advantageous to make provision for a wave-like ring as the means for connecting the space holder to the adjacent body parts at the ends of the cylinder-like base body, said ring being notable for a wave-like arrangement of fillets or a zigzag arrangement of fillets around the body surface. In this way, serrations and cavities are formed simply on the upper and lower side of the ring, which are capable of being used for connecting to adjacent body parts or body tissue.
In a preferred embodiment, the cylinder pipe-like rings or pipes for connecting the space holder to adjacent body parts are provided with a series of diamond- or rhombus-like cavities around the cylinder pipe, with the rows of diamond-like cavities in the axial direction offset from each other by half a diamond. With this shape, the operator can simply adjust the length of the lattice-like or network-like pipes to the desired length. This may be done simply by cutting off the pipes at the desired length transverse to the longitudinal direction, as a result of which corresponding serrations are again formed at the cut end by the diamond-like cavities.
The lattice-like or network-like pipes or rings, which are used as means of connecting the space holder to adjacent body parts, may be connected in various ways to the cylinder-like base body, especially by non-positive or frictional, positive or material union means. For this purpose, provision can be made on the cylinder-like base body and/or the network-like, lattice-like or wave-like pipes or rings, i.e. the means of connection, for corresponding holding means for mutual engagement or holding. Especially, it has proved advantageous here to make provision on the pipe-shaped or ring-shaped connecting means for especially radially inward pointing prongs or serrations that engage with the cylinder-shaped base body or, for example, can be co-moulded during the manufacture of the cylinder-like body.
To obtain the elasticity or flexibility of the cylinder-like base body, a correspondingly elastic material may be used to form the cylinder-shaped body, in particular, bio-compatible polymer, such as high molecular polyethylene or medical grade silicone rubber. Apart from homogeneous formation of the cylinder-like body from a single material, it is also conceivable to realize the cylinder-like body, especially the solid cylinder, from composite material or as a multicomponent part, since, especially through appropriate selection of the corresponding components or of the composite material, particularly ideal adjustment to the desired properties is facilitated. However, it is important here that all components have corresponding elasticity in order that problems in the interaction of rigid and elastic components may be avoided.
Preferentially, the elastic material is also to be chosen such that the cylinder-shaped body, expressed in terms of its longitudinal direction, may be extended or compressed by approximately 0.5 to 20%, especially 1 to 15%, or/and the intended means of connecting the ends can swivel by approximately 0.5 to 10°, especially 1 to 6° out of the longitudinal axis of the space holder. A correspondingly adjusted space holder thus facilitates the requisite mobility of the space holder combined with adequate stability.
It has proved particularly advantageous for the cylinder-shaped body to be formed from a cylinder-like core and a cylinder-like sleeve arranged co-axially with the core, with the core and sleeve capable of having different mechanical properties. Preferentially, the core, which has to sustain less extension, is made more rigid, whereas the sleeve has greater elasticity to facilitate larger extension.
Further advantages, characteristics and features of the object of the present invention become clear from the following detailed description of two sample embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The purely schematic diagrams show the following:
FIG. 1 a 3D view of a first space holder of the invention in a partially exploded view, and in
FIG. 2 a 3D view of a second space holder of the invention in a partially exploded view;
FIG. 3 a side view of a connecting ring with several rows of diamond shaped cavities arranged such that they are offset from each other in the axial direction by a half diamond;
FIG. 4 an oval cross-sectional shape of a cylinder-like base body; and
FIG. 5 a pea-shaped cross-sectional shape of a cylinder-like base body.
DETAILED DESCRIPTION
FIG. 1 shows a 3D view of a first embodiment of the space holder of the invention with a cylindrical body 1 having provision for two connecting rings 2 at the ends of the cylindrical body 1 for connecting the space holder to the adjacent body parts, e.g. bones or cartilage in, for example, the human body. Cylindrical body 1 is made as a solid cylinder from an elastic polymer, such as high molecular polyethylene or medical grade silicone, with cylinder-shaped body 1 being made up of two parts, namely a cylindrical core 8 and a cylinder pipe-shaped sleeve or cover 7 , which is arranged coaxially around core 8 . Due to the two-component structure of core 8 and sleeve 7 , different materials having different properties, such as strength, elasticity etc, can be used for optimally adjusting the mechanical properties of cylinder-shaped body 1 to requirements.
Connecting rings 2 , which are arranged at the ends of cylinder-shaped body 1 , have identical shapes in the sample embodiment shown, but may also have different shapes. Connecting rings 2 possess an inner diameter that roughly corresponds to the outer diameter of cylinder-shaped body 1 such that they can be pushed over the ends of cylinder-shaped body 1 . The outer diameter of cylinder-shaped body 1 can be made somewhat larger than the inner diameter of connecting ring 2 in order that tensioning of the cylinder-shaped body 1 and/or connecting ring 2 may cause the connecting ring to sit firmly by non-positive means on cylinder-shaped body 1 . In this selected variant, connecting rings 2 project by a thickness d 1 , which corresponds to the wall thickness of connecting ring 2 , over the body surface of cylinder-shaped body 1 . Furthermore, connecting rings 2 are arranged on cylindrical body 1 such that they project by a height h 1 in the axial direction beyond the ends of cylinder-shaped body 1 . It is thus possible for serrations 3 provided for at the side ends of connecting rings 2 to engage with adjacent body tissue at the site of the implantation.
Connecting rings 2 in the embodiment shown in FIG. 1 are formed such that triangular cavities 5 at the two ends of connecting ring 2 create trapezoidal serrations 3 , provision for which is made at the side opposite cylinder-shaped body 1 for engaging with and clinging onto adjacent body tissue.
In addition, connecting ring 2 has diamond-shaped cavities 4 , provision for which is made such that they are adjacent to each other around the entire ring. As a result, connecting ring 2 is formed again to itself by a number of diamond-shaped interconnected fillets 6 , with the tips of the diamonds formed by fillets 6 cut-off so that trapezoidal serrations 3 are formed. Since connecting ring 2 in the sample embodiment shown projects over cylindrical body 1 approximately from the centre of the diamonds 4 , each diamond-shaped cavity 4 in the ring 2 shown in the lower part of FIG. 1 has an upper region 10 in which only a recess as far as the cylindrical body 1 is formed due to diamond-shaped cavity 4 , whereas provision is made in lower region 11 for a fully open aperture (correspondingly in upper ring 2 ). Both recess 10 and aperture 11 enable the space holder to grow into and knit together with the body tissue.
Aside from the force fit or snug fit of the connecting rings on cylindrical body 1 , there are other ways of effecting a permanent and especially non-twisting connection between connecting rings 2 and cylindrical body 1 . For example it is possible to make provision for protrusions (not shown) on the inside of connecting rings 2 and to also mould, for example, the connecting rings 2 or the protrusions during the manufacture of cylinder-shaped body 1 by injection moulding into cylinder-shaped body 1 , in which case the projections would then be enveloped and occluded by the plastic compound of cylinder-shaped body 1 , as a way of effecting the permanent connection between cylinder-shaped body 1 and connecting rings 2 . In addition, however, a large number of other connecting means and techniques are conceivable.
Through forming the cylinder-shaped body 1 as a solid body and especially as a two component body with core 8 and sleeve 7 , optimum load distribution and load accommodation are possible, with, especially by forming core 8 and sleeve 7 differently as regards mechanical properties, a desired property profile capable of being set. For example, core 8 can be designed to be more rigid than jacket 7 such that, given flexural stress on the space holder about the radial axis 13 shown by way of example, the especially highly extended or compressed external areas of sleeve 7 exhibit extensive yielding capability, whereas core 8 , which only has to accommodate less extensive extension or compression, exhibits greater rigidity such that the space holder overall has the property of readily facilitating minor bending, while increasing bending is met with a disproportionate increase in resistance. But also axial extension or compression along longitudinal axis 12 is optimally effected by the elastic solid cylinder 1 of the embodiment shown in FIG. 1 .
FIG. 2 shows a second embodiment of a space holder of the object of the invention in an illustration corresponding to FIG. 1 . Therein, the same or similar components with identical references are shown so that, with the exception of the differences described below, the considerations above also apply here.
In the embodiment of FIG. 2 , cylindrical body 1 is also made from an elastic polymer, with the exception that it is a single-piece body made from one component, i.e. cylinder-shaped body 1 is made from a single material in a single piece. However, the ends of cylinder-shaped body 1 have a reduced diameter for a limited length of the longitudinal axis 12 of cylinder-shaped body 1 such that a shoulder 9 is formed. The diameter is thereby reduced by twice the thickness d 2 , which corresponds to the wall thickness of connecting ring 2 , such that connecting ring 2 arranged at shoulder 9 is flush with the body surface of cylinder-shaped body 1 .
In this embodiment, also, the connecting rings 2 are formed such that, in the arrangement in shoulder 9 of cylinder-shaped body 1 , they project over the ends of cylinder-shaped body 1 by a height h 2 in order again to give the spikes 3 formed at the ends the possibility of engaging with adjacent body tissue at the site of implantation.
The embodiment shown in FIG. 2 also differs from the embodiment shown in FIG. 1 as regards the shape of connecting rings 2 . The connecting rings 2 used here are notable for the fact that they have a wave-like or a zigzag shaped arrangement of fillets 6 , such that triangular cavities 5 are formed between the fillets 6 at the ends and trapezoidal spikes 3 are again present between triangular cavities 5 .
By virtue of the arrangement of connecting rings 2 in shoulders 9 of cylinder-shaped body 1 , the triangular grooves 5 on the side facing cylinder-shaped body 1 form recesses 10 with cylinder-shaped body 1 that again enable the space holder to grow into the body tissue.
On the upper connecting ring 2 of FIG. 2 is shown by way of example the manner in which, for example, a connection may be effected between connecting rings 2 and cylinder-shaped body 1 by rods 15 projecting radially inward. In this regard and also by way of example is shown in connecting ring 2 aperture 14 , through or into which rod 15 can be pushed or screwed such that it projects radially inward inside connecting ring 2 . Rod 15 can be fixed to connecting ring 2 by suitable means of attachment, such as thread and counter-nut. Connecting rings 2 prepared in this way can, for example, then be inserted into an injection mould so that cylinder-shaped body 1 can then be moulded from a bio-compatible polymer. Radially inwardly projecting rods 15 of connecting rings 2 are then occluded in cylinder-shaped body 1 and produce a permanent, especially also a non-twisting connection between connecting rings 2 and cylinder-shaped body 1 . Admittedly, it is also conceivable to produce cylinder-shaped body 1 beforehand, to push connecting rings 2 onto shoulders 9 and then to press rods 15 through apertures 14 into cylinder-shaped body 1 or into the polymer material of cylinder-shaped body 1 or to guide them into corresponding holes and then to secure rod 15 in a suitable way, e.g. via screw connections on connecting ring 2 . In addition to the connecting possibilities described explicitly here for connecting connecting rings 2 and cylinder-shaped body 1 , numerous other suitable connecting techniques are conceivable.
FIG. 3 shows a side view of an alternative connecting ring 2 with several rows of diamond-shaped cavities that are offset to each other in the axial direction by a half diamond.
As indicated by the dashed line 14 in FIG. 3 , a connecting ring 2 designed in this way can be shortened to the corresponding desired length by cutting along cutting line 14 of connecting ring 2 such that spikes 3 are again formed at the point of separation by diamond-shaped connected fillets 6 .
FIGS. 4 and 5 are schematic cross-sectional diagrams of the different cross-sectional shapes of cylinder-like body 1 , with FIG. 4 showing an oval cross-sectional shape and FIG. 5 a pea-shaped cross-section. | The present invention concerns a space holder, especially for vertebrae or intervertebral discs for implantation into human or animal organisms, having a cylinder-like body ( 1 ) and, at the ends of the cylinder-like body, means ( 2 ) provided for connecting to adjacent body parts, said cylinder-like body ( 1 ) essentially being formed as a solid cylinder from at least one material that is elastically deformable under the conditions of use, such that the space holder is compressible and extensible in the axial direction and, with reference to means ( 2 ) provided at the ends for connecting the space holder to adjacent body parts, can bend about a radial axis of rotation ( 13 ). | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process of laying and constructing oil- or natural gas-bearing pipelines over permafrost soil or sub-soil and more particularly in polar regions, such as tundra land, and to pipes and pipelines adapted to and useful for placing them on permafrost soil or sub-soil.
2. Description of the Prior Art
Large oil and natural gas reserves are available in the polar regions and especially in the arctic regions. However, to get the existing energy to the market represents tremendous problems. Plans of pipelines have been drawn up and construction thereof has been started, for instance, to move crude oil from the Prudhoe Bay to Valdez, Alaska, a distance of 798 miles. A number of other pipelines has been planned or proposed. Most of these pipelines are installed on pilings above ground. For instance, 400 miles of the Prudhoe Bay-Valdez pipeline "will require 88,000 support columns" as pointed out by DEAN HALE in the article on "Pipeline Activity in Full Swing" in the "Pipeline and Gas Journal" July 1974, pp. 27 et seq. "The mere act of drilling the holes for the pilings (it is not feasible to drive pilings in permafrost) and setting them in place to provide the pipe supports, will be a colossal undertaking, unlike any pipeline ever built." The design and building of foundations in polar regions and especially in tundra lands for oil- and gas-carrying pipelines and other equipment are complicated by the fact that tundra is actually nothing else than a frozen bog, extending to considerable depths, known as permafrost.
Unless specific pressures between the foundation and the soil are kept several times lower than those used even in the softest soils, the ice component of the permafrost flows under the load and the foundation sinks with its equipment.
The cost of foundations designed for these conditions becomes prohibitively high, more than the pipeline itself as every cubic yard of material for the foundations has to be transported frequently over many miles of tundra land.
Digging down through the permafrost layer to get to some rock ledge can sometimes mean hundreds of feet and, with few exceptions, is out of question. Even if practically possible, the cost would be prohibitive. Very deep piling has been used, but it has its complications and again, the weight of materials to be brought to the sites entails high costs.
As to laying the pipeline directly onto the permafrost soil, tests have shown that within a short period of time the pipeline will "melt" its way down and will sag critically, creating prohibitive bending stresses in the pipes, finally leading to catastrophic pipe rupture. Indeed, not only the weight of the pipeline when filled with oil, but also the relatively high temperatures required to pump the oil through the pipeline must be taken into consideration because these factors contribute to sinking of the pipeline.
A method has been proposed wherein the pipeline is carried by a layer of insulating gravel, sometimes combined with plastic foam. Unless enormous quantities of gravel and foam are used requiring costly transportation of the bulk of such kind of support, the permafrost gives way and the pipeline will sink beyond control.
Furthermore, constructing the pipeline in the above described manner requires additional construction of haul roads for moving the large amounts of material and equipment required.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide means for a safe support for pipelines traversing permafrost soil and more particularly the tundras, which means do not require the heretofore used supporting means such as pilings etc.
Another object of the present invention is to provide a simple and effective process of laying and constructing pipelines over permafrost soil, for instance, permafrost soil of a tundra, said process avoiding the disadvantages of having to provide the heretofore used costly and expensive foundations for pipelines.
Another object of the present invention is to provide pipes suitable for constructing pipelines to be laid on permafrost soil and especially permafrost tundra soil.
Still another object of the present invention is to provide simple and effective coupling or joining means for coupling and connecting two pipes with each other without having to weld the pipes together, said coupling or joining means being readily attachable to the ends of the pipes and forming somewhat flexible expansion joints between two pipes.
Other objects of the present invention and advantageous features thereof will become apparent as the description proceeds.
In principle the present invention is concerned with providing pipes to be assembled to pipelines for transporting petroleum, natural gas, and other liquid fluids from a source located in the arctics over permafrost soil or sub-soil to a desired collecting, storing, or refining establishment by allowing the pipes composing the pipeline to sink partly into the permafrost liquefied by the heat emanating from the warm oil or gas passing through the pipeline, but to prevent complete submersion in the permafrost by the application of suitable buoyancy means or floats which, attached to the pipes, will prevent the pipeline from sinking fully into the liquefied ice component of the permafrost, so that part of the system (pipe plus buoyancy means) will still be found above the surface of the molten permafrost.
These buoyancy means are either of the "continuous" type and may surround the pipe like a jacket over its entire length or they are separate floaters which are distributed along the length of the pipe. Or a combination of said two types of buoyancy means can be used.
Of course, in either case the specific gravity of the floats has to be lower and preferably considerably lower than that of water so that no excessive volumes of the floats are required. Advantageously the specific gravity of the buoyancy means is between about 0.03 and about 0.20 and preferably between about 0.05 and about 0.1. To achieve this result the buoyancy means or float may be air- or gas-filled or even evacuated hollow bodies. Preferably they consist of a rubber or plastic foam material of light weight which is enclosed by a water and air impermeable covering or is of the integral skin foam type. The light-weight foam buoyancy means are preferably encased by sleeves of low-temperature alloy steel or casings. In place of foam rubber or plastic, such as urethane foam, vinyl foam especially cross-linked vinyl foam, polystyrene foam, low-density polyethylene foam, and others, there can also be used -- although less advantageously -- cork, sponge, balsa wood, and the like, provided their specific gravity is sufficiently low to carry the pipeline filled with oil or gas.
Providing the pipeline with such buoyancy means, for instance, providing it with a continuous floating jacket, has the further advantage that the heat of the oil pumped through the pipeline is preserved to a greater extent than when using a non-protected pipeline.
A simple way of constructing a "buoyant" pipeline under conditions less difficult than those of the tundra, would be to weld pipe elements of commercially available lengths together, to carry the welded pipes thus formed on appropriate supports, to wind the buoyancy imparting and heat protective material directly or spirally around the welded pipes, and then to lower the buoyant pipes onto the permafrost ground so that they sink and become partially submersed therein when the hot oil is pumped through the pipe line floating on or within the permafrost.
However, manipulating all the equipment required for such a procedure under the open air conditions of the tundra and moving it along as the pipeline "grows" is neither simple nor practical. Besides, some kind of flexible expansion joints has to be incorporated into the pipeline.
According to an especially preferred embodiment of the present invention relatively short pipeline units are produced by welding together several, commercially available "sublengths" of pipes. The resulting units are then provided with appropriate flanges with seals to which suitable flexible joints can be attached. A continuous sleeve, preferably of foam material, is then applied to the pipe units between the extreme flanges, thus forming a "field unit", as explained hereinafter.
The lengths of such prefabricated "field units" may be, for instance, 150 feet to 300 feet for a pipe of an inner diameter of 48 inches.
Prefabricated field units of such a length can readily be transported, for instance, by helicopters from strategically located assembly points to the end of the growing pipeline.
All welding work as well as the application of the foam material is carried out in established work shops under conditions not affected by the weather on the outside and the field units can be moved as soon as the weather permits, for instance, by air lift to their final location.
Unquestionably the favorable working conditions under which the assembly of the field units takes place, will yield better results. Welding control means can be applied far better in the shop than outdoors. Indoor pipe welding can be done with the pipes rotating and the welding head stationary, thus considerably simplifying the welding operation and eliminating formation of the unpleasant "overhead" portion of the weld. As a result thereof, a uniformly perfect weld is achieved under optimum conditions of efficiency and at the lowest cost imaginable.
The buoyancy imparting and heat insulating jacket of foam material can likewise be applied in the shop. This has the great advantage that the temperature conditions required for foaming can readily be controlled. Such a temperature control cannot easily be obtained when applying the foam material outside of a building.
An elastic joint can now be bolted onto one of the above described flanges of one pipe at the work shop. It is even possible to insert the bolts into the opposite flange of another pipe to be joined to the first mentioned pipe by means of the elastic and flexible joint, and the bolts can be held in place in said flange. Thus final joining of the two pipes can be carried out at the site of construction so that field work is reduced to a minimum. Jig positioned nuts can be tack welded onto the inside face of the flange for facilitating field work.
The foam material jacket can be at least locally protected by a relatively thin metallic or plastic sleeve, unless integral skin-type foam is used. For lifting purposes appropriate "ears" extending from the flanges are provided. Such an arrangement, whereby the lifting ears are provided at the end flanges of the field unit, limits its length to about 150 feet for a 48 inch pipe. If field units of a length up to 300 feet are to be installed, such field units cannot be transported to the site of construction by supporting them from their ends due to their becoming bent. Therefore, for instance, carrying belts located at about 20 % and 80 % of the total length of the field units must be provided so as to lift them without bending.
While a pipeline consisting of such bolted together field units may theoretically be more expensive materialwise than a pipeline consisting of simple steel pipes welded together, although the latter would also need expansion joints, elimination of any kind of foundation represents an enormous saving.
On the other hand, the heat insulating foam jacket will very soon pay for itself by reducing fuel consumption for keeping the crude oil at a temperature fit for pumping. The reheating stations can be placed at a much greater distance from each other than when using pipes without foam jackets. This also will result in considerable savings.
The pipeline according to the present invention which is carried by the permafrost in molten condition is quite immune to earthquakes in contrast to pipelines carried by solid supports such as pilings and the like.
Repairs can be effected more readily by replacing the damaged field unit by a spare part and do not require welding in the open field. Since most probably any trouble will occur at the joints, a spare joint can readily be inserted after lifting part of the pipeline out of the molten permafrost. Such lifting is rendered possible due to the arrangement of elastic joints between the field units.
Of course, it is necessary to "unstress" the joint before it is disconnected. For this purpose the two field units which are connected by the joint in question, can readily be lifted out of the molten permafrost in exact alignment, preferably in a horizontal position. This has the further advantage that by locally lifting sections of the pipeline, the oil will flow away from the lifted section, thus facilitating disconnection of the joint to be inspected or replaced.
The pipeline assembly according to the present invention has the further advantage that the oil can readily be removed from the pipeline by successively lifting one field unit after another thus allowing the oil to flow back towards the pumping station and/or into a reservoir. This is not possible in any other system of pipeline support.
Another advantage of providing a pipeline according to the present invention consists in the possibility of readily disassembling and using it at another location, if the necessity arises, after it has served its purpose at the original location.
As mentioned hereinabove, the actual field work is limited to air-lifting the field units to their location and bolting the elastic joint of one field unit to the free flange of another field unit.
The flexible joint which may be a metallic joint or may consist of other materials, may be provided, if desired and/or required, with a protective sleeve placed over the joint.
Since, in general, the field units can be connected with each other more rapidly than when flown, for instance, by helicopter to the construction site, laying of the pipeline can procede with "gigantic strides", i.e. in a small fraction of the time required by any other method or system under the severe conditions of the tundra.
According to an advantageous embodiment of the present invention sliding expansion joints as they are known to the art may be included in the pipeline from time to time. These joints can be connected by means of flanges and bolts to an elastic joint of the field unit.
Although it is preferred to make the pipes and the pipeline of metal and especially of steel, for instance, of special readily weldable, low temperature alloy steel, it is also possible to use re-inforced plastic as pipe material. Plastic material has the advantage that it is partly insulating and the buoyancy and floating of a pipe consisting of such plastic material will be more readily accomplished than when using steel pipes. However, welding or otherwise connecting the commercially available lengths to the final length of a field unit present a problem and, although it could be done with plastic material, it would be more complicated than the welding of steel pipes. In addition thereto a plastic tube field unit must have sufficient strength to resist bursting. For this purpose it must be protected with circular re-inforcing elements. But it must also be provided with longitudinal re-inforcing elements to withstand the bending stresses during lifting and positioning the field units. Furthermore, connection of the steel flanges at the ends of the field units with the plastic pipes presents considerable problems. Thus the costs of such plastic pipelines would be very high. For this reason metal and especially steel is the preferred pipe material.
According to another embodiment of the present invention metallic and especially steel pipes with flanges welded thereon and with ears for lifting the pipes or pipeline field units as they are described hereinabove, are provided with a metallic, preferably steel protective cover for the foam material enclosing the pipes. Said steel protective covering or jacket is made up of two parts, preferably of two halves, namely a top part and a bottom part. Said parts may, for instance, be shaped so that they result in a hexagonal cover of the pipes.
The bottom half of said hexagonal shell or cover may be provided with pipe-carrying brackets which are spaced from each other at a suitable distance and which are positioning the pipe in said bottom trough-like part while the plastic foam is introduced into the system, i.e. the space between the pipe and the hexagonal metallic jacket, after the top part has been attached thereto.
A preferred procedure of assembling the field unit consisting of pipes, bottom part or trough of the jacket and upper part or cover of the jacket, and plastic foam material enveloping the field unit consists in placing the pipe of the field unit with its flanges and ears into the bottom part or trough of the metallic jacket whereby it is spaced from said bottom part by brackets provided therein which carry the pipe. The bottom part is welded together from smaller parts and is welded to the flanges of the pipe. Then a suitable length of the upper part of the jacket, i.e. part of the upper cover which is also preferably in half-hexagonal shape is welded unto the flange of the pipe and also onto the opposite part of the lower trough-like part of the jacket. Preferably simple spacers are provided between the upper part of the pipe and the upper part of the jacket or its covering part so as to maintain the desired space between said covering part and the pipe.
The plastic foam-producing materials, preferably a mixture of a polyalcohol and an isocyanate and preferably a catalyst, foam stabilizer, and blowing agent which are admixed to the polyalcohol are introduced into the space between the pipe and the jacket in a similar manner as this is known for reaction molded urethane foam. Other foam-producing materials can, of course, also be used for filling the space between pipe and part of the covering jacket with foam. If necessary, foaming is promoted by heating the lower part of the covering. Care must be taken that said part space is only partly filled, for instance, only filled by two thirds with the foam and that its open end is kept substantially free of foam. Otherwise it will be difficult, if not impossible, to weld the next section of the upper part of the jacket to the preceding part and to the lower part so as to form another space between pipe and enveloping jacket into which again the plastic foam-producing material is introduced. By proceeding step by step and section by section in this manner, it is possible to finally envelope the entire length of the respective pipeline field unit with the foam material between its protective, preferably hexagonal cover and the pipe. The last section of the upper part of the protective cover is welded to the end flange of the field unit. Thereby either said last section or the end flange is provided with an opening through which the foam-producing material is introduced.
To avoid overheating of the foam-producing material when welding the next section of the upper part of the protective envelope to the preceding part and the lower part thereof it is advisable to effect welding at a certain distance from the foaming material, for instance, at a distance of about 3 feet by not completely filling the entire space between upper and lower part of the jacket and the pipe. This has the further advantage that the welding heat will cause prompt reaction and foam formation. Some plastic foams are formed by exothermic reaction. They require only a small amount of additional heat which is readily supplied by welding.
It is to be pointed out that one of the advantages of the half-hexagonal form of the foam protective jacket is its ability of fitting one into the other when placed upon each other. Thus the space occupied by said trough and cover parts of the jacket is reduced to a minimum thus facilitating considerably their transportation. Of course, the pipe flanges can also be of hexagonal shape when providing a foam protective jacket of hexagonal cross-section.
Another advantage of a foam-protective jacket as described hereinabove is that if voids are formed between consecutive sections of foam material, such voids will only make the field unit lighter and provide even more buoyancy, since water is excluded from the welded structure.
While formation of the above described "troughs" and "covers" can be performed by conventional butt welding, the welded connection between the trough and the cover can consist of a kink or bend provided at the edge of the trough which engages the edge of the cover. A very rapid "top" weld of the joint between trough and cover can then be performed with minimum heating of the surrounding material.
Another advantage of the hexagonal form of the jacket consists in its bottom being flat-shaped thus producing comfortable contact between the pipeline and the tundra soil. The flat surface of the top of the jacket permits walking thereon, especially in view of the fact that the buoyancy of the floating pipeline will easily support one or even several men for carrying out any required preparatory or maintenance work. Likewise it is very easy to install bridges over said flat-shaped cover so as to allow wild animals or even humans to cross the pipeline.
Still another advantage of the substantially rigid hexagon-shaped, foam material-protecting shell or jacket is based on the following consideration:
When hot oil flows through the pipeline according to the present invention, the buoyancy of the foam material protecting jacket keeps the line about one-tenth of its section area above the water level and about nine-tenths of it submerged. When, for any reason, the oil is removed from the pipeline, the latter will float in the water at a much higher level than when it is full.
Therefore, the buoyancy of the pipeline is to be calculated and the pipes with foam envelope and protective shell be designed so that the water level for an empty pipe is somewhat below the cross-sectional center line of the hexagon-shaped jacket, i.e. where the wall of the jacket extends by 60° outwardly with regard to the pipe, on both sides of its center line.
Then, if the media into which the pipeline is partly immersed freeze due to lack of heat of the flowing oil and thus exert pressure against the sloping walls of the hexagonal shell, this pressure will push the pipeline upwardly. As a result thereof, the pipeline will not be crushed by the pressure exerted by the freezing medium.
According to another embodiment of the present invention construction and assembly of the hexagon-shaped jacket or shell surrounding the pipe may be effected in the following manner so as to take care of intensive stress forces to which the pipe and its shell are exposed under the influence of changes in the surrounding temperature in the field. When assembling the pipe line field units in the workshop, the temperature to which the various parts, pipes, flanges, pipe supports within the shell or jacket, and the shell are exposed, will be substantially the same. However, in the field the pipeline will be in contact with the warm oil flowing therethrough and thus its temperature will be higher than that the surrounding media i.e. frozen or fluid tundra soil or permafrost. Due to these differences in temperature compression stresses will be created in the pipe and tensile stresses in the shell, said stresses being inversely proportional to their respective cross-sectional areas.
Therefore, the strong peripheral welds between troughs and covers are replaced by positioning tack welds, while the longitudinal welds between troughs and covers are maintained. As a result thereof relatively short sleeve shells positively fixed in their mid-length to the pipe body are formed and the ends of these shells while correctly located radially with regard to the pipe, are free sliding in the direction of the axis of the pipe. When the pipe expands from heat, the relatively short shells will remain evenly distributed over the length of the pipe elements and the field units, i.e. the pipe elements and their elastic joints.
According to a modification of this procedure solid plastic skin which may or may not adhere to the foam material is formed over the latter. This plastic skin or envelope will prevent water from entering the foam material. When constructing the pipeline accordingly, it is very easy to prevent water from getting between adjacent parts of the foam-filled shells simply by using plastic or rubber belts binding and sealing each pair of shells.
To increase the stiffness of the faces of the hexagonal shell parts, it is preferred to provide them with embossed ribbing transverse to the axis of the hexagon. Such a positioning of the ribbing will not prevent that the empty pipe line is pushed upwardly as described hereinabove.
A preferred procedure to assemble field units of the pipeline according to the above described embodiment of the present invention is as follows:
1. Pipe sections of commercially available lengths are welded together and to the hexagon-shaped end flanges to which nuts have been previously attached.
2. Central fixed supports for the pipe which are preferably located at the mid-lengths of each shell section, are then welded to the pipe at its proper places.
3. The bottom sections of the shell, i.e. the troughs are aligned in contact with each other and end supports, if provided, are welded to the troughs.
4. The welded pipe with its flanges is now placed into the aligned troughs, where it is carried by the fixed central support and may rest on the end supports welded to the troughs, whereupon the central supports can also be welded to the troughs.
5. If metallic or plastic separators are provided between the foam material of each shell, they are now placed opposite the junction of the shells. In this case any longitudinal welding is preferably effected before the foam producing agents are introduced. The foam producing agents are then introduced into the upper or covering parts of the shell or jacket through appropriate holes preferably in the horizontal parts of the cover parts.
6. Said upper or cover parts which preferably are re-inforced by the provision of stiffening and carrying means serving to support said parts on the upper surface of the pipe or by having embossed ribs are then placed on their corresponding troughs and the troughs and the covers are longitudinally welded to each other. If no separators are provided between shells, the longitudinal welds can be effected gradually, i.e. simultaneously with the introduction of the foam producing agents.
Such a construction does not create high tensile stresses in the foam protecting shell when the pipeline is heated by the hot oil passing therethrough. Accordingly the shell is constructed in short length sections and each shell section is attached to the pipe substantially at a middle distance from the ends of the shell element. In operating conditions, when the pipeline is laid on permafrost tundra soil, the shells remain substantially unchanged whereas the pipe will expand under heat. Whereas the foam material should preferably be adherent to the pipe body, the foam should, at least towards the end portions of the shells, be slidable within the interior of the shells. Otherwise the gap occuring in between the shells will be tearing apart the foam material opposite the gaps. In order to minimize the effect of the uneven expansion of the pipe proper and of the shell or shells, it is suggested to pre-heat the pipe during formation of the foam material to a temperature between the temperatures to which the different parts of a field unit may be exposed in actual use. For instance, if the lowest outside temperature is -65° F. and the highest temperature of the oil flowing through the pipe is +185° F., i.e. if the maximum difference in temperature is 185° F. + 65° F. = 250° F., it is advisable to pre-heat the pipe during formation of the foam material to about one half of the maximum temperature difference of 125° F. above the workshop temperature which may be about 70° F., i.e. to pre-heat the pipes to about 195° F.
As a result of this pre-heating procedure during manufacture of the field unit the maximum stresses encountered in the foam material due to unequal temperatures of pipe and shell or shells will be reduced to about one half of the stresses encountered when foam is formed in a non-pre-heated pipe (or a non-pre-cooled shell or shells).
According to such an embodiment of the present invention no "peripheral" welds are effected between the shells. However, it is desirable to weld the two extreme shells to the hexagon pipe flanges. In this case, in order to limit the stresses to which the shell metal is exposed, to a uniform value, the two extreme shells welded to the flanges are preferably only half as long as the other shells. Welding the shells to the flanges may replace the fixed pipe and trough supports otherwise provided in the middle of the shells, and only one "sliding support" need be used.
According to another embodiment of the present invention there are provided between the pipes, when assembling the pipeline, commercially available expansion joints. While such expansion joints may be quite adequate under ordinary climatic conditions, they may not be suitable under the extreme temperature variations of the arctic or antarctic where the temperature varies between minus 60° F. and the hot oil temperature which can be plus 190° F., i.e. a variation of 250° F. Selection of suitable sealing materals for such standard expansion joints may also cause great difficulties.
According to the present invention a U-shaped pipe expansion joint is provided which will compensate for any expansion or contraction of the main pipeline by the use of a single additional element to those employed in the construction of a field unit, namely an elbow-shaped element constructed similarly to a field unit. Such elbow elements are preferably constructed as follows:
A flange-less cast steel or welded up elbow is welded to two premachined flanges, carrying the welded-on nuts, as described hereinabove for the flanges of the field units. Suitable half hexagon-shaped angular plates are premanufactured and welded together to form a hexagonal shell to envelope the pipe elbow. Such a shell can be welded -- but need not be welded -- to both pipe flanges and the space between pipe elbow and surrounding shell can be filled with the plastic foam.
The U-shaped expansion joints may be assembled in the following manner:
1. Starting at the last flexible joint of the pipeline there are successively provided:
an elbow,
a flexible joint,
a field unit which preferably is shorter than the usual field units,
again a flexible joint,
an elbow,
a flexible joint,
an elbow,
again a field unit as above connected to the elbow by its flexible joint,
a flexible joint,
an elbow and
the flexible joint of the continuous field unit of the main pipeline.
Obviously such as construction is quite complicated.
2. According to another embodiment it is possible to eliminate four flexible joints. In this case there are successively provided starting at the last flexible joint of the pipeline:
an elbow,
a straight pipe or field unit,
an elbow,
a flexible joint,
another elbow,
again a straight pipe or field unit,
an elbow, and
the flexible joint of the continuous field unit of the main pipeline.
Such an expansion joint, of course, will not be as flexible as the expansion joint described under (1), but it will be simpler to construct. The loss in expansion may be compensated for by making the straight pipes somewhat longer than in the expansion joint under (1). Although such an expansion joint is somewhat simpler to construct, welding of the elbows to the straight pipes so that they form an S-shaped structure will be more difficult because it requires a modified rotating welding fixture.
3. Instead of using 90° elbows in the expansion U-joints described hereinabove under (1) or (2), there may be made use of the "zig-zag" method of compensating for expansion and contraction of the pipeline. For this purpose modified field units each composed of a straight pipe length and a pipe elbow, all enclosed by their respective hexagon foam-filled shells, are connected by flexible joints or even rigid joints. Rigid joints are used particularly for pipelines under very high pressure. Such expansion joints are used in a self-supporting zig-zag type oil pipeline.
Prefabricated field units according to the present invention can still be constructed regardless which angle of the zig-zag arrangement of the pipeline is selected and by which method the pipes are connected in such zig-zag fashion, i.e. whether they are connected rigidly or flexibly.
A preferred and practical "turn" of the zig-zag is a turn at an angle of 45°. A pipe elbow of an angle of 45°, whether it is made of a steel casting or is produced by welding, can be obtained much simpler than a 90° elbow.
When providing shell sections freely sliding in the direction of the axis of the expanding or contracting pipes as explained hereinabove, every other shell may be made slightly larger than "normal", so as to allow a slight overlap of the "even" shells over the "odd" ones. This could be done by either increasing the even hexagons by an amount equal to the thickness of the shell material or, having all shells of similar dimensions, provide for marginal kinks which could be overlapped by the non-kinked edges of the non-kinked shells. In such a design it is possible to completely omit the end sliding supports of the non-kinked shells (in view of the limited widths of the shells) and, if the kinked design is used, omit even the central fixed supports of the non-kinked shells.
The advantages of constructing and laying the pipeline directly onto the tundra permafrost soil according to the present invention may be summarized as follows:
1. No foundations or piles are required.
2. The pipeline is mass-prefabricated in relatively short sections, i.e. field units, which can be produced under workshop conditions while working full time, regardless of the weather, and the field units can be stored. Weather permitting, the field units are transported to the site and are connected, for instance, by bolt fasteners to the last link of the growing pipeline.
3. This method permits to use a simple, powerful welding method, thus reducing the welding time to between one-half and one-third of that required by the presently used method and producing an improved weld. This is due to the fact that the limited pipe lengths can be rotated and Heli-Arc or submerged arc welding methods can be used under shop conditions, while presently outdoor "Automatic Guidance (AGS) Systems" must be employed whereby the welding machine turns around the stationary pipe.
4. The method further permits to form the insulating foam material likewise under shop conditions by using the pipe itself and an outer protective shell as a perfect mold for the foam material. Thus fitting of the foam to the pipe and to the shell is eliminated and the bulk of foam is reduced many times so as to facilitate transportation to the pipe laying site.
5. Minimum outdoor work is required, namely picking up the field units at the shop, transporting them to the pipe laying sites, aligning them with cranes, and bolt-connecting them to the growing pipeline.
6. The bulk of the finished field units is only about 60% greater than that of the 48 inch pipe alone, calculated for a pipe wall thickness of five-eights inch.
7. The earthquake hazard is greatly reduced because the pipeline is so to say "waterborne".
8. The whole pipeline can readily be relocated to a new site when the original oil field has been exhausted.
BRIEF DESCRIPTION OF THE DRAWINGS
The attached drawings illustrate the present invention but do not limit the same thereto. In said drawings,
FIG. 1 shows a typical "short" field unit carried by its ends:
FIG. 2 shows a typical "long" field unit which is too flexible to be carried by its ends and thus is provided with appropriate belts which support this type of field unit;
FIG. 3 diagrammatically shows the possibility of lifting the pipeline in order to inspect or replace a damaged joint.
FIG. 4 in positions a, b, c, and d shows a method of emptying the pipeline by progressively lifting successive parts of it.
FIG. 5 shows a longitudinal half-section of a field unit in its upper part and an elevation in its bottom part.
FIG. 6 shows two half-sections of the field unit of FIG. 5, namely the left half cross-section taken at X--X of FIG. 5, while the right one is taken at Y--Y of FIG. 5.
FIG. 7 shows a longitudinal section of an elastic joint connected to two field units at an enlarged scale with respect to that of FIG. 5, said FIG. 7 illustrating the lifting ears used with the short field units, as they are used for transporting such units to the sites of construction of the pipeline.
FIG. 8 shows, in perspective view, a pipeline (i.e. without elastic joint) with its hexagon flanges and with foam material protected by a hexagon prismatic sleeve composed of four panels A, B, C, and D of smaller length.
FIG. 9 is a side view of such a pipeline element in partial section.
FIG. 10 is a sectional view of the joint before longitudinally welding together of "trough" and "cover" of the shell.
FIGS. 11, 12, 13, and 14 are cross-sectional views of a pipeline element according to FIG. 9, showing various supports of the pipe in the bottom part of the shell, i.e. the trough, and a support of the top part of the shell, i.e. the cover, on the pipe.
FIG. 15 is a longitudinal sectional view diagrammatically showing an end portion of a field unit of the design in which the foam-protecting sleeve is subdivided into shorter shell sections.
FIG. 16 is a cross-sectional view at a larger scale than FIG. 15 through an end support of the pipe in the shell.
FIG. 17 is a longitudinal sectional view at X--X of FIG. 16.
FIG. 18 is a cross-sectional view and FIG. 19 a longitudinal sectional view of the central, fixed support of the pipe in the trough, i.e. the bottom half of the shell.
FIG. 20 is a cross-sectional view of the cover, i.e. the top part of the shell, showing the sliding contact of the cover reinforcing T-pieces on the pipe.
FIG. 21 shows the shell support provided in kinked overlapping shells in longitudinal diagrammatic sectional view of the lower part of the pipe.
FIGS. 22 and 22A are enlarged views of the kinks of the bottom half-hexagons of the shell, i.e. of the troughs showing inner and outer kinks of the shell sections.
FIGS. 23, 24, and 25 show diagrammatically the various ways of constructing expansion "U" joints by using elbows of pipes and shells especially made in accordance with the principle according to which the field units are constructed, said expansion U-joints using flexible joints and preferably shorter field units.
FIG. 23 illustrates an expansion joint using five flexible joints.
FIG. 24 illustrates an expansion joint using "S"-shaped pipes and shells.
FIG. 25 illustrates an expansion joint in which four of the flexible joints of FIG. 23 are replaced by simple couplings bolted to the pipe and shell elbows.
FIG. 26 shows the S-shaped pipe used in the expansion joint system of FIG. 24, whereas
FIG. 27 shows the S-shaped pipe used in the expansion joint system of FIG. 24 but with the additional "dead" flanges for better positioning of the shell around the pipe.
FIG. 28 illustrates more in detail the two flexible joints (for instance, of the left upper corner of FIG. 23) showing the end of a field unit, a flexible joint, an elbow, another flexible joint, and the end of another field unit.
FIG. 29 is a view similar to that of FIG. 28 but representing the upper left corner of FIG. 25 showing the end of a field unit, a flexible joint, an elbow, a simple rigid coupling followed by the end of another field unit.
FIG. 30 illustrates the pattern of a rectangular sheet of metal said pattern being followed when making the shell elbows.
FIG. 31 illustrates the manner in which the sheet is bent into an upper and lower section of the shell elbow.
FIG. 32 shows a method of positioning the shell elbow or the straight shell on a band welded to the flange.
Like numerals in the drawings represent like parts therein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 represent assembled pipe field units. As stated above, FIG. 1 shows the short-type field unit 1-S and FIG. 2 the long-type field unit 1-L. Means 14 for lifting the field units, for instance, ears for hook-lifting are provided at the ends of the short-type field units 1-S of FIG. 1 and means 15 at appropriate places at a suitable distance from the ends of the long-type field units 1-L of FIG. 2.
The Roman numerals on FIGS. 3 and 4 designate successive field units of the pipe line. These Figs. illustrate the manner in which the pipeline is lifted out of the melted permafrost either, as in FIG. 3, for inspecting and/or replacing a specific field unit 1 and/or an elastic joint 3 between field units or, as in FIG. 4 for completely emptying the pipeline, if necessary. Dotted line 19 represents the surface level of the molten permafrost around the floating pipeline when it is filled with oil. Position a in FIG. 4 shows the highest point of the lifted pipeline between field units I and II. As soon as the oil has run out of that Section I/II, unit I may be lowered back into the molten permafrost and field units II and III are lifted so that the joint between said units II and III becomes the highest point, as shown in position b of FIG. 4. After the oil in the pipeline has run out from field units II and III, successive field units III and IV, IV and V, and so forth are lifted and replaced as shown in positions c and d of FIG. 4. In this manner it will be possible to completely drain the pipeline of its oil in the direction of the arrow. In this manner any spillage of oil can be avoided, because the pipe field units need not be removed while the pipeline is still filled with oil.
In FIG. 5 a number of pipes 4 of commercial length are welded together to pipe element 2 at the welds 5. Flanges 6 are connected to pipe element 2, i.e. to the end pipes by welds 7. Lifting ears 14 are welded to pipe 4 and/or flange 6. Nuts 8 are tacked onto the inner face of flange 6 opposite corresponding holes in said flange 6. Weldment 2A has been formed. Bolts 11 are clamping together ring-plate 10, flange 16a of elastic joint assembly 3, and flange 6 of pipe weldment 2A.
FIG. 6 shows in cross-sectional view two half sections of a field unit. In this Fig. the surface level of the molten permafrost is indicated by 19 when the pipeline is filled with crude oil and by 20 when the oil has been removed, i.e. the pipeline is empty. The left half of said FIG. 6 is a cross-sectional view through field unit 1W along the line X--X of FIG. 5 while the right half thereof is a cross-sectional view along the line Y--Y of FIG. 5. Foam material jacket 12 is provided about pipe element 2 for buoyancy and heat insulation. Said foam jacket 12 is protected by outer shell 13.
FIG. 7 illustrates more in detail the arrangement of an elastic, flexible expansion joint 3 between two field units 1W. As in FIGS. 5 and 6, the end of pipe 4 is welded to flange 6 by welds 7 with nuts 9 tackwelded to the inner face of flange 6 facing corresponding holes in said flange 6. Foam material 12 and outer shell 13 envelop pipe element 2. Ear 14 for hook-lifting is attached to pipe 4 and flange 6. Expansion joint assembly 3 consists of elastic material 16 with flange-like extensions 16a through holes of which clamping bolts 11 are passed. Expansion joint 3 is provided with protective sleeve 18. Size and number of clamping bolts 11 depend, of course, upon the diameter of the pipeline, the pressure under which the oil is pumped therethrough, and on the necessity of effecting oil-tight contact between flanges 6 and flange-like extensions 16a of expansion joint 3. The number and size of the reinforcing rings, spirals, or other means 17 is determined also by the necessity of the expansion joint to withstand the pressure of the oil in the pipeline, without, however, interfering with the elasticity of the joint.
Protective sleeves 18, clamped onto the outside edges of flanges 16a of the elastic joint 3, can be arranged so that they provide extra buoyancy if the clamping is kept on the upper part of the system.
Sleeve 18 can be made of metal or plastic material.
FIG. 8 illustrates, in perspective view, a preferred and advantageous shape of the shell surrounding the enveloping foam material and the pipe. As pointed out hereinabove, the hexagonal shape of said shell has many advantages. FIG. 8 shows that the shell may consist or several panel sections designated by A, B, C, D, which cover round pipe element 2. As is evident from said FIG. 8, several panels of the hexagonal shell are provided. These shell sections are provided with reinforcing and positioning means as they will be described hereinafter in connection with the subsequent drawings. Flange 21 is welded to the pipe and may also be welded to the first and last shell sections A and D. Preferably flange 21 is of the same size and shape as the shell envelope. However, it could also be somewhat larger. Bolt holes for clamping bolts 11 for fastening flanges 21 to flexible joints 3 (see FIGS. 5 and 7) are also shown. The shell sections A, B, C, and D consist of trough parts 22 and cover parts 23.
FIG. 10 shows a preferred way of connecting trough part 22 with cover part 23 of the shell. The edges of trough part 22 are bent to provided kink 24 and the edges of cover part 23 are welded thereon by longitudinal welds 25 in a rapid and simple manner to yield a light and safe weld. Of course, other ways and means of connecting trough parts 22 and cover parts 23 of the shell may also be employed.
In FIG. 9 pipe 2 is supported in trough part 22 by supports 27 which are tack welded to said trough part 22. In the illustrated field unit 1W the shell is composed of four sublengths A, B, C, and D which are supported by the four pipe supports 27. Likewise four cover supports 28 which can also serve as stiffening ribs for the cover parts 23 as shown in FIG. 14, are provided.
Trough parts 22 and cover parts 23 are welded to each other as shown in FIG. 9 by longitudinal weld 25, while welds 26a and 26b connect the sublengths of trough parts 22 and cover parts 23.
As is evident from FIG. 9, trough part 22 and cover part 23 of section A have been welded to each other and by weld 26c to hexagon flange 21. The space between the part of pipe 2 enveloped by the shell A formed by said trough and cover parts 22 and 23, is filled with plastic foam. Section B of FIG. 9 shows one way in which foam is introduced into the space between pipe 2 and shell section B enveloping pipe 2. The foam forming material 12 is introduced into said space by means of one or several lances 30 depositing it thereinto. Thereby foam 12 forms slope 29 within said space during its formation. By more and more withdrawing lances 30 during introduction of the foam forming material, sections A, B, and C are successively filled. The last section D can be filled with foam through manhole 31 after withdrawing the lances.
FIGS. 11, 12, 13, and 14 show in cross-sectional view the construction of the pipe supports 27 in the trough parts 22 of the shell (FIGS. 11, 12, and 13) and that of the cover supports 28 and 28A in the cover parts 23 of the shell (FIGS. 11 and 14). As shown in FIG. 11 carrier 28 in the form of an I-beam is preferably welded to the horizontal part of the cover at right angles to the general direction of the pipe and thus forms a substantial stiffener for cover parts 23. Said cover carrier 28, as shown in FIG. 14, can be completed by a longitudinal beam which, even if of only light section, results in substantially increasing the carrying capacity of the horizontal part of cover part 23 so that heavier loads can be carried by said cover part.
FIG. 11 shows a support 27 of pipe 2 in trough part 22, said support being a weldment composed of a burned- bent- and-welded structure which is tack-welded to trough 22 and holds pipe 2 on an 120° angle. The thickness of the foam material 12 in the space between trough part 22 and pipe 2 equals the height of said beam.
Pipe support 27 in FIG. 12 is composed of a weldment which is welded to trough part 22 but holds the pipe only on a 60° angle. In contrast thereto, the pipe support 27 as shown in FIG. 13 consists of plates with stiffeners welded to the pipe itself, the plates taking support at the two bottom angles of the trough.
While FIG. 9 shows only one set of stiffener-supports 27 for each of the shell panels A, B, C, and D of FIG. 9, the panels can also be several yards (meters) long. In this case it is advantageous to provide at least two such stiffener supports 27.
Several openings for introducing the foam-forming material 12 into and for filling the hollow space between pipe 2 and the hexagon shell with foam can be provided after all weldments have been completed. However, such openings require corresponding closures and, besides, afford but a very restricted control over the foam-filling operation. Therefore, as described hereinabove, the preferred procedure is as follows.
The required number of commercially obtainable pipe lengths 4 are welded together to form pipe 2 and two flanges 21 are welded to their ends (welds 7 of FIG. 7).
Appropriate lengths of trough parts 22 are welded together. The required pipe supports 27 are placed in position and welded to trough parts 22 as shown in FIGS. 11 or 12. Or they are welded to pipe 2 as shown in FIG. 13. The ends of trough parts 22 with pipe supports 27 are welded to the hexagon pipe flanges 21.
Stiffeners 28 are welded onto cover parts 23.
Cover part 23 of shell "A" is placed onto trough part 22 of shell element A and one end of cover part 23 is welded to hexagon pipe flange 21 (weld 26c).
Cover part 23 and trough part 22 of shell element A are then welded together longitudinally forming welding seam 25.
The thus created hollow space A between pipe 2 and shell section A is then filled, for instance, up to one yard (one meter) ahead of the free end of shell section A with the foam material.
Cover part 23 of shell panel "B" is then placed on pipe 2 extending from shell section A and on through part 22 of said shell panel B.
Cover part 23 and trough part 22 of shell section B are welded to shell section A and are welded together at longitudinal seam 25.
Foam-forming material is introduced into the space between pipe 2 and cover and trough parts 23 and 22 of shell section A to completely fill the same and into the corresponding space of shell section B up to about one yard (one meter) from the open end of said section B.
FIG. 9 illustrates this step of the foam introducing procedure showing lance 30 and foam material sloping at 29.
The procedure is the same for joining additional shell panels C and, if required, more panels.
The last shell panel (panel D in FIG. 9) is connected to the preceding panel (panel C in FIG 9) by placing cover part 23 of shell panel D on pipe 2 resting on trough part 22 of panel D and welding said cover part 23 to the corresponding cover part 23 of panel C.
Cover part 23 and trough part 22 forming shell panel D are then welded to hexagon pipe flange 21 which is attached to pipe 2 by weld 26d.
Finally cover parts 23 and trough part 23 of shell panel D are joined to each other by welding at welding seam 25.
The foam-forming material is introduced into the empty part of shell panel C and into shell panel D through manhole 31 which, after filling panel D completely, is either permanently sealed by screwing a manhole cover thereon or which is fluid-tightly sealed by welding thereon the manhole cover.
It is evident that lance 30 must be of a length somewhat longer than the longitudinal extension of the cover part 23, so that the empty end part of the preceding shell section can readily be filled with foam-forming material.
In FIG. 15 there are provided in trough part 22 sliding end pipe supports 32 for pipe 2 while preferably fixed central pipe supports 33 are inserted at an approximately equal distance from the ends of trough part 22. Likewise, corresponding sliding supports 34 are provided in cover parts 23. The pipe lengths 4 are welded together at weld 36 forming a pipe element 2. But the various pipe lengths need not be related to the lengths of the shell panels formed by cover parts 23 and trough parts 22. Gaps 35 may exist between consecutive shell sections. Each shell section thus is composed of relatively short lengths of a trough part 22 and a cover part 23 which comprise two end pipe supports 32, if required, a fixed central pipe support 33, and two or three reinforcing cover supports 34. The upper half-hexagon of the shell, i.e. the cover part 23 is welded longitudinally to the lower half-hexagon of the shell, i.e. the trough part 22 along weld 25 as shown in FIGS. 9 and 11.
Sliding end support 32 as shown in FIGS. 16 and 17, is composed of two rectangular plates 37 and channel part 38 which are welded together by welds 45 and 46. Plates 37 are welded to trough part 22 by weld 47 while channel part 38 is welded to trough part 22 by weld 48. Pipe 2 is simply supported by the edges of plates 37 and by the back of channel part 38.
Fixed central support 33, as shown in FIGS. 18 and 19, is composed of base 39. Web 40 is welded thereto (weld 49), stiffened by six ribs 41 and 42, welded to the base 39 by welds 50 and 51, welded to pipe 2, welds 52 and 53, welded to web 40, welds 54 and 55. All these welds (49 to 55) are performed before pipe 2 is put into trough part 22, i.e. the fixed central support 33 is welded to pipe 2. After the trough part 22 is correctly placed under the pipe, welds 56 are made, thus permanently connecting said pipe 2 with said trough part 22.
As shown in FIGS. 15 and 20, reinforcing supports 34 of cover part 23 are made of cross T-beams 28 welded to cover part 23 by welds 57 with longitudinal T-beams 28A welded to cover part 23 by welds 58. The two T-beams 28 and 28A are welded together by welds 59 and 60. The two T-beams 28 and 28A are not firmly connected to pipe 2, thus permitting relative movement when pipe 2 is heated up by the oil flowing therethrough.
The upper edges of plates 37 as well as the back of channel part 38 will also permit relative movement of sliding supports 32 when changes in temperature, although quite rarely, take place. For a better understanding of the structure of the pipe supports, the foam material has been omitted in the drawings.
In FIG. 21 showing a longitudinal section of the lower part of a pipe and its shell, the trough 22 is composed of kinked trough parts 22K, of kinked half trough part 22KK welded to hexagon flange 21, and of non-kinked trough part 22N. Kinked trough parts 22k support at their ends part of main pipe 2. The position of kinked trough parts 22K with respect to pipe 2 is fixed by median supports 33. Non-kinked trough parts 22N are not provided with end supports. Their central supports 33A are shown in dotted lines to indicate that they can be omitted.
FIGS. 22 and 22A show, in about actual size, the end of a kinked trough part 22K, the kink thereon 61, and the beginning of a non-kinked trough part 22. Of course, kink 61 can be made so as to protrude outwardly of the general line of the shell as shown in FIG. 22A, or inwardly as shown in FIGS. 21 and 22.
The upper cover part 23 of the shell can be constructed in a similar manner with kinked cover parts 23K, kinked half-cover part 23KK, and non-kinked cover part 23N.
FIG. 23 shows a pipeline expansion joint with normal flexible joints 3 of the field units 1 with combined pipe and shell elbows 62, elastic joint 3U providing flexibility of the expansion joint in combination with said flexible joints 3. Reduced length field units 1R and flexible joints 3E in combination with elbows 62 and elastic joints 3U eliminate the necessity of specifically producing S-shaped pipes and shell elements as shown in FIGS. 26 ad 27.
FIG. 24 illustrates an U-shaped expansion joint with only one extra flexible joint 3U, connected to the flexible joints 3 of the pipeline by means of S-shaped pipe elements shown without dead flanges in FIG. 26 and with dead flanges 63 in FIGS. 24 and 27.
FIG. 25 shows the use of a simple rigid coupling 64 in the construction of a U-shaped joint in which a relatively inexpensive joint 64 replaces the more expensive flexible joints 3E of FIG. 23.
Coupling 64 is composed of two hexagon flanges like flanges 21 of FIGS. 9 and 15 connected by a sufficient length of a collar enabling bolt connection between the elbows 62 and the reduced length field unit 1R (without flexible joints) by said coupling 64.
FIG. 26 shows the simplest S-shaped pipe line element 65 composed of a weldment comprising flange 21, elbow 62, a reduced pipe and shell element 1R, another elbow 62, and flange 21.
FIG. 27 is similar to FIG. 26 except that dead flanges 63 (without bolt holes) are added at the ends of pipe 1R. These flanges 63 facilitate mutual positioning of the shells around pipe 65 of the S-shaped component and its elbows.
FIG. 28 shows in some detail the entry end of the expansion joint as schematically shown in FIG. 23. It is evident that the angles forming the shell elbow element divide the 90° of the elbow in four equal parts (see FIG. 29). Should it be desired to build a shell for a 45° elbow, the hexagon flange would have to be placed at the line X--X of FIG. 28. (This is not for the expansion joint).
FIG. 29 shows more in detail the expansion joint according to the diagram of FIG. 25, in its upper left corner.
FIG. 30 shows the developed outline of the plate b o -b o -b o -b o to be cut according to c o -d-d-c o , then folded at 60° according to lines a-d-d -a, the b o lines taking position b-b of FIG. 30 and forming the horizontal joints of the hexagon in FIG. 31, which is section XX of FIG. 28.
Thus portions I, II, and III of FIG. 30, when bent according to FIG. 31 (along lines a-d-d-a of FIG. 30), will form parts I, II, and III of the shell elbow of FIGS. 28 and 29.
The shells of the pipeline elbows can be welded to at least one of their flanges or they can simply be put onto an hexagon outline band 66 which is welded to the flanges, the dimensions of this outline corresponding to the kink 61 described in FIG. 22.
FIG. 32 shows a section through shell section part I of elbow 62, through band 66, and through flange 21 to which band 66 is welded. Pipe 2 is also welded to flange 61.
After placing the elbow shells around bands 66 (one on each flange 21) it is now possible to perform horizontal welding at the lines b--b of FIG. 30 or at points b of FIG. 31 and then to fill the hollow space between pipe elbow and the shell of the elbow with the foam material through appropriate holes (not shown).
It may be pointed out that the zig-zag arrangement as described hereinabove is not only used in the construction of the expansion joints but the entire pipeline may be laid in zig-zag fashion including rigid angles and no flexible joints at all.
As described hereinabove, the shells as shown in FIGS. 21 and 22 may have not only an inward kink but also, as shown in FIG. 22A, an outward kink. While the external appearance of the inwardly kinked shell of FIG. 22 has a smoother surface, the outwardly kinked shells of FIG. 22A have the advantage that they present a smoother surface within the shells so that the foam material inside the shells can slide more easily during expansion and contraction of the pipe and the shell body.
The following expressions have been used in the foregoing specification and denote the following parts of the pipeline assembly:
"Field Unit": The field unit 1 can be short or long. It comprises the weldment 2, the foam jacket, its protective shell, and the flexible joint. 1-S in the attached drawings represents the short field unit and 1-L the long the long field unit, while 1-W is the field unit 1 without the flexible joint 3.
"Weldment": The weldment comprises the weld pipes 4 of commercial length, the round flanges 6 or the hexagonal flanges 21, and the lifting ears, if any, but not the shell, nor the foam jacket.
"Flexible Joint": the assembled flexible joint is indicated in the drawings by the numeral 3.
"Pipe": The commercially available length of pipe is indicated in the drawings by the numeral 4.
"Pipe Elements": The pipe element 2A corresponds to weldment 2, but without flanges 6 or 21.
The following examples show the water lifting force and the buoyancy for a 48 inch oil pipeline according to the present invention. The buoyancy and water lifting force as well as the weight of the pipeline are calculated for a steel pipe of 1,220 mm. inner diameter and a wall thickness of 15 mm; a steel shell of 5 mm. thickness and an outer diameter of 1,600 mm. for a round shell and of 1,600 mm. for the plane parts of a hexagonal shell; an oil density of 0.95; and a foam density of 0.15. Thus the inner diameter of the pipe is 48 inches, its wall five-eighths inch thick, while the shell has an outer diameter or a plane dimension of the hexagon plane of 63 inches and a wall thickness of three-sixteenths inch.
______________________________________Round Shell:Weight per m. of length: Oil 1,110.52 kg. Pipe proper 456.85 kg. Foam 113.76 kg. Shell 196.68 kg. Total weight 1,877.81 kg.Water lifting force: 2,010.68 kg.Resulting buoyancy 132.87 kg.corresponding to about 7% of weight.Hexagon Shell:Weight per m. of length: Oil 1,110.52 kg. Pipe proper 456.85 kg. Foam 144.33 kg. Shell 216.87 kg. Total weight 1,928.57 kg. Reinforcements 100.00 kg. Final total weight 2,028.57 kg.Water lifting force: 2,250.25 kg.Resulting buoyancy 221.67 kg.corresponding to about 11% of weight.______________________________________
According to another embodiment of the present invention it is not necessary to make the shell of several independent sections as described and illustrated, for instance, in FIGS. 21, 22, and 22A. The entire shell for each pipe unit can also be made of corrugated material; because due to the corrugations the shell will yield to the differences in temperature between pipe and shell without creating dangerous stresses. Such a construction will permit welding not only of the pipe to the flanges but also of the one piece-shell thereto, thus making completely water-tight the field unit of pipe and shell filled with foam. Of course, the shell of corrugated material may be of round cross-section or it may have a hexagon shape. | Self-supporting pipelines, especially useful for installations in arctic and antarctic regions and floating on permafrost even when said permafrost is molten, comprise prefabricated field units of assembled pipe elements composed of pipes enveloped by spaced shells and having within the space between pipe and shell buoyancy-imparting and insulating means such as foamed plastic. Said pipe elements are connected with each other by flexible joints to form the pipeline. The pipelines do not require foundations or piles. The field units can be mass-prefabricated under workshop conditions independently from the weather. | 5 |
FIELD OF INVENTION
[0001] This invention relates to devices for producing electrical power, pressurized water or other useful work from surface waves on a water body.
[0002] More particularly, this invention relates to wave energy converters wherein either all or a substantial portion of the energy captured or produced is from one or more submerged devices relying on overhead wave induced subsurface differences in hydrostatic pressure and/or enhanced surge or pitch which expand and contract or otherwise deform or deflect one or more gas filled submerged containers, thereby producing useful work. Such expansion and contraction is enhanced or supplemented by wave focusing, reflection or diffraction techniques and/or by overhead surface floating bodies.
BACKGROUND OF THE INVENTION
[0003] Wave energy commercialization lags well behind wind energy despite the fact that water is several hundred times denser than air and waves remain for days and even weeks after the wind which originally produced them has subsided. Waves, therefore, efficiently store wind kinetic energy at much higher energy densities, typically averaging up to 50 to 100 kw/m of wave front in many northern latitudes.
[0004] Hundreds of uniquely different ocean wave energy converters (OWECs) have been proposed over the last century and are described in the patent and commercial literature. Less than a dozen OWEC designs are currently deployed as “commercial proto-types.” Virtually all of these suffer from high cost per average unit of energy capture. This is primarily due to the use of heavy steel construction necessary for severe sea-state survivability combined with (and in part causing) low wave energy capture efficiency. Only about 10% of currently proposed OWEC designs are deployed subsurface where severe sea-state problems are substantially reduced. Most subsurface OWECs are, unfortunately, designed for near shore sea bed deployment. Ocean waves lose substantial energy as they approach shore (due to breaking or reflected wave and bottom and hydrodynamic friction effects). Near shore submerged sea bed OWECs must be deployed at greater depths relative to average wave trough depths due to severe sea-state considerations to avoid breaking wave turbulence, and depth can not be adjusted for the large tidal depth variations found at the higher latitudes where average annual wave heights are greatest. Wave induced subsurface static pressure oscillations diminish more rapidly in shallow water as the depth below waves or swell troughs increases.
[0005] Only a few prior art subsurface devices use gas filled or evacuated containers like the present invention, producing container deformation in response to overhead swell and trough induced static pressure changes. None of the prior art subsurface OWECs capture both hydrostatic (heave) and hydrokinetic wave energy (surge or pitch) which represents half of all wave energy. None of these prior art subsurface OWECs enhance or supplement energy capture with overhead floating bodies. All of the prior subsurface deformable container OWECs suffer from high mass (and therefore cost) and low energy capture efficiency (even more cost) usually due to near shore or sea bed deployment and high mass. None of these have the tidal and sea-state depth adjustability of the present invention needed for enhanced energy capture efficiency and severe sea-state survivability. None have the low moving mass (allowing both short wave and long swell energy capture) and the large deformation stroke (relative to wave height) needed for high capture efficiency of the present invention.
[0006] At least two prior art devices use two variable volume gas filled containers, working in tandem, to drive a hydraulic turbine or motor. Gardner (U.S. Pat. No. 5,909,060) describes two sea bed deployed gas filled submerged inverted cup shaped open bottom containers laterally spaced at the expected average wavelength. The inverted cups are rigidly attached to each other at the tops by a duct. The cups rise and fall as overhead waves create static pressure differences, alternately increasing and decreasing the gas volume and hence buoyancy in each. The rise of one container and concurrent fall of the other (called an “Archemedes Wave Swing”) is converted into hydraulic work by pumps driven by said swing.
[0007] Similarly, Van Den Berg (WO/1997/037123 and FIG. 1 ) uses two sea bed deployed submerged average wavelength spaced interconnected pistons, sealed to underlying gas filled cylinders by diaphragms. Submerged gas filled accumulators connected to each cylinder allow greater piston travel and hence work. The reciprocating pistons respond to overhead wave induced hydrostatic pressure differences producing pressurized hydraulic fluid flow for hydraulic turbines or motors.
[0008] The twin vessel Archemedes Wave Swing (“AWS”) of Gardner (U.S. Pat. No. 5,909,060) later evolved into a single open bottomed vessel ( FIG. 2 ) and then more recently Gardner's licensee, AWS Ocean Energy has disclosed an enclosed gas filled vessel (an inverted rigid massive steel cup sliding over a second upright steel cup) under partial vacuum ( FIG. 3 ). Partial vacuum, allowing increased stroke, is maintained via an undisclosed proprietary “flexible rolling membrane seal” between the two concentric cups. Power is produced by a linear generator ( FIG. 2 shown) or hydraulic pump driven by the rigid inverted moving upper cup. An elaborate external frame with rails and rollers, subject to fouling from ocean debris, is required to maintain concentricity and preserve the fragile membrane.
[0009] FIG. 4 (Burns U.S. 2008/0019847A1) shows a submerged sea bed mounted gas filled rigid cylindrical container with a rigid circular disc top connected by a small diaphragm seal. The disc top goes up and down in a very short stroke in response to overhead wave induced static pressure changes and drives a hydraulic pump via stroke reducing, force increasing actuation levers. Burns recognizes the stroke and efficiency limitations of using wave induced hydrostatic pressure variations to compress a gas in a submerged container and attempts to overcome same by arranging multiple gas interconnected containers perpendicular to oncoming wave fronts. North (U.S. Pat. No. 6,700,217) describes a similar device. Both are sea bed and near shore mounted and neither is evacuated or surface vented like the present invention to increase stroke and, therefore, efficiency.
[0010] FIG. 5 (Meyerand U.S. Pat. No. 4,630,440) uses a pressurized gas filled device which expands and contracts an unreinforced bladder within a fixed volume sea bed deployed rigid container in response to overhead wave induced static pressure changes. Bladder expansion and contraction within the container displaces sea water through a container opening driving a hydraulic turbine as sea water enters and exits the container. Expansion and contraction of the submerged bladder is enhanced via an above surface (shore mounted) diaphragm or bellows. High gas pressure is required to reinflate the submerged bladder against hydrostatic pressure.
DISCLOSURE OF THE PRESENT INVENTION
[0011] According to embodiments of the present invention, one or more gas tight containers are submerged to a depth slightly below anticipated wave and swell troughs. The container(s) have a fixed depth rigid end or surface held at relatively fixed depth relative to the water body mean water level or wave troughs by either a flexible anchoring means, with horizontal depth stabilization discs or drag plates, or by a rigid sea bed attached spar or mast, or the bottom itself. A second movable rigid end or surface opposes said first fixed end or surface. Said fixed and movable ends are separated and connected by and sealed to a flexible, gas tight, reinforced, elastomer or flexible metal bellows, or a diaphragm or accordion pleated skirt also suitably reinforced against collapse from container internal vacuum or external hydrostatic pressure. Overhead waves and troughs produce hydrostatic pressure variations which compress and expand said containers, respectively, bringing said movable end closer to and further from said fixed depth end. Container expansion and contraction (or “stroke”) is enhanced by either partial evacuation of said container or venting of said containers' gas to a floating surface atmospheric vent or to a floating surface expandable bellows or bladder, or reservoir. Without said partial evacuation or atmospheric venting, said stroke and hence energy capture would be reduced several fold. The relative linear motion between said containers' fixed and movable ends is connected to and transferred to a hydraulic or pneumatic pumping means or, mechanical or electrical drive means. The pressurized fluid flow from said hydraulic or pneumatic pumping can drive a motor or turbine with electric generator. Mechanical means can direct drive a generator via rack and pinion gearing, oscillating helical drive or other oscillating linear one or two way rotational motion means. Electrical drive means can be by a linear generator. After compression return and expansion of said containers and its' movable end can be assisted by mechanical (i.e. springs) pneumatic (compressed gas), hydraulic or electric means. Efficiency can be further enhanced by delaying said compression and expansion until hydrostatic pressure is maximized and minimized, respectively via the use of pressure sensors and control valves. Power recovery can occur on either or both strokes. The submerged depth of said containers relative to the sea bed and wave troughs can be hydrostatically sensed and adjusted by a hydrostatic bellows or by hydraulic or electro-mechanical drives for tides to maintain high efficiency by maintaining a relatively shallow submerged depth. The submerged depth can also be increased or the device can be temporarily compressed or locked down during severe sea-states to increase survivability. The stroke or linear motion produced by said container's compression and expansion and applied to said pumping or drive means can be reduced and its' drive force correspondingly increased by use of leveraged connecting means such as rack and pinion or reduction gears, scissor-jacks, linear helical drivers, or lever and fulcrum actuators. High hydraulic pressure can be produced even in moderate sea states by the sequential use of multiple drive cylinders of different sectional areas or by using multi-stage telescoping cylinders. The linear oscillating motion of said container(s) expansion and contraction can be converted into smooth one way turbine, pump, motor or generator rotation via the use of known methods including accumulator tanks, flow check (one way) valves and circuits or mechanical drives, ratchets and flywheels. Mechanically connecting said moving second surface to any floating overhead device, including said floating vent buoy or a floating wave energy converter further increases stroke, energy capture and efficiency. Suitably shaping, inclining (towards wave fronts) and extending the surfaces of said moving second surface provides major additional energy capture. Wave reflection (off a back wall) and focusing also increase both potential (heave) and kinetic (surge and pitch) wave energy capture. The subject device may have a typical diameter and stroke of 5-10 meters and produce 0.25 MW to 1 MW of electrical power. Elongated or multi-unit devices may have major dimensions and outputs of several times that.
Distinguishing Features Over Prior Art
[0012] The subject invention provides substantial advantages over the prior art. Van Den Berg (WO/1997/037123), shown in FIG. 1 , requires two shallow water sea bed mounted pistons rather than the one of the present invention, separated by an average wavelength. A gas tight chamber is maintained below each piston by a rolling membrane seal. The rolling membrane seal limits stroke and, therefore, energy capture and is vulnerable to frictional wear between the piston and cylinder and near shore debris caught within the seal. The two chambers are connected to two gas accumulator tanks to slightly increase piston travel and rebound rather than utilize the partial evacuation or surface or atmospheric venting of the present invention. The piston connecting rods drive hydraulic pumps which drive a hydraulic motor and generator. Twin chamber devices spaced one average wavelength apart are inherently inefficient as wavelengths are very seldom at their average value. At 0.5 or 1.5 times average wavelength, such devices produce no energy. Submerged shallow sea bed mounted devices must be placed well below the average wave or swell trough depth to survive breaking waves in severe sea-states. Wave induced static pressure differences diminish rapidly with depth in shallow water. Shallow water sea bed mounted devices must be rugged and therefore costly as well as inefficient. Unlike the present invention, depth of sea bed devices can not be adjusted for tides.
[0013] Gardner (U.S. Pat. No. 5,909,060) also proposes a twin chamber shallow sea bed device which is essentially two inverted open bottomed cup shaped air entrapped vessels spaced an “average” wavelength apart and rigidly connected by an air duct. One vessel rises as the other falls (like a swing) pumping hydraulic fluid for an hydraulic motor generator. The device is called an “Archemedes Wave Swing.” A single vessel open bottom shallow sea bed mounted variant ( FIG. 2 ) is also described, the upside-down air entrapped cup moves up and down in response to overhead wave induced static pressure variations driving a generator with a mechanical or hydraulic drive. Unlike the present invention, which uses an evacuated or surface or atmospheric vented closed vessel, Gardner's up and down movement, and therefore output and efficiency, is restricted because the vessel is not evacuated or vented to atmosphere or an accumulator. The entrapped air is, therefore, compressed thus restricting movement, efficiency, and output. The open bottom also presents problems such as weed fouling and air loss (absorption in water) not encountered in the closed vessel of the subject invention. Shallow water or sea bed mounting also raises costs and lowers efficiency as previously described in Van Den Berg above.
[0014] Gardner licensed U.S. Pat. No. 5,909,060 to AWS Ltd. which published an “improved” evacuated enclosed vessel design in November 2007 (as depicted in FIG. 3 ). Air under partial vacuum is entrapped between a moving rigid (heavy) inverted cylindrical cup shaped upper vessel ( 11 in down position, 12 in up position) which slides over a similar slightly small diameter stationary up oriented cup shaped vessel affixed to the sea bed. Partial vacuum is maintained by a “flexible rolling membrane seal” ( 14 in down position and 15 in up position). To prevent frictional seal wear and binding between the moving and stationary cup, an elaborate marine foulable “ectoskeleton” or frame 16 with rollers 17 or skids is required. The movable inverted cup drives a hydraulic piston 18 providing pulsed pressurized flow on each down stroke. Unlike several embodiments of the present invention, no power is produced on the upstroke which is used to hydraulically return the piston 18 and movable inverted cup 11 and 12 to its' up position 12 .
[0015] The present invention differs from the published AWS design of FIG. 3 in the following major ways:
1. The flexible elastomer bellows and smaller (plate not cup) light weight (fiberglass) moving surface of the present invention reduces total and moving mass several fold and is, therefore, several fold less costly (light weight flexible (elastomer) sidewalls vs AWS heavy rigid steel overlapping sidewalls). Low moving mass of the present invention greatly increases responsiveness allowing both wave and swell kinetic energy capture vs. the heavy AWS mass for swells only. Low moving mass also allows effective timing, or delayed release, of the compression and expansion strokes until the wave crest and trough, respectively, are overhead preserving precious stroke length until hydrostatic forces are at a maximum (for compression) and minimum (for re-expansion). This “latching” control alone can increase the energy capture efficiency of heaving mode OWECs several fold (see cited references Falnes & McCormick). 2. Certain preferred embodiments of the present invention use direct or indirect atmospheric venting, rather than the partial vacuum used by AWS which may be more difficult to maintain sea water leak free and may compromise hydraulic seals. Partial vacuum also results in some gas compression on the vessel compression stroke which reduces stroke and, therefore, energy capture. 3. Certain preferred embodiments of the present invention utilize overhead surface floating buoys connected to the flexible reinforced bellows container to enhance compression or expansion of said containers or otherwise supplement energy capture. 4. No expensive, heavy, high maintenance, marine debris fouled ectoskeleton/cage with exposed rollers (to maintain concentric cylinder in cylinder movement) is required for the present invention. 5. No “flexible rolling membrane seal” (a fragile high wear, high maintenance item) is required with the present invention. Partial container evacuation combined with hydrostatic seawater pressure draws this seal into the container interior reducing container volume and increasing seal wear. 6. The membrane seal and concentric overlapping cups of the AWS device restricts stroke to less than half that of a present invention device of comparable size, halving cost and doubling energy capture. 7. The “rolling membrane seal” limits the AWS device to a circular horizontal planar section. An oblong section possible with the present invention, may be oriented transverse to the wave front direction (parallel to the waves) and, can capture more energy per unit of horizontal planar area and width. The sides of a circle have very little frontal area and capture. 8. The rigid near shore sea bed attachment post of the AWS device ( 19 in FIG. 3 ) does not allow depth adjustment for tides or optimized energy capture or protection from severe sea-states like the adjustable depth mooring systems of the present invention. 9. Embodiments of the present invention use a force multiplier or leveraged connecting means and/or multi-staged or multiple sequenced drive cylinders to increase stroke while maintaining higher capture efficiency than the AWS device ( FIG. 3 ). 10. The device of the present invention, unlike the AWS device, can be oriented vertically (with either fixed or moving surface up), horizontally, to also capture lateral wave surge energy, or in any other orientation.
[0026] Burns (2008/0019847A1, 2007/025384/A1, and 2006/0090463A1) and FIG. 4 also describes a submerged sea bed mounted pressurized gas filled cylindrical container 11 having a small diaphragm 39 flexibly connecting a rigid movable top 25 , 28 to the top of cylindrical side walls 17 . The top and attached small diaphragm move slightly in response to overhead swell induced static pressure changes driving a leveraged 63 hydraulic pump 47 . To overcome gas compression stroke limitations, Burns in some embodiments uses multiple adjacent gas interconnected containers, but they are too close to each other to be effective. North U.S. Pat. No. 6,700,217 describes a very similar container and small diaphragm, without gas evacuation, venting or gas interconnection.
[0027] The present invention overcomes the limitations of Burns and North in like manner to the AWS/Gardner limitations described in 1-10 above. More particularly or in addition:
1. Neither Burns nor North use surface or atmospheric venting or partial evacuation like the present invention to reduce container gas compressive/resistance and greatly increase stroke and energy capture. 2. Neither Burns nor North or any other submerged vessel prior art use any means before, after on or floating above their vessels to focus or capture any kinetic wave energy representing 50% of all wave energy. Likewise no submerged vessel prior art use a mechanical connection between said submerged vessel and a surface float to increase the stroke and energy capture of said submerged vessel. 3. While Burns and North have less moving mass than AWS, their total mass (and therefore cost) is probably greater due to their heavy walled ( 11 and 17 ) ballasted sea bed mounted containers. 4. Burns' and North's small unreinforced diaphragms 29 severely limit their power stroke lengths to a small fraction of the overhead wave height and, therefore, a like small fraction of energy capture rather than a substantial or even majority stroke to wave height ratio of the present invention. 5. Burns' power stroke (and, therefore, energy capture efficiency) is limited by his return means, which uses stroke limiting container internal gas pressure. 6. Burns' attempts to improve his poor stroke and energy capture efficiency in his latest application (2008/0019847A1) by aligning a series of pressurized gas interconnected containers into the direction of wave travel in an “arculated” shape is ineffective in overcoming gas compressive resistance because his containers span less than ½ average wave length. 7. Sea bed mounting of Burns' devices further severely reduces potential energy capture efficiency because sea bed mounting places Burns' movable device tops substantially below average wave trough depth due to tides and severe sea-state device protection considerations. Wave induced static pressure fluctuations fall off drastically with increased depth in shallow water as previously stated.
[0035] Meyerand U.S. Pat. No. 4,630,440 ( FIG. 5 ) shows a submerged sea bed deployed gas filled unreinforced bladder 18 within a larger rigid sea water filled container 26 . Meyerand's “bladder in a box” differs materially from the “reinforced flexible bellows” with one fixed rigid end surface and an opposing moving rigid end surface of the present invention. Meyerand's bladder is connected via an air duct to a second shore or surface floating bladder 34 . Sea water enters and exits the rigid container 26 , in response to overhead wave induced pressure changes on the bladder 18 , through a single opening pipe containing a sea water driven turbine-generator. Meyerand's '440 suffers the same limitations of near shore sea bed mounted hydrostatic pressure driven devices previously described. The long pneumatic hose 24 between the submerged container 26 with bladder 18 and the shore or surface based bladder 34 produces substantial pneumatic flow efficiency losses. It also reduces the submerged bladder response time limiting energy capture to long swells and not waves. Most significantly, to get Meyerand's “constant pressure” and “constant volume” two bladder system to reinflate when a trough is overhead (Meyerand's only “return means”), the operating “constant pressure” must be extremely high to support and lift the water column above it (45 psi per 100 ft. of water depth). This high “constant pressure”, “constant volume” gas needed for submerged bladder inflation severely limits submerged bladder volume changes and energy capture. The present invention does not use high pressure gas within the container and surface vent or bellows as its' return means. The container gas pressure is approximately one (1) atmosphere or lower allowing several times more stroke and energy capture.
[0036] Margittai (U.S. Pat. Nos. 5,349,819 and 5,473,892) describes a flexible gas (air) filled submerged (sea bed placed) container which expands and contracts in response to overhead wave induced hydrostatic pressure changes. The rigid top surface is rigidly affixed to and drives a vertical 1 stroke sea water open cycle pump. Unlike the present invention, Margittai does not vent or evacuate his container (he actually “inflates” or pressurizes it to hold its shape against submerged hydrostatic pressure and to provide his only return or re-expansion means, thereby limiting his stroke and wave energy absorption several fold. Margittai uses a simple bladder unreinforced against external hydrostatic pressure, unlike the “reinforced bellows” of the present invention (reinforced against both internal vacuum and external hydrostatic pressure). Margittai relies upon severely stroke and efficiency limiting internal air pressurization for his return means rather than the mechanical or hydraulic return means of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a submerged elevation sectional view of the Prior Art by Van Den Berg 1997/037123.
[0038] FIG. 2 is a submerged elevation sectional view of the Prior Art of Gardner U.S. Pat. No. 5,909,060.
[0039] FIG. 3 is a submerged elevation sectional view of the Prior Art of AWS Ltd. as described in the published 29 October-11 November “The Engineer” (pgs. 26 and 27).
[0040] FIG. 4 is a submerged elevation sectional view of the Prior Art by Burns (2008/0019847A1).
[0041] FIG. 5 is an elevation view of Meyerand U.S. Pat. No. 4,630,440.
[0042] FIG. 6 shows a submerged elevation sectional view of a preferred embodiment of application Ser. No. 12/454,984 ( FIG. 15 ) incorporated herein by reference.
[0043] FIG. 7 shows a submerged elevation sectional view of one embodiment of the present invention comprising a vertically oriented partially evacuated or surface vented reinforced flexible bellows container with a said second moving surface extended beyond said bellows top and inclined toward prevailing wave fronts driving a telescoping hydraulic cylinder powering a sea bed hydraulic motor generator. Mooring, tidal depth adjustment, and depth fixing means are also shown.
[0044] FIG. 8 shows submerged elevation sectional ( 8 a ) and plan view ( 8 b ) of one embodiment of the present invention comprising an expanded partially evacuated or surface vented reinforced flexible bellows container, said bellows being flexibly inclined toward prevailing wave fronts. Said second moving surface is extended both forward and down (towards oncoming waves) and rearward and upwards for increased wave kinetic energy capture. Said bellows extensions having spring loaded vents or flaps reducing hydrodynamic drag when said second moving surface is re-extended.
[0045] FIG. 9 shows a submerged elevation sectional view of one embodiment of the present invention similar to FIG. 8 , but comprising a hinged movable surface over said second moving surface, said hinged surface driving a hydraulic cylinder supplementing the hydraulic drive cylinder within said bellows.
[0046] FIG. 10 shows submerged elevation ( 10 a ) and plan ( 10 b ) views of one embodiment of the present invention comprising a fixed depth inclined shoaling plane in front of said bellows container and a fixed wave reflective wall behind said bellows container, relative to the direction of oncoming waves. Wave funneling and focusing means are also incorporated.
[0047] FIG. 11 shows an elevation view of a preferred embodiment of the present invention similar to FIG. 8 except also comprising a floating surface vent buoy mechanically connected through a lever to said submerged container so as to assist in compression and expansion of said container when waves and troughs, respectively pass overhead.
[0048] FIG. 12 shows an elevation partial (cutaway) sectional view of an embodiment of the present invention comprising a submerged vertically oriented bellows chamber with extended and inclined moving said second surfaces vented to and lever connected to a surface floating bellows. An air turbine generator produces power from alternating gas flow through a duct connecting said bellows.
[0049] FIG. 13 shows a submerged isometric view of one embodiment of the present invention showing multiple partially evacuated or surface vented elongated flexible bellows containers having common inclined said second moving surface extending both forward (toward oncoming waves) and rearward and common fixed first surface hinged together.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0050] FIGS. 1-5 show prior art previously discussed. FIG. 6 shows a preferred embodiment of U.S. patent application Ser. No. 12/454,984 (FIG. 15) incorporated herein by reference and of which this application is a Continuation-in-Part.
[0051] FIG. 7 shows an embodiment of the present invention similar to FIG. 6 . Stationary surface 1 (sealed to a reinforced flexible bellows 3 ) is part of a molded or fabricated lower hull 100 which may have integral buoyancy chambers 101 . Moving surface 2 is part of upper hull 102 which may also contain buoyancy chambers 101 which may also serve as expansion chambers. Flexible bellows 3 is supported against external hydrostatic pressure and, optionally internal partial vacuum, by (internal only) support rings 6 . Bellows expansion return is via return spring 44 which return can be assisted or replaced by the 3 stage telescoping hydraulic drive cylinder 103 . Bellows internal support rings 66 could be replaced by a helically wound spring (not shown) also serving as said return means. Said bellows 3 and drive cylinder 103 are protected from severe lateral loads and deflection if required by an internal central slide tube or rails sliding within mating tubes or rails 105 in both the top and bottom hulls. Such sliding is facilitated by rollers or bearings 106 . The bellows 3 is further supported against lateral or shear loads by cross members 107 also rolling on said slide tube or rails 104 . The drive cylinder 103 is hydraulically connected to a sea bed mounted “power pod” 110 via hydraulic lines 108 and 109 passing through a rigid mast or spar 111 . Said single “power pod” can service multiple bellows via additional hydraulic lines (not shown). The upper mast 111 houses or supports a tidal depth adjusting jack screw 112 driven by electric or hydraulic jack screw drive 113 . Said power pod is sealed against sea water and houses high pressure hydraulic fluid accumulator tanks 114 , hydraulic motor 115 , electric generator 116 , and controls. The hydraulic circuit contains control valves 117 on high pressure supply and low pressure return lines which may be used to delay or time the drive cylinder 103 power (down) stroke and return stroke until the wave crest 5 or trough (shown), respectively, are overhead, for maximum stroke length and energy capture (per Ref. cited and included “latching” by Falnes and McCormick). Fixed surface 1 is held in deep water at a relatively fixed depth by the buoyance of the gas filled bellows container 4 and any buoyance chambers 101 and drag planes, plates or discs 118 . Said spar 111 and said container can be held in a relatively vertical position by three or more upper cables 119 and three or more lower cables 120 affixed to three or more anchor points 121 . The upper surface 125 of upper hull 102 is inclined toward prevailing waves with the leading extension 126 curving slightly downward creating an “artificial shoal” increasing the wave height above it (and hydrostatic pressure below it) and producing and absorbing supplemental “surge” kinetic energy. The trailing extension 127 curves upward directing waves upward and also reflecting waves back, both also increasing wave height and energy capture
[0052] FIG. 8 shows an embodiment of the present invention similar to FIG. 7 . Like FIG. 7 , upper said moving surface 125 has leading 126 and trailing 127 extensions as well as lateral extensions 128 to increase wave height and capture horizontal (surge) wave kinetic energy component. To reduce the hydrodynamic drag of these extensions, hinged 130 vents or flap panels ( 131 leading and 132 trailing) are spring loaded 133 about said hinges 130 such that lateral wave particle motion keeps said panels closed when waves move overhead and said bellows containers 4 are compressing and said springs 133 open said panels 131 and 132 when troughs are overhead and said bellows containers 4 are re-expanding reducing return stroke drag losses. Unlike FIG. 7 , the central axis of movement 134 of said bellows chambers 4 is rotatably inclined forward about hinge 140 preferably from 20 to 120 degrees (from vertical up), and more preferably from 30° to 90°, to capture a larger portion of oncoming wave horizontal (surge) kinetic energy component which both compresses container 4 and rotates it rearward about hinge 140 . Said rotation about hinge 140 compresses supplemental hydraulic drive cylinders 141 . Such rotation is restored after each wave surge by return springs 142 on said drive cylinders 141 , or spring 143 attached to said fixed mast 111 . Such surge component is increased by the “artificial shoal” forward extension 125 which extension should preferably be from 90° to 150° regardless of the orientation angle of said containers central axis of movement 134 . Container extended top moving surface 125 also has vertical “side shields” or vanes 135 to prevent oncoming waves piling up on extended surface 125 from prematurely spilling off before driving surface 125 downward. Said side shields 135 are converging providing a wave funneling or focusing effect. Said side shields 135 also keep said bellows container oriented into oncoming wave fronts.
[0053] FIG. 9 shows an embodiment of the present invention similar to FIG. 8 except that a movable upper surface 137 curving or extending upwards and rotatably hinged 138 to said moving second surface 125 drives supplemental hydraulic drive cylinder 139 (with optional return spring). Alternatively, said hinged surface 137 could also drive main drive cylinder 103 if its' shaft were extended (and sealed) through surface 125 (not shown).
[0054] FIG. 10 a (elevation) and 10 b (overhead plan view) show submerged embodiment of the present invention similar to FIGS. 8 and 9 . Like FIG. 8 or 9 , said containers axis of compressive movement is inclined forward. Said container is rigidly attached to the fixed depth mast of spar 111 rather than pivoting (like FIGS. 8 and 9 ). Said inclination angle can be adjusted by compression bolt 155 . Like FIG. 7 , said mast or spar 111 has a retractable section 145 allowing the devices above it to be raised or lowered in depth to compensate for tides, average wave height, or severe sea states. The bellows container 3 and mooring system can be of construction similar to that described in FIG. 7 . Said bellows container 3 is shown in the compressed position with wave 5 cresting directly overhead. Like FIG. 7 , said moving surface 2 has a central section 125 , a downward curved leading section 126 (facing toward oncoming prevailing wave fronts) and an upward curving section 127 . The fully expanded position of said bellows container 3 and said surfaces 125 , 126 , 127 are shown as dotted lines. Said moving surface also has vertical side walls 135 as described in FIGS. 8 and 9 . Said bellows container 3 is preceded by an “artificial shoaling” surface 146 which is inclined or curved downward which surface acts like a shallow sea bed bottom increasing wave height and converting deep water wave particle circular motion (and wave kinetic energy) into horizontal motion (wave surge motion) for enhanced capture by surfaces 125 and 127 . Said shoaling surface 146 has generally vertical converging side shields 147 . Said surface 146 is wider at its entrance 148 than at its exit 149 near said container downward curved leading section 126 . Said shoaling surface entrance 146 also has to relatively flat vertical surfaces 156 or wave refraction surfaces aligned with and extending from shoal entrance 148 all generally parallel to prevailing waves (crests and troughs). Said wave refraction surfaces 156 and shoaling surface converge, focus, or funnel additional wave height and energy on to and in to said bellows moving surface 125 , 126 , 127 increasing wave energy capture. Said shoaling surface 146 with side shields 147 and refracting surface 156 are fixably mounted by support arm 150 onto said stationary mast or spar 111 .
[0055] Behind said bellows container 3 is a generally vertical wave reflecting wall 152 affixed to stationary mast 111 by its' support arm 153 . Wave crests 154 impacting said wall 152 reflect back over said bellows container 3 further increasing wave height 154 available for energy capture by bellows container 3 . Said reflecting wall 152 can be passive (as shown) or “active” if mounted in hinged manner with energy absorbing means (as per FIG. 11 ).
[0056] FIG. 11 shows an embodiment of the present invention with forward and rearward extensions of central movable surface 125 like FIG. 7 , 8 or 10 . It may also be preceded by a fixed shoaling surface (not shown) like 146 of FIG. 10 with similar converging and refraction features. Like FIGS. 8 and 9 , said bellows container may be flexibly attached via hinged joint 140 to fixed mast 111 and have supplemental energy absorption means (cylinder 141 ) with optional mechanical return means (springs 142 ). Compression and expansion of bellows container 4 is supplemented by surface float base 161 with optional surface vent bellows 160 mounted above said base 161 attached at pivot 168 to said submerged bellows central moving surface 125 by multiple lever arms 165 rotating about fulcrum arm 162 hinge or pivot points 163 . The distant end of lever arm 165 is flexibly attached to multiple vertical connecting rods 166 at lower end hinge joint 167 . The flexible upper end joints 168 of said connecting rods 166 is attached to said surface float base 161 . Like FIG. 10 , a wave reflecting wall 169 can be attached to and span between the upper portions of said vertical connecting rods 166 . Because surface float base 161 with optional vent bellows 160 will have more vertical movement than said bellows moving surface 125 , said fulcrum pivot point 163 will be closer to the bellows pivot point 164 than said connecting rod pivot point 167 . For added travel and shock absorption, said connecting rod 166 can have a (spring 170 ) mounted telescoping section 171 . Said bellows float can be fitted with supplemental wave energy (pitch mode) drive cylinders 172 with return springs 173 . Said connecting rods 166 bases can also be fitted with supplemental drive cylinders 174 and return springs 175 . Reflecting wall 169 is connected to said connecting rods 166 . Alternatively, said reflecting wall could be affixed to the surface float base 161 . If the optional vent bellows 160 is used on top of the surface float 161 , then a flexible gas vent duct 176 is used to allow free gas flow between said submerged bellows container 4 and said floating surface vent bellows 160 . If no surface vent bellows 160 is used, the interior of bellows container 4 is partially evacuated to reduce interior gas compression resistance.
[0057] FIG. 12 shows a sectional elevation of an embodiment of the present invention utilizing a fixed (shown) submerged inclined bellows container 4 (like FIG. 11 ) with an adjustable base hinged about pivot 140 with sublemental energy absorption by cylinder 141 and extended and curved bellows top surface ( 125 , 126 , 127 ) (also like FIG. 11 ). Fixed shoaling surfaces (like FIG. 10 ) or “active” (powered) wave reflective back walls (like FIG. 11 ), could also optionally be used. The submerged bellows container 4 is shown expanded with a trough overhead with and a vent surface bellows compressed by return springs 185 or weighted top surface 190 . When an ensuing wave crest passes overhead gas from said submerged bellows container 4 flows through duct sections 180 , 181 and 182 before passing through two-way air turbine generator 184 and through float base 161 expanding surface bellows 160 and tensioning float bellows return springs 185 or lifting weighted top 190 . When the next wave trough passes overhead, the tensioned return springs 185 compress said surface bellows 160 driving gas through said two way turbine generator 184 housed in the base of surface float 161 and then through duct section 180 and back into submerged bellows container 4 re-expanding it and tensioning its' return springs 186 . Internal concentric telescoping glide tubes or rails (as described for FIG. 7 ) can provide lateral stability if needed. Wave reflecting wall 181 can be at least partially hollow and also serve as gas duct 181 or house air turbine generator 184 (not shown). Like FIG. 11 , lever arm 165 , hinged about fixed fulcrum 163 , attaches moving submerged bellows surface 125 at pivot point 164 to telescoping spring loaded connecting rod 166 at attachment point 167 .
[0058] FIG. 13 shows a submerged or semi-submerged embodiment of the present invention utilizing multiple partially evacuated gas tight elongated compressible bellows containers 4 mounted on a common base 190 held at relatively fixed depth by multiple downward masts or spars 111 with depth fixing, adjustment and mooring means as described in FIG. 7 . Common (shown) or multiple (not shown) moving upper surface 191 has a forward (oncoming wave facing) downward sloped section 192 optionally flexibly connected to said common base 190 by hinges 194 . The rearward upsloping section 193 of said common moving upper surface may also serve as a passive (shown) or active powered (not shown) wave reflector wall increasing wave height, and both hydrostatic and kinetic wave energy capture as previously described. Frontal inclined or downward sloping frontal section 192 acts as a shoaling surface further increasing wave kinetic energy capture as previously described (in FIGS. 7 , 8 and 9 ) or it may be preceded by a fixed shoaling surface (as described in FIG. 10 ). Base 190 can be hinged 140 to stationary masts 111 as previously described (in FIGS. 8 , 9 , and 11 ) with supplemental energy capture by cylinders 141 and return springs 142 or rigidly attached (not shown). Primary energy capture as overhead wave crests compress surface 191 towards base 190 is via hydraulic cylinders 103 with return springs 44 as previously described in FIGS. 7 , 8 , 9 , 11 and 12 . Elongated bellows containers as shown have major advantages over round “point source” wave energy absorbs by spanning more wave front per unit of container (or buoy) area or volume. Large containers arranged in series front to back, span a larger portion of each wave length (25% to 50% of total wave length) increasing wave capture efficiency. The hinged front 194 eliminates the need for lateral supports for drive cylinders 103 .
[0059] Modifications, improvements, and combinations of the concepts described herein may be made without departing from the scope of the present invention. | An ocean wave energy device uses large gas filled and surface vented or partially evacuated flexible containers each having rigid movable ends and rigid fixed depth ends connected by flexible bellows, suitably reinforced against external hydrostatic pressure, submerged to a depth below anticipated wave troughs. One or more said containers compress and expand as waves and troughs, respectively, pass overhead driving hydraulic or pneumatic, pumping means producing pressurized fluid flow for a common sea bed motor-generator or for other uses or on-board direct drive generators. Mechanical, hydraulic or pneumatic means re-expand said containers when a wave trough is overhead. Power output is augmented by mechanically connecting said rigid moving surfaces to surface floats, which may also provide said submerged container venting such that as waves lift and troughs lower said floats, said containers are further compressed and re-expanded, respectively. Power output is further augmented by wave kinetic energy capture through focusing, reflection and refraction. | 8 |
BACKGROUND OF THE INVENTION
The present invention pertains to an improved drill bit for forming boreholes as in drilling oil and gas wells. Moore particularly, the present invention pertains to drill bits which employ and contain polycrystalline diamond cutting elements, and are usually referred to as "PDC" drill bits.
Many "PDC" drill bits of the prior art experience a destructive whipping action, or radial vibration of the drill bit which randomly occurs during rotary operation due to clearance between the outside of the drill bit and the wall of the borehole. This whipping tendency intensifies in proportion to the hardness or toughness of the formation being drilled and in proportion to the rotational speed of the drill bit, causing impact contact between the cutting elements of the drill bit and the formation material being drilled, which in turn results in fractured, chipped, or displaced cutting elements, thus drastically shortening the operating life of the drill bit and causing the operating life to be inconsistent and unpredictable.
Another problem often found in prior art "PDC" drill bits is erosion which is caused by high velocity drilling fluid acting on the cutting mountings of the cutting elements, on the drill bit face, and on other components of the bit. This shortens the operating life of the drill bit.
Another problem associated with prior art "PDC" drill bits is balling, plugging, or packing of cut material onto the face of the drill bit due to uneven or unbalanced fluid flow over the face of the drill bit which results in reduced penetration rates and inadequate and uneven cooling of the cutting elements and thereby unpredictably diminish the resultant drilling operation.
Because of the above problems, "PDC" drill bits have heretofore been used economically only in drilling a very limited range of different rock and earth formations. U.S. Pat. Nos. 712,887 (Wyczynski); 2,857,141 (Carpenter); and 3,062,303 (Schultz) each contain radially acting stabilizing means. However, as the respective specifications show, each of those are based on considerably different and less effective principles of operation than the present invention.
SUMMARY OF THE INVENTION
A stabilized drill bit having a main body of general cylindrical configuration and a pin end opposed to a lower drill face. The lower drilling face is of a particular novel configuration and includes cutters thereon for penetrating geological formations when the drill bit is rotated and making hole. A throat is formed longitudinally through the main body for passage of drilling fluid from a drilling string, through the bit, and through the drilling face. The drilling fluid exits the bit and flows across the face in a novel manner.
A plurality of circumferentially arranged bores are formed from the outer surface of the bit into communication with the bit throat. Hydraulically actuated stabilizing members are reciprocatingly received within the bores. Each of the stabilizing members have an outer face which is retracted into alignment with the outer surface of the bit, and which can be extended outwardly from the surface of the bit and into engagement with the wall of a borehole.
Hydraulic means are incorporated into the bit by which each of the stabilizing members are forced to move in a direction outwardly of the main body when the hydrostatic pressure within the throat is greater than the hydrostatic pressure measured at the face of the stabilizing members. The hydraulic means maintains the stabilizing members in the extended configuration, and as the face of the stabilizing member is worn, the member is further extended into engagement with the borehole wall.
The hydraulic means further enables retraction of the stabilizing members respective to the borehole wall surface when the pressure drop across the face of the bit has been equalized.
One object of the present invention is to provide a "PDC" drill bit having a substantially increased operating life with equal or greater drilling penetration rate than prior art "PDC" drill bits and having the capability of drilling more predictably and economically through an extremely wide range of different rock and earth formations.
Another object of this invention is to provide a drill bit having reduced tendency to whip, or radially vibrate, during rotary operation.
Another object of the present invention is to provide an improved drill bit having reduced tendency to ball or plug.
Another and further object of this invention is to provide a "PDC" drill bit that is economical to manufacture.
An additional object of the invention is the provision of a rotary drill bit having retractable stabilizer members arranged about the circumference thereof which can be extended into engagement with the borehole wall while making hole.
Other objects and advantages of the present invention will be apparent upon consideration of the following specification, with reference to the accompanying drawings forming part thereof, and in which like numerals correspond to like parts throughout the several views of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal, cross-sectional view of the invention;
FIG. 2 is a bottom view of the invention of FIG. 1;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a reduced, cross-sectional view taken along line 4--4 of FIG. 1;
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 1;
FIG. 6 is a diagrammatical, flattened, inverted, partial side view taken along line 6--6 of FIG. 2 for purposes of simplifying the drawing;
FIGS. 7-14, respectively, are inverted, partial cross-sectional views taken along lines 7-14, respectively, of FIG. 2; and,
FIG. 15 is a diagrammatical, part cross-sectional view of a drilling operation with the bit of the present invention being schematically illustrated therewith.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures of the drawings, and in particular FIG. 1, the present invention comprises an improved drilling bit, generally indicated by the numeral 110. The bit has a main body 21 made of a suitable material such as steel. The main body 21 is generally cylindrical in shape and the upper end thereof is threaded in a conventional manner, or is otherwise provided with a known means for attachment to the end of a drill pipe or "drill string". The main body 21 has a central fluid passage or throat 22 extending from the top threaded end, along the central axis towards the lower end or face 23. The lower marginal end of the bit can be an integral part of the bit, as seen in FIG. 1, or it can be a separate member suitably attached to the main body 21.
Near the face 23, the throat 22 branches into the illustrated two flow ports 24 which extend from the throat 22 and through the face 23. Flow restrictors 25 are installed in each of the ports 24 and are retained in place by snap rings 26 or other suitable retaining means. Opposed flow slots 27 are machined into the face 23 and into the sides of the main body 21 as more clearly seen in FIGS. 2 and 5. The slots 27 communicate with the two port 24, and as seen in FIGS. 1 and 2, each slot commences at the respective ports 24 and then spirals outward in a direction opposite to the normal rotational direction of the bit. The slots continue along opposite sides of the face 23, then extend up the opposite sides of the main body 21.
In FIGS. 1-2, the bit has mounted thereon a plurality of commercially available polycrystalline diamond cutters such as the illustrated cutting elements 1 through 18. The cutting elements 1-18 preferably are the STRATAPAX (TM) manufactured by The General Electric Company. The cutters are installed in a conventional manner, such as by mounting the cutters on a stud, and pressing the stud into mounting holes formed in the face 23. The cutting elements 1-18 preferably are arranged in two opposite spiral patterns directly behind the flow slots 27, such as illustrated in FIG. 2.
In FIG. 1, the cutters 1-18 are spuriously drawn side by side to show the cutting profile. In actual practice, the cutters 1-18 are each advantageously positioned to cut distinct but overlapping circular paths during the drilling operation, so that a continuous and complete cutting operation is achieved on the bottom of a borehole.
FIGS. 6 and 14 show extra cutters 52 which are added to the periphery of the bit to enhance the ability of the bit to maintain accuracy of the diameter of the borehole. Any number of peripheral or "gauge" cutters 52 may be added as needed. Each of the cutters 1-18 and the gauge cutters 52 are oriented with respect to the main body 21 to engage the formation at the most optimum cutting angle and thereby provide optimum penetration rate of the bit.
The present invention includes a plurality of novel radial stabilizing pistons 29 installed in complementary radial bores 30 formed through the sides and into the main body 21 of the bit 110 to intersect the throat 22. The bores 30 are symetrically arranged about the longitudinal axis of the bit. The pistons 29 are arranged to be positioned as near the face 23 as possible after allowing sufficient space for the other illustrated components therebetween. The preferred embodiment of FIGS. 1-4 show eight such pistons 29, however any suitable number may be employed. The pistons 29 are reciprocated by differential pressure thereacross, with each piston 29 having a small diameter at the inner end thereof and a large diameter at the outer end thereof. The radial bores 30 have corresponding diameters respective to the small end of the pistons 29 facing radially inward towards the center axis of the main body 21 and with the large ends of the pistons 29 facing radially outward. The pistons 29 may be installed directly in the main body 21 as shown, or alternatively may be installed in a separate body (not shown) which is removably attachable to the main body 21. The pistons 29 are slidably sealed to the sides of the radial bores 30 by o-rings 31, or similar means, so that a sealed variable volume chamber 32 is formed between the smaller and larger ends of each piston 29. The chambers 32 increase in volume as the pistons 29 move radially outward and decrease in volume as the pistons 29 move radially inward. The inward travel of the pistons 29 is limited by the larger diameter portion of the pistons 29 abutting against the shoulder formed at the bottom of the larger diameter portion of the bore 30. The outward travel of the pistons 29 is limited by the illustrated shoulder 33'. The pistons 29 are prevented from rotating in the bore 30 by a detent formed by punch impressions 33, or other suitable means, which slidably engage grooves 28 formed along the side of the pistons 29. The grooves 28 extends from the rim of the outer ends of the pistons 29, inwardly along the side of the pistons 29, to a position just short of the outer o-ring seals 31, thus allowing adequate outward travel of the pistons 29, without disrupting any of the seals 31. Each piston 29 may contain one or more grooves 28 as needed.
The outer face of the pistons 29 are provided with wear resistant tungsten carbide buttons 36 pressed into complementary axial holes formed in the face of the pistons 29, so that the wear resistant button 36 is flush or aligned with the outer face of the piston 29, thereby making the outer ends of the pistons 29 wear resistant. The pistons 29 may alternatively be made entirely of a wear resistant material such as ceramic, or may be made wear resistant by other known expedients.
In the cross-sectional illustration of FIG. 4, a check valve 34 is seen to be provided with a corresponding fluid passage 35 for each chamber 32 to allow an incompressible hydraulic fluid, such as viscous oil, to enter but not leave the variable chamber 32. In the embodiment of FIGS. 1-4, a common cylindrical fluid reservoir 51 is provided to pairs of chambers 32 and to respective pairs of check valves 34, with the fluid inlet ends of the check valves 34 being positioned within the reservoir 51. The reservoir 51 is arranged radially respective to the longitudinal central axis of the main body 21. The reservoir 51 is illustrated as being located between pairs of chambers 32 and check valves 34. A small, concentric radial hole 46 extends radially inward into communication with the throat 22, and into communication with the respective passages 35, and provides a means by which a blocking valve assembly 45 can be actuated.
Each radial hole 46 is fitted with one blocking valve 45, which includes a valve element and a mating valve seat formed at one end of a sleeve 50. The blocking valve assembly 45 is arranged to selectively block or freely allow fluid flow into or out of the reservoir 51. The inner end of each blocking valve 45 is reciprocatingly sealed respective to the corresponding radial bore 46 by an o-ring 49, or similar seal means, and is arranged to function as a piston, with the o-ring 49 positioned inward relative to the corresponding pair of passages 35. The outer end of each blocking valve 45 is reduced in diameter respective to the holes 46, to allow fluid to pass from the passage 35 into the hole 46 and vice versa, and includes an end portion which is shaped to be received in sealed relationship against the illustrated valve seat of the sleeve 50. The inward travel of each valve 45 is limited by the illustrated shoulder; however, a snap ring or similar retainer positioned within the inner extremity of each hole 46 can serve as an alternative. The outward travel of each valve 45 is limited by the outer end thereof seating and sealing against the valve seat of the sleeve 50. Each sleeve 50 is fastened and sealed in the illustrated fixed position within each corresponding hole 46, and is positioned to provide the desired contact with respect to the corresponding valve 45. The length and inner bore of the sleeves 50 are sized to accommodate shanks 44 of isolating caps 43 so that the shanks 44 can reciprocate freely in a guided manner within the bore of the sleeves 50.
The isolating caps 43 are received within the bore of the reservoir 51, and are movably sealed in a reciprocating manner therein by o-rings 48, so that hydraulic fluid contained therewithin is isolated from contaminants from without. The caps 43 have the before mentioned rigidly attached shanks 44 which are radially oriented into the sleeves 50 to stabilize the caps 43. The shanks 44 are grooved or flattened to allow fluid to pass through the sleeve 50 into and out of the reservoir 51. The caps 43, with their shanks 44, are arranged to freely move in a stabilized manner as fluid enters or leaves the reservoir 51 to thereby accommodate any change in volume. The radial travel of the caps 43 is sufficient to provide adequate fluid displacement for the corresponding chambers 32. The outward travel of the caps 43 is limited by punch impressions 47 formed on the rim of the reservoirs 51, or by other suitable stop means.
During assembly of the apparatus of the present invention, the chambers 32, check valves 34, passages 35, holes 46, and the reservoir 51 are all filled with a suitable hydraulic fluid, and all gas bubbles are evacuated therefrom so that an incompressible fluid is contained therein. Hydraulic fluid can be filled through resealable drilled holes located in the caps 43, or in the body 21, or the filling could be completed before the caps 43 are installed, or various other filling methods might be utilized in order to achieve this desired result.
As best seen illustrated in FIGS. 1 and 5, each of a plurality of additional wear resistant buttons 36 are pressed flush into each of a plurality of radial holes arranged symmetrically around the outer periphery of the lower marginal end of the main body 21 at a location immediately above the face 23. Any other suitable means may be employed to protect the periphery of the main body 21 from undue abrasion and wear.
In FIG. 1, the flow restrictors 25 are each arranged to provide optimum fluid flow restriction therethrough while also providing relatively low fluid output velocity therefrom into the flow slots 27 and onto the face 23. In the present embodiment, each of the flow restrictors 25 comprise a plurality of commercially available wear resistant nozzles 37 having an o.d. corresponding to the size of the ports 24 so that each port 24 contains a first or uppermost nozzle, one or more intermediate nozzles, and an outlet or lowermost nozzle. In the present embodiment, the first nozzle in each port 24 is inverted or otherwise shaped to provide diffused fluid flow and has its orifice 41 sized to provide optimum fluid flow restriction. The intermediate nozzles located in each port 24 are also inverted or otherwise shaped to provide diffused fluid flow, but have their orifices sized to provide relatively low fluid flow restriction. The outlet nozzle in each port 24 is non-inverted or otherwise shaped to provide straightened fluid flow, and its orifice 42 is sized to provide relatively low fluid output velocity. All the nozzles 37 are sealed to the walls of the ports 24 by o-rings 38. Different quantities, shapes, and sizes of nozzles 37 may be installed in the ports 24 depending upon the kind and degree of fluid control desired. Also, the restrictors 25 may be of one piece, multistage construction rather than of a plurality of series connected individual nozzles. The restrictors 25 are thus arranged to provide both a means for developing a desired fluid pressure drop and a means for reducing the resultant fluid escape velocity.
In FIGS. 2 and 6-14, a fluid flow isolating ridge 39 extends from one side of the face 23 along the trailing edge of the cutters 1-18 on the first side of the face 23, across the center of the face 23, then along the trailing edge of the cutters 1-18 on the second side to the opposite side of the face 23. The ridge 39 is affixed or made integrally respective to the face 23 and is the minimum thickness for achieving the necessary required strength. The height of the flow isolating ridge 39 beyond the face 23 is equal to the height of the cutters 1-18 so that the ridge 39 contacts the bottom of the borehole during the drilling operation.
In FIGS. 2, 6-8, and 14, a plurality of fluid flow isolating ribs 40 extend concentrically along the face 23 from the trailing side of the ridge 39 along paths concentric with the main body 21 to the leading edges of the corresponding slots 27. The ribs 40 are solidly attached to the ridge 39 and to the face 23 and are the minimum thickness considered necessary for the required strength. The height of the ribs 40 beyond the face 23 is equal to the height of the cutters 1-18 and to the height of the ridge 39 so that the ribs 40 similarly contact the bottom of the borehole during the drilling operation. The ribs 40 are symmetrically located on the face 23 spaced radially from the center of the face 23 the maximum distance that provides adequate fluid flow isolation. The ridge 39 and the ribs 40 are of a material, such a steel, that can be worn away readily by rubbing against the bottom of a borehole while making hole.
As seen in FIGS. 1 and 3, parallel wrench flats 53 are machined onto opposite sides of the neck portion of the main body 21 in the conventional fashion to accommodate conventional tools for attaching or detaching the bit 110 to a drill pipe 62.
In FIG. 15, a borehole 60 has a drill string 62 and drill collar 64 therein with the bit 110 attached to the lower end thereof. A drilling rig 70 manipulates the drill string 62. Drilling fluid flows at 72 into the string and is returned through a rotating blowout preventor 74 in the usual manner.
In operation, the upper threaded end of the main body 21 is attached in the conventional manner to the lower end of a drill pipe, or drill string 62 and is then inserted in a borehole 60 and rotated in the conventional manner. The bit is forced downward against the bottom of the borehole by weight applied to the drill string in the conventional manner. As the invention is continuously rotated with weight applied, the ridge 39, the ribs 40, and the cutters 1-18 are all rubbed against the bottom of the borehole. The ridge 39 and the ribs 40 are reduced in height due to wear against the bottom of the borehole; however, the edges of the cutters 1-18 wear only slightly due to their material of construction. Thus, the cutters 1-18 penetrate the bottom of the borehole and remove material therefrom as the bit is rotated with weight applied. The action of the cutters 1-18, moves the cuttings from in front of the cutters 1-18 into the slots 27. The gauge cutters 52 remove material from the wall of the borehole and there by achieve the desired diameter of the bore hole. Conventional drilling fluid, supplied in the conventional manner from a suitable pump, is continuously pumped downward at 72, through the drill string 62, through the throat 22 of the present invention, through the flow restrictors 25, through the flow slots 27, then back up the bore hole annulus located outside of the drill string. The cut material is carried along by the flowing drilling fluid and is thus removed at 74 from the borehole.
Since the pressure drop across an orifice varies approximately as the square of the change in flow rate of a fluid flowing through the orifice, then the resultant fluid volume flowing through both orifices 41 (i.e. both restrictors 25) of the present invention will remain practically equal or balanced when appropriate total fluid volume and pressure is maintained. The orifices 41 can be sized to provide a predetermined or desired pressure drop for any given fluid flow rate. At any given fluid flow rate, the greater the pressure drop the more firmly equalized or balanced the flow through the restrictors 25 becomes. Also, each corresponding port 24, flow restrictor 25, and flow slot 27 forms and provides an isolated fluid path because the ridge 39 and the ribs 40 all contact the bottom of the borehole and thus prevent drilling fluid flowing in one slot 27 from escaping that slot except at the upper end of that slot. The flow of drilling fluid through either of the slots 27 will not become overbalanced or diverted and will therefore continue to flow adequately through each slot 27 and thereby force out the cut material even if packing or clogging tends to occur. Accordingly, balling or plugging is effectively avoided on the face 23 of the present bit.
Due to the configuration and arrangement of the flow restrictors 25, the velocity of the flowing drilling fluid as it leaves the restrictors 25 and enters the slots 27 is kept low enough so that no appreciable fluid erosion occurs on any part of the present bit even when a relatively high fluid flow rate and resultant pressure drop is maintained.
Drilling fluid flowing through the present bit is at a relatively elevated pressure within the throat 22 because of the pressure drop measured across the restrictors 25. Therefore, an outward force is exerted on the smaller end of the pistons 29, forcing the outer ends of the pistons 29 to move outward to any one of a range of extended positions and into relatively light contact with the wall of the borehole. Also, the blocking valves 45 are forced outward so that the outer ends of the valves 45 are seated in sealed relationship against the valve seat end of the sleeves 50, blocking any fluid flow therethrough. As the pistons 29 move outward, the chambers 32 expand in volume, causing a pressure differential which forces the hydraulic fluid from the reservoir 51, through the check valves 34, through the passages 35 and into the chambers 32. The caps 43 move inward to accommodate the reduced volume within the reservoirs 51. The check valves 34 prevent any reverse flow of hydraulic fluid and thus provides a hydraulic barrier within the chambers 32 so that the pistons 29 cannot move inward from any extended position, even when an extreme opposite force is exerted inwardly on the pistons 29 from the wall of the borehole. In like manner, as the outer ends of the pistons 29 slowly wear due to friction against the wall of the borehole, the pistons 29 continually move slowly outward and more hydraulic fluid is drawn into and retained within the chambers 32. Thus, means are provided by which the pistons 29 are continually compensated for wear and remain in constant contact with the wall of the borehole. Accordingly, the present invention provides means by which a drill bit is prevented from whipping or radially vibrating. During this time, the cutters 1-18 and the gauge cutters 52 are positioned where they are protected from impact damage and from the premature failure which may otherwise result therefrom.
Reduced circulation of drilling fluid reduces the pressure drop across the restrictors 25, and the fluid pressure within the throat 22 is therefore reduced until it becomes equalized with respect to the fluid pressure on the outside of the main body 21. Thus, in this condition, no outward force is exerted against the pistons 29 or the blocking valves 45. Hence, the outer ends of the blocking valves 45 are no longer sealed against the valve seat ends of the sleeves 50 and fluid is therefore allowed to flow therethrough. Thus, in this condition, when an inward force is exerted on the outer ends of the pistons 29, hydraulic fluid flows freely out of the chambers 32, through the passages 35, against the outer ends of the blocking valves 45, forcing the blocking valves inward away from the valve seat of the sleeves 50, so the fluid flows through the sleeves 50 past the shanks 44, and into the reservoirs 51. At this time, the caps 43 can move outward to accommodate the added fluid volume within the reservoirs 51. Therefore, the pistons 29 can be selectively allowed to retract inward by removing fluid pressure within the throat 22.
The main body 21 and the holes and passages therein, the pistons 29, blocking valves 45, sleeves 50, and the caps 43 with shanks 44 all can be readily fabricated by convenional methods, such as machining or molding. The cutters 1-18, o-rings 31, wear resistant buttons 36, nozzles 37, o-rings 38, and the gauge cutters 52 are all readily available commercial products which can be installed in the bit of the present invention. Various different check valves 34 of conventional design may be either built into the present bit or purchased separately and assembled thereinto. Thus, the present invention can be readily and economically manufactured.
Having thus described the invention, it is to be understood that certain modifications in the construction and arrangement of the parts thereof may be made, as deemed necessary, without departing from the scope of the appended claims. | A stabilized drill bit has a cylindrical main body, a formation cutting face at the lower end of the body, and means by which the upper end of the bit can be connected into a drill string. A drilling fluid flow passageway extends axially through the main body and provides flow of drilling fluid to the drilling face. A plurality of hydraulic actuated stabilizing members are arranged circumferentially about the throat and within the main body. Stabilizing members have a borehole wall engaging face thereon which can be retracted flush with the outer surface of the main body, and extended away from the main body face and into contact with the borehole wall, thereby stabilizing the drill bit as the bit is rotated while making hole. Hydraulic means is connected to the stabilizing members by which the members are progressively extended toward the borehole wall as the members become worn, and which normally prevents retraction of the stabilizing members so long as drilling fluid pressure is effected within the passageway. The stabilizing members are retracted when the drilling fluid is reduced to a predetermined value. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for synthesis of nucleic acids, especially to a method for synthesis of nucleic acids by means of a polymerase chain reaction (hereinafter abbreviated as a PCR).
[0003] 2. Description of the Related Art
[0004] A PCR method is a procedure capable of amplifying an intended DNA fragment as much as several hundred thousand-fold by repeating a process comprised of dissociation of a DNA strand into single strands, binding of primers with sandwiching a particular region of the DNA strand, and a DNA synthesis reaction by the action of a DNA polymerase. The PCR method is described in Japanese Laid-open Patent Publication No. S61-274697 which is an invention by Mullis et al.
[0005] A PCR procedure can be used as a highly sensitive method for analyzing nucleic acids in various samples, and particularly it can be used in analysis of nucleic acids in a sample derived from an animal body fluid. The PCR procedure is therefore used for such a purpose of diagnosis or monitoring of an infection, a hereditary disease, and a cancer. The PCR procedure is also suited to DNA typing tests for a transplantation, a paternity test, medical treatments based on an individual genetic information, and the like. For these purposes, a peripheral blood is often selected as a test object.
[0006] One drawback of the PCR procedure is that the reaction is inhibited by pigments, proteins, saccharides, or unknown contaminants. Namely, many DNA polymerases including TaqDNA polymerase derived from Thermus aquaticus, a typical thermostable DNA polymerase, are widely known to allow the PCR to be inhibited potently by even a trace amount of living body-derived contaminants existing in the PCR reaction solution. Therefore, the PCR procedure requires a process in which a cell(s), a protozoan (protozoa), a fungus (fungi), a bacterium (bacteria), a virus(es) and the like (hereinafter referred to as a gene inclusion body) are isolated from a subject and then nucleic acids are extracted from the gene inclusion body prior to a DNA amplification. Such process has conventionally been a procedure in which the gene inclusion body is decomposed using an enzyme, a surfactant, a chaotropic agent, or the like, and then nucleic acids are extracted from the decomposed product of the gene inclusion body using, for example, phenol or phenol/chloroform. Recently, an ion-exchange resin, a glass filter, or a reagent having an effect of agglutinating proteins is used in the step of the nucleic acid extraction.
[0007] It is difficult, however, to completely remove impurities by purifying nucleic acids in a sample using these procedures, and furthermore, an amount of nucleic acids in a sample recovered by these purification procedures often varies among experiments. For these reasons, a subsequent nucleic acid synthesis may sometimes be unsuccessful, especially when a content of the intended nucleic acid in the sample is low. In addition, these purification procedures involve complicated manipulations and are time-consuming, and there is a high opportunity for contamination during the procedures. Therefore, a simpler, more convenient and effective method of a sample pretreatment is desired in order to solve these problems.
[0008] When a body fluid such as blood and a liquid excretion sample such as urine are left to stand, sedimentation of solid components such as cells, bacterial body components and the like occurs to cause heterogeneity in the distribution of cells or bacterial bodies containing an intended nucleic acid. It was therefore necessary to uniformly distribute the solid components in these samples by agitating the samples in advance before the sample addition, when these samples are used for a direct amplification of a nucleic acid.
[0009] A peripheral blood is often used, as a test material for a genetic testing. We have hitherto devised methods that provide a nucleic acid synthesis procedure capable of directly amplifying an intended nucleic acid in blood. However, when a whole blood sample is left to stand, sedimentation of blood cells, bacterial body components, or other components occurs to cause heterogeneity in the distribution of blood cells, bacterial bodies, and other components containing the intended nucleic acid. It was therefore necessary to achieve uniform distribution by agitating the sample in advance before its addition, when the blood sample is directly subjected to the PCR. Likewise, the same step was also required when a body fluid and a liquid excretion sample are directly used in the PCR.
SUMMARY OF THE INVENTION
[0010] The present inventor invented a process in which a sample is treated with a surfactant, then stored and used without further treatments, as a template for nucleic acid synthesis. The present invention is particularly useful in a method of nucleic acid synthesis in which a body fluid such as blood and a liquid excretion itself such as urine are mixed with a nucleic acid amplification reaction solution and allowed to react, for treating a sample with a surfactant before the reaction and, for example, thereby destructing solid components containing nucleic acids to disperse them uniformly in the sample liquid. In addition, such treatment is expected to have bactericidal, virucidal, and the like effects and thereby reduce the possible risk of infection of a worker caused by a biological sample that is inherent in handling biological samples.
[0011] Thus, the present invention is a method for synthesis of nucleic acids to amplify an intended nucleic acid from a sample which comprises homogenizing a living body-derived sample and then directly adding the homogenized sample to a reaction solution to amplify the nucleic acid.
[0012] The present invention is the method for synthesis of nucleic acids wherein the sample is homogenized using a surfactant.
[0013] The present invention is the method for synthesis of nucleic acids wherein the surfactant is an ionic surfactant.
[0014] The present invention is the method for synthesis of nucleic acids wherein the ionic surfactant is an anionic surfactant.
[0015] The present invention is the method for synthesis of nucleic acids wherein the anionic surfactant is at least one selected from the group consisting of salts of N-lauroylsarcosine and dodecyl sulfates (e.g. SDS).
[0016] The present invention is the method f or synthesis of nucleic acids wherein the homogenized sample is subjected to nucleic acid synthesis in a reaction solution containing a nonionic surfactant.
[0017] The present invention is the method for synthesis of nucleic acids wherein Tween 20 and/or Nonident P40 is used as the nonionic surfactant.
[0018] Further, the present invention is a method of sample storage, which comprises homogenizing a living body-derived sample and storing the homogenized sample.
[0019] According to the present invention, by treating the sample with the surfactant before the reaction, solid components such as cells or bacterial bodies containing nucleic acids can be destructed and uniformly dispersed in the sample liquid, and therefore it is not necessary to agitate the sample in advance for uniformly distributing the solid components in the sample. In addition, the present invention enables long-term sample storage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 shows an electrophoretogram of amplified products obtained by the PCR in which a sample treated with a lysis solution was directly added to a PCR reaction solution.
[0021] [0021]FIG. 2 shows an electrophoretogram of amplified products obtained by the PCR in which a sample treated with a lysis solution was stored for a long period and then directly added to a PCR reaction solution.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention is a method for synthesis of nucleic acids to amplify an intended nucleic acid from a sample which comprises homogenizing a living body-derived sample and then directly adding the homogenized sample to a reaction solution to amplify the nucleic acid.
[0023] As used herein, the term “homogenizing” means a treatment by which nucleic acids are uniformly dispersed in a sample liquid. The term “directly” means no pretreatments other than homogenization is required.
[0024] It is preferred to use a surfactant for homogenization. The surfactant includes an anionic surfactant, a cationic surfactant, an amphoteric surfactant, and a nonionic surfactant. When the sample is subjected to nucleic acid amplification within a short period, any of these groups may be adopted. Specific examples of the anionic and the nonionic surfactants are described afterwards. As the cationic surfactant, for example, cetyltrimethylammonium bromide or dodecyltrimethylammonium bromide may be used, and as the amphoteric surfactant, for example, CHAPS, lecithin, lysolecithin, phosphatidylethanolamine, or N-dodecyl-N,N-dimethyl-3-ammonio-1-propane sulfonate may be used.
[0025] However, aggregates appear over time and cause heterogeneity in the distribution of nucleic acids in the sample liquid. To solve this problem, the present inventor further investigated and succeeded in avoiding formation of aggregates by using a certain concentration of an anionic surfactant. For example, a blood sample is treated with the anionic surfactant such as dodecyl sulfates (hereinafter collectively referred to as SDS), salts of N-lauroylsarcosine including sodium salt of N-lauroylsarcosine (abbreviated hereinafter to SARKOSYL) and other metallic salts of N-lauroylsarcosine, deoxycholates including sodium deoxycholate and other metallic salts of deoxycholate, or cholates including sodium cholate and other metallic salts of cholate for homogenization. In this treatment, SDS or SARKOSYL is mixed with the sample liquid to attain a concentration of 0.5% or more, preferably about 2%, in order to store the sample for a long period stably in the homogeneous condition.
[0026] However, a potent inhibition of the reaction is observed if the PCR is conducted by directly adding a sample treated with the ionic surfactant to a standard reaction solution conventionally used. Therefore, the present inventor further investigated to find a way to suppress the reaction inhibition, and found that this reaction inhibition can be suppressed by using a nonionic surfactant in the reaction. The nonionic surfactant, which may be used, includes, but not limited to, Nonidet P40, Tween 20, digitonin, n-dodecyl maltoside, octyl glycoside, octyl thioglycoside, Triton X-100, sucrose laurate, and Tethit. Nonidet P40 and/or Tween 20 are used at a concentration each of 0.5% or more, preferably 1 to 5%, in the amplification reaction solution.
[0027] The nonionic surfactant may be mixed with the sample liquid homogenized by the ionic surfactant and then added to the reaction solution, or may be added in advance to the reaction solution, and thus the order of addition is not specifically defined.
[0028] Furthermore, by homogenizing a sample according to the present invention, it becomes possible to store the sample for a long period. The present invention therefore provides a method of sample storage, which comprises homogenizing a living body-derived sample and storing the homogenized sample. Although a period capable of storing the sample varies depending on the kind of the sample, the kind of the surfactant used for homogenization, concentration, storage condition, and the like, a blood sample can be stored, for example, for several years even at room temperature when treated with the anionic surfactant.
[0029] In the present invention, the term “sample” means a gene inclusion body in a living body-derived sample or the living body-derived sample itself, and the term “living body-derived sample” refers to an animal or a plant tissue, a body fluid, an excretion, and the like. The term “gene inclusion body” refers to a cell, a protozoan, a fungus, a bacterium, a virus, and the like. Body fluids include blood, cerebrospinal fluid, milk, and saliva; excretions include feces, urine, and sweat; and cells include leukocytes and platelets, although they are not so limited.
[0030] The nucleic acid amplification reaction solution conventionally contains a pH buffer as well as salts such as MgCl 2 and KCl, primers, deoxyribonucleotides, and a nucleic acid polymerase. The salts mentioned above may be replaced with other salts as appropriate. In addition, various substances including proteins such as gelatin and albumin and dimethyl sulfoxide are sometimes added.
[0031] The pH buffer is prepared by a combination of tris(hydroxymethyl)aminomethane and a mineral acid such as hydrochloric, nitric, or sulfuric acid, and a preferred mineral acid is hydrochloric acid. Alternatively, various other pH buffers, including pH buffers comprising a combination of Tricine, CAPSO (3-N-cyclohexylamino-2-hydroxypropanesulfonic acid), or CHES (2-(cyclohexylamino)ethanesulfonic acid) and caustic soda or caustic potash, may be used. The pH-adjusted buffer is used at a concentration between 10 mM and 100 mM in the nucleic acid amplification reaction solution.
[0032] The term “primer” refers to an oligonucleotide that acts as an initiation site of synthesis in the presence of nucleic acids, reagents for amplification and other substances. The primer is desirably single-stranded, and a double-stranded primer may also be used. When the primer is double-stranded, it is desirable to convert it into its single-stranded form prior to the amplification reaction. The primers may be synthesized using known methods, or may be isolated from living organisms.
[0033] The term “nucleic acid polymerase” means an enzyme that synthesizes nucleic acids by adding deoxyribonucleotides or a chemical synthesis system doing so. Suitable nucleic acid polymerases include, but not limited to, DNA polymerase I derived from E. coli , the Klenow fragment of a DNA polymerase derived from E. coli , T4 DNA polymerase, TaqDNA polymerase, T. litoralis DNA polymerase, TthDNA polymerase, PfuDNA polymerase, and a reverse transcriptase.
[0034] Furthermore, according to the present invention, pH adjustment of the reaction solution for gene amplification produces a synergistic effect. For example, at a temperature of 25° C., the pH is 8.1 or more, and preferably from 8.5 to 9.5.
[0035] In the present invention, polyamines may also be added to the reaction solution for gene amplification.
EXAMPLES
[0036] The present invention is further described in the following examples which are not intended to restrict the invention.
Experimental Example 1
[0037] A present example describes an experiment in which the PCR was conducted by directly adding a blood sample treated with a final concentration of 2% of SARKOSYL. Human citrated blood was used as the sample. Two microliters of one of lysates having various blood concentrations were directly added to a PCR reaction solution (total volume: 50 μl), and the PCR was conducted. The PCR reaction solution used contained 10 mM Tris-HCl, 50 mM KCl, 1.5 mM MgCl 2 , 200 μM each of dATP, dCTP, dGTP and dTTP, 2.5% Nonidet P40, 0.4 μM each of the primers, and 1.25 units of Taq DNA polymerase (TaKaRa Taq: Takara Shuzo, Kyoto, Japan).
[0038] The PCR primers were oligonucleotides having a nucleotide sequence of the plus strand (GH20, SEQ ID. NO. 1) or the minus strand (GH21, SEQ ID. NO. 2) located within the human beta-globin coding region, and these primers may produce 408 bp of an amplification product by the PCR (Saiki, R. K., Gelfand, D. H., Stoffel, S., Scharf, S. J., Higuchi, R., Horn, G. T., Mullis, K. B. and Erlich, H. A. (1988) Science 239, 487-491).
[0039] GH20: 5′ GAAGAGCCAAGGACAGGTAC 3′
[0040] GH21: 5′ GGAAAATAGACCAATAGGCAG 3′.
[0041] The PCR involved a preheating at 94° C. for 4.5 minutes, 40 cycles each of which consists 1 minute at 94° C. followed by 1 minute at 55° C. followed by 1 minute at 72° C., and then the final polymerization at 72° C. for 7 minutes. After the completion of the PCR, 5 μl of the reaction solution was subjected to an electrophoresis on a 2.5% agarose gel in TAE (40 mM Tris-acetate, 1 mM EDTA, pH 8.0) containing 0.5 μg/ml ethidium bromide to detect the amplification products.
[0042] [0042]FIG. 1 shows the electrophoretogram of PCR products obtained by the PCR in which the sample treated with the lysis solution was directly added to the PCR reaction solution.
[0043] In the figure, a lane M indicates molecular weight makers; a lane 1 indicates the result obtained with the lysate of which blood content was ½; a lane 2 indicates the result obtained with the lysate of which blood content was ¼; and lanes 3-12 similarly indicate the results obtained with the lysates of which blood contents were 2-fold serially diluted ones in the order. A lane N indicates the result obtained by adding 2% SARKOSYL solution containing no blood.
[0044] It can be seen from the figure that the PCR product could be detected stably and strongly in the lanes 1-12.
Experimental Example 2
[0045] This example describes an experiment in which a blood sample was treated with a final concentration of 2% of SARKOSYL, stored for 10 months at room temperature, and then directly added to a reaction solution to conduct the PCR. Human citrated blood was used as the blood sample. Two microliters of one of lysates having various blood concentrations were directly added to a PCR reaction solution (total volume: 50 μl), and the PCR was conducted. The composition of the PCR reaction solution, conditions for the PCR and for the electrophoresis after the PCR were the same as in Experimental Example 1. The electrophoretogram is shown in FIG. 2.
[0046] In the figure, a lane M indicates molecular weight makers; a lane 1 indicates the result obtained with a lysate of which blood content was ½; a lane 2 indicates the result obtained with the lysate of which blood content was ¼; and lanes 3-12 similarly indicate the results obtained with the lysates of which blood contents were 2-fold serially diluted ones in the order. A lane N indicates the result obtained by adding 2% SARKOSYL solution containing no blood.
[0047] It can be seen from the figure that the PCR product could be detected stably and strongly as same as in FIG. 1 even when the samples had been stored for a long period after the lysis treatment.
[0048] Although the nonionic surfactant was used in this example, it is not necessarily essential to use the nonionic surfactant, since the PCR can be stably achieved in the absence of nonionic surfactants if the amount of a blood lysate added to the PCR reaction solution is reduced.
1
2
1
20
DNA
artificial sequence
primer
1
gaagagccaa ggacaggtac 20
2
21
DNA
artificial sequence
primer
2
ggaaaataga ccaataggca g 21 | An object of the present invention is to provide a method of treatment and a method of storage that are useful in conducting a nucleic acid synthesis procedure capable of directly amplifying an intended nucleic acid in a living body-derived sample without purification steps.
The present invention provides a method for synthesis of nucleic acids in which a living body-derived sample itself is mixed with a reaction solution for gene amplification and allowed to react, which method comprises treating the sample with a surfactant before the reaction to destruct solid components such as cells or bacterial bodies containing nucleic acids and uniformly disperse them in the sample liquid. | 2 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a balance with a housing that accommodates the weighing mechanism and the weighing electronics. The housing has at least three positioning feet to stand on a supporting surface, with at least two of the positioning feet being height-adjustable so that the balance can be set up in a level position.
[0002] Balances of the kind encompassed by the invention are used primarily in laboratories, production facilities and stock rooms and are distinguished in particular by a weighing pan with a large surface area. They often have three positioning feet to stand on, which are arranged at the corners of an isosceles triangle. This kind of support presents the problem that the balance is easily destabilized when a load is placed eccentrically on the weighing pan, or under any other off-center force, i.e. under a vertical force that is applied outside of the tipping boundary. In this condition, the balance no longer stands on its three positioning feet and is therefore no longer in the correct reference position.
[0003] The known state of the art includes balances such as the PR model series by the Swiss company Mettler-Toledo GmbH, that have three positioning feet resting on a supporting surface, where two of the positioning feet that are located near the corners at the front of the balance are height-adjustable by means of a screw arrangement. The adjustable feet serve to set the balance into a level position or, stated more precisely, into the reference position in which the weighing accuracy of the balance was adjusted. A third positioning foot is arranged midway, i.e., in a place on the centerline at the bottom of the balance near the rear end of the balance. This balance, particularly in model versions with a large-area weighing pan, is equipped with two additional feet, referred to as stabilizer feet. After the balance has been level-adjusted, the stabilizer feet are backed out far enough from their screw threads in the bottom of the balance housing until they are in firm contact with the supporting surface on which the balance rests, so that the balance is supported also at the two rear corners. Consequently, the balance cannot tip over even under loads that are placed off the centerline in the rearward portion of the weighing pan.
[0004] The foregoing concept of screw-adjustable stabilizer feet has the disadvantage that the point where the stabilizer feet come into contact with the supporting surface cannot be exactly determined, which entails the risk that the stabilizer feet are turned out too far so that at least one of the positioning feet is raised slightly from the supporting surface, which puts the balance again out of its reference position. Furthermore, it is not immediately and clearly evident to the user, in which direction he needs to turn the screw-adjustable stabilizer foot.
[0005] A balance that is disclosed in JP 10 048 035 A has two positioning feet that are height-adjustable to put the balance into a leveled position and are located near the corners at the front of the balance housing where an indicating- and operating unit is arranged. At the rear of the balance housing, a lever extending over nearly the entire width of the balance is attached to a fulcrum on the centerline of the balance and has a stabilizer foot at each end. The lever can be locked in position at its fulcrum on the balance housing, or it can be released to allow a rotation about the fulcrum point. The preferred means for locking and releasing the lever is a screw which in its tightened condition clamps the lever against the balance housing. The balance is leveled in the released condition of the lever where the balance always rests on all four feet. After the balance has been level-adjusted to its correct reference position, the lever is locked, whereby the stability of the reference position is secured as the balance in its operating state continues to rest on four feet.
[0006] This balance suffers from the drawback that the locking of the lever is accomplished by means of a screw, which creates the risk that at the instant of locking, a torque can be exerted on the lever, which could possibly put the balance out of its reference position again. In addition, the arrangement of the foregoing description is extremely sensitive to vibrations, especially if the lever is not designed to be particularly rigid. To design the lever with adequate rigidity would, however, require more space.
OBJECT OF THE INVENTION
[0007] The present invention therefore has the objective to provide a balance, in particular a balance that has a large weighing pan, with a device to secure the stability of the balance in a simple and reliable manner during and after the leveling of the balance in its reference position.
SUMMARY OF THE INVENTION
[0008] A balance according to the invention has a housing that accommodates the weighing mechanism and the weighing electronics. The housing has at least three support points configured as positioning feet to stand on a supporting surface, with at least two of the positioning feet being height-adjustable so that the balance can be set up in a level position. In addition to the at least three positioning feet, the inventive balance has at least one stabilizer foot which is configured so that it can be unlocked and thereby enabled to remain in contact with the supporting surface while the balance is being adjusted to a level position. After the level adjustment has been completed, the stabilizer foot is locked in place to secure the stability of the set reference position. A positioning foot in the present context means any one of the feet that serve to set up the balance in its working position on a support surface.
[0009] The concept of securing the stability of the balance through the means of one or more stabilizer feet makes it impossible for the balance to tip under an eccentrically placed weighing load, a risk that exists in particular in balances with a large weighing pan.
[0010] In a preferred arrangement, the at least one stabilizer foot is kept in contact with the supporting surface by means of a spring force.
[0011] To hold, guide, lock and release the at least one stabilizer foot, the balance has a stabilizer foot device, which is preferably arranged at the underside of the balance housing and is preferably configured to be fastened to the balance housing from the outside. This has the advantage that a balance that is already in the possession of a customer can be retrofitted with the required number of stabilizer foot devices.
[0012] The stabilizer foot device serves to release and lock the at least one stabilizer foot, so that during the level adjustment, the balance is supported on at least four points without being thereby put in a statically indeterminate condition, because the height setting of the stabilizer foot will flexibly adjust itself. After the level adjustment has been completed, the stability of the balance in the level position is secured by locking the stabilizer foot. The locking position is adjustable within a continuous, step-less range. As a further advantage, the inventive stabilizer foot device is simple and effort-free to operate.
[0013] An actuating lever is the preferred means for locking and releasing the connection that secures the stabilizer foot. Specifically, the locking of the stabilizer foot, i.e., the securing of its position, is accomplished by means of a clamping connection.
[0014] In preferred embodiment, the stabilizer foot device includes a flexure pivot that reaches around the stabilizer foot. The actuating lever has a cam that is eccentrically contoured relative to the center of rotation of the lever. The clamp-tightening action is the result of the eccentric cam changing the gap between the parts that are joined together by the flexure pivot, specifically a clamping jaw and a mounting part.
[0015] In another embodiment according to the invention, the stabilizer foot device has a tapered wedge block that is connected to a leaf spring, where the clamping action is the result of a pre-tension of the leaf spring which tightens the contact pressure between the tapered wedge block and the stabilizer foot.
[0016] In a particularly advantageous embodiment of the invention, the stabilizer foot of the balance—when the latter is set up in its operating position—is pushed against the supporting surface by means of a helix spring. The spring constant and the compressive pre-tension of the helix spring under the weight of the balance are designed so that the stabilizer foot in its unlocked condition always remains in contact with the support surface, but without thereby lifting any of the positioning feet of the balance from the support surface. Preferably, the spring force of the helix spring (or the resultant of the spring forces, in case the balance is equipped with more than one stabilizer foot) amounts to about three fifths of a force that would cause one of the positioning feet to be lifted off the support surface.
[0017] In a preferred embodiment of the inventive balance, two of the positioning feet are equipped with wheel-shaped rotary knobs for adjusting the leveled position of the balance. Preferably, two positioning feet are arranged at the front of the balance housing, while a third positioning foot is arranged on the centerline close to the back end of the balance housing. Alternatively, the two height-adjustable positioning feet can be arranged near the rear end of the balance housing, while the third positioning foot is arranged on the center line near the front side of the balance. In either case, the stabilizer foot devices are arranged laterally on both sides of the third positioning foot.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A detailed description of the inventive balance follows below with references to the drawings which represent an exemplary embodiment, wherein:
[0019] FIG. 1 gives a three-dimensional view of the balance with its display and operating unit;
[0020] FIG. 2 illustrates the balance in a view from below, with the stabilizer foot devices attached to the underside, where the device on the left is shown in the unlocked condition and the device on the right is shown in the locked condition;
[0021] FIG. 3 a gives a three-dimensional view of the stabilizer foot device of FIG. 2 ;
[0022] FIG. 3 b represents a plan view of the device of FIG. 3 a;
[0023] FIG. 3 c represents a side view of the device of FIG. 3 a , shown partially in cross-section to illustrate the arrangement of the device relative to the balance housing and the supporting surface;
[0024] FIG. 4 a gives a three-dimensional view of a further embodiment of the stabilizer foot device; and
[0025] FIG. 4 b shows the device of FIG. 4 a under a different viewing angle.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] FIG. 1 shows a balance 1 of a kind that is used for example in a laboratory, a production facility, or a stockroom. The balance 1 has a balance housing 3 in which the weighing cell and weighing electronics (not visible in the drawing) are enclosed. The weighing pan 2 is connected to the weighing cell. In the illustrated example, the weighing pan 2 extends over nearly the entire top of the balance housing 3 . The balance 1 rests on three positioning feet, only one of which (identified with the reference symbol 5 ) is visible in the drawing. The positioning foot 5 , as well as a second, invisible positioning foot along the front portion of the balance, are each equipped with a turning wheel 42 for the height adjustment of the positioning foot whereby the balance can be set up in a level position. The height adjustment of a positioning foot 5 is made by turning the foot into or out of a screw thread in the balance housing 3 . Arranged at the front of the balance housing 3 is a display- and operating unit 4 with a display screen 7 and keys for the operation of the balance 1 .
[0027] A stabilizer foot device 8 can be seen on the side of the balance 1 that faces away from the display- and operating unit 4 . The part of the device that is visible is an actuating lever 9 which serves to release and to lock a stabilizer foot (not visible), as will be explained in detail hereinafter. The balance 1 is equipped with one stabilizer foot device 8 each near both of the rear corners of the balance housing, as may be seen in FIG. 2 .
[0028] The arrangement of the three positioning feet 5 , 5 ′ is illustrated in FIG. 2 , which gives a view of the underside of the balance 1 without the display- and operating unit 4 . Also arranged on the underside of the balance 1 is a cable guide channel 16 for the storage of an unused length of cable connecting the balance 1 and the display- and operating unit 4 . The latter can be attached to the balance as shown in FIG. 1 or set up separately near the balance. The cable enters the balance housing 3 through a passage 17 .
[0029] The central portion 15 of the underside of the balance housing 3 protrudes outward in relation to the border area 14 of the underside. The balance housing further has recessed handholds 18 , which make it easy to get a grip on the balance 1 when lifting it from the support surface. In the illustrated example, the third positioning foot 5 ′, which is arranged on the central portion 15 of the underside of the balance housing 3 , has the shape of a raised ridge with a triangular profile. Of course, different shapes are conceivable for the design of the positioning foot 5 ′, such as a simple raised post.
[0030] Stabilizer foot devices 8 are arranged to the right and left of the third positioning foot 5 ′, near the rear corners of the balance. The arrangement of the stabilizer foot devices is mirror-symmetric. The stabilizer foot device on the left side of FIG. 2 is shown in the unlocked condition of the stabilizer foot 6 , with the lever 9 pulled out from the balance housing 3 . In contrast, the stabilizer foot device on the right side of the drawing is shown in the locked condition of the stabilizer foot 6 , where the lever 9 is folded flat against the balance housing 3 . In the balance shown in FIG. 2 , no parts of the installed stabilizer foot device 8 protrude laterally from the balance housing 3 when the stabilizer foot 6 is in the locked condition. FIG. 2 shows an arrangement and configuration of the stabilizer foot device 8 where the lever 9 is moved in a substantially horizontal plane of rotation. This has the advantage to make it directly evident to a user if a lever 9 turned outward from the housing, indicating that the stabilizer foot 6 of the respective stabilizer foot device 8 is in the unlocked condition.
[0031] FIGS. 3 a to 3 c represent different detail views of the embodiment of a stabilizer foot device 8 that is shown in FIG. 2 . In addition, FIG. 3 c illustrates how the device 8 is situated in relation to the balance housing 3 and the supporting surface 20 on which the balance 1 is set up. The adjacent portions of the supporting surface 20 and the balance housing 3 are shown in sectional view.
[0032] FIG. 3 a gives a perspective view of the stabilizer foot device 8 seen at an oblique angle from above, i.e., looking at the topside of the device which, in the installed condition, faces towards the balance housing 3 . The end of the stabilizer foot 6 that faces towards the balance housing 3 has a recess 10 surrounded by a collar 43 . A helix spring is held captive between the balance housing 3 and the recess 10 under a compressive biasing force. In the unlocked condition, the pre-tension of the spring pushes the stabilizer foot 6 downward against the supporting surface 20 (see FIG. 3 c ). The collar 43 has a slightly larger diameter than the main portion of the stabilizer foot to prevent the stabilizer foot from falling out if the stabilizer foot device 8 is released while the balance is not resting on a supporting surface. The stabilizer foot device 8 includes a clamping jaw 13 that is connected to a mounting part 12 through a flexure pivot 11 . The clamping jaw 13 is tightened by applying a force to its other end, whereby the stabilizer foot 6 is clamped tight between the clamping jaw 13 and the mounting part 12 and thereby secured in a fixed position. The end of the clamping jaw 13 that faces away from the stabilizer foot 6 is coupled to the actuating lever 9 through a shackle arrangement that is connected to the clamping jaw and to the actuating lever through articulated joints. The shackle arrangement consists of two shackle plates 19 which are connected to each other at the ends by connector bolts 21 , 21 ′. The mounting part 12 and the clamping jaw 13 both engage the shackle arrangement from the inside. More specifically, the end of the clamping jaw 13 that faces away from the stabilizer foot bears against the connector bolt 21 and partially embraces the latter. The second connector bolt 21 ′ forms the center of rotation of the actuating lever 9 . The actuating lever 9 is shaped so that its inside contour which faces towards the stabilizer foot device 8 rests in formfitting contact against the mounting part 12 (see FIG. 3 b ).
[0033] The actuating lever 9 has a cam 22 which is contoured eccentrically relative to the center of rotation and bears against the mounting part at the opposite end from the stabilizer foot. When the actuating lever 9 is pulled outward at its gripping end 23 , i.e., clockwise relative to its center of rotation in FIG. 3 a , the contact point between the eccentric cam contour 22 and the mounting part 12 shifts in the direction of decreasing contour radius on the contour curve, so that the distance between the clamping jaw 13 and the fastening part 12 becomes wider and the clamp lock on the stabilizer foot 6 between the clamping jaw 13 , flexure pivot 11 and mounting part 12 is released. When the lever is subsequently pushed back to rest against the stabilizer foot device, the contact point between the eccentric cam 22 and the mounting part 12 shifts back in the direction of increasing contour radius on the contour curve, so that the shackle arrangement is pulled towards the lever 9 , whereby the clamping jaw 13 is tightened, so that the stabilizer foot 6 is locked in place again.
[0034] FIG. 3 b shows a view of the stabilizer foot device 8 from below, i.e., from the side that faces away from the balance housing 3 in the installed condition of the stabilizer foot device. The drawing shows how the clamping jaw 13 , the flexure pivot 11 and the mounting part 12 embrace the stabilizer foot 6 , so that only a small force on the clamping jaw 13 is required in order to lock the clamp hold on the stabilizer foot. The actuating lever 9 has a grip cover 24 which for ergonomic reasons is made of a polymer material. The lever 9 with the grip cover 24 is longer than the clamping jaw 13 and the mounting part 12 , so that the user can reach with one finger behind the overhanging rim of the grip cover 24 to pull the lever 9 outward. The screws 25 serve to attach the stabilizer foot device 8 to the balance housing 3 by turning the screws into tapped holes that are provided for this purpose in the bottom of the balance housing 3 .
[0035] FIG. 3 c , which shows a side view of the stabilizer foot device 8 , illustrates the arrangement of the latter in relation to the balance housing 3 and the supporting surface 20 which are both drawn in sectional representation. The drawing shows how the stabilizer foot device 8 is arranged between the balance housing 3 and the support surface 20 on which the balance 1 is standing. The stabilizer foot device 8 is attached to the balance housing 3 by means of the screws 25 . The upper shackle plate 19 of the shackle arrangement occupies a recess 27 of the balance housing 3 . A helix spring 26 , seated together with the stabilizer foot 6 in a further recess 28 of the balance housing 3 , is pre-tensioned between the stabilizer foot 6 and the balance housing 3 . When the locked stabilizer foot 6 is unlocked by pulling the actuating lever 9 on a balance 1 that is set up for operation, the stabilizer foot, pushed down by its own weight and the spring force, continues to rest on the supporting surface 20 while being vertically movable relative to the clamping jaw 13 , flexure pivot 11 and mounting part 12 , so that the stabilizer foot adjusts itself to the changing distance between the balance housing 3 and the supporting surface 20 , for example when the level position of the balance 1 is being adjusted. By pushing the lever 9 back against the stabilizer foot device 8 and thereby locking the stabilizer foot 6 in place, the stabilizer foot is secured in its new position. As a result, the balance 1 with an arrangement of the positioning feet 5 , 5 ′ and stabilizer feet 6 as shown in FIG. 2 is able to rest on 5 points of the supporting surface 20 without being thereby put into a statically indeterminate condition.
[0036] It is considered self-evident that the spring constant and the compressive pre-tension of the helix spring 26 under the weight of the balance 1 are designed so that the stabilizer foot 6 always stays in contact with the support surface when the stabilizer foot device 8 is in its unlocked condition, but without exceeding an amount of spring force that would lift any of the positioning feet 5 , 5 ′ of the balance 1 from the support surface. The spring force of the helix spring 26 is preferably some fractional amount, specifically about three-fifths, of the force that would cause one of the positioning feet to be lifted off the support surface.
[0037] The embodiment of a stabilizer foot device 8 shown in FIGS. 3 a to 3 c is designed for installation on the right and left sides of the balance housing 3 . To allow the same device to be used on the right or left side, the bolt-shaped stabilizer foot 6 can be turned over in relation to the stabilizer foot device 8 , so that the recess 10 always faces towards the balance housing 3 . Although the grip cover 24 is configured specifically for either a right-side installation or a left-side installation of the stabilizer foot device 3 , this does not present a problem as the grip cover is designed to be slipped in place on the lever 9 .
[0038] A different embodiment of a stabilizer foot device 108 according to the invention is illustrated in FIGS. 4 a and 4 b . In the perspective view of FIG. 4 a , the stabilizer foot device 108 is seen from above at an oblique angle, i.e., showing the side which in the installed condition of the device is facing towards the balance housing 3 . The stabilizer foot device 108 has a housing 31 which is connectable to the balance housing 3 by means of screws (not shown in the drawing) through the holes 29 . A holder 30 which is configured as a part of the housing 31 constrains the bolt-shaped stabilizer foot 106 so that it can only move along one direction, i.e., only in the vertical direction of the balance 1 on which the stabilizer foot device 108 is installed and which is set up in the operating position. The constraint has the form of a guide track in the holder 30 , which embraces about half of the circumference of the stabilizer foot 106 . The housing 31 has an interior space 32 to accommodate a helix spring (not shown in the drawing) that is connected to the stabilizer foot 106 and pushes the latter against the supporting surface 20 , and to also accommodate a part of the stabilizer foot 106 itself with the required free space for the stabilizer foot 106 to move up or down.
[0039] Analogous to the stabilizer foot device 8 of FIG. 3 , the spring force in the foregoing embodiment is selected in appropriate proportion to the weight of the balance 1 , so that the stabilizer foot 106 is kept in firm contact with the supporting surface 20 without lifting any of the positioning feet 5 , 5 ′ of the balance 1 from the supporting surface.
[0040] The stabilizer foot 106 does not have a circular cross-section but is flattened on opposite sides of its circumference. This prevents on the one hand a rotation of the stabilizer foot 106 and on the other hand provides a contact surface for a tapered wedge block 33 that serves to secure the stabilizer foot 106 in its holder 30 . In the unlocked condition, the wedge block 33 is movable along an inclined ramp surface 34 that faces towards the inside of the housing 31 . A leaf spring 35 , which serves to lock the stabilizer foot 106 in its set position, engages a slot 36 of the wedge block 33 , so that there is a form-fitting connection between the leaf spring and the wedge block. The friction at the contact surfaces of the stabilizer foot 106 and wedge block 33 on the one hand and of the wedge block 33 and ramp surface 34 on the other hand prevents a complete release of the stabilizer foot 106 from the stabilizer foot device 108 .
[0041] FIG. 4 b shows the stabilizer foot device 108 seen at an oblique viewing angle from below in relation to the installed position of the device on the underside of the balance housing 3 . This drawing illustrates with particular clarity how the stabilizer foot 106 is guided on one side by the guide track 37 and on the other side by the wedge block 33 . The leaf spring 35 is shaped so that it reaches around the stabilizer foot 106 as well as the holder 30 with the guide track 37 and engages the grove 36 of the wedge block. The end of the leaf spring (to the right of the wedge block 33 in FIG. 4 b ) forms a roughly triangular tongue 38 that is slightly bent away from the stabilizer foot housing 31 .
[0042] The actuating lever 109 in the foregoing embodiment is a two-armed lever that is rotatable about a fulcrum point 39 which has a fixed position on the stabilizer foot housing. The user operates the device through the long lever arm 40 . When the free end of the long lever arm 40 is pulled away from the housing 31 , i.e., in the clockwise direction in FIG. 4 b , the short lever arm 41 slides under the triangular tongue 38 of the leaf spring 35 and thereby pulls the leaf spring away from the housing 31 . Consequently, the wedge block is pulled in the same direction, whereby the stabilizer foot 106 is released so that it can move along the guide track 37 under the force of the helix spring.
[0043] The stabilizer foot devices of the foregoing detailed description are intended as representative examples for a multitude of possible stabilizer foot devices. The inventive concept can be embodied in other forms, for example in a device where the stabilizer foot is locked and unlocked only by a lever with an eccentrically contoured cam and/or where the contact to the supporting surface is maintained only by gravity, i.e., by the weight of the stabilizer foot. It is further possible that a stabilizer foot is moved up and down by means of a motor that is integrated in the stabilizer foot device and that the position of the stabilizer foot is secured by blocking the motor.
[0044] If the positioning feet of a balance are not arranged at the corners of an isosceles triangle, but are located at three of the four corners of a balance housing with an approximately rectangular footprint, it is advantageous to arrange a stabilizer foot device according to the invention near the fourth corner, so that the inventive device stabilizes the balance during the leveling process and secures the stability of the balance in the set position, after the level adjustment has been completed.
[heading-0045] List of Reference Symbols
[none]
1 balance
2 weighing pan
3 balance housing
4 display- and operating unit
5 , 5 ′ positioning foot
6 , 106 stabilizer foot
7 display screen
8 , 108 stabilizer foot device
9 , 109 actuating lever, lever
10 recess
11 flexure pivot
12 mounting part
13 clamping jaw
14 border area
15 central portion
16 cable guide channel
17 passage
18 recessed handhold
19 shackle plate
20 supporting surface
21 , 21 ′ connector bolts
22 eccentric cam
23 gripping end of actuator lever
24 grip cover
25 screws
26 helix spring
27 recess
28 recess
29 hole
30 holder
31 housing, stabilizer foot housing
32 interior space
33 wedge block
34 ramp surface
35 leaf spring
36 slot
37 guide track
38 triangular tongue
39 fulcrum point
40 long lever arm
41 short lever arm
42 turning wheel
43 collar | A balance ( 1 ) with a housing ( 3 ) containing the weighing mechanism and associated electronic components has at least three positioning feet ( 5, 5 ′) to stand on a supporting surface ( 20 ), at least two of the positioning feet ( 5 ) being height-adjustable for setting the balance ( 1 ) into a level position. In addition, the balance ( 1 ) has at least one stabilizer foot ( 6, 106 ) which can be locked and unlocked, so that for adjusting the level position of the balance, the stabilizer foot is released and thereby enabled to stay in contact with the supporting surface ( 20 ), and after the level adjustment of the balance has been completed, the stabilizer foot is locked in place to secure the stability of the balance ( 1 ) in its set position. | 6 |
This application is a 371 of PCT/US97/09965 filed Jun. 6, 1997.
TECHNICAL FIELD
The present invention relates to the bleaching of fabrics.
BACKGROUND
Peroxygen bleach-containing compositions have been described in laundry applications as laundry detergents, laundry additives or even laundry pretreaters.
Indeed, it is known to use peroxygen bleach-containing compositions in laundry treatment applications to boost the removal of encrustated stains/soils which are otherwise particularly difficult to remove, such as grease, coffee, tea, grass, mud/clay-containing soils and the like. However, we have found that a drawback associated with such peroxygen bleach-containing compositions is that said compositions may damage fabrics, resulting in loss of tensile strength, especially when used in pretreatment application, i.e. when applied directly (neat) onto the fabrics, and left to act onto said fabrics for prolonged periods of time before washing the fabrics.
It is thus an object of the present invention to provide improved fabric safety upon bleaching, especially in pretreatment applications where the compositions are left neat into contact with the fabrics for prolonged periods of time before washing.
Indeed, when bleaching fabrics with a composition comprising a peroxygen bleach like hydrogen peroxide, it has been found that the presence of metal ions such as copper and/or iron and/or manganese and/or chromium on the surface of the fabrics and/or the exposure to UV radiation from sunlight of the fabrics after having been contacted with the peroxygen bleach-containing composition, produces fabric damage resulting in loss of tensile strength of the fabric fibres. Indeed, it is speculated that the presence of metal ions such as copper and/or iron and/or manganese and/or chromium on the surface of the fabrics, especially on cellulosic fibres, and/or the exposure of the fabrics to UV radiation from sunlight catalyses the radical decomposition of peroxygen bleaches like hydrogen peroxide. Thus, it is believed that a radical reaction occurs on the surface of the fabric with generation of free radicals, which results in loss of tensile strength.
It has now been found that improved fabric safety can be achieved by formulating a bleaching composition where hydrogen peroxide is substituted by selected hydroperoxides as the bleaching agent, or mixtures thereof.
U.S. Pat. No. 5,284,597 discloses a composition for treating soft surfaces, essentially carpets, which comprise amongst other things tertiary alkyl hydroperoxide. The compositions are said to be safer to colors.
U.S. Pat. No. 3,574,519 discloses the bleaching of textiles where the bleaching agent is an organic hydroperoxide. Organic hydroperoxides are said to be economically attractive. '519 does not discuss the problem of safety to fabrics.
BE 831.277 discloses the bleaching of textiles with the help of a mixtures of bleach activators, one of which being from the class of triazine hydroperoxides. Triazine hydroperoxides are said to be potentially damaging to the colors of fabrics. '277 does not discuss the problem of safety to fabrics.
U.S. Pat. No. 3,753,915 discloses the bleaching of fabrics with a granular composition comprising salts of hydroperoxides. '915 does not discuss the problem of safety to fabrics.
SUMMARY OF THE INVENTION
In its broadest embodiment, the present invention encompasses the use of hydroperoxides for the bleaching of fabrics, for reducing the loss of tensile strength in said fabrics.
The present invention further encompasses processes of bleaching fabrics, starting from a liquid composition comprising a hydroperoxide. The processes include the steps of contacting said fabrics with the liquid bleaching composition neat or diluted, and subsequently rinsing said fabrics. In the preferred embodiment, when the fabrics are "pretreated", the composition is applied neat on the fabrics, and the fabrics are subsequently washed in a normal wash cycle.
DETAILED DESCRIPTION OF THE INVENTION
In its broadest embodiment, the present invention encompasses the use of a hydroperoxide as a bleaching agent in a process of bleaching fabrics for reducing the loss of tensile strength in said fabrics.
In other words, the present invention is based on the finding that fabric damage resulting in tensile strength loss is reduced, when a composition comprising a hydroperoxide, or mixtures thereof, is used to bleach fabrics, as compared to the same composition where hydrogen peroxide is used instead of hydroperoxide.
It is speculated that reduced fabric damage observed herein is due to the much lower reactivity of free radicals generated from hydroperoxides vs. those generated from hydrogen peroxide.
In addition, it is speculated that with hydroperoxides, there is a lower dependence of fabric damage from heavy metal pollution, probably because the formation of a complex between the metal and the peroxide molecule is more difficult than with hydrogen peroxide.
The tensile strength in a fabric may be measured by stretching said fabric until it breaks. The force needed to break the fabric is the "Ultimate Tensile Stress" and may be measured with a stress-strain INSTRON® machine available from INSTRON. The loss of tensile strength is the difference between the tensile strength of a fabric taken as a reference, i.e. a fabric which has not been bleached, and the tensile strength of the same fabric after having been bleached. A tensile strength loss of zero means that no fabric damage is observed.
As a first essential element, the liquid compositions suitable to be used according to the present invention comprise a hydroperoxide, or mixtures thereof, as the bleaching agent. Suitable hydroperoxides for use herein include alkyl hydroperoxides and organomineral hydroperoxides.
Suitable alkyl hydroperoxides for use herein are according to the formula ##STR1## in which each R1, R2 and R3 is, independently, a hydrogen atom or a hydrocarbon radical having from 1 to 30 carbon atoms. The hydrocarbon radical can be a linear or a cyclic hydrocarbon chain, and the linear and the cyclic hydrocarbon chain can be straight or branched, saturated or unsaturated. Also, two of the R groups can be part of the same cyclic hydrocarbon. One or more R groups in the above formula can be a single or condensed aromatic radical, alkyl-aryl radical or cycloalkyl-aryl radical.
All the above R radicals can also be substituted by heteroatoms or group of heteroatoms, such as hydroperoxide (--OOH) groups, halogen atoms, hydroxy groups, nitrates, suphonyls, nitro groups, ethers, carboxylic groups and esters. All these groups can also be present as substituents of one or more positions of the R radicals.
Preferred alkyl hydroperoxides for use herein are tert-butyl hydroperoxide, cumyl hydroperoxide, 2,4,4-trimethylpentyl-2-hydroperoxide, di-isopropylbenzene-monohydroperoxide, tert-amyl hydroperoxide and 2,5-dimethyl-hexane-2,5-dihydroperoxide.
Suitable organomineral hydroperoxides for use herein are according to the formula
R.sub.m M(OOH).sub.n
where M is a metal atom like Si, Sn, Ge or Sb and R is a radical defined as R1, R2, R3 above. Preferred organomineral hydroperoxides for use herein are (CH 3 ) 3 SiOOH, (C 6 H 5 ) 2 CH 3 SiOOH, (C 6 H 5 ) 3 SiOOH, (n-C 6 H 13 ) 3 SiOOH, (CH 3 ) 3 SnOOH, (C 6 H 5 ) 3 Sb(OOH) 2 . Most preferred for use herein are (CH 3 ) 3 SiOOH, (C 6 H 5 ) 3 SiOOH.
Typically, the compositions herein comprise from 0.01% to 5.0%, preferably 0.015% to 4.0%, most preferably from 0.02% to 2.0% of available oxygen provided by said hydroperoxide.
The compositions to be used according to the present invention must be liquids. As used herein, "liquid" includes "pasty" compositions, and liquid compositions herein preferably have a viscosity of from 5 cps to 10000 cps at 50 rpm shear rate and at 20° C. temperature.
Preferably, the compositions to be used herein are aqueous. Said aqueous compositions have a pH as is of from 2 to 11, preferably from 3 to 10 and more preferably from 3.5 to 9.5 when optimum chemical stability for the hydroperoxides has been observed. The pH of the compositions can be adjusted for instance by using organic or inorganic acids, or alkalinizing agents.
The compositions used in the present invention may further comprise any surfactant including nonionic, anionic, cationic, zwitterionic and/or amphothereic surfactants.
Accordingly, the compositions used in the present invention preferably further comprise a nonionic surfactant, or mixtures thereof. Typically, the compositions used in the present invention comprise from 0.1% to 50% by weight of the total composition of said nonionic surfactant, or mixtures thereof, preferably from 0.3% to 30% and more preferably from 0.4% to 25%.
Suitable nonionic surfactants to be used herein are fatty alcohol ethoxylates and/or propoxylates which are commercially available with a variety of fatty alcohol chain lengths and a variety of ethoxylation degrees. Indeed, the HLB values of such alkoxylated nonionic surfactants depend essentially on the chain length of the fatty alcohol, the nature of the alkoxylation and the degree of alkoxylation. Surfactant catalogues are available which list a number of surfactants, including nonionics, together with their respective HLB values.
Suitable chemical processes for preparing the nonionic surfactants for use herein include condensation of corresponding alcohols with alkylene oxide, in the desired proportions. Such processes are well known to the man skilled in the art and have been extensively described in the art. As an alternative, a great variety of alkoxylated alcohols suitable for use herein is commercially available from various suppliers.
Particularly suitable to be used herein as nonionic surfactants are hydrophobic nonionic surfactants having an HLB (hydrophilic-lipophilic balance) below 16, preferably below 15, more preferably below 12, and most preferably below 10. Those hydrophobic nonionic surfactants have been found to provide good grease cutting properties.
Preferred hydrophobic nonionic surfactants to be used in the compositions according to the present invention are surfactants having an HLB below 16 and being according to the formula RO--(C 2 H 4 O) n (C 3 H 6 O) m H, wherein R is a C 6 to C 22 alkyl chain or a C 6 to C 28 alkyl benzene chain, and wherein n+m is from 0 to 20 and n is from 0 to 15 and m is from 0 to 20, preferably n+m is from 1 to 15 and, n and m are from 0.5 to 15, more preferably n+m is from 1 to 10 and, n and m are from 0 to 10. The preferred R chains for use herein are the C 8 to C 22 alkyl chains. Accordingly suitable hydrophobic nonionic surfactants for use herein are Dobanol® 91-2.5 (HLB=8.1; R is a mixture of C 9 and C 11 alkyl chains, n is 2.5 and m is 0), or Lutensol® TO3 (HLB=8; R is a C 13 alkyl chains, n is 3 and m is 0), or Lutensol® AO3 (HLB=8; R is a mixture of C 13 and C 15 alkyl chains, n is 3 and m is 0), or Tergitol® 25L3 (HLB-=7.7; R is in the range of C 12 to C 15 alkyl chain length, n is 3 and m is 0), or Dobanol® 23-3 (HLB=8.1; R is a mixture of C 12 and C 13 alkyl chains, n is 3 and m is 0), or Dobanol® 23-2 (HLB=6.2; R is a mixture of C 12 and C 13 alkyl chains, n is 2 and m is 0), or Dobanol® 45-7 (HLB=11.6; R is a mixture of C 14 and C 15 alkyl chains, n is 7 and m is 0) Dobanol® 23-6.5 (HLB=11.9; R is a mixture of C 12 and C 13 alkyl chains, n is 6.5 and m is 0), or Dobanol® 25-7 (HLB=12; R is a mixture of C 12 and C 15 alkyl chains, n is 7 and m is 0), or Dobanol® 91-5 (HLB=11.6; R is a mixture of C 9 and C 11 alkyl chains, n is 5 and m is 0), or Dobanol® 91-6 (HLB=12.5 ; R is a mixture of C 9 and C 11 alkyl chains, n is 6 and m is 0), or Dobanol® 91-8 (HLB=13.7 ; R is a mixture of C 9 and C 11 alkyl chains, n is 8 and m is 0), Dobanol® 91-10 (HLB =14.2 ; R is a mixture of C 9 to C 11 alkyl chains, n is 10 and m is 0), or mixtures thereof. Preferred herein are Dobanol® 91-2.5, or Lutensol® TO3, or Lutensol® AO3, or Tergitol® 25L3, or Dobanol® 23-3, or Dobanol® 23-2, or mixtures thereof. These Dobanol® surfactants are commercially available from SHELL. These Lutensol® surfactants are commercially available from BASF and these Tergitol® surfactants are commercially available from UNION CARBIDE.
Preferred compositions to be used herein further comprise an anionic surfactant, or mixtures thereof. Said anionic surfactants act as wetting agent, i.e. in laundry application they wet the stains on the fabrics, especially on hydrophilic fabrics, and thus help the hydroperoxide perform its bleaching action thereby contributing to improved laundry performance on bleachable stains. Furthermore, anionic surfactants allow to obtain clear compositions even when said compositions comprise hydrophobic ingredients such as hydrophobic surfactants. Typically, the compositions to be used herein comprise from 0.1% to 20% by weight of the total composition of said anionic surfactant, or mixtures thereof, preferably from 0.2% to 15% and more preferably from 0.5% to 13%.
Particularly suitable for use herein are sulfonate and sulfate surfactants. The like anionic surfactants are well-known in the art and have found wide application in commercial detergents. These anionic surfactants include the C8-C22 alkyl benzene sulfonates (LAS), the C8-C22 alkyl sulfates (AS), unsaturated sulfates such as oleyl sulfate, the C10-C18 alkyl alkoxy sulfates (AES) and the C10-C18 alkyl alkoxy carboxylates. The neutralising cation for the anionic synthetic sulfonates and/or sulfates is represented by conventional cations which are widely used in detergent technology such as sodium, potassium or alkanolammonium. Preferred herein are the alkyl sulphate, especially coconut alkyl sulphate having from 6 to 18 carbon atoms in the alkyl chain, preferably from 8 to 15, or mixtures thereof.
The compositions for use herein may further comprise a foam suppressor such as 2-alkyl alkanol, or mixtures thereof, as a highly preferred optional ingredient. Particularly suitable to be used in the present invention are the 2-alkyl alkanols having an alkyl chain comprising from 6 to 16 carbon atoms, preferably from 8 to 12 and a terminal hydroxy group, said alkyl chain being substituted in the α position by an alkyl chain comprising from 1 to 10 carbon atoms, preferably from 2 to 8 and more preferably 3 to 6. Such suitable compounds are commercially available, for instance, in the Isofol® series such as Isofol® 12 (2-butyl octanol) or Isofol® 16 (2-hexyl decanol). Typically, the compositions suitable to be used herein comprise from 0.05% to 2% by weight of the total composition of a 2-alkyl alkanol, or mixtures thereof, preferably from 0.1% to 1.5% and most preferably from 0.1% to 0.8%.
The compositions herein may further comprise a variety of other optional ingredients such as builders, stabilisers, chelants, soil suspenders, dye transfer agents, radical scavengers, solvents, brighteners, perfumes, and dyes.
In the present invention, the liquid bleaching composition comprising the hydroperoxide needs to be contacted with the fabrics to be bleached. This can be done either in a so-called "pretreatment mode", where the composition is applied neat onto said fabrics before the fabrics are rinsed, or washed then rinsed, or in a "soaking mode" where the liquid composition is first diluted in an aqueous bath and the fabrics are immersed and soaked in the bath, before they are rinsed, or in a "through the wash mode", where the liquid composition is added on top of a wash liquor formed by dissolution or dispersion of a typical laundry detergent. As discussed earlier, the composition to perform the processes herein is in the form of a liquid as opposed to a solid or a gas.
It is also essential in both cases, that the fabrics be rinsed after they have been contacted with said composition, before said composition has completely dried off.
Indeed, it has been found that water evaporation contributes to increase the concentration of free radicals onto the surface of the fabrics and, consequently, the rate of chain reaction. It is also speculated that an auto-oxidation reaction occurs upon evaporation of water when the liquid compositions are left to dry onto the fabrics. Said reaction of auto-oxidation generates peroxy-radicals which may contribute to the degradation of cellulose. Thus, not leaving the liquid compositions, as described herein, to dry onto the fabric, in a process of pretreating soiled fabrics, contributes to the benefits according the present invention, i.e. to reduce the tensile strength loss when pretreating fabrics with liquid peroxygen bleach-containing compositions.
In the pretreatment mode, the process comprises the steps of applying said liquid composition in its neat form onto said fabrics, or at least soiled portions thereof, and subsequently rinsing, or washing then rinsing said fabrics. In this mode, the neat compositions can optionally be left to act onto said fabrics for a period of time ranging from 1 min. to 1 hour, before the fabrics are rinsed, or washed then rinsed, provided that the composition is not left to dry onto said fabrics. For particularly though stains, it may be appropriate to further rub or brush said fabrics by means of a sponge or a brush, or by rubbing two pieces of fabrics against each other.
In another mode, generally referred to as "soaking", the process comprises the steps of diluting said liquid composition in its neat form in an aqueous bath so as to form a diluted composition, i.e., a composition comprising from 0.0001% to 0.2%, preferably 0.0002% to 0.02% of available oxygen provided by said hydroperoxide. The fabrics are then contacted with the aqueous bath comprising the liquid composition, and the fabrics are finally rinsed, or washed then rinsed. Preferably in that embodiment, the fabrics are immersed in the aqueous bath comprising the liquid composition, and also preferably, the fabrics are left to soak therein for a period of time ranging from 30 minutes to 48 hours, preferably from 1 hour to 24 hours.
In yet another mode which can be considered as a sub-embodiment of "soaking", generally referred to as "bleaching through the wash", the liquid composition is used as a so-called laundry additive. And in that embodiment the aqueous bath is formed by dissolving or dispersing a conventional laundry detergent in water. The liquid composition in its neat form is contacted with the aqueous bath, and the fabrics are then contacted with the aqueous bath containing the liquid composition. Finally, the fabrics are rinsed.
Depending on the end-use envisioned, the compositions herein can be packaged in a variety of containers including conventional bottles, bottles equipped with roll-on, sponge, brusher or sprayers, or sprayers.
The invention is further illustrated by the following examples.
EXAMPLES
Example 1
A liquid composition is prepared which comprises:
______________________________________ Cumyl Hydroperoxide 10%Dobanol 23.3 8.6%Dobanol 45.7 6.4%C12 Alkyl Sulfate 2%Water and minors up to 100%______________________________________ pH = 4, trimmed with Sulphuric acid
In a pretreatment mode, this composition is applied neat on the stained portion of a fabric and left to act thereon for 5 minutes. Then the fabric is washed with a conventional detergent and rinsed.
Example 2
The following liquid composition is prepared:
______________________________________tert-Butyl Hydroperoxide 10%Dobanol 45.7 6.0%Dobanol 23.6,5 6.0%C25-AE2.5-S (ethoxylated alkyl sulfate) 6.0%Water and minors up to______________________________________ 100% pH = 4, trimmed with Sulphuric acid
In a bleaching-through-the-wash mode, this composition is contacted with an aqueous bath formed by dissolution of a conventional detergent in water. Fabrics are then contacted with the aqueous bath comprising the liquid detergent, and the fabrics are rinsed. This composition can also be used in a pretreatment mode, where it is poured neat on the stains on the fabrics, and left to act for 5 minutes, and the fabrics are washed.
Example 3
The following liquid composition is prepared:
______________________________________ tert-Butyl Hydroperoxide 5%Dobanol 91.10 1.6%Dobanol 23.3 1.5%C10 AS 1.7%Isofol 12 ® 0.5%Water and minors up to 100%______________________________________ pH = 4, trimmed with Sulphuric acid
This composition can be used in a pretreatment mode, or in a bleaching-through-the-wash mode, as described in examples 1 and 2. It can also be used in a soaking mode, where 100 ml of the liquid compositions are diluted in 10 liters of water. The fabrics are then contacted with this aqueous bath containing the composition, and left to soak therein for a period of time of 24 hours. The fabrics are eventually rinsed.
Example 4
A liquid detergent composition is prepared as follows:
______________________________________Cumyl Hydroperoxide 10%Dobanol 23.3 8.6%Dobanol 45.7 6.4%C12 AS 2%Water and minors up to 100%______________________________________ pH = 6, trimmed with Sulphuric acid
This composition is used in a pretreatment mode, as described in the examples above.
Example 5
The following liquid composition is made:
______________________________________2,5-dimethyl-hexane-2,5-dihydroperoxide 5%Dobanol 23.3 8.6%Dobanol 45.7 6.4%C25-2.5EO-S 2%Water and minors up to______________________________________ 100% pH = 5, trimmed with Sulphuric acid
This composition is used in a pretreatment mode as described in the previous examples. | Stains are removed from fabrics by means of metallo-hydroperoxides during an otherwise conventional laundering process. Hydroperoxides based on silicon, tin and antimony are used to effect stain removal without reducing the tensile strength of said fabrics. | 2 |
TECHNICAL FIELD
The invention relates generally to the field of computer power supplies and, more particularly, to a method and apparatus for protecting a computer power supply from overload over a wide ambient temperature range using a no-trim circuit.
BACKGROUND
Computer power supplies are experiencing continually increasing demands of high performance, high reliability, and low cost. For example, limits require a computer power supply to shut off if its output exceeds a certain threshold. The power supply should meet these limits over a wide temperature range, such as from 10° C. to 50° C. ambient, and over a wide input voltage range, such as from 90 VAC to 135 VAC. In response to such limits, some power supplies have incorporated temperature-sensitive overload protection circuits. These overload protection circuits shut the computer power supply off before a predetermined maximum rated voltage-current load is exceeded.
A typical overload protection circuit includes a comparator for receiving and comparing a computer supply voltage and a second voltage indicating the current consumption of the computer. A trip point for the comparator can be adjusted to meet the limits by incorporating a variable resistor potentiometer ("pot") between the two voltages. By using a pot, variability from one power supply to the next can be accounted for during the manufacture of the computer. Typically, the pot is adjusted, or "trimmed", by the computer manufacturer to ensure accurate shut offs of the power supply. Once the pot is trimmed, glue is formed over the pot to prevent it from changing during the lifetime of the computer. Although this typical solution has limited success, pots are inherently variable, especially in response to changes in temperature. Furthermore, the trimming and gluing of the pot is an extra step in the manufacture of a computer and therefore is relatively expensive and subject to error.
Therefore, what is needed is an overload protection circuit that allows a power supply to meet certain limits, yet doesn't have the inherent problems associated with pots.
SUMMARY
A technical advance is achieved by an improved overload protection circuit for protecting a computer power supply from overload over a wide ambient temperature range. The improved overload protection circuit, which compares two voltage signals in order to shut off the computer power supply when certain limits are exceeded, is implemented without any pots or other trim circuits. Instead, a resistive temperature device is utilized to counter the effects of increasing ambient temperature on the overload protection circuit.
A technical advantage is that, despite any increase in ambient temperature, an over-current-protection trip point for the overload protection circuit remains near desired levels across most ambient temperatures.
Another technical advantage is that the overload protection circuit does not require any additional handling or trimming during the manufacture of the computer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a computer with an overload protection circuit utilizing features of the present invention.
FIG. 2 is a schematic diagram of one implementation of the overload protection circuit of FIG. 1.
FIG. 3 is a graph of test results comparing the operation of the overload protection circuit of FIG. 2 with a conventional overload protection circuit.
DETAILED DESCRIPTION
Referring to FIG. 1, reference numeral 10 generally designates a personal computer. The computer 10 includes a power supply 12, an alternating current "AC" power cord 14, a computer power supply bus VCC, a circuit board 16, and a plurality of computing circuits represented by a memory 18 and a microprocessor 20. The circuit board 16 includes connectors (not shown) that interconnect the plurality of computing circuits 18, 20, and connect the VCC bus to the computing circuits. In operation, the power supply 12 converts AC power received through the power cord 14 into regulated direct current "DC" power. The power supply 12 provides the regulated DC power at a predetermined voltage level, which is driven through the VCC bus to the plurality of computing circuits 18, 20. The plurality of computing circuits 18, 20 utilize the power supplied through the VCC bus to perform conventional computing tasks.
The computer 10 also includes an overload protection circuit 30 for use with the power supply 12. The overload protection circuit 30 receives the VCC bus from the circuit board 16, an output voltage VOUT from the power supply 12, and a transformer voltage VTRANS. The transformer voltage VTRANS is connected to a secondary transformer coil (not shown) of the power supply 12. The overload circuit 30 drives a shut-off signal 32, which informs the power supply 12 that certain predetermined conditions have been exceeded, as described in greater detail below.
Referring to FIG. 2, connected between the power supply output voltage VOUT and the transformer voltage VTRANS is a current sense inductor L1 which reflects a change in current as a change in voltage. In the implementation herein described, the current sense inductor L1 is part of the power supply 12, but alternative implementations may include the current sense inductor with the overload protection circuit.
The overload circuit 30 includes resistors R1, R2, R3, and R4, a capacitor C1, a positive coefficient resistive temperature device ("RTD") 34, a comparator 36 and a shunt regulator SR1. In the implementation herein described, the shunt regulator SR1 is a TL431 manufactured by National Semiconductor Company of Santa Clara, Calif.
The comparator 36 detects when the power supply 12 is overloaded, or above a predetermined voltage-current limit. When such a situation exists, the overload protection circuit 30 reaches an over-current-protection ("OCP") trip point and transitions the shut off signal 32 accordingly, thereby signaling the power supply 12 to power down. In actuality, the OCP trip point overload protection circuit 30 varies somewhat with temperature. However, the variance of the OCP trip point for the overload protection circuit 30 is relatively small.
For the sake of example, representative values will be shown, it being understood that the overload protection circuit 30 may accommodate many different situations. The power supply output voltage VOUT is set at 5 V and the maximum predetermined limit of operation for the power supply 12 is 240 VA. A maximum current for the transformer voltage VTRANS is calculated to be 48 A (48 A=240 VA/5 V), although 45 A is targeted for reasons of reliability. The capacitor C1 is 10 μF, the RTD 34 is 200 Ω, and the resistors R1, R2, R3, R4 are 10 KΩ, 330 Ω, 22 KΩ, and 2.4 KΩ, respectively. The operating ambient temperature range is 10° C. to 50° C. Variations in current between the transformer voltage VTRANS and power supply output voltage VOUT are due to the resistance of the current sense inductor L1, which increases as ambient temperature increases. The voltage drop across the inductor L1 increases since the resistance of the inductor increases with an increase in ambient temperature, even though the current drawn at VOUT remains constant.
To compensate for the change in resistance of the current sense inductor L1, the resistance of the RTD 34 increases as ambient temperature increases. Hence, the trigger point where the output of the comparator 32 goes to a low impedance is the same for the same output current drawn at VOUT. As a result, despite an increase in ambient temperature, the OCP trip point for the overload protection circuit 30 remains near the 45 A target across most ambient temperatures.
Referring to FIG. 3, to illustrate the benefits of the overload protection circuit 30, its performance will be compared with a conventional overload protection circuit by a graph 40. For the sake of comparison, the conventional overload protection circuit will have the same components as the overload protection circuit 30, except instead of having resistor R2 and RTD 34, the conventional circuit has a 1000 Ω pot properly trimmed. The graph 40 has a horizontal axis designating ambient temperature and a vertical axis designating the OCP trip point for the overload protection circuit. A curve 42 represents the performance of the overload protection circuit 30, while curves 44a and 44b represent the performance of the conventional overload protection circuit. There are two curves 44a and 44b for the conventional overload protection circuit because of the inherently variable nature of the pot, as well as the unpredictable increase in resistance of the current sense inductor L1. It should be noted that the curve 42 is relatively flat, having a low OCP trip point of 39 A at 50° C. and a high OCP trip point of 43 A at 10° C. In comparison, it should also be noted that both curves 44a and 44b have a high OCP trip point of 45 A at 10° C., due to the appropriate trimming of the pot, mentioned above, but have low OCP trip points of 35 A and 30 A, respectively, at 50° C. Those of ordinary skill in the art will recognize that such low OCP trip points are highly undesirable.
It is understood that the invention described herein can take many forms and embodiments, the embodiments described herein are intended to illustrate rather than limit the invention. For example, the overload protection circuit 30 may be simply altered to accommodate a positive thermocouple coefficient device, such device being less expensive than the negative coefficient RTD described above. Furthermore, certain applications that require exact precision for shut off can include additional analog circuitry using on/off transistors switch circuits to shut off the power supply 12 by having separate overload protection circuits for different temperature ranges, the on/off transistors appropriately selecting among the separate circuits according to the ambient temperature. Therefore, variations may be made without departing from the spirit or purpose of the invention. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | In a computer, an overload protection circuit for protecting the computer's power supply from overload over a wide ambient temperature range. The overload protection circuit, which compares two voltage signals in order to shut off the computer power supply when certain limits are exceeded, is implemented without any pots or other trim circuits. Instead, a resistive temperature device is utilized to counter the effects of increasing ambient temperature on the overload protection circuit. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the following provisional applications, of which the entire disclosure of each is hereby incorporated by reference for all purposes: U.S. Prov. App. No. 60/527,145, filed Dec. 10, 2003 by Bura et al. and entitled “Analyzing Domain Ownership Information”; U.S. Prov. App. No. 60/528,568, filed Dec. 10, 2003 by Bura et al. and entitled “Policing Internet Domains”; U.S. Prov. App. No. 60/530,354, filed Dec. 17, 2003 by Bura et al. and entitled “Policing Internet Domains”; and U.S. Prov. App. No. 60/530,355, filed Dec. 17, 2003 by Bura et al. and entitled “Analyzing Domain Ownership Information.”
This application is also related to the following commonly-owned, co-pending applications, of which the entire disclosure of each is hereby incorporated by reference for all purposes: U.S. patent application Ser. No. 11/009,530, filed on a date even herewith by Bura et al. and entitled “Analyzing Domain Ownership Information”; U.S. application Ser. No. 11/009,531, filed on a date even herewith by Bura et al. and entitled “Analyzing Domain Ownership Information”; and U.S. patent application Ser. No. 11/009,529, filed on a date even herewith by Bura et al. and entitled “Policing Internet Domains”.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the United States Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
The Internet is undergoing explosive growth. Each day, millions of new web pages are created and many millions of people interact online. To link to an Internet website, a computer user typically enters a domain name that represents an IP (Internet protocol) address. Each domain name is unique and is assigned to a holder by one of a plurality of domain name registrars. It is the prevailing trend for businesses to establish and maintain presence in the marketplace via their websites and/or email addresses. Thus an Internet domain name may be highly valuable as an advertising and selling tool. Businesses generally try to acquire domain names which reflect their trademarks and brand names, also regarded as valuable intellectual property.
As Internet use has expanded, cybersquatters have tried to acquire domain names solely for the purpose of selling them to businesses whose brand names correspond to the domain names. Although legislation has been passed in an attempt to curb this practice, domain name squatting still continues. Additionally, it is increasingly common for web site operators to unknowingly acquire, in good faith, domain names that infringe upon other parties' trademark rights. Quite often, registration of an Internet domain name requires no trademark search or query before the registration process is initiated and completed.
Companies and individuals striving to preserve their rights in trademarks are finding it necessary to engage in Internet domain enforcement. Such enforcement may include, for example, opposing another's use of a domain name reflective of a trademark or brand name. Domain enforcement may involve hunting on the Internet for registered domain names that, for example, infringe, dilute or disparage a trademark or brand name. Enforcement also may entail demanding that a holder of such a domain relinquish the domain name and/or initiating a complaint or other enforcement action relating to one or more of such domains. Hunting for such domain names on the Internet tends to be not only time consuming but also hit-or-miss in view of the sheer volume of Internet use. Initiating and maintaining enforcement action against infringers also may be costly and time consuming.
BRIEF SUMMARY OF THE INVENTION
The present invention, in one set of embodiments, provides methods, systems and software that may be used to generate and manage enforcement actions against domains that are potentially and/or actually infringing rights of a user. Merely by way of example, some embodiments provide methods for identifying one or more domain names potentially subject to enforcement activity by a user. According to further embodiments, methods are provided for obtaining domain information regarding potential and/or actual infringing domains for a user. In certain embodiments, the present invention provides methods for analyzing domain information concerning potential and/or actual infringing domains and generating one or more enforcement messages for sending to one or more parties associated with the potentially and/or actually infringing domain names.
The present invention, in one set of embodiments, provides methods, systems and software that may be used to generate and send enforcement messages to parties associated with domains potentially subject to enforcement activity. Merely by way of example, a particular set of embodiments provides methods of identifying domain names potentially subject to enforcement actions according to received data. According to particular embodiments, enforcement messages may be generated for the domain names identified as potentially subject to enforcement action. In certain embodiments, enforcement messages may be sent to parties associated with the domain names identified as potentially subject to enforcement action.
Certain embodiments of the present invention provide methods, systems and software that may be used to facilitate enforcement of an Internet domain. Merely by way of example, particular embodiments provide methods for identifying domain names subject to enforcement by a user. In particular embodiments, in response to input from the user, an enforcement action cycle against an identified domain name may be commenced.
Particular embodiments of the present invention provide methods of identifying potentially objectionable domain names. The method may comprise, merely by way of example, searching a database for WHOIS information matching a search criterion other than a domain name and/or identifying one or more domain names associated with matching WHOIS information from the searching. In certain embodiments, identifying one or more domain names comprises identifying recurrences of WHOIS information associated with the one or more domain names.
Further embodiments provide systems, which may, in some cases, implement the methods of the invention. Merely by way of example, a system in accordance with some embodiments may comprise one or more computers. In particular embodiments, the computer(s) may be configured to gather from the Internet WHOIS data, which may pertain to one or more domain names. The computer(s) may be further configured to include the domain names and/or the gathered WHOIS data in a database. The computer(s) may then be configured to search the database for WHOIS data other than a domain name. At least one of the domain names thus may be identified. The search may be performed in response to user input.
In accordance with another set of embodiments, the computer(s) may be configured to gather from the Internet WHOIS data pertaining to a domain name, perhaps in response to a WHOIS inquiry, which may specify the domain names to a domain name registrar. The computer(s) may further provide the domain name to the user, possibly in response to the user inputting some or all of the gathered WHOIS data other than the domain name.
In some embodiments, the system may further comprise a database, which might include gathered WHOIS data and/or domain names, and/or one or more spiders, which may be configured to gather additional WHOIS data from the Internet, perhaps for inclusion in the database.
In some cases, enforcement actions may be taken against objectionable domain names. In certain aspects, enforcement actions may include the sending of email messages to person(s) associated with the objectionable domain name(s). By way of example, email messages may include cease and desist messages. In other aspects, templates for email messages may be stored in a database for selection and use by a user. In further aspects, information associated with objectionable domain names may be automatically included into email messages. In accordance with another set of embodiments, responses to enforcement messages may be recorded and/or stored in a database.
A further set of embodiments provides for categorizing and flagging domain name information. In certain aspects, software may generate icons to display the status of objectionable domain names.
Some embodiments of the present invention provide for the generation and management of actions against groups of objectionable domain names. In further embodiments, computer(s) and/or associated software provide for analysis of the status of enforcement actions. Status of enforcement actions may include information concerning delivery of a message to a party associated with an objectionable domain name and/or whether or not a response has been received. In some embodiments, the computer(s) and software may cause flags and alerts to be generated to a user depending upon the status of enforcement.
Further 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 various embodiments 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
The present invention will become more fully understood from the detailed description and the accompanying drawings.
FIG. 1 is a flow diagram of a method of facilitating enforcement of an internet domain according to various embodiments of the present invention.
FIG. 2 is a block diagram of a system for enforcing an internet domain according to various embodiments of the present invention.
FIG. 3 illustrates a screen displaying a summary of domain name watch information according to various embodiments of the present invention.
FIG. 4 illustrates a screen showing detailed information pertaining to a plurality of domain names according to various embodiments of the present invention.
FIG. 5 illustrates an icon legends window according to various embodiments of the present invention.
FIG. 6 illustrates a screen listing a plurality of enforcement actions and a plurality of templates according to various embodiments of the present invention.
FIG. 7 illustrates a screen displaying results of a search based on an email address according to various embodiments of the present invention.
FIG. 8 illustrates a template configuration screen according to various embodiments of the present invention.
FIG. 9 illustrates an enforcement action preview screen according to various embodiments of the present invention.
FIG. 10 illustrates a screen displaying WHOIS information according to various embodiments of the present invention.
FIG. 11 illustrates a message screen according to various embodiments of the present invention.
FIG. 12 illustrates a screen in which is displayed a window including domain enforcement action details according to various embodiments of the present invention.
FIG. 13 illustrates an enforcement action follow-up screen according to various embodiments of the present invention.
FIG. 14 illustrates a message configuration window according to various embodiments of the present invention.
FIG. 15 illustrates a window including domain enforcement action details according to various embodiments of the present invention.
FIG. 16 illustrates a window including WHOIS-related information according to various embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description of various embodiments of the present invention is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
One set of embodiments provides methods of facilitating enforcement of an internet domain. An exemplary method in accordance with some embodiments is indicated generally in FIG. 1 by reference number 20 . It should be noted generally that, unless the context clearly indicates otherwise, the terms “domain” and “domain name” are used interchangeably herein. Referring to FIG. 1 , at step 24 , data may be received for identifying one or more domain names potentially subject to enforcement activity by a user. At step 28 , one or more enforcement messages may be generated for sending to one or more parties associated with the domain name(s). At step 32 , it may be determined whether user input has been received. If so, at step 36 enforcement message(s) may be sent to the party(ies).
In accordance with particular embodiments, computer systems and/or software programs may be used to facilitate enforcement of an Internet domain (including without limitation computer systems and/or software programs that implement methods of the invention, such as the method 20 described above). An exemplary system is generally referred to in FIG. 2 by reference number 100 . The system 100 may be operated, for example, by a provider of domain enforcement support services to domain name holders seeking to police their Internet domains.
Generally, the system 100 may include one or more computer(s) 104 configured to identify at least one domain name as subject to enforcement activity by a user of the system 100 . The system 100 may allow the user to initiate, via a graphical user interface (GUI), at least one enforcement action cycle relative to at least one of the domain name(s), as further described below. It should be noted generally that the one or more computers 104 of the system 100 may include various kinds and/or combinations of computers, which may include but are not limited to server(s), personal computer(s), mainframe(s), switch(es) and/or processor(s) in combination with one or more memories.
The system 100 may, in some embodiments, include a software GUI driver 108 in communication with one or more computers 112 operated by one or more users of the system 100 , for example, in a multi-user collaborative environment via the Internet 116 . The GUI driver 108 may also communicate with a database 120 , further described below, in which WHOIS data is stored in a searchable format.
Generally, and as known in the art, WHOIS data provides information pertaining to persons and/or organizations associated with an Internet domain. A plurality of databases 124 that hold WHOIS data are made available over the Internet, typically on a low-volume basis, to those who, for example, wish to determine who or what organization operates a particular domain. In general, WHOIS data is collected by domain name registrars from applicants who are registering domain names. WHOIS data obtained from a domain name registrant typically identifies an organization and/or contact associated with the domain name being registered. WHOIS data also typically identifies, among other elements of information, primary and secondary name servers for a domain name.
A plurality of domain name registrars register names in widely used top-level domains such as .com, .org, .net, .info, .biz and others which are managed by the Internet Corporation for Assigned Names and Numbers (ICANN). Registrars may also be authorized (by ICANN and/or by other authorities) to register names in country-code top level domains, such as .uk, .us, .ch, and others. WHOIS data for a particular domain name typically is included in at least one, but generally in not all, registrar WHOIS databases 124 publicly available over the Internet. Some domain names are “hidden,” in that they are registered and managed by registrars utilizing servers other than ICANN root servers. WHOIS data generally is available from the registrars for hidden top-level domains, which include, for example, .arts, .golf, and .cars. WHOIS data may also be generated under circumstances other than in connection with registering a domain name. WHOIS information may be made available in a WHOIS database 124 on a server operated, for example, by a company or institution, to provide contact information pertaining to individual employees and/or departments.
Additionally, at least some information that could be found in a WHOIS database 124 (including without limitation primary and secondary name server information for a given domain) may also be kept on root name servers 128 . Root name servers are distributed throughout the world and maintain domain information, including primary and secondary name server information for each domain as known in the art. When a client (which can include, merely by way of example, an Internet browser) wants to resolve a hostname and/or a domain name (e.g., if a user wishes to access the host and/or the domain, such as to view a web page, etc.), the client attempts to locate the IP (Internet Protocol) address for the domain name. The client first queries name servers of an Internet service provider (ISP) for the Internet user. If the ISP name servers have not cached an IP address for the requested domain name, at least one root name server (for example, one or more of the root name servers 128 shown in FIG. 2 ) may be queried to identify the name servers of the domain name. The root name server(s) return the requested name server information to the ISP, which then requests the domain name IP address from at least one of the domain name servers. The name server(s) return the requested IP address to the ISP, which typically caches the IP address and returns it to the client. As described in U.S. patent application Ser. No. 11/009,530, already incorporated by reference, WHOIS data may also be obtained via one or more IP registry databases.
The system 100 may, in some embodiments, include one or more software robots or spiders 132 , for example, that “crawl” through Internet websites and follow hypertext links to obtain information over the Internet. The spiders 132 may gather WHOIS data pertaining to various domain names, including but not limited to universal resource locators (URLs) and email addresses. WHOIS data gathered by the spider(s) may be formatted and stored in the searchable WHOIS database 120 as further described below. It should be noted generally that the terms “WHOIS data” and “WHOIS information” as used herein may include data appropriate for inclusion in a WHOIS database 124 , whether or not such data is actually present and/or found in a WHOIS database 124 . Examples of a variety of types of WHOIS data are described in U.S. patent application Ser. No. 11/009,530, already incorporated by reference.
In some embodiments, the system 100 may locate and supply WHOIS and/or root name server data in response to requests for WHOIS information. Such a request may come via the Internet 116 , for example, from a prospective domain name registrant (indicated in FIG. 2 by a computer 136 ) attempting to determine whether a domain name may be available for registration. In accordance with some embodiments, when such a request is received, the system 100 may query at least one WHOIS database 124 for WHOIS data pertaining to the domain name in question and return any such data to the requestor. In embodiments of the present invention, the system 100 may be operated by a domain name registrar that maintains its own WHOIS database 124 . Additionally or alternatively, for example, if no such WHOIS data is found, the system 100 may query at least one root name server 128 to determine whether any primary/secondary server information is listed for the domain name in question (as could be the case, for example, if a domain name were registered but had invalid or no WHOIS data). The system 100 may return to the requester 136 any such data found in the root name server(s) 128 .
The system 100 also may store such WHOIS data and/or root name server data in the searchable WHOIS database 120 . The database 120 thus may include data obtained by the system 100 from various sources which store and/or provide such data in various formats, as previously described. The system 100 may be configured to format and/or store such data in the database 120 to allow a user to search the database 120 , for example, to find any domain(s) having WHOIS data matching a given search criterion or criteria. Merely by way of example, WHOIS data may be obtained from WHOIS databases 124 in a variety of formats, each having different fields, different organization of fields, etc. The system 100 , therefore, may be configured to reformat the obtained WHOIS data for consistency before, after, or during the process of storing the WHOIS data in the searchable database 120 . Such reformatting may be performed by SQL commands, parsing engines, and/or any other appropriate vehicle.
In accordance with embodiments of the present invention, a user of the system 100 may enter into the system 100 one or more character strings, where each string may be all or part of one or more brand name(s) and/or trademark(s) of interest to the user (hereinafter referred to as the user “watch list”). Additionally or alternatively, the user may directly identify one or more domain names that may be subject to enforcement action, by entering character string(s) including such domain name(s). In some embodiments, the system 100 may search the Internet periodically (e.g., hourly, daily, weekly, etc.) for any registration activity of domain names that include the string(s). In accordance with embodiments of the present invention, the system 100 may report any such domain names and related activity to the user and provide any ownership information (e.g., WHOIS information) found for such domains.
In some embodiments, the user may select any or all reported domains and may specify one or more enforcement actions to be implemented relative to the selected domain(s). In accordance with particular embodiments, the term “enforcement action” may include a computer-implemented and/or computer-implementable procedure relating to domain enforcement activity against one or more domain names. Enforcement actions may include, but are not limited to, delivery of an email message (which might be, for example, a cease-and-desist message to an email address for a contact person associated with an infringing domain, a dispute notification to a registrar associated with an infringing domain, etc.).
The term “enforcement action cycle” may include the implementation of an enforcement action followed by the implementation of a reaction procedure, i.e., a procedure relating to a reaction (or lack thereof) relative to the implemented enforcement action. For example, in some embodiments, the user may cause the system 100 to implement an enforcement action, e.g., to send a cease-and-desist letter to a domain name contact person. The user may subsequently receive, e.g., from the contact person, an email or telephone response to the cease-and-desist message. In some embodiments, the user may indicate via the GUI 108 that a response was received. Optionally, the user may be allowed to enter text describing the response. The user may also use the GUI 108 to indicate, for example, that no response was received to an implemented enforcement action. In accordance with some embodiments, the system 100 may store the response information, as further described below, and thus may complete an enforcement action cycle.
In embodiments of the present invention, the GUI 108 may allow the user to initiate enforcement actions concurrently with respect to a plurality of domains. Such a group of enforcement actions is referred to herein as an “enforcement action group” and is described in further detail below. For example, the user may instruct the system 100 to send one or more email messages, for example, to a plurality of email addresses for a group of related domains. Also as further described below, an enforcement action initiated by the user but not yet implemented by the system 100 , whether singly or in an enforcement action group, may be modified. Thus, for example, and as further described below, before the user causes the system 100 to implement an enforcement action, for example, by instructing the system 100 to deliver an email message, the user may change and/or customize the message.
Merely by way of example, FIG. 3 illustrates an exemplary screen 200 . In embodiments of the present invention, as shown in FIG. 3 , the GUI driver 108 may display summary information. For a brand 204 and/or search string(s) 208 , such information may include a tally 212 of new domains detected, a tally 216 of previously detected domains, and/or a tally 220 of hidden domains.
Merely by way of example, FIG. 4 illustrates an exemplary screen 250 . The exemplary screen 250 may be configured to show detailed information pertaining to a plurality of domain names 254 obtained by the system 100 that match a string for a brand in the user watch list. For each of the domain names 254 , a button 258 may be activated to display available WHOIS data, if any. Intelligence type (e.g., whether new, current, hidden, expired or ad hoc) and/or intelligence status (e.g., whether a domain is new, or owned by the user or a third party) may be edited using a button 262 . Hosting change and hosting status information for a domain name 254 may be displayed in columns 264 and 266 respectively.
In accordance with a set of embodiments, the system 100 may allow a user filter the display in various ways. Merely by way of example, the user may specify (e.g., via a drop-down menu 270 ), that the system 100 display a particular type of domain, e.g., parked, active and/or new domains. The user also may select from options 272 to cause the system 100 to display domains according to whether a domain is hidden or not hidden. A drop-down menu 274 may provide the user to specify the aging of displayed domain names. A search option 278 allows the user to enter additional search criteria, which can be used, for example, to limit the number of displayed domain names 254 to those of particular interest to the user.
An enforcement display option 280 may allow the user to see an enforcement status 282 and/or enforcement details 284 for a given domain name as further described below. Alternatively and/or in addition, the user also may be provided the ability to select an enforcement action option 286 for a given domain name, also further described below. Column 290 allows the user to check off domain(s) which have been reviewed on the screen 250 by the user. Columns 292 and 294 indicate dates a domain was first checked and last checked. A status column 296 may indicate a status assigned by the user to a domain. An assigned status in column 296 may be, for example, “slanderous”, “squatted” or “ours.”
In some embodiments, the system 100 may categorize and/or flag domain name information in various ways. Merely by way of example, FIG. 5 illustrates an icon legend 300 that may include icons 304 indicating, for example, the discovery of a potentially slanderous derivative of a brand, a change in a domain's hosting status, whether a web server was detected serving content for a domain, and/or a home page that appears consistent with a parked domain.
In the foregoing exemplary manner, the system 100 may identify one or more domain names as subject to possible enforcement activity. The system 100 may also allow the user to initiate one or more enforcement action cycles. Merely by way of example, FIG. 6 illustrates an exemplary screen 310 that may be displayed when the user activates the enforcement option 286 . The screen 310 may list a plurality of enforcement action groups 322 . In some embodiments, each group 322 has a name 324 and description 326 given to it by the user. In further embodiments, a date field 328 may indicate a date of last activity.
In particular embodiments, each enforcement action group 322 may include one or more enforcement actions relating to one or more domains 254 selected by the user. The screen 310 may be configured to display a tally 352 of domains 254 included in each group 322 . Each group 322 may also have an associated status 330 . Merely by way of example, an enforcement action group 322 may have a status of “saved” (for example, for modification by the user), “done” or “executing.” In an embodiment, group 322 that is “done” is completed; that is all email message(s) associated with the group 322 have been sent by the system 100 . In another embodiment, and as further described below, an “executing” group 322 includes one or more email messages still awaiting delivery by the system 100 . In some cases, a group 322 that is “done” or “executing” may be viewed by activating a “view actions” button 332 associated with the group 322 . A group 322 that has not yet been selected for execution may be edited by the user upon activating an associated edit button 334 as further described below. As indicated by up- and down-arrows 342 , output on the screen 310 may be sorted by particular fields, e.g., by date 328 , status 330 , and/or name 324 , in ascending or descending order.
A search option 356 helps the user to identify domains included in the groups 322 based on particular WHOIS data. For example, the user may select a search field from a drop-down menu 358 . Search fields may include, for example, domain name, email address, administrative user, and/or organization. Results of such a search may be shown in a screen. Merely by way of example, FIG. 7 illustrates a screen 320 configured to display results of a search. In embodiments, a column 306 indicates results of such a search. It is shown, for example, in FIG. 7 that, for an email address Squatter@companysite.com, a plurality of matches are present for domains in the group 322 . As further described below, the user may use buttons 332 and/or 334 to display domain information for any matching domains and, for example, customize enforcement activity with respect to some or all of such domains.
The system 100 may provide that a user may create and save a plurality of templates for email messages, e.g., cease-and-desist messages for delivery to one or more infringing domain holders. Referring again to FIG. 6 , an area 354 indicates that, in this example, four templates have been created and saved by the user, as further described below. Templates may be edited, for example, by pressing an associated edit button 338 . As further described below, each template may have a variety of fields (some of which may correspond to fields found in typical email messages), including without limitation a name 344 , a description 346 , “Cc” information 348 and “Bcc” information 350 . Template information in the display area 354 may be sorted by template name 344 , “Cc” information 348 and “Bcc” information 350 .
Some embodiments provide a “create template” button 340 (and/or similar functionality) to allow a user to display a template configuration screen, an exemplary illustration of which is numbered in FIG. 8 as 360 . The user may enter into fields 362 and 364 a new template name 344 and new description 346 which may be used subsequently to retrieve and reference the template being created. The user may also enter information indicating a message subject into a field 366 . The user may enter a priority into field 372 and a return receipt address into field 374 . The user may also enter “Cc” and “Bcc” information 348 and 350 , as previously described with reference to FIG. 6 .
The user may enter, into a field 370 , “From” information which may include a return email address for the user and/or for a proxy for the user, such as an administrative email address, etc. (This from information may be used, for example, to populate one or more fields in a message created from a template, including without limitation a “FROM:” field, a “REPLY-TO:” field, etc.) In some embodiments, when a message configured using the template configuration screen 360 is emailed to a recipient, the message may be emailed from one or more computers 104 of the system 100 (shown in FIG. 2 ), for example, as further described below. A recipient may reply to such email by replying to the address included in the “from” information 370 . In other embodiments, an email message configured using the template configuration screen 360 may be emailed to a recipient in cooperation with the user's electronic mail application running, for example, on a computer 112 (shown in FIG. 2 ) associated with the user. For example, the message is sent to a recipient from the user's email address listed in the “from” information 370 .
The user may enter a message into a message text area 368 , using any of a variety of methods (including, merely by way of example, by cutting and pasting, by typing, by importing a document, etc.). It should be noted that recipient information “anchors” 380 , including a domain name anchor 382 , an administrator name anchor 384 , and an organization name anchor 386 , may be placed by the user into the message area 368 . The “anchors” 380 may subsequently be automatically replaced by data associated with the appropriate domain(s) 254 before the system 100 sends email message(s) based on a template created using the screen 360 .
When a user activates an edit button 334 (shown in FIG. 6 ) for an uncompleted enforcement action group 322 , a screen 400 may be displayed as shown in FIG. 9 . A facility (such as a template preview menu 404 ) may allow the user may display and/or edit any templates that have been saved and not yet sent. The user may rename and/or save a modified template by activating a save option 406 . Thus, for example, the user may individualize a template where it is desired to send a customized message to a particular recipient. As may be seen in a template 336 being previewed as shown in FIG. 9 , anchors 380 have been inserted by the user into the template 336 , to be replaced by appropriate information obtained, for example, from the searchable WHOIS database 120 , before a message based on the template 336 is sent. An option 408 allows the user to group outbound messages by email address. A notification option 412 may allow the user to send enforcement action updates to a third party, e.g., to in-house or outside counsel, and/or, if desired, to create a report of such updates (e.g., by creating a spreadsheet comprising the updates). The report may also be sent to a third party.
In some embodiments, Hyperlinks 416 may be provided to the domains 254 included in the enforcement action group 322 shown in the screen 400 . Thus, the user may check website status or other online information of interest pertaining to a particular domain 254 . A “wrap” field 420 , when activated, may allow the user to assemble an enforcement history for delivery, for example, to outside counsel, as further described below.
As noted above, in some embodiments, data from the searchable WHOIS database 120 may be inserted automatically into one or more email messages to be sent in connection with an enforcement action group 322 . In such embodiments, the screen 400 may include, without limitation, a column 430 for domain name(s), a column 434 for email address(es) to receive email message(s), a column 438 for administrator information pertaining to the domain name(s), a hosting status column 442 ; and/or a template column 444 indicating which template is being used for an email being sent with respect to a given domain name. Although not shown in FIG. 9 , organization data may be displayable for domain names in the screen 400 . Information may be sorted for display in the screen 310 , for example, by domain name 430 , address 434 , administrator information 438 and/or hosting status 442 . Additionally or alternatively, by clicking on the appropriate icon 304 , the user may link to (e.g. download, view in a web browser, etc.) a parked or active host site for a particular domain 254 . In such manner, a user may check, for example, if a domain is actively hosted and/or gain access to information that might not be available from the searchable WHOIS database 120 . If a user obtains such information, he/she may enter it manually into the appropriate column and/or field of the screen 400 . The screen 400 may also have a save field 490 and/or an execution field 492 further described below.
A “WHOIS” field 424 , when activated for a given domain name, may cause WHOIS information to be displayed as shown in FIG. 10 . FIG. 10 illustrates a screen 450 in which a window 454 is displayed. The window 454 may display WHOIS information retrieved from the searchable WHOIS database 120 (and/or from a traditional WHOIS database 124 ) for the given domain name 254 . In certain aspects, the user can, for example, compare the WHOIS information to information in a template 336 under consideration.
Referring again to FIG. 4 , some embodiments may allow a user to selectively activate one or more enforcement action options 286 to select one or more enforcement action groups 322 . The user may preview and/or edit a enforcement action group 322 as described above. Referring to FIG. 9 , by activating the save field 490 , the user may save the enforcement action group 322 for future activity. When, for example, a group 322 has been previewed, edited and/or is ready for execution, the user may activate the execution field 492 . The system 100 may then retrieve (e.g., from the searchable WHOIS database 120 ) and/or insert appropriate recipient information into the anchors 380 of the appropriate email template(s) 336 . The system 100 may then send those email messages for which sufficient information is available to recipients associated with the appropriate domain(s) 254 via the Internet 116 .
FIG. 11 displays an exemplary screen 460 , which may be displayed, according to a set of embodiments, after an enforcement action group 322 is activated for execution via field 492 . As indicated by the screen 460 , the system 100 may hold email for any domain 254 for which no email address is available from the searchable WHOIS database 120 . In one embodiment, the system 100 may immediately proceed to search the Internet as previously described to obtain an appropriate email address for a held message. The system may also periodically check the searchable WHOIS database 120 and/or a traditional WHOIS database 124 to determine whether such information has become available.
Additionally or alternatively, when previously unavailable WHOIS information has been obtained, it may be entered manually (e.g., as described above with reference to FIG. 9 ), whereupon the system 100 may format and send the appropriate email message(s). In certain aspects, when all such message(s) have been sent for a particular enforcement action group 322 , the system 100 may mark the group 322 as “done.”
In any single enforcement action group 322 , various templates 478 may be prepared and/or sent to domains 254 . The system 100 may keep track of which template(s) 478 have been sent to a particular domain 254 . The system 100 may assist a user in managing responses (and/or lack thereof) to enforcement actions in the group 322 . For example, as previously mentioned with reference to FIG. 4 , a user may view details for a particular domain name 254 by activating an enforcement details field 284 in the screen 250 . Referring now to FIG. 12 , in some embodiments, when the user activates one of the fields 284 , a window 470 may be displayed in the screen 250 . Displayed in the window 470 , in some embodiments, are details for enforcement action cycle(s) initiated and/or implemented with respect to the particular domain 254 . Specifically, such details may include status 472 , response(s) 474 , action date(s) 476 , template(s) 478 , “To” email address(es) 480 , Cc and/or Bcc information 482 , administrator information 484 , and/or organization information 486 (selected but not visible in the window 470 ).
A user may add and/or update follow-up information as shown in the window 470 , for any or all domains 254 in a completed or executing enforcement action group 322 , by activating a “view actions” button 332 from screen 310 (shown in FIG. 6 ). FIG. 13 illustrates embodiments of a status screen 600 displayed for a selected group 322 . The status field 472 , response 474 , action date 476 , template field 478 and “To” field 480 (shown for an individual domain 254 in FIG. 12 ) are among those that may be displayed and/or displayable on the screen 600 for each domain 254 included in the group 322 . A user may activate a drop-down menu 604 in combination with one or more selection options 606 to select an appropriate entry for one or more of the response field(s) 474 . In some aspects, the user may insert, for example, “No Reply”, “Mail Bounced”, “Follow Up”, “Will Comply”, or “Escalate” in accordance, for example, with a response (or absence of response) pertaining to the particular domain 254 . The user may also document a response in detail, for example, by cutting and pasting an email response from a domain into a note field 608 , or by entering comments into the notes field 608 . When the user enters “Escalate” in a response field 474 for a given domain name, the system 100 may display a history of enforcement activity for that domain name. The user may cause such information to be “wrapped” for transfer, for example, to outside counsel as further described below.
In certain aspects, by selecting one or more domains via selection option(s) 606 in combination with a “Re-enforce” option 612 , the user may include the selected domain(s) in a new enforcement action group 322 . The user may select one or more templates and/or create new template(s) as previously described, for use in the new group 322 . In aspects of the present invention, the user may, for example, send another email that is more aggressive than a previous email sent to a recalcitrant domain holder.
When a user decides, for example, that it is time to consult outside counsel for purposes of filing suit against a domain holder, the user may cause the system 100 to gather all information pertaining to the domain. Specifically, the user may activate the “wrap” field 420 (shown in FIG. 9 ) and provide for assembly of an enforcement history as follows. A message template window, numbered in FIG. 14 as 650 , may be displayed to the user, who enters an email address in a field 654 and/or a message for a recipient, e.g., outside counsel, into a field 658 . The user may specify, as packaging options 662 , whether, for example, to include enforcement action cycle(s), response notes 608 , information from the searchable WHOIS database 120 (and/or another WHOIS database 124 ) pertaining to the domain at issue, and/or to package enforcement action details as a spreadsheet. Relevant enforcement action cycles may be displayed by selecting a tab 666 from the window 650 . Such action(s) may be displayed in a window indicated generally in FIG. 15 by reference number 680 . Information from the searchable WHOIS database 120 (and/or another WHOIS database 124 pertaining to the domain at issue may be displayed by selecting a tab 668 from the windows 650 or 680 . Such information may be displayed in a window indicated generally in FIG. 16 by reference number 690 . The user may activate a dispatch option 692 (shown in FIG. 14 ) to cause the foregoing domain-related information to be sent via email to the email address field 654 .
The foregoing embodiments may allow a domain holder to keep watch over what otherwise could be an overwhelming task. When, for example, domain names conflicting with a company brand name are numbered in the hundreds, embodiments of the foregoing systems and methods may simplify the processes not only of detecting such domains, but also of notifying domain holders, keeping track of responses from domain holders, and/or following up on such notifications and responses. Further embodiments may provide for the quick detection of conflicting domains. In some aspects of the present invention, detection of conflicting domains may occur within a day or two after domain name registration. In other embodiments, because domain registration information may be obtained quickly, for example, from the searchable WHOIS database, domain enforcement may be facilitated quickly. In a particular set of embodiments, the automatic insertion of WHOIS data, for example, into email cease-and-desist messages, may greatly simplify and increases the accuracy of communication with holders of conflicting domains. In further embodiments, because email messages may be sent automatically when addressing information becomes available from the searchable WHOIS database, a user may rest assured that most, if not all, such email will eventually be sent.
In accordance with some embodiments of the invention, the methods and procedures described above may be performed with a dedicated client software application in communication with a server application. Other embodiments feature a single application program, which may reside on a client computer, such as a PC, etc., and which may be configured to access one or more databases, as described above. A particular set of embodiments may be implemented as a set of one or more web applications (which might feature client- and/or server-side scripts, Java applets, CGI applications, etc) configured to interface with one or more databases, which might be resident on one or more servers. In such embodiments, for example, a user might use a web browser to access screens such as the screens illustrated by FIGS. 3-16 , allowing the use of certain embodiments by a user located at any location with access (e.g., via a LAN, a WAN, the Internet, etc.) to a server on which the system is implemented.
In the foregoing description, for the purposes of illustration, various methods and/or procedures were described in a particular order. It should be appreciated that in alternate embodiments, the methods and/or procedures may be performed in an order different than that described. It should also be appreciated that the methods described above may be performed by hardware components and/or may be embodied in sequences of machine-executable instructions, which may be used to cause a machine, such as a general-purpose or special-purpose processor or logic circuits programmed with the instructions, to perform the methods. These machine-executable instructions may be stored on one or more machine readable media, such as CD-ROMs or other type of optical disks, floppy diskettes, ROMs, RAMs, EPROMs, EEPROMs, magnetic or optical cards, flash memory, or other types of machine-readable media suitable for storing electronic instructions. Merely by way of example, some embodiments of the invention provide software programs, which may be executed on one or more computers, for performing the methods and/or procedures described above. In particular embodiments, for example, there may be a plurality of software components configured to execute on various hardware devices. Alternatively, the methods may be performed by a combination of hardware and software.
Hence, while detailed descriptions of one or more embodiments of the invention have been given above, various alternatives, modifications, and equivalents will be apparent to those skilled in the art without varying from the spirit of the invention. Moreover, except where clearly inappropriate or otherwise expressly noted, it should be assumed that the features, devices and/or components of different embodiments may be substituted and/or combined. Thus, the above description should not be taken as limiting the scope of the invention, which is defined by the appended claims. | The present invention, in one set of embodiments, provides methods, systems and software that may be used to generate and manage enforcement actions against domains that are potentially and/or actually infringing rights of a user. Merely by way of example, some embodiments provide methods for identifying one or more domain names potentially subject to enforcement activity by a user. According to further embodiments, methods are provided for obtaining domain information regarding potential and/or actual infringing domains for a user. In certain embodiments, the present invention provides methods for analyzing domain information concerning potential and/or actual infringing domains and generating one or more enforcement messages for sending to one or more parties associated with the potentially and/or actually infringing domain names. | 6 |
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
This invention relates generally to folders and more particularly to a folder where a pocket is formed in fabric being advanced to sewing instrumentalities of a sewing machine and wherein a strip is directed into the pocket.
The folder includes a guide means for folding a marginal edge of the fabric to form a hem or pocket and guide means for directing a relatively narrow strip or web into the pocket. While the strip may be of various widths and constructed of various selected materials, in a preferred embodiment, the strip is formed of rubber or other suitable elastic constructions.
The strip guide means is an integral part of the fabric foldover process and includes a first guide section disposed at approximately a right angle with respect to the direction of movement of fabric through the fabric guide means, and a second guide section for guiding the strip generally in the same direction as the fabric. At least a portion of the second section of the strip guide means cooperates with the fabric guide means to define a channel for the strip material. The channel narrows adjacent the feed-out ends to a width slightly narrower than the strip width.
The fabric guide means has portions defining a slit adjacent the exit end which permits the strip located within the guide channel to move into abutment with the inner marginal edge of the fabric, thus the fabric and strip feeding as one component to the sewing instrumentalities. When a rubber strip is used, the rubber and fabric leaving the folder feed as one component. The rubber can be run in a completely relaxed state, or if directed through a tensioning device, the fabric can be gathered by relaxation of the rubber as it leaves the sewing instrumentalities.
One of the primary objects of the invention is the provision of a new and improved folder for directing a relatively narrow strip into a fold or pocket of a fabric.
Another object of the invention is the provision of a folder for lining and directing a strip into abutment with an advancing fabric so that they feed toward the sewing instrumentalities as one component.
Other objects and advantages of the invention will become apparent when considered in view of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary perspective view of a sewing machine having the folder of the present invention attached thereto;
FIG. 2 is an enlarged bottom plan view of the folder illustrating the movement of the strip and fabric there through;
FIG. 3 is an enlarged, fragmentary, bottom plan view of the folder, with sections broken away to illustrate the various sections of the strip guide;
FIG. 4 is an enlarged, fragmentary, elevational view of the exit end of the folder;
FIG. 5 is an enlarged, fragmentary view of the folder, taken along line 5--5 of FIG. 2, illustrating the change of direction of the strip and the positioning within the fabric guides;
FIG. 6 is an enlarged, fragmentary view of the fabric and strip guide mechanism; and
FIG. 7 is an enlarged cross-sectional view of the strip guide adjacent the entrance end thereof.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawing, the folder 10 preferably is of metal construction having a generally rectangular fabric support plate 12, a support base 16, a fabric guide 18, a strip guide 20 and a tension device 22. The fabric support plate 12 is secured by suitable means to the support base 16. The support base is mounted upon sewing machine 28 by means of fasteners 24 such that the main fabric guide 18 is generally aligned with the stitching mechanism 26. The support base 16 includes an arm 30 which extends approximately to the center of the plate 12 for attachment to the underneath side thereof. A portion of the base 16 may also be secured directly to exterior portions of the main guide 18.
The fabric support plate 12 has downturned marginal edges 34, as shown by FIGS. 1, 2 and 6, to facilitate the folding and feeding of a piece of fabric 36 to the sewing machine stitching mechanism 26. One end of the plate 12 is configured to define the main guide 18 which includes a generally U-shaped channel 15 for receiving the fabric 36. Referring to FIGS. 5 and 6, the plate 12 is curved at 40 downwardly and inwardly. The plate is reversely curved at 42 downwardly and outwardly approximately 180° and is again curved upwardly and inwardly as at 44. Section 41 interconnecting curves 40, 42 and section 43 interconnecting curves 42, 44 are generally parallel with each other and with the uppermost surface of plate 12. The distance between sections 41, 43 and between curves 40, 44 may vary depending upon the thickness of the fabric and strip to be folded and sewn. Curved section 42 serves as a stop or abutment for an edge portion of the fabric 36.
The fabric piece 36 is advanced towards the sewing machine mechanism 26 in the direction of the arrow A, FIGS. 1 and 2, and with an edge being urged into the main guide 18 with the marginal edge abutting the curved portion 42.
The elastic strip 14 may be advanced from a suitable supply source, not shown, through the tensioning mechanism 22 and to the strip guide 20. As illustrated by FIG. 1, the strip 14 may be directed to the folder 10 through an opening 13 in the sewing machine table and then along a tortuous course due to the tensioning device 22. The strip is initially directed in the direction of the arrow B, FIG. 2, which is at an angle of 90° with respect to the direction of fabric 36.
The tensioning means 22, in the embodiment illustrated, consists of a wire member bent into a desired configuration to define a series of parallel guide segments 52. One end portion of the wire is suitably secured to the plate 12 by conventional means. To apply the desired tension to the advancing strip 14 the strip may be directed over and under a selected number of segments 52. The tensioning device 22 may be eliminated completely if so desired.
The guide 20 for the strip 14 includes a first section 50 which cooperates with the bottom portion of plate 12 to define a generally tubular channel. The section 50 is of generally C-shaped cross-section, as shown by FIG. 7, and includes a first surface 51 maintained in spacsed, generally parallel relation with a plate 12, by flanges 53. The section 50 is fixedly attached to the bottom side of the plate 12 by suitable means. The guide 20 includes a second section 60 FIG. 3. which serves to change the direction of a strip 14 approximately 90°. The section 60, in the embodiment illustrated, consists of a tongue-like extension of the surface 51 which is bent at generally right angles to form a diagonal guide edge 62 and extends into the space intermediate the bottom of plate 12 and the section 41 of main guide 18 as shown by FIG 6. A wall 55, FIG. 6, is provided between the section 41 of guide 18 and the plate 12 and cooperates with surface 51, section 41 and curved portion 40 to define a guide channel 57 for the strip 14. The width of the guide channel 57 narrows slightly at the feed-out end such that the width of the strip is slightly wider than the width of the feed-out end of channel 57. It is to be noted that adjacent the feed-out end of guide section 60, a portion of the plate at curved portion 40 is cut away to define a slot 47. See FIG. 4. This slot permits the strip to extend through the slot 47 from channel 57 into channel 15 of main guide 18 and over into engagement with the fabric piece 36 as both exit from the folder and facilitates feeding of the strip 14 with the fabric 36 as one component. Both the fabric 36 and strip 14 advance to the sewing instrumentalities 26 where they are secured together by stitching 64, FIG. 2. In a preferred embodiment, the strip 14 is completely encapsulated within the fold of the fabric 36, as shown by FIG. 2. However, preferably at least one line of stitching 64 passes through the strip 14.
FIG. 4 shows an elevational view of the exit end of the folder, and the fabric 36 and strip 14 as they emerge from the folder just prior to being sewn together by instrumentalities 26. Note that the left side of the strip 14 abuts the fold in the fabric 36.
The folder of the instant invention is unique in that the guide 20 is an integral part of the fabric fold-over process. The section 60 of the guide 20 cooperates with guide 18 to guide the strip 14 with the fabric 36 folded thereabout. With the guide slit at 47 at the delivery end of the folder the elastic strip and fabric are guided as one component.
If the strip 14 is of elastic material, it may be run in a completely relaxed state as it leaves the folder since it engages and feeds along with the fabric 36. If tension is applied to the elastic strip, such as by tension device 22, the fabric 36 may be gathered by relaxing the strip 14 as it leaves the machine sewing mechanism.
While sections 50 and 60 of guide 20 have been described as of integral construction, and while guide 18 has been described as integral with plate 12, the various guides and guide sections may be of discrete, separate elements. | A folding apparatus for a sewing machine which includes a first guide for folding a marginal edge portion of fabric to define a pocket or hem and a second guide for directing a relatively narrow web or strip from an area remote to an operator work area to an area partially within the first guide. A portion of the first guide defines a slot which permits a portion of the narrow web to extend into abutment with fabric defining the pocket such that the fabric and web feed to the sewing machine as one component. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to wireless burst communications receivers especially for high-rate indoor applications. The invention particularly relates to MLSE based joint carrier, channel, timing and data estimation receivers.
BACKGROUND OF THE INVENTION
[0002] In time-division burst communication systems intersymbol interference (ISI) and noise, along with errors in the carrier phase and the sample timing, are the primary impediments to reliable data reception. Realising reliable high-rate burst communications involves the following key techniques: efficient equalisation to combat the severe ISI caused by frequency-selective fading channel; carrier recovery to compensate for the frequency offset and phase noise; timing recovery to compensate for timing offset and channel estimation for efficient equalisation.
[0003] It will be appreciated by those skilled in the art that the equalisers can be classified as linear equaliser, decision feed back equalisers (DFE), and maximum-likelihood sequence estimation (MLSE) equaliser. Among them MLSE utilising Viterbi algorithm is considered an optimal equaliser.
[0004] There is a huge amount of work on joint carrier, channel and data estimation for TDMA systems. Early in 1974, Ungerboeck proposed a adaptive receiver structure in Gottfried Ungerboeck “Adaptive maximum likelihood receiver for carrier modulated data transmission systems”, IEEE Trans. on Comm., Vol. com-22, No.5, May 1974 pp 624-636. This jointly estimates carrier, timing, channel and data. Based on the Ungerboeck's concept, R.D.'avella et al proposed a receiver structure in Renato D'Avella, Luigi Moreno, and Marcello Sant'Agostino, “An adaptive MLSE receiver for TDMA digital mobile radio”, IEEE Journal on Selected Area in Communications, Vol.7, No.1, January 1989 pp 122-129. In this RENATO's system, a new CIR (channel impulse response) estimate is obtained from each received burst, which is used to drive the coefficients of the matched filter (MF). The channel variations during the transmission can be compensated by the adaptation loops by adjusting the MF coefficients, the Viterbi processor parameters and the signal phase. During the adaptation, gradient algorithms are used to minimise the mean square error as suggest by Ungerboeck. We can see that two independent adaptation functions: the CIR variation tracking and phase variation tracking are adopted. The CIR tracking is implemented by adjusting the MF coefficients and the Viterbi processor parameters, and the phase adaptation is performed immediately before the Viterbi processor in order to minimise the overall loop delay.
[0005] Although the above CIR tracking could noticeably improve the system performance where the preamble sequence is at the beginning of the burst, it seems to be less useful in GSM systems where the preamble is in the middle of the burst. Moreover, this adaptation procedures obviously increase the processing load. To solve this problem, Ling, et al., “Method and apparatus for providing carrier frequency offset compensation in a TDMA communication system”, U.S. Pat. No. 5,245,611, Sep. 14, 1993 proposed a improved receiver structure for TDMA systems to compensate for carrier frequency offset and the caused CIR variation. The CIR estimate is assumed to be constant for the whole burst. The modified Ling receiver structure includes: the phase is corrected before matched filter (a big loop adaptation compared to the RENATO's small loop adaptation); the adaptation of the MF coefficients and VA parameters are not adopted; several frequency offset estimation methods are proposed. This modified structure possess much lower complexity and acceptable performance.
[0006] However, these above MLSE receivers can only compensate for small frequency offset which cause distortion of the channel on burst-by-burst basis. This is because MLSE may introduce a quite long decision delay, which is prohibitive to the applications of decision-directed phase-lock-loop (PLL) to track the large frequency offset. To increase the frequency tracking range, MLSE with tentative decision combined with PLL is also adopted in Serizawa, et al., “Carrier phase synchronous type maximum likelihood decoder”, U.S. Pat. No. 5,311,523, May 10, 1994. This does not contain a long delay, and shows good tracking performance when SNR is high. However, in such a phase lock loop, when the tentative decision is not correct, the problem of error propagation result, this is especially so in the low SNR condition. To solve the problem of error propagation of tentative decision, per-survivor processing (PSP) technique are extensively studied in art for joint carrier, channel and data estimation, e.g. in Serizawa above and Khalid A. Hamied, and Gordon L. Stuber, “An adaptive truncated MLSE receiver for Japanese personal digital cellular”, IEEE Transaction on Vehicular Technology, Vol.45, No.1, February, 1996 pp 41-50.
[0007] The intuitive rational for PSP technique used in MLSE is straightforward: whenever the incomplete knowledge of some quantities prevents us from calculating a particular transition metric in a precise and predictable from, we use estimates of those quantities based on the data sequence associated with the survivor leading to that transition. If any particular survivor is correct (an event of high probability under normal operating conditions), the corresponding estimates are evaluated using the correct data sequence. Since at each stage we do not know which survivor is correct (or the best), we extended using the best data sequence available (which is the sequence associated to it), regardless of our temporary ignorance as to which survivor is the best. When per-survivor processing (PSP) technique is used combined with MLSE, no decision delay is introduced into the PLL as same as in tentative decision methods, at the same time, the error propagation is avoided.
[0008] It is worthwhile noting that in the Ungerboeck's MLSE receiver, RENATO's receiver, and Ling's invention, besides a quite long decision delay caused by the Viterbi processor, extra delay is introduced into the PLL in RENATO's receiver and Ling's invention, which further narrow the frequency tracking range of the PLL. In these receivers, the detected phase error in the PLL is computed by comparing the signal sample at the Viterbi processor input with a replica of the same signal sample based on the decision output and the CIR. Therefore, the extra delay caused by signal reconstruction is introduced into the PLL, which limits the allowable carrier frequency offset ranges that can be compensated. Therefore, RENATO and Ungerboeck's MLSE receivers only consider small carrier frequency offset, which causes distortions within each received signal on a burst-by-burst basis.
[0009] In the Ling's improved MLSE receiver, although several frequency offset method are proposed to improve the accuracy and stability of the system, the PLL delay further increases as it adopted a big-loop architecture (the phase retotation was performed prior to the matched filter). The circuit for adjusting the regenerated carrier by utilising the phase error calculated on the basis of the detected data has a remarkably large delay time in the control loop, therefore, it is impossible to attain a good characteristics in the frequency and phase tracking. Namely, the circuit has disadvantages that a frequency tracking range becomes remarkably narrow, a time required for the synchronisation is remarkably long.
[0010] Although the MLSE receiver adopting tentative decision and combined with the PLL has a quite large tracking range, its BER performance is not so satisfied especially in the low SNR due to error propagation. Whereas PSP-based MLSE receivers, which can obtain a small delay as same as the MLSE receiver tentative decision, have much larger tracking range and much better BER performance at the low SNR. However, PSP MLSE receivers are characterised by a very high complexity in the implementation. First, if the state number of the Viterbi processor is also doubled, i.e., besides the survivor metrics for N states, the phase for N states are required to be stored in the each step of Viterbi processing. In addition, from the viewpoint of the PLL tracking performance, PSP technique which adopts LMS algorithm to track the carrier phase, is equivalent to a first-order PLL. As we know the extensively adopted second-order PLL has much better tracking performance than the first-order PLL.
[0011] Therefore, in a high-rate indoor wireless communication system where there may be a large frequency offset caused by either a Doppler frequency shift or a frequency difference between a transmitter and receiver's local oscillator, it would be extremely advantageous to provide an alternative MLSE receiver structure capable of providing large carrier frequency offset compensation and accurate joint channel/data estimation, while overcoming the shortcomings of the prior art.
SUMMARY OF THE INVENTION
[0012] In general terms the present invention provides a wireless burst communications receiver especially for high rate indoor applications which utilises a fine frequency/phase estimation and tracking process which is advantageously combined with a large range coarse frequency/phase offset process. The fine frequency tracking function or apparatus uses a maximum-likelihood sequence estimation (MLSE) equaliser in combination with a dual mode phase lock loop (PLL). The PLL comprises a phase detector with a switchable input, one input option from the output of the MLSE or a memory component containing a copy of the expected preamble sequence. The second input option between a delayed and a non-delayed input of the MLSE. Initially the phase detector input is switched to the known preamble and non-delayed MLSE input to allow the phase lock loop to initialise and effectively adjust the phase of the incoming signal to correspond with the known preamble. One input is then switched from memory to the output of the MLSE following the processing delay required for it to process the first signal samples. The other input is switched to a delayed MLSE input, the delay corresponding to the processing delay of the MLSE. The PLL can then correct for changes in carrier frequency/phase during the burst.
[0013] In particular, the present invention provides a phase lock loop (PLL) circuit for receiving a burst signal including a repeated preamble sequence and a data sequence, the circuit comprising a maximum likelihood sequence estimator (MLSE) and means for determining the phase difference between a signal at the output of the MLSE and a corresponding delayed signal at the input of the MLSE, and phase rotating means for rotating the phase of said burst signal dependent on said phase difference, the output of said means being coupled to the MLSE input, wherein the phase determining means is further arranged to determine the phase difference between a non-delayed signal at the MLSE input and a stored preamble sequence signal.
[0014] This arrangement has several advantages including reducing the PLL acquisition time. By combining this with a large range coarse frequency of said estimation and correction function, there is provided a wide range frequency offset estimation and correction function with low implementation complexity and cost compared with other MLSE type receiver structures.
[0015] In particular, the invention provides a receiver having the above PLL together with means for differentially multiplying a sample of a first said preamble sequence with a corresponding sample of a second said preamble sequence, means for determining a phase rotation angle dependent on said difference and which angle is indicative of said estimate, a PLL having a mixer which receives a signal, an MLSE having an input coupled to the mixer, and a phase detector, the phase detector arranged to determine the phase difference between a signal at an output of the MLSE and a corresponding delayed signal at the MLSE input, the PLL further having mixer input means which is arranged to provide a rotating signal to the mixer in order to adjust the frequency of the received signal which the mixer outputs to the MLSE, said rotating signal being dependent on said phase difference, wherein the phase detector is arranged to be switchable between said MLSE output and a training sequence memory, and between said MLSE delayed input and a non-delayed MLSE input.
[0016] The invention also provides a phase error detector which further reduces PLL loop delay and improves phase tracking performance.
[0017] In particular the present invention provides a phase detector having an input coupled to the output of a maximum likelihood sequence estimator (MLSE) and a second input coupled to the input of said MLSE, the detector comprising delay means for delaying the second input signal by a delay time corresponding to the processing delay of the MLSE, and processing means arranged to determine the phase difference between the first and delayed second inputs, the processing means arranged to determine the imaginary part of the result of dividing the second input by the first input, said part corresponding to the phase difference.
[0018] Embodiments of the invention present a MLSE type receiver structure that integrates various estimation methods in an optimum way and adaptive manner for high-rate indoor wireless communications. Skillfully utilising the preamble sequence (CAZAC sequence) in the beginning of the burst, a simple and high accuracy frequency offset estimator is adopted. Then a small-loop structure based on the integration of MLSE and PLL is proposed. It is proven that the receiver structure can be optimised if Ungerboeck's MLSE is utilised and combined with the proposed dual mode PLL.
[0019] The residual frequency error and phase error are removed by applying a mixed data-aided and decision-directed PLL, and a new phase error detector method is proposed which introduces much smaller phase lock loop delay to improve the tracking performance of the PLL. This dual-mode PLL removes the residual frequency error and phase noise in two steps. First, the data-aided PLL is adopted by utilising the preamble sequence, which has zero decision delay. This step completes the initialisation of the PLL and help the PLL enter into the lock-state from the pull-in state. Then the PLL is switched to the decision-directed mode, the decision value from the output of the MLSE is feedback to the phase detector, the detected phase error passes through a second-order loop filter and drives the NCO. The output of NCO is used to correct the phase of the received signal. In the decision-directed model, the loop delay is mainly determined by the decision delay inherent in the MLSE.
[0020] An advantage of embodiments of the present invention is that such a receiver structure trades off accurate compensation for wide range frequency offset and low implementation complexity, as compared to other MLSE type receiver structures. This is achieved by using the property of the preamble CAZAC sequence for coarse frequency offset estimation and initiation of the PLL.
[0021] Unlike many prior art MLSE receivers, embodiments of the invention do not use PSP which requires lots of hardware, and instead overcomes the problem of potentially large offset by bypassing decision delay by switching PLL to known preamble initially to get coarse frequency and hence avoid problem of large frequency offset and slow response in typical PSP architectures.
[0022] By utilising Ungerboeck's unwhitened MLSE we can decrease the complexity of the Viterbi processor and improve the BER performance of the system. Moreover, we can optimise the receiver structure by combining this with the proposed dual-mode PLL.
[0023] The proposed new phase error detector used in the PLL further decreases the PLL loop delay and improves the phase tracking performance.
[0024] The above receiver structure improvements are advantageously combined with the following coarse frequency offset estimation and correction functions.
[0025] The present invention also provides an estimator for determining an estimate of frequency offset associated with a received burst signal having a repeated training sequence; the estimator comprising means for differentially multiplying a sample of a first said sequence with a corresponding sample of a second said sequence and means for determining a phase rotation angle dependent on said difference and which angle is indicative of said estimate.
[0026] Preferably the samples of each said training sequence are statistically independent, and wherein the estimator further comprises means for averaging said differences for a number of samples of said first and second sequences.
[0027] Preferably said sequences are Pseudo Random or Constant Amplitude Zero Auto-Correlation sequences.
[0028] Preferably said phase angle determining means comprises an arc tangent function applied to said difference.
[0029] There is also provided a frequency corrector comprising means for differentially multiplying a sample of a first said sequence with a corresponding sample of a second said sequence; means for determining a phase rotation angle dependent on said difference and which angle is indicative of said estimate and a frequency shifter which shifts the phase of said received signal by said phase rotation angle.
[0030] Preferably the phase shifter comprises an NCO having an input coupled to said phase rotation output and which generates a correction frequency dependent upon said output and which is mixed with said received signals.
[0031] The repeated symbols within a sequence can be treated as statistically independent when using certain well-known sequences (e.g. PN or CAZAC) which allows for an improved frequency offset estimate. As is well-known, Pseudo Random (PN) and Constant Amplitude Zero Auto-Correlation (CAZAL) sequences provide that samples within a sequence are statistically independent. This is because each sequence in the preamble is normally chosen or designed to possess noise-like or pseudo-random properties. With repeated sequences, this statistically independent property (within each sequence of the entire preamble) allows the effect of a multipath (frequency-selective) communication channel on the quality of a frequency estimate to be substantially reduced by the combined process of differential multiplication and averaging. The averaging process removes the products which have statistically independent symbols while retaining only those which has identical symbols corresponding to the repeated sequences.
[0032] As the estimator exploits the use of preambles with periodic sequences or symbols, the estimation performance of this technique is particularly robust against frequency selective channel. Due to the feedforward nature of the frequency corrector, the implementation is highly suited for burst mode modem design. In a burst mode transmission system, the frequency offset is assumed to be invariant throughout each received packet. The frequency offset of many individually received packets can however be different. Therefore a single frequency estimate determined from the preamble of each packet can be used to cancel the frequency offset of that packet. Compared to feedback architecture, a feedforward estimator allows frequency offset to be estimated very reliably in a single-shot fashion. The estimator is then shut off during the remaining packet since it is not required to track any residual frequency offset since it is assumed to be invariant.
[0033] Whilst these various aspects of the invention are advantageously combined, they can also be implemented independently in receiver structures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] [0034]FIG. 1 is the diagram block of the considered transmitter's baseband structure.
[0035] [0035]FIG. 2 is the data structure of a WPAN system.
[0036] [0036]FIG. 3 is the diagram block of the considered receiver's baseband structure.
[0037] [0037]FIG. 4 is the block of coarse frequency offset estimator.
[0038] [0038]FIG. 5 is the integration method of MLSE and two-mode PPL.
[0039] [0039]FIG. 6 shows BER v SNR for prior art and inventive MLSE
[0040] [0040]FIG. 7 shows BER v SNR for prior art and inventive receiver architectures.
[0041] Table 1: CAZAC sequence
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The baseband function blocks of a transmitter are schematically depicted in FIG. 1. The core of the baseband transmitter is the differential PSK mapping and the complex filter shaping. The channel model is also included in this figure. The high data rate WPAN and WLAN systems in indoor environment are low-mobility systems. Therefore, generally the channel can be considered as a frequency-selective and time-invarying fading channel for each burst transmission. This means that once the CIR (channel impulse response) is estimated, it is suitable for the whole packet. The data structure of a WPAN system (see IEEE802.15.3) are shown in FIG. 2. A physical layer preamble is added before the message payload to aid receiver algorithms related to synchronisation, carrier-offset recovery, and signal equalisation. The preamble consists of multiple periods of a special sequence of 16 symbols called a CAZAC sequence, which demonstrates a constant amplitude zero auto-correlation property. The CAZAC sequence shall be denoted as {c 0 , c 1 . . . , c 15 }. Each element, c i , of the CAZAC sequence shall have a complex value representing the inphase and quadrature components of a QPSK-type sequence, as shown in Table 1.
[0043] [0043]FIG. 3 is a block diagram of a baseband receiver which is employed to recover the modulated data. The received digitised samples are the complex signal sequence oversampled 4 times. Thereafter, the digitised complex samples are applied to the burst synchronisation and timing recovery circuit. In this circuit as well known in the art, a complex correlation is performed between the received samples and a complex replica of the preamble sequence stored in memory device. This correlation is to be computed upon the reception of each burst signal and will be used to provide both synchronisation and an estimate of the CIR. According to the preferred embodiment, the burst synchronisation and timing are accomplished by searching the complex correlation for the peak magnitude. Upon location of the synchronisation signal pattern, a CIR estimate are performed in accordance with well known channel sounding procedures. It will be appreciated by those skilled in the art that the correlation yields a complex result carrying both amplitude and phase information and represents a sounding of channel.
[0044] Based on the estimated timing and burst synchronisation, the preamble sequence is downsampled to symbol rate and input to the frequency offset circuit. With obtained frequency offset estimate, the phase of the received signal is rotated to correct any large frequency error. At the same time, the received signal samples are downsampled from the 4× symbol rate to 2× symbol rate and input to the matched filter.
[0045] Preferably the frequency offset estimation and correction is achieved by the method described in applicant's co-pending application SG 200203670.5, the contents of which are hereby incorporated. A schematic of this estimator is shown in FIG. 4.
[0046] The frequency offset is coarsely estimated by modifying Cox's method proposed for OFDM system T. M. Schmidl and D. C. Cox, “Robust frequency and timing synchronization for OF DM”, IEEE Trans. Commun., Vol. 45, No.12, pp1613-1621, December 1997. This uses one unique symbol which has a repetition within half a symbol period to obtain the burst synchronisation and frequency offset estimation. This method allows a large acquisition range for the carrier frequency offset. In the present embodiment, utilising the unique property of CAZAC sequence, a modified method is used. Compared to the original method, this method requires a fixed length (16) correlator to derive the frequency offset.
[0047] A complex signal symbol a k , belonging to an M-ary alphabet, is transmitted over a complex linear channel characterized by impulse response h(t) (this filter represents the cascade of the transmitter filter, the physical channel, and the receiver filter). The complex envelope of the received signal can be expressed by a discrete model,
r k = j ( 2 π Δ f k + φ ) ∑ n = 0 L h n a k - n + n k ( 1 )
[0048] where n k denotes the equivalent baseband white Gaussian noise with power spectrum N o /2, independent of the data sequence. {h(n)} is the CIR which is obtained by channel estimator, and A f denotes the frequency offset normalised to the symbol rate. The frequency offset estimator exploits the property of the periodic CAZAC sequence, and a correlation is performed according to the symbol rate,
1 32 ∑ k = 0 15 r k r k - 16 * = j2π Δ f · 16 1 32 ∑ k = 0 15 ∑ n1 ∑ n2 h n1 h n2 * c k - n1 c k - 16 - n2 * ( 2 )
[0049] In the following, two properties of the CAZAC sequence will be used. First, the preamble sequence made up of the repetition of 16 CAZAC symbols, i.e. c k =c k −16. Secondly, CAZAC sequence is a special PN sequence which has a good cyclic correlation property, i.e.;
1 32 ∑ k = 0 15 c k - n1 c k - 16 - n2 * = { 0 n1 ≠ n2 1 n1 = n2 ( 3 )
[0050] Moreover, with a normalised Rayleigh fading channel, in most cases we have Σ n1 |h n1 | 2 =1 (no complex power normalisation is needed) and hence the following relation is obtained,
1 32 ∑ k = 0 15 r k r k - 16 * = j2π Δ f · 16 ( 4 )
[0051] The estimated frequency offset can be represented as,
Δ f ^ = arg { 1 32 ∑ k = 0 15 r k r k - 16 * } 2 π × 16 ( 5 )
[0052] In Cox method, consider two repeated training symbols which are identical to each other at the receiver except for a phase shift caused by the carrier frequency offset. If the conjugate of the first symbol is multiplied by the second (delay time T d later), the frequency offset can be estimated by some operations. The estimated range depends on delay time T d . The effect of channel fading should be cancelled, therefore, the normalizer is needed.
[0053] In the modified method according to the present embodiment, the property of CAZAC sequence is used, and delay time is fixed at the length of each sequence (16) (the estimated normalised frequency offset is up to 0.06). The effect of channel fading is cancelled successfully just by a moving average, which decreases the implementation complexity. This is explained in more detail in the above referred co-pending application.
[0054] In accordance with the second embodiment, an MLSE equaliser is utilised in conjunction with the estimated CIR to recover the data sequence. There are two classic MLSE equaliser, Formey's MLSE receiver and Ungerboeck's unwhitened MLSE—see previous references. Ungerboeck's MLSE consists of a matched filter which maximises the SNR of the Viterbi input, a sampler operating at the symbol rate, and a modified Viterbi processor (which needn't square operation in metric calculation) for estimating the information sequence from the sampler output. In Formey's MLSE, the receiver consists of a whitened matched filter, i.e., a matched filter followed by a transversal filter that whitens the noise, a symbol rate sampler, and a conventional Viterbi processor to perform ML sequence estimation. In Formey's receiver, whitening of the noise is essential because the conventional Viterbi processor requires that noise components of successive samples be statistically independent.
[0055] Although Ungerboeck's MLSE has a lower complexity, Formey's MLSE is more extensively employed. This is because the two MLSEs have no essential difference in the implementation for TDMA systems where adaptive equaliser is required, and the matched filter and whitening matched filter have same complexity when implemented by LMS (least-means-square) or RLS (recursive-least-square) algorithm. Hence Ungerboeck's MLSE has only slight complexity advantage. Furthermore, Formey's MLSE is more attractive in the application since it adopts conventional Viterbi algorithm. However, this is not true for the indoor WAPN systems.
[0056] In an indoor wireless burst communication system over a quasi time-invarying fading channel, the preamble sequence is utilised to obtain quite accurate CIR estimate for each burst, which is constant for the whole burst. Hence the coefficients of the matched filter can be easily set up as h MF =h*(−t). Whereas, the whitening filter converts the original overall CIR to a minimum-phase impulse response whose energy is concentrated in its first several samples. In the considered system, the whitening filter design possesses much higher complexity. First, the transmitted data is organised in bursts, each one containing a preamble sequence for timing, frequency offset and channel estimation. In most cases the preamble sequence is too short for the application of recursive adaptation algorithms like LMS or RLS algorithms for adjustment of the whitening filter coefficients. Therefore, a closed-form calculation using the result of channel estimation is necessary. Many methods well known in art either require matrix inversion or the solving of Yule-Walker equation, which introduce high complexity into Formey's receiver. Therefore Ungerboeck's MLSE, which does not need a whitening filter, substantially reduces the implementation complexity.
[0057] In Formey and Ungerboeck's MLSE, it will be appreciated by those skilled in the art that the matched filter (MF) provides the absolutely largest SNR, the elimination of ISI by a subsequent whitening filter diminishes the SNR. Therefore, Ungerboeck's MLSE is identical to the Formey's MLSE if there is no ISI at the MF output. In the presence of ISI, ISI at the MF output has not essential influence on the error performance of the Ungerboeck's MLSE, whereas ISI affects the error performance of the Formey's MLSE through the loss of SNR. Moreover, through simulations it has been demonstrated that Ungerboeck's MLSE and its reduced-complexity format (DFSE: decision feedback sequence estimate) can achieve better BER performance than Formey's MLSE and DFSE, which is shown in FIG. 6. Actually, this can be easily understood, the whitening filter is of infinite length in general, but an FIR implementation is generally required in practice, which makes the assumption of a minimum phase response at the whitening filter output not true in general. Consequently, the imperfection of the whitening filter design causes Formey's MLSE and DFSE performance degradation.
[0058] As previously discussed, embodiments of the present invention are directed at presenting a MLSE type receiver structure that integrates various estimation algorithms in an optimum way and adaptive manner for high-rate indoor wireless communications. Therefore, it is preferred to use Ungerboeck's MLSE receiver, which can optimise the system implementation and the BER performance. We will see that the optimality of adopting Ungerboeck's MLSE will be further demonstrated in the third embodiment. In accordance with the second embodiment, in operation, T/2-spaced matched filter is adopted in Ungerboeck's MLSE equaliser, hence each symbol is made up of 2 samples in the output of the matched filter. However, one sample per data symbol is sufficient to provide data/phase detection (which result in the minimised complexity for Viterbi processor). It is therefore desirable to pick the best sample per symbol according to the preferred synchronisation circuit.
[0059] The frequency error of the received signal is coarsely corrected with the estimated frequency offset, however, the residual frequency error and phase error still exist. After the frequency corrector, the Ungerboeck's MLSE is employed for data estimation. At the same time, estimated data output by MLSE equaliser is feedback to a phase lock loop (PLL) to compensate for the residual frequency error and phase jitter. Therefore, in accordance with the third embodiment, a novel integration of Ungerboeck's MLSE and PLL is proposed. After the frequency correction, the received signal can approximately be represented as:
r k = j φ k ∑ n = 0 L h n a k - n + n k ( 6 )
[0060] where Ø k represents the phase error due to residual frequency error and phase noise. In this embodiment, a dual-mode phase-lock loop is utilised to remove the residual frequency error and phase noise. In accordance with this embodiment, the preamble sequence is skillfully utilised, the Ungerboeck's MLSE equaliser and phase error detector are optimally integrated. The loop delay of PLL is minimised by trading off the implementation complexity and the acquisition speed and tracking performance of the PLL.
[0061] The carrier recovery circuit with data-aided and decision-directed mode PLL is shown in FIG. 5. The output of the phase rotator at the kth epoch, x(k) is expressed as
x ( k )= r k e −jθ(k) (7)
[0062] where θ(k) is the carrier phase from the numerical control oscillator (NCO) for the phase rotation of the received signal. The detected phase error, which includes the effects of phase jitter, frequency offset and phase offset, can be expressed as,
ε ( k ) = Im [ x ( k ) c k ] ( 8 )
[0063] Where ε can be approximated as the residual phase error because of the following conditions. First Ungerboeck's MLSE is adopted, in which the matched filter accomplishes the phase equalisation (i.e. s 0 is a real value, where {s i , i=−L, . . . , L} denotes autocorrelation of the CIR); secondly the main path power is much higher than the interference path power
( s 0 > ∑ i = 1 L s i ,
[0064] which can be met in most cases.
[0065] In conventional schemes, the preamble data or decision output passes through a signal reconstruction module, and then is used to detect the phase error. The phase error detector of the embodiment results in less accurate detection; however this loss is trivial compared with the advantages generated.
[0066] In conventional schemes, the signal reconstruction require both the precursor and postcursor signal, and extra delay of two times of channel memory is introduced. Moreover, in the decision-directed mode, postcursor decision outputs are not available. In addition, the more precursor and postcurcor decision output are used, the larger high probability of error propagation. Therefore, using the proposed scheme, the loop delay is minimized and fast acquisition speed can be obtained by PLL. Moreover, this phase error detector possesses much smaller complexity, the loop delay is minimised, and fast acquisition speed can be obtained by PLL.
[0067] In the data-aided PLL utilising the known preamble sequence as the feedback, which result in zero loop delay except the delay introduced by the loop filter, the initialisation of the PLL can be efficiently accomplished, and the phase error can be quickly acquired. The PLL enters into lock state from pull-in state in a short time. Actually, this is a very efficient PLL training stage. After the preamble sequence is received and data segment is coming, the PLL is switched to the decision-directed mode. In the data segment, the corresponding phase detection function can be expressed as
ε ( k ) ≈ I m [ x ( k - d ) r ^ ( k - d ) ] = ε ( k - d ) ( 9 )
[0068] where r(k−d) denotes the recovered data output by the MLSE equaliser, and d denotes the decision delay in the MLSE equaliser. In this decision directed mode, the PLL tracks the variation of the phase error and compensates for it. The tracking range depends on the loop delay d, and the larger d results in the narrower tracking range. Therefore, the decision delay in the MLSE equaliser limits the carrier tracking performance.
[0069] After the phase detection, the detected error signal passes through the loop filter and derives the required phase to drive the NCO. These two function blocks can be expressed as:
θ( k )=θ( k− 1 )+{ε( k )}* {f( k )} (10)
[0070] where * represents convolutional operation and f(k) denotes the loop filter response. The setup of the loop filter f(k) is most crucial to the performance of the PLL. A second order PLL is adopted in this embodiment, and the transfer function of its digital loop can be represented as:
F ( z ) = K 1 + K 2 1 - z - 1 ( 11 )
[0071] The loop filter coefficients K 1 , K 2 can be calculated according to the tracking performance of PLL and noise bandwidth. The method to set K 1 and K 2 is well known in the art, and does not require additional discussion here.
[0072] If the PLL can efficiently compensate for the phase error caused by residual frequency error, phase offset and phase jitter, the input to the MLSE can be expressed as
x k = r k - j θ k = ∑ n = - L L s n a k - n + n k ( 12 )
[0073] evidently the input signal to MLSE equaliser is only the ISI—corrupted signal. Using Unger-broeck's MLSE, the desired data a k can be estimated.
[0074] It is well known in the art that the decision delay introduced by MLSE equaliser will significantly narrow the tracking range of the PLL, therefore an alternative to PSP-technique based carrier recovery is proposed. The present embodiment can achieve the same or slightly better performance than standard PSP technique when the same frequency corrector is used. Moreover, only 1/N implementation complexity and cost is needed, here N denotes the state number of Viterbi processor.
[0075] In standard PSP, the PLL is included into the MLSE algorithm itself. Therefore, for each state of Viterbi algorithm, one PLL is needed. However, in the embodiment, the phase is rotated outside of MLSE, and the decision output of MLSE is used for phase error detector (therefore only one detector), therefore, only one PLL is needed.
[0076] It is well known in the art that Ungerboeck's MLSE operates directly on the discrete output of the matched filter, and the modified Viterbi algorithm (VA) is adopted. The state of VA is
μ k−1 =( a k−L ,a k−L+1 , . . . ,a k−1 ) (13)
[0077] the maximum likelihood (ML) estimation is obtained by maximising the metric given by
Γ k (μ k )=Γ k−1 (μ k−1 )+λ(μ k−1 ,μ k ) (14)
[0078] where μ(μ k−1 , μ k ) is called branch metric. When PSP technique is used to recover the carrier, associated with the state transition μ k →μ k+1 the branch metrics become
λ ( μ k → μ k + 1 ) = Re [ a ^ k ( 2 r k - j θ k - s 0 a k - 2 ∑ m = 1 L s m a k - m ) ] ( 15 )
[0079] where r k denotes the received signal after frequency corrector, and â k denotes the decision of a k . θ is the estimated phase error, which is derived by the PSP method and adapted by the LMS algorithm. Using PSP technique, â k can be obtained, and the desired phase error is
{circumflex over (θ)} k+1 ={circumflex over (θ)} k +K 1 Im{r k â k e −j{circumflex over (θ)} k } (16)
[0080] where K 1 is a constant. Comparing (16) with (10), we can see that LMS method is equivalent to the first order PLL method, except that the second component in (16) is the phase error Im{r k *â k e −jθk } is the loop filter of the first-order PLL.
[0081] The above discussion on the PSP-based MLSE receiver indicates that a PLL is needed for each state of Viterbi processor. Moreover, besides the survivor metrics for each state, the phase metric for each state are required to be stored. Hence the required storage is also doubled. Whereas only one PLL is needed in the present invention. If there are N states for Viterbi processor, the complexity of the present invention is only 1/N of the PSP based MLSE receiver.
[0082] As is known a first order PLL can only track the phase step variation, and the second order PLL has much faster and wide tracking performance than the first order PLL especially in the presence of residual frequency error. Using the same system architecture, the BER comparison of PSP receiver and the present invention is shown in FIG. 7, which clearly indicates that the present invention can achieve equivalent or slightly better performance than PSP receiver. The embodiments of the present invention are optimally combined by trading off the tracking range, complexity and performance.
[0083] The invention is applicable to the receiver of high-rate wireless indoor communications, especially in wireless indoors communications systems which employ time-division burst transmission, where the rate of change of CIR is slower than the burst duration.
TABLE 1 CAZAC sequence CAZAC sequence element Value c 0 1 + j c 1 1 + j c 2 1 + j c 3 1 + j c 4 −1 + j c 5 −1 − j c 6 1 − j c 7 1 + j c 8 −1 − j c 9 1 + j c 10 −1 − j c 11 1 + j c 12 1 − j c 13 −1 − j c 14 −1 + j c 15 1 + j | The present invention relates to wireless burst communications receivers especially for high-rate indoor applications. The present invention provides a phase lock loop (PLL) circuit for receiving a burst signal including a repeated preamble sequence and a data sequence, the circuit comprising a maximum likelihood sequence estimator (MLSE) and means for determining the phase difference between a signal at the output of the MLSE and a corresponding delayed signal at the input of the MLSE, phase rotating means for rotating the phase of said burst signal dependent on said phase difference, the output of said means being coupled to the MLSE input, wherein the phase determining means is further arranged to determine the phase difference between a non-delayed signal at the MLSE input and a stored preamble sequence signal. | 7 |
TECHNICAL FIELD
[0001] This invention relates in general to footwear and, more particularly to a shoe of a selectively versatile character, which is uniquely constructed for interchangeability of use.
BACKGROUND ART
[0002] Heretofore, numerous efforts have been undertaken to develop shoes for men and women that in appearance through facile alteration by the wearer. Prior art is extensive with footwear having changeable components to achieve a variety of purposes.
[0003] Most of such earlier attempts have been directed to what might be considered ornamental effects to increase the style of the shoe, such as shown in Smith's U.S. Pat. No. 4,267,649. Other efforts have been directed toward alternation in components for style, purposes of color and design; see e.g. Bailey's U.S. Pat. No. 4,887,369; Smith's U.S. Pat. No. 4,267,649; Halford's U.S. Pat. No. 5,083,385; Blakely's U.S. Pat. Pub. No. 2001/0052195 A1; Dupree et al. U.S. Pat. No. 5,848,484; and Dupree's U.S. Pat. No. 4,958,447.
[0004] Additionally, various efforts have been made to create a versatile shoe for athletic purposes. Most of such attempts have been for one specific athletic purpose or another (e.g. roller skating or bowling), such as Clementi's U.S. Pat. No. 4,706,392. Other interchangeable shoes focused on creating a sole suitable for the insertion of tools to practice various sports as shown by Schaefer's U.S. Pat. No. 4,114,295 and Aveni's U.S. Pat. No. 5,459,948.
[0005] There has been some focus in creating a versatile water shoe, although not interchangeable, serving many purposes as shown by U.S. Pat. Nos. 5,802,740; 5,960,565; 5,732,480; 5,771,610; and 5,737,853.
[0006] Yet other inventions have focused on making a comfortable, affordable, easy to use versatile shoe. For example, Throneburg's U.S. Pat. No. 5,724,753 discloses a footwear system that includes a sock specifically made for the shoe. Others patents simply disclose slippers and sandals that are lightweight and affordable for beach use, e.g. Huard et al. U.S. Des. Pat. No. D450,179 S.
SUMMARY OF THE INVENTION
[0007] The present invention embodies an interchangeable article of footwear. The footwear includes an outer sole of unitary construction and an inner sole adapted to be housed by the outer sole. The outer sole of unitary construction includes a united toe, central and heel portion. The top sole sits upon the toe, central and heel portion of the shoe making it a single unit. This outer sole unit can be used as a shoe itself, as a sandal, or as the sole for other transformations of footwear.
[0008] The central portion of this outer sole unites toes and heel portion be an arch supporter which made be covered with materials such as Kevlar or composite materials. As a fastener for the outer sole, two bands of materials, such as hook-and-loop fasteners, can attach by a variety of means around the toe and ankle portion of the shoe. The ankle portion is also attached to a heel supporter that curves around the upper back heel of the shoe. The ankle portion is also attached to a heel supporter that curves around the upper back heel of the shoe. The abovementioned increased arch support permits sliding of wearer's arch. It also permits ready flexing and bending of the shoe within a zone intermediate to the heel and sole to provide increased walking comfort and natural flexing.
[0009] The outer sole may include a mechanism to adjust the height of the same or the softness/firmness level of the shoe. The preferred mechanism includes a dial, a switch mechanism; and may include a magnetic fluid (or MR fluid) that may serve as a shock absorber and to adjust the softness/firmness of the footwear. The mechanism may be placed at different location of the outer sole.
[0010] The sandal is the bottom sole of the interchangeable article of footwear invention, wherein diverse interchangeable inner shoes (also referred to as inner soles) may be inserted at user's preference. Wearer according to his or her specific needs or intended use can combine this inner shoe style and outer shoe type. Therefore, this outer sole may include variations of this invention by inserting one of the components or inner shoes/soles mentioned herein under, but it may also be worn as a sandal on its own.
[0011] The inner footwear (inner shoe or inner sole) is an interchangeable component that is housed by the outer sole without being permanently attached to the outer sole or sandal. Moreover, this component may be inserted into the outer sole or sandal and used as a sneaker, amongst other uses. The sports shoe or sneaker can be removed and the sandal worn on its own.
[0012] Other preferred versions of the present invention include an inner sole adapted to replicate to configuration, comfort, and uses of a water shoe, slipper, or sock insole. A preferred sock insole includes a two unit padding, one unit to be attached to the upper portion of the sock's heel and the other for the lower portion of the sock's heel. Padding in two units enables the sole to be attachable to socks of different sizes. In addition, the sock may include an elastic strap at the middle of the sock, providing wearer with massages. This elastic strap assists the wearer relieve pain and serve as an extra foot support.
OBJECTS AND ADVANTAGES OF THE INVENTION
[0013] The present invention constitutes a significant improvement in several aspects over such previously identified efforts of the cited references and the prior art. Although the above-mentioned patent examples may be suitable for the particular purposes that they address, they are not suitable for the purposes of the present invention heretofore described.
[0014] Accordingly, an object of the invention is to provide a shoe designed for men, women, and children and having components of an interchangeable nature which are uniquely independent to provide greatly improved quick and simple alteration of the shoe to effect numerous uses permitted by said components.
[0015] Another object of the invention is to provide a shoe of the character stated which will accommodate various foot sizes and yet, for all such sizes is not only comfortable to the wearer, but also retains “imperative usefulness.”
[0016] A further object of the invention is the provision of a shoe that permits ready flexing and bending of the shoe within a zone intermediate the heel and sole to provide increased walking comfort and natural flexing.
[0017] A still further object of the present invention is to provide a shoe with increased arch support for the wearer to enhance walking comfort. In the junior version (for children or teenagers) the increased arch support is particularly important given low friction materials used for the arch support, such as Kevlar, carbon fiber, Teflon, or any man made plastic. This band surface would permit sliding of wearer's arch.
[0018] Another object of the invention is to provide a shoe that provides a stable and mechanically secure structural nature with the independent component of the sandal footwear and which should become even more stable and mechanically secure when the components of the shoe are in their various states of assembly.
[0019] Yet another object of the invention is to provide a shoe that embodies cooperative elements that are selectively configured by easy manipulation to provide quick and easy alteration of the utility and the appearance of the shoe.
[0020] It is a further object of the present invention to provide a shoe with multiple interchangeable constituents which may be easily disposed into chosen activity without resort to extrinsic tools and without requiring advance skill on the part of the wearer so that the average individual can quite simply and rapidly bring about the desired use within the range provided.
[0021] It is a still further object of the present invention to provide a shoe adapted for supporting various uses corresponding to particular activities through the attachment or detachment of a particular shoe to the outer sole.
[0022] An additional object of this invention is to provide an article of footwear that may be accommodated as a sock insole or sock slipper including elastic that provides increased firmness of the sock and massages wearer's foot. This sock insole or sock slipper can also assist the wearer relieve pain and serve as an extra foot support.
[0023] It is yet another object of the present invention to provide a shoe of the character stated which may be most economically manufactured; which is extremely durable in usage; and which in and of itself serves the purpose of several pairs of shoes so as to bring about a substantial savings to the user.
[0024] These objects of the invention are not meant to be exclusive. Furthermore, some features may apply to certain versions of the invention, but not others. Other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, and accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0025] FIG. 1A to 1D are side elevation views of the embodiments of the footwear, from right to left, as an outer sole or sandal ( FIG. 1A ), sports' shoe ( FIG. 1B ), water shoe ( FIG. 1C ), and sock insole/slipper shoe ( FIG. 1D ).
[0026] FIG. 2 is a side view of the footwear as an outer sole or sandal.
[0027] FIG. 3 is a side view of the footwear as a water shoe without the outer sole or sandal attached.
[0028] FIG. 4 is a side view of the invention comprising the sandal or outer sole with a sports shoe as the inner sole/shoe inserted into the outer sole.
[0029] FIG. 5 is a side view of another embodiment of the footwear without the outer sole or sandal attached.
[0030] FIG. 6A and FIG. 6B are side elevation views of, from left to right, the sports shoe without the outer sole attached ( FIG. 6A ) and of the outer sole/sandal ( FIG. 6B ).
[0031] FIG. 7 is a side elevation view of the sports shoe and the outer sole or sandal.
[0032] FIG. 8 is a side view of the interchangeable shoe.
[0033] FIG. 9 is a side view of one embodiment of the outer sole or sandal of the invention featuring the dial control mechanism.
[0034] FIG. 10 is a side elevation view of the one embodiment of the outer sole or sandal of the invention featuring the dial control.
[0035] FIG. 11 is a front view of one embodiment of the outer sole or sandal of the invention, featuring the dial control mechanism.
[0036] FIG. 12 is a side view of the one embodiment of the invention
[0037] FIG. 13 is a side view of one of the independent inner soles of the invention, the sock insole.
[0038] FIG. 14 is a side view of an inner sole or inner shoe.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0039] Turning first to FIG. 1A-D , the present invention embodies an interchangeable article of footwear 100 . As FIGS. 2 and 3 show, the footwear 100 includes an outer sole 102 of unitary construction and an inner sole 104 adapted to be housed by the outer sole 102 . The outer sole 102 of unitary construction includes a united toe portion 110 , central portion 112 , and heel portion 114 . The top sole includes the toe, central, and heel portion of the shoe making it a single unit. This outer sole unit can be used as a shoe itself, as a sandal, or as the sole for other transformations of footwear. The outer sole may be made of various materials such as inflexible materials including wood, metal, and the like or flexible materials including rubber, plastic, leather, fabric or man-made materials.
[0040] The central portion 112 of this outer sole unites toe portion 110 and heel portion 114 by an arch supporter. In the preferred embodiment of the invention, this arch supporter may be covered with materials such as but not limited to Kevlar or composite materials. Other embodiments of the present invention may include a curved toe portion for increased firmness of the wearer's foot inside the outer sole.
[0041] Turning now to FIGS. 4 and 5 , two bands of materials, e.g. VELCRO, attach by a variety of means around the toe and ankle portion of the outer sole 102 of the shoe 100 . The ankle portion 114 is also attached to a heel supporter that curves around the upper back heel of the outer sole 102 of the shoe 100 . The abovementioned increased arch support permits sliding of wearer's arch. It also permits ready flexing and bending of the shoe within a zone intermediate to the heel and sole to provide increased walking comfort and natural flexing. FIG. 4 and FIG. 10 further depict an outer sole handle 150 . The handle 150 is an outcropping of the outer sole 102 that allows a wearer to grasp the outer sole 102 while removing his foot from the interior of the outer sole 102 .
[0042] As FIGS. 9-12 illustrate, the outer sole may include an adjustment mechanism 120 to adjust the height of the same or the softness/firmness level of the shoe. This adjustment mechanism 120 includes a dial and to a switch mechanism; wherein rotation of the dial would actuate a threaded lift screw, and displacement of the switch would actuate a lever lift platform. Preferred materials for the composition of the adjustment mechanism include metals and plastics. The mechanism may also include a magnetic fluid (or MR fluid) that may serve as a shock absorber and to adjust the softness/firmness of the footwear. This mechanism may be placed at different locations of the outer sole, such as the rear end section of the sole or on a lower end section of the sole. The preferred embodiment of the invention includes a dial mechanism working in mechanical conjunction with the magnetic fluid to adjust these characteristics at user's preference. In the preferred embodiment, this dial mechanism is placed on the rear end section of the sole, as per FIGS. 10 and 11 . In addition, this mechanism 120 may be adjusted manually, mechanically, or electronically. In the preferred embodiment, this mechanism shall be adjusted manually. In the preferred embodiment, this mechanism shall be adjusted manually.
[0043] Generally designated in FIGS. 2 and 9 is a sandal 100 embodiment of the present invention. The outer sole 102 accepts diverse interchangeable inner shoes (not shown), which may be inserted at user's preference. Wearer according to his or her specific needs or intended use can combine multiple inner sole styles with the outer sole 102 . Therefore, this outer sole 102 may include variations of this invention by inserting one of the components or inner shoes/soles, but it may also be worn as a sandal on its own.
[0044] The preferred embodiment of this element of the invention is constructed of leather or any man made materials. The material from which the present invention is constructed should ensure that the configuration of the outer sole remains unaltered structurally upon the inclusion and removal of the inner sole.
[0045] FIGS. 6-8 illustrate the physical interrelationship between the outer sole 102 and inner sole 104 of the present invention. The inner sole 104 may be used without being attached to the outer sole or sandal. Moreover, this component may be inserted into the interior of the outer sole 102 or sandal and used as a sneaker, amongst other uses. As shown by FIG. 6B , the outer sole 102 need not necessarily include physical attachment means located on the inner sole (not shown); rather, in most instances it will be sufficient that the fastener 130 of the shoes obstruct the release of the inner sole 104 —as opposed to physical anchoring means (e.g. VELCRO) located on both the interior of the outer sole and the interior of the inner sole. As shown by FIG. 6B and FIG. 1B , the preferred fasteners 130 of the present invention include VELCRO straps and shoelaces; however, other forms of fasteners known in the shoe arts will similarly be amenable to the present invention. As detailed by FIG. 7 , the inner sole 104 enters the interior of the outer sole 102 by the same route that the human foot would take; which in the case of VELCRO fasteners may be through the fasteners, or in the case of shoelaces, may be only through the foot entrance and not through the released fasteners. The sports shoe or sneaker can be removed and the sandal worn on its own.
[0046] FIGS. 4 and 8 illustrate the preferred embodiment of the footwear as a sports shoe or sneaker. Here, the inner sole has been strapped and secured to the outer sole and are both worn in conjunction.
[0047] FIGS. 1C and 3 illustrate the water shoe 100 , which is preferably made of rubber or any other made material resistant to water. This is a water impermeable shoe and may have alternative uses to that of an article of footwear to be used in or with water. This element of the invention may be used as an entity to which the outer sole 102 can be attached and the footwear 100 worn as a beach sandal.
[0048] As shown by FIG. 13 , A preferred sock insole 104 acts to mimic a slipper and includes a two unit padding, one padding unit 142 to be attached to the upper portion of the sock's heel and the other padding unit 142 for the lower portion of the sock's heel. Padding in two units enables the sole to be attachable to socks of different sizes. In addition, the sock may include an elastic strap 144 at the middle of the sock, providing wearer with massages. This elastic strap 144 assists the wearer relieve pain and serve as an extra foot support.
[0049] In instances where in the insole is a sock, the sock may be made of materials such as but not limited to cotton, nylon, etc.; the outer sole may be made of materials such as but not limited to plastic, gel, rubber, or leather.
[0050] FIGS. 12 and 14 show an evening shoe 100 of the present invention with an alternate version of the adjustment mechanism. The adjustment mechanism includes a pin 160 adapted to fit into multiple grooves 162 . The heel 164 includes a perforated lower heel portion 166 slidably inserted into an upper heel portion 168 . The upper heel portion 168 includes at least one groove 162 to mate with one or more grooves on the lower heel portion 166 . To adjust the height of the evening shoe 100 , the user would simply remove or release the pin 160 , slide the lower heel 166 to the proper adjustment setting such that a groove of the upper heel is flush with a groove of the lower heel, and insert the pin. The inner sole 104 is removable from the outer sole 102 .
[0051] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | An article of footwear an outer sole that houses a removable inner sole. The interchangeable nature allows different uses, appearances, and configurations. The outer sole can be used as a shoe itself (e.g. a sandal) or as the sole for other transformations. Various types of footwear elements can be inserted into/over the outer sole, allowing conversion of the footwear into a sports, formal, sandal, water, slipper, dress, ornamented shoe or other footwear. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/664,125, filed Mar. 22, 2005, and entitled Ring Binder Mechanism with Spring Lock Actuator, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a ring binder mechanism for retaining loose-leaf pages, and in particular to an improved ring binder mechanism for opening and closing ring members and for locking closed ring members together.
[0003] A ring binder mechanism retains loose-leaf pages, such as hole-punched pages, in a file or notebook. It has ring members for retaining the pages. The ring members may be selectively opened to add or remove pages or closed to retain pages while allowing the pages to be moved along the ring members. The ring members mount on two adjacent hinge plates that join together about a pivot axis. An elongate housing loosely supports the hinge plates within the housing and holds the hinge plates together so they may pivot relative to the housing.
[0004] The undeformed housing is slightly narrower than the joined hinge plates when the hinge plates are in a coplanar position (180°). So as the hinge plates pivot through this position, they deform the resilient housing and cause a spring force in the housing that urges the hinge plates to pivot away from the coplanar position, either opening or closing the ring members. Thus, when the ring members are closed the spring force resists hinge plate movement and clamps the ring members together. Similarly, when the ring members are open, the spring force holds them apart. An operator may typically overcome this force by manually pulling the ring members apart or pushing them together. Levers may also be provided on one or both ends of the housing for moving the ring members between the open and closed positions. But a drawback to these known ring binder mechanisms is that when the ring members are closed, they do not positively lock together. So if the mechanism is accidentally dropped, the ring members may unintentionally open.
[0005] Some ring binder mechanisms have been modified to include locking structure to block the hinge plates from pivoting when the ring members are closed. The blocking structure positively locks the closed ring members together, preventing them from unintentionally opening if the ring mechanism is accidentally dropped. The blocking structure also allows the housing spring force to be reduced because the strong spring force is not required to clamp the closed ring members together. Thus, less operator force is required to open and close the ring members of these mechanisms than in traditional ring mechanisms.
[0006] Some of these ring mechanisms incorporate the locking structure onto a control slide connected to the lever. The lever moves the control slide (and its locking structure) to either block the pivoting movement of the hinge plates or allow it. But a drawback to these mechanisms is that an operator must positively move the lever after closing the ring members to position the locking structure to block the hinge plates and lock the ring members closed. Failure to do this could allow the hinge plates to inadvertently pivot and open the ring members, especially if the mechanisms are accidentally dropped.
[0007] Some locking ring binder mechanisms use springs to move the locking structure into position blocking the hinge plates when the ring members close. Examples are shown in co-owned U.S. patent application Ser. No. 10/870,801 (Cheng et al.), Ser. No. 10/905,606 (Cheng), and Ser. No. 11/027,550 (Cheng). These mechanisms employ separate springs to help lock the mechanisms.
[0008] Accordingly, there is a need for a simple ring binder mechanism that readily locks ring members together when the mechanism is closed without requiring additional spring components to do so.
SUMMARY OF THE INVENTION
[0009] A ring mechanism for holding loose-leaf pages generally comprises a housing and rings for holding the loose-leaf pages. Each ring includes a first ring member and a second ring member. At least one of the ring members is movable relative to the housing and the other ring member between a closed position and an open position. In the closed position, the two ring members form a substantially continuous, closed loop for allowing loose-leaf pages retained by the rings to be moved along the rings from one ring member to the other. In the open position, the two ring members form a discontinuous, open loop for adding or removing loose-leaf pages from the rings. An actuation system of the mechanism comprises first and second hinge plates supported by the housing for pivoting motion relative to the housing, and an actuator mounted on the housing for movement relative to the housing to cause the pivoting motion of the hinge plates. The at least one ring member is mounted on the first hinge plate for movement between the open and closed positions. The actuation system is adapted to deform upon movement of the actuator to delay the pivoting motion of the hinge plates from the movement of the actuator.
[0010] In another aspect, the ring mechanism comprises a housing and hinge plates supported by the housing for pivoting motion relative to the housing. Rings hold loose-leaf pages on the mechanism. Each ring includes a first ring member and a second ring member. The first ring member is mounted on a first of the hinge plates for movement with the hinge plate relative to the second ring member between a closed position and an open position. In the closed position, the two ring members form a substantially continuous, closed loop for allowing loose-leaf pages retained by the rings to be moved along the rings from one ring member to the other. In the open position, the two ring members form a discontinuous, open loop for adding or removing loose-leaf pages from the rings. The mechanism also comprises an actuator mounted on the housing for movement relative to the housing. The actuator is adapted to reconfigure itself during operation of the ring mechanism in moving the ring members between the closed position and the open position.
[0011] Other features of the invention will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective of a notebook incorporating a ring binder mechanism according to a first embodiment of the invention;
[0013] FIG. 2 is an exploded perspective of the ring mechanism;
[0014] FIG. 3 is an enlarged side view of a lever of the mechanism;
[0015] FIG. 4 is a top side perspective of the ring mechanism at a closed and locked position with the lever in a first relaxed position;
[0016] FIG. 5 is a bottom side perspective thereof;
[0017] FIG. 6 is an enlarged fragmentary perspective of the ring mechanism with a portion of a housing broken away and with a ring member removed to show internal construction;
[0018] FIG. 7 is a side view thereof with the housing and ring members removed;
[0019] FIG. 8 is a top side perspective of the ring mechanism at a closed and unlocked position with the lever in a deformed position;
[0020] FIG. 9 is a bottom side perspective thereof;
[0021] FIG. 10 is an enlarged fragmentary side view thereof with the housing and ring members removed;
[0022] FIG. 11 is a topside perspective of the ring mechanism at an open position with the lever at a second relaxed position;
[0023] FIG. 12 is a bottom side perspective thereof;
[0024] FIG. 13 is an enlarged fragmentary side view thereof with the housing and ring members removed to show internal construction;
[0025] FIG. 14 is a top side perspective of a ring mechanism according to a second embodiment at the closed and locked position;
[0026] FIG. 15 is an enlarged top side perspective of a lever thereof;
[0027] FIG. 16 is a side view of the ring mechanism;
[0028] FIG. 17 is a bottom side perspective of a ring mechanism according to a third embodiment at the closed and locked position;
[0029] FIG. 18 is an enlarged side view of a lever thereof;
[0030] FIG. 19 is an enlarged fragmentary side view of the ring mechanism with a housing and ring members removed;
[0031] FIG. 20 is an enlarged fragmentary side view similar to FIG. 19 with the mechanism at the closed and unlocked position; and
[0032] FIG. 21 is an enlarged fragmentary side view similar to FIG. 19 with the mechanism at the open position.
[0033] Corresponding reference numbers indicate corresponding parts throughout the views of the drawings.
DETAILED DESCRIPTION
[0034] Referring to the drawings, FIGS. 1-13 show a ring binder mechanism according to a first embodiment generally at 1 . In FIG. 1 , the mechanism 1 is shown mounted on a notebook designated generally at 3 . Specifically, the mechanism 1 is shown mounted on a spine 5 of the notebook 3 between a front cover 7 and a back cover 9 hingedly attached to the spine 3 . The front and back covers 7 , 9 move to selectively cover or expose loose-leaf pages (not shown) retained by the mechanism 1 in the notebook 3 . Ring binder mechanisms mounted on surfaces other than a notebook, for example, a file, do not depart from the scope of this invention.
[0035] As shown in FIG. 1 , a housing, designated generally at 11 , supports three rings (each designated generally at 13 ) and a lever (broadly, “actuator,” and designated generally at 15 ). The rings 13 retain loose-leaf pages on the ring mechanism 1 in the notebook 3 while the lever 15 operates to open and close the rings so that pages may be added or removed. Referring now also to FIG. 2 , the housing 11 is shaped as an elongated rectangle with a uniform, roughly arch-shaped cross section, having at its center a generally flat plateau 17 . A first longitudinal end of the housing 11 (to the left in FIG. 1 and to the right in FIG. 2 ) is generally open while a second, opposite longitudinal end is generally closed. A pair of mounting arms, each designated 19 ( FIGS. 2 and 4 ), extend downward from the housing plateau 17 at the open end, while bent under rims, each designated at 21 ( FIGS. 2 and 5 ), extend lengthwise along longitudinal edges of the housing 11 from the first longitudinal end of the housing to the second longitudinal end. Mechanisms having housings of other shapes, including irregular shapes, or housings that are integral with a file or notebook do not depart from the scope of this invention.
[0036] The three rings 13 of the ring binder mechanism 1 are substantially similar and are each generally circular in shape ( FIGS. 1, 4 , and 5 ). As shown in FIGS. 1 and 2 , the rings 13 each include two generally semi-circular ring members 23 a , 23 b formed from a conventional, cylindrical rod of a suitable material (e.g., steel). The ring members 23 a , 23 b include free ends 25 a , 25 b , respectively, formed to secure the ring members against transverse misalignment (relative to longitudinal axes of the ring members) when they are together (e.g., FIGS. 1, 4 , and 5 ). The rings 13 could be D-shaped as is known in the art within the scope of this invention. Ring binder mechanisms with ring members formed of different material or having different cross-sectional shapes, for example, oval shapes, do not depart from the scope of this invention.
[0037] As also shown in FIG. 2 , the ring mechanism 1 includes two substantially identical hinge plates, designated generally at 27 a , 27 b , supporting the ring members 23 a , 23 b . respectively. The hinge plates 27 a , 27 b are each generally elongate, flat, and rectangular in shape and are each somewhat shorter in length than the housing 11 . Four corresponding cutouts 29 a - d are formed in each of the hinge plates 27 a , 27 b along an inner edge margin of the plate. A bent down finger 31 extends longitudinally away from a first end of each of the hinge plates 27 a , 27 b (to the right in FIG. 2 ). The fingers 31 are each narrower in width than the respective hinge plates 27 a , 27 b and are positioned with their inner longitudinal edges generally aligned with the inner longitudinal edges of the plates. The purpose of the cutouts 29 a - d and fingers 31 will be described hereinafter.
[0038] Referring to FIGS. 2 and 3 , the lever 15 includes a grip 33 with an inverted “L” shape, a body 35 (“first portion”) attached to the grip, and a tongue 37 (“second portion”) attached to the body. The grip 33 is somewhat broader than both the body 35 and the tongue 37 ( FIG. 2 ) and facilitates grasping the lever 15 and applying force to move the lever. In the illustrated ring mechanism 1 , the body 35 is formed as one piece with the grip 33 for substantially conjoint movement with the grip. The body 35 may be formed separate from the grip 33 and attached thereto without departing from the scope of the invention.
[0039] As shown in FIG. 3 , the tongue 37 of the lever 15 is attached to the body 35 by a flexible bridge 39 (or “living hinge”) formed as one piece with the body and tongue. A mechanism having a lever in which a bridge is formed separate from a body and/or tongue for connecting the body and tongue does not depart from the scope of the invention. The bridge 39 is generally arch-shaped and defines an open channel 41 between the tongue 37 and body 35 . The tongue 37 extends away from the body 35 at the bridge 39 and channel 41 in general parallel alignment with an upper lip 35 a of the body and defines a C-shaped space between the body and tongue (above the bridge). It is envisioned that the lever 15 is formed from a resilient plastic material by, for example, a mold process. But the lever 15 may be formed from other materials or other processes within the scope of this invention. A ring mechanism having a lever shaped differently than illustrated and described herein does not depart from the scope of the invention.
[0040] As also shown in FIG. 3 , the lever 15 includes a pivot bulb 43 located toward an end of the tongue 37 opposite the bridge 39 . The bulb 43 may be separate from the tongue 37 and releasably attached thereto by a tab (not shown) inserted through an opening (not shown) in the tongue. As another example, the bulb 43 may be formed as one piece with the tongue 37 within the scope of this invention.
[0041] Referring again to FIG. 2 , the ring mechanism 1 includes an elongated, generally flat, rectangular travel bar designated generally at 45 . The travel bar includes a rectangular mounting groove 47 at a first end (to the right in FIG. 2 ) and three block-shaped locking elements (each designated generally at 49 ) along a bottom surface. The locking elements 49 are spaced apart longitudinally along the travel bar 45 with one locking element adjacent each longitudinal end of the travel bar, and one located toward a center of the travel bar. The travel bar 45 may have other shapes or greater or fewer than three locking elements 49 within the scope of this invention. The travel bar 45 could be formed without locking elements and instead carry wedges, for example, that move the hinge plates 27 a , 27 b.
[0042] The locking elements 49 of the illustrated travel bar 45 are each substantially similar in shape. As best shown in FIGS. 7, 10 , 12 , and 13 , each locking element 49 includes a narrow, flat bottom 53 and generally vertical sides 55 a - d. The side 55 a facing away from the lever 15 is angled and the lateral sides 55 b , 55 d are converging toward their bottoms to form the narrow, flat bottom 53 . In the illustrated embodiment, the locking elements 49 are formed as one piece of material with the travel bar 45 by, for example, a mold process. But the locking elements 49 may be formed separately from the travel bar 45 and attached thereto without departing from the scope of the invention. Additionally, locking elements with different shapes, for example, block shapes (e.g., no angled sides or converging sides), are within the scope of this invention.
[0043] The ring binder mechanism 1 in assembled form will now be described with reference to FIGS. 4-7 in which the mechanism is illustrated with the ring members 23 a , 23 b in the closed position and the lever 15 in an upright position. The lever 15 pivotally mounts on the first, open end of the housing 11 at the mounting arms 19 of the housing ( FIGS. 4-6 ). A mounting opening 57 ( FIG. 2 ) in each mounting arm 19 aligns with the channel 41 of the lever 15 . A hinge pin 59 passes through the aligned openings 57 and channel 41 to pivotally mount the lever on the housing 11 . It is envisioned that the mounting arms 19 are one piece with the housing 11 , but they may be formed separately from the housing and attached thereto without departing from the scope of the invention.
[0044] As shown in FIG. 6 , the travel bar 45 is disposed within the housing 11 behind the housing's plateau 17 . It extends lengthwise of the housing 11 , in generally parallel orientation with a longitudinal axis LA ( FIG. 2 ) of the housing, with the locking elements 49 extending away from the housing. Two elongate openings, each designated 61 (only one is shown in FIG. 6 ; see also, FIG. 2 ), through the travel bar 45 align with two rivet openings, each designated 63 (only one is shown in FIG. 6 ; see also, FIG. 2 ) of the housing plateau 17 . Grooved rivets, each designated 65 (only one is shown in FIG. 6 ; see also, FIG. 2 ), secure to the housing 11 at the rivet openings 63 and extend through the respective elongate openings 61 of the travel bar 45 to vertically support the travel bar within the housing. The travel bar 45 fits within the grooves of the rivets 65 , allowing it to slide in translation lengthwise of the housing 11 relative to the rivets.
[0045] Referring to FIGS. 6 and 7 , the travel bar 45 is operatively connected to the lever 15 by an intermediate connector, designated generally at 67 . In the illustrated embodiment, the intermediate connector 67 is a wire bent into an elongate, roughly rectangular form ( FIG. 2 ). The intermediate connector 67 may have other shapes or be formed from other material within the scope of this invention. A first end of the intermediate connector 67 is open and includes two free ends 69 a , 69 b ( FIG. 2 ) that fit within openings 71 a , 71 b ( FIG. 3 , only opening 71 b is visible) in the body 35 of the lever 15 to form a pivoting connection. A second, closed end of the intermediate connector 67 is narrowed and includes a bent end 73 ( FIG. 2 ) that fits within the mounting groove 47 of the travel bar 45 . The bent end 73 secures the intermediate connector 67 to the travel bar 45 at mounting groove 47 to either push against the travel bar or pull on the travel bar. The bent end 73 allows the intermediate connector 67 to pivot relative to the travel bar 45 to accommodate small vertical movements of the intermediate connector that occur when the lever 15 pivots. A ring binder mechanism lacking an intermediate connector (e.g., in which a travel bar is pivotally connected directly to a lever) does not depart from the scope of this invention.
[0046] As shown in FIGS. 5 and 6 , the hinge plates 27 a , 27 b are interconnected in parallel arrangement along their inner longitudinal edge margins, forming a central hinge 75 having a pivot axis. This is done in a conventional manner known in the art. As will be described, the hinge plates 27 a , 27 b can pivot about the hinge 75 upward and downward. The four cutouts 29 a - d in each of the two individual hinge plates 27 a , 27 b ( FIG. 2 ) align to form four openings also designated 29 a - d in the interconnected plates ( FIG. 5 ). The housing 11 supports the interconnected hinge plates 27 a , 27 b within the housing below the travel bar 45 . The outer longitudinal edge margins of the hinge plates 27 a , 27 b loosely fit behind the bent under rims 21 of the housing 11 for allowing them to move within the rims when the hinge plates pivot. As shown in FIG. 7 , the fingers 31 of the hinge plates 27 a , 27 b (only one hinge plate 27 a is shown) extend into the C-shaped space of the lever 15 between the tongue 37 and the upper lip 35 a of the body 35 so that lower surfaces of the hinge plates engage the lever bulb 43 .
[0047] The ring members 23 a , 23 b are each mounted on upper surfaces of respective ones of the hinge plates 27 a , 27 b in generally opposed fashion, with the free ends 25 a , 25 b facing (see also, FIG. 2 ). The ring members 23 a , 23 b extend through respective openings, each designated 77 , along sides of the housing 11 so that the free ends 25 a , 25 b of the ring members can engage above the housing (e.g., FIG. 4 ). The ring members 23 a , 23 b are rigidly connected to the hinge plates 27 a , 27 b as is known in the art and move with the hinge plates when they pivot. Although in the illustrated ring binder mechanism 1 both ring members 23 a , 23 b of each ring 13 are each mounted on one of the two hinge plates 27 a , 27 b and move with the pivoting movement of the hinge plates, a mechanism in which each ring has one movable ring member and one fixed ring member does not depart from the scope of this invention (e.g., a mechanism in which only one of the ring members of each ring is mounted on a hinge plate with the other ring member mounted, for example, on a housing).
[0048] As shown in FIG. 5 , two mounting posts 79 a , 79 b (see also, FIG. 2 ) are secured to the illustrated ring mechanism 1 to mount the mechanism on, for example, a notebook 3 (e.g., FIG. 1 ) in any suitable manner. The posts 79 a , 79 b attach to the housing 11 at mounting post openings 81 a , 81 b ( FIG. 2 ) of the plateau 17 located toward the longitudinal ends of the housing. A first mounting post 79 a (toward the left in FIG. 5 ) extends through the intermediate connector 67 and through mounting post opening 29 d of the interconnected hinge plates 27 a , 27 b.
[0049] Operation of the ring mechanism 1 will be described with reference to FIGS. 4-13 . As is known, the hinge plates 27 a , 27 b pivot downward and upward relative to the housing 11 and move the ring members 23 a , 23 b mounted thereon between a closed position (FIGS. 1 , 4 - 10 ) and an open position ( FIGS. 11-13 ). The hinge plates 27 a , 27 b are wider than the housing 11 when in a co-planar position (180°), so as they pivot through the co-planar position, they deform the housing and create a small spring force in the housing. The housing spring force biases the hinge plates 27 a , 27 b to pivot away from the co-planar position, either downward or upward. The ring members 23 a , 23 b close when the hinge plates 27 a , 27 b pivot downward (i.e., the hinge 75 moves away from the housing 11 (e.g., FIG. 5 )). The ring members 23 a , 23 b open when the hinge plates 27 a , 27 b pivot upward (i.e., the hinge 75 moves toward the housing 11 (e.g., FIG. 12 )).
[0050] In FIGS. 4-7 , the ring mechanism 1 is in a closed and locked position. The hinge plates 27 a , 27 b are hinged downward, away from housing 11 , so that the ring members 23 a , 23 b of each ring 13 are together in a continuous, circular loop, capable of retaining loose-leaf pages. The lever 15 is vertical relative to the housing 11 and in a first relaxed position (the lever is shown in this position in FIG. 3 also) with the lever bulb 43 engaging the lower surfaces of the hinge plates 27 a , 27 b . The locking elements 49 of the travel bar 45 are above the hinge plates 27 a , 27 b generally aligned with the hinge 75 with their narrow, flat bottoms 53 contacting the upper surfaces of the hinge plates. As shown in FIG. 5 , the locking elements 49 are adjacent respective locking element openings 29 a - c , but are substantially out of registration with the openings. Together, the travel bar 45 (vertically supported by the grooved rivets 65 ) and locking elements 49 oppose any force tending to pivot the hinge plates 27 a , 27 b upward to open the ring members 23 a , 23 b (i.e., they lock the ring members closed).
[0051] To unlock the ring mechanism 1 and open the ring members 23 a , 23 b , an operator applies force to the grip 33 of the lever 15 and pivots it counter-clockwise (as viewed in FIGS. 4, 6 , and 7 ). As shown in FIGS. 8-10 , the grip 33 and body 35 of the lever 15 move relative to the tongue 37 , which is held stationery by the hinge plates 27 a , 27 b under the spring force of the housing 11 . The intermediate connector 67 simultaneously moves with the body 35 and transfers the pivoting movement of the lever 15 around the mounting post 79 a to the travel bar 45 . The travel bar slides toward the lever 15 and moves the locking elements 49 into registration with the respective locking element openings 29 a - c of the hinge plates 27 a , 27 b . The bridge 39 between the lever body 35 and lever tongue 37 flexes and tensions as the open channel 41 closes and the body moves into engagement with the tongue ( FIG. 10 ). If the lever 15 is released before the hinge plates 27 a , 27 b pivot upward through their co-planar position (i.e., before the ring members 23 a , 23 b open), the tension in the bridge 39 will automatically recoil (and push) the grip 33 and body 35 back to the vertical position, moving the travel bar 45 and locking elements 49 to the locked position.
[0052] The lever channel 41 , now closed, no longer shields the tongue 37 from the pivoting movement of the grip 33 and body 35 . Continued opening movement of the lever 15 causes the body 35 to conjointly pivot the tongue 37 . The lever bulb 43 causes the interconnected hinge plates 27 a , 27 b to pivot upward over the locking elements 49 at the locking element openings 29 a - c and relative to the mounting post 79 a at the mounting post opening 29 d . Once the hinge plates 27 a , 27 b pass just through the co-planar position, the housing spring force pushes them upward, opening the ring members 23 a , 23 b ( FIGS. 11-13 ). The lever 15 can be released. The tension in the bridge 39 recoils (and pushes) the grip 33 and body 35 away from the tongue 37 , which is held stationary against the hinge plates 27 a , 27 b via the lever bulb 43 engaging the lower surfaces of the hinge plates. The channel 41 opens and the travel bar 45 moves slightly away from the lever 15 . The lever is again relaxed, in a second relaxed position substantially identical to the first relaxed position (e.g., FIG. 3 ), and the locking elements 49 are at rest within the respective hinge plate openings 29 a - c free of any forces tending to move them relative to the housing 11 .
[0053] To close the ring members 23 a , 23 b and return the mechanism 1 to the locked position, an operator manually pushes the free ends 25 a , 25 b of the ring members together. The hinge plates 27 a , 27 b pivot downward, and rotate the lever tongue 37 clockwise (as viewed in FIGS. 11 and 13 ). The tongue 37 initially moves the grip 33 and body 35 to seat the locking elements 49 against tangs 83 at the edges of the locking element openings 29 a - c of the hinge plates 27 a , 27 b (the tangs are ramped to assist the locking elements 49 in moving out of the openings). The tongue 37 then moves relative to the grip 33 and body 35 , which are held stationary by the locking elements 49 against tangs 83 ( FIG. 13 ). The lever channel 41 closes (and the lever bridge 39 flexes) allowing the hinge plates 27 a , 27 b to pivot to and through the co-planar position and past the narrow bottoms 53 of the locking elements 49 . The angled sides 55 a of the locking elements 49 allow the locking elements to move incrementally away from the lever 15 and out of the respective opening 29 a - c as the hinge plates 27 a , 27 b move down. This allows the lever 15 to pivot slightly with the tongue 37 as the tongue channel 41 closes. The angled sides of the locking elements are not necessary for operation though.
[0054] Once the hinge plates 27 a , 27 b clear the bottoms 53 of the locking elements 49 , the tongue 37 pushes the body 35 and grip 33 to the vertical position and the travel bar 45 and locking elements move to the locked position. The ring members 23 a , 23 b of the ring mechanism 1 could be closed by a modified lever capable of engaging the hinge plates 27 a , 27 b and pivoting them downward within the scope of the invention.
[0055] It should now be apparent that the flexibility of the lever bridge 39 allows the grip 33 and body 35 of the lever 15 to move relative to the tongue 37 . This moves the lever 15 between the relaxed position ( FIGS. 3-7 and 11 - 13 ) and a deformed (broadly, “reconfigured”) position ( FIGS. 8-10 ). The deformed position of the lever 15 is an unstable, intermediate position in which the bridge 39 is tensioned to always move the grip 33 , body 35 , and tongue 37 to the relaxed position (i.e., reconfigure the lever).
[0056] When the lever 15 pivots to open the ring members 23 a , 23 b , the travel bar 45 and locking elements 49 move immediately and prior to the tongue 37 and bulb 43 pivoting the hinge plates 27 a , 27 b upward. This lost motion caused by the open channel 41 allows the locking elements 49 to move into registration with the locking element openings 29 a - c of the hinge plates 27 a , 27 b before the hinge plates pivot. They do not interfere with the desirable pivoting movement of the hinge plates 27 a , 27 b . After the locking elements 49 move into registration with the respective openings 29 a - c, the channel 41 closes and the grip 33 , body 35 , and tongue 37 conjointly pivot to move the hinge plates 27 a , 27 b upward.
[0057] In addition when the ring members 23 a , 23 b are open and the lever 15 is relaxed, the locking elements 49 and travel bar 45 are free of forces tending to move them to the locked position. Thus, there is no tendency for the open ring members 23 a , 23 b to inadvertently close under the influence of the lever 15 , locking elements 49 , or travel bar 45 as an operator loads or removes pages from the ring members 23 a , 23 b.
[0058] Similarly when the ring members 23 a , 23 b are moved to the closed position, the lever channel 41 allows the hinge plates 27 a , 27 b to pivot downward over the locking elements 49 before the grip 33 and body 35 of the lever 15 push the travel bar 45 and locking elements 49 to the locked position. Here, the lost motion caused by the open channel 41 maintains a continuous engagement between the lever tongue 37 and the hinge plates 27 a , 27 b (via the lever bulb 43 ) without risk of the mechanism jamming in the open position (e.g., as may occur if the lever tongue is unable to move downward with the hinge plates because the locking elements 49 wedge against edges of the locking element openings 29 a - c of the hinge plates, holding the hinge plates from further pivoting downward). The continuous engagement between the lever tongue 37 and the lower surfaces of the hinge plates 27 a , 27 b (via lever bulb 43 ) ensures that the body 35 and grip 33 of the lever 15 move fully to their vertical position when the hinge plates 27 a , 27 b are pivoted downward (and the ring members 23 a , 23 b are closed), moving the travel bar 45 and locking elements 49 fully to the locked position.
[0059] Thus, the ring binder mechanism 1 effectively retains loose-leaf pages when ring members 23 a , 23 b are closed, and readily prevents the closed ring members 23 a , 23 b from unintentionally opening. The lever 15 positions the travel bar 45 and its locking elements 49 in the locked position when the ring members 23 a , 23 b close, eliminating the need to manually move the lever 15 to positively lock the mechanism 1 . The ring mechanism 1 incorporating the locking lever 15 requires no additional biasing components (e.g., springs) to perform the locking operation, and requires no specially formed parts to accommodate such biasing components.
[0060] FIGS. 14-16 show a second embodiment of the ring binder mechanism generally at 101 . The ring mechanism 101 is substantially the same as the ring mechanism 1 of the first embodiment previously described and illustrated in FIGS. 1-13 , and parts of this ring mechanism 101 corresponding to parts of the prior ring mechanism 1 are designated by the same reference numerals, plus “100”. In this ring mechanism 101 , however, the lever 115 has a low profile in that it includes a substantially flat grip 133 . The lever 115 mounts on the housing 111 ( FIGS. 14 and 16 ) as previously described for the ring mechanism 1 of FIGS. 1 - 13 , and the flat grip 133 is positioned in general alignment (i.e., is generally co-planar) with the plateau 117 of the housing. In all other aspects, including operation, the ring mechanism 101 is the same as the ring mechanism 1 of FIGS. 1-13 .
[0061] FIGS. 17-21 show a third embodiment of the ring binder mechanism generally at 201 . Parts of this ring mechanism corresponding to parts of the ring mechanism 1 of the first embodiment of FIGS. 1-13 are designated by the same reference numerals, plus “200”. This mechanism 201 is substantially the same as the ring mechanism 1 of FIGS. 1-13 , with the exception that the lever 215 is formed without a bridge and without a channel between the body 235 and the tongue 237 . Other components of the ring mechanism 201 , as well as assembly of the components, are substantially the same as those of the mechanism 1 of FIGS. 1-13 .
[0062] Operation of the ring mechanism 201 will be described with reference to the enlarged fragmentary views of FIGS. 19-21 . In FIG. 19 , the ring mechanism 201 is in the closed and locked position (similar to the closed position of the ring mechanism 1 of FIGS. 1-13 ). To unlock the ring mechanism 201 and open the ring members 223 a , 223 b , an operator pivots the lever 215 outward and downward (counter-clockwise as viewed in FIG. 19 ). The lever body 235 pulls the travel bar 245 and locking elements 249 toward the lever 215 , while the lever bulb 243 simultaneously pushes upward on the hinge plates 227 a , 227 b (only one hinge plate 227 a is shown). But the locking elements 249 , still behind the hinge plates 227 a , 227 b , block their upward movement. So as the lever 215 continues to pivot, the lever bulb 243 flexes (and tensions) the hinge plates 227 a , 227 b adjacent the fingers 231 ( FIG. 20 ). Once the locking elements 249 (only one is shown) move into registration with the locking element openings 229 a - c (only opening 229 c is shown) of the hinge plates 227 a , 227 b , the tensioned hinge plates immediately pivot upward, through the co-planar position ( FIG. 21 ) to open the ring members 223 a , 223 b (the ring members are not shown). If the lever 215 is released before the hinge plates 227 a , 227 b pivot through the co-planar position, the tensioned hinge plates will push down on the lever bulb 243 and pivot the lever 215 back to the vertical position, moving the travel bar 245 and locking elements 249 to the locked position. The tension in the hinge plates 227 a , 227 b dissipates and the lever 215 can be released. The bulb 243 of the tongue 237 remains in engagement with the lower surfaces of the hinge plates 227 a , 227 b , and the spring force of the housing 211 holds the hinge plates hinged upward. The locking elements 249 are at rest within the respective hinge plate cutout openings 229 a - c free of any forces tending to move them to the locked position.
[0063] As in the ring mechanism 1 of FIGS. 1-13 , to close the ring members 223 a , 223 b of this mechanism 201 and return the mechanism to the locked position ( FIG. 19 ), an operator manually pushes the free ends 225 a , 225 b of the ring members together. In this ring mechanism 201 , the hinge plates 227 a , 227 b pivot downward and cause the lever bulb 243 and tongue 237 to rotate clockwise (as viewed in FIG. 21 ). The tongue 237 pushes the grip 233 and body 235 to seat the locking elements 249 against the tangs 281 at the edges of the locking element openings 229 a - c of the hinge plates 227 a , 227 b (this engagement is not necessary for operation). The locking elements 249 instantaneously resist movement of the lever 215 , and thus downward movement of the hinge plates 227 a , 227 b , causing the hinge plates 227 a , 227 b to slightly flex adjacent their fingers 231 . The hinge plates 227 a , 227 b bend down while the lever 215 and finger 231 remain relatively stationary. The angled sides 255 a of the locking elements 249 allow the locking elements to move small amounts away from the lever 215 as the hinge plates 227 a , 227 b bend, allowing the lever to pivot slightly. Once the hinge plates 227 a , 227 b clear the narrow bottoms 253 of the locking elements 249 , the tension in the flexed hinge plates immediately pivots the lever 215 to its vertical position, pushing the travel bar 245 and locking elements 249 to the locked position.
[0064] In this ring mechanism 201 , the unique cooperation between the lever 215 , the hinge plates 227 a , 227 b , and the locking elements 249 allows the mechanism to operate between the closed and locked position and the open position. When opening the ring members 223 a , 223 b , the hinge plates 227 a , 227 b briefly flex upward to allow the lever 215 to pivot to move the locking elements 249 into registration with the locking element openings 229 a - c of the hinge plates. The lever 215 , together with the tension from the flexed hinge plates 227 a , 227 b and the spring force of the housing 211 , then pivot the hinge plates over the locking elements 249 to open the ring members 223 a , 223 b . When closing the ring members 223 a , 223 b , the hinge plates 227 a , 227 b again flex to allow the plates to pivot downward over the locking elements 249 (the angled sides 255 a of the locking elements 249 also aid in this operation, but are not necessary for this operation).
[0065] Components of ring binder mechanisms of the embodiments described and illustrated herein are made of a suitable rigid material, such as a metal (e.g. steel). But mechanisms having components made of a nonmetallic material, specifically including a plastic, do not depart from the scope of this invention.
[0066] When introducing elements of the ring binder mechanisms herein, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Moreover, the use of “up” and “down” and variations of these terms is made for convenience, but does not require any particular orientation of the components.
[0067] As various changes could be made in the above without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A ring mechanism for retaining loose-leaf pages comprises a housing and ring members for holding loose-leaf pages that are moveable relative to the housing between an open and closed position. An actuation system moves the ring members and includes hinge plates pivotally mounted on the housing and a lever actuating pivoting movement of the hinge plates in at least one direction (e.g., moving the hinge plates and ring members to the open position). The lever is connected to a travel bar that moves lengthwise of the housing between a position blocking pivoting movement of the hinge plates and a position allowing pivoting movement of the hinge plates. At least one of the lever and the hinge plates deforms when the lever moves to delay pivoting movement of the hinge plates so that the lever may move the travel bar so that it does not block movement of the hinge plates. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/331,671, entitled “Method and Apparatus for Printing Radiopaque Indicia” and filed May 5, 2010, the contents of which application are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a method and apparatus for printing radiopaque indicia on a medical device and, more specifically, to a method and apparatus for printing radiopaque marking fluid onto a venous access port.
BACKGROUND
[0003] Venous access ports for the infusion and/or withdrawal of fluids from a patient are known in the art. Such ports generally comprise a needle-penetrable septum, a cap, and a port housing comprising a fluid reservoir. The needle-penetrable septum is disposed on the port housing to seal the fluid reservoir. The cap secures the septum to the port housing. Such ports additionally include a discharge port comprising a fluid passageway that communicates with the fluid reservoir and a catheter secured to the discharge port.
[0004] It is desired to provide a venous access port assembly that provides a medical practitioner with capability to discern an important property of the port assembly after the port assembly has been implanted into a patient.
SUMMARY OF THE INVENTION
[0005] In accordance with an exemplary aspect of the present invention, there is provided a method of printing radiopaque indicia on a medical device. The method includes applying radiopaque marking fluid to a surface of a plate comprising one or more etchings having a depth of at least 0.0001 inches, exposing the radiopaque marking fluid on the surface of the plate to air to allow the radiopaque marking fluid to achieve a sufficient level of tackiness, and transferring the radiopaque marking fluid to a medical device. The radiopaque marking fluid comprises a clear ink and tungsten particulates having a particulate size of more than one micron.
[0006] In accordance with a further exemplary aspect of the present invention, there is provided a printing apparatus for printing radiopaque indicia on a medical device. The printing apparatus includes a plate comprising one or more etchings having a depth of at least 0.0001 inches, a cup containing a radiopaque marking fluid, a jig for holding a medical device, and a pad for transferring radiopaque marking fluid deposited within the one or more etchings to the medical device. The radiopaque marking fluid comprises a clear ink and tungsten particulates having a particulate size of more than one micron. The cup is configured to be inverted and pressed against the plate to effect a fluid seal of the radiopaque marking fluid against the plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For the purpose of illustration, there are shown in the drawings certain exemplary embodiments of the present invention. In the drawings, like numerals indicate like elements throughout. It should be understood, however, that the invention is not limited to the precise arrangements, dimensions, and instruments shown. In the drawings are included the following figures:
[0008] FIG. 1A illustrates an exemplary printing apparatus comprising a cup, a plate, and a pad, wherein the printing apparatus in an idle state (first position) in which the cup is disposed over etchings in the plate, in accordance with an exemplary embodiment of the present invention;
[0009] FIG. 1B illustrates the exemplary printing apparatus in a second position in which the cup has been translated off the etchings in the plate, in accordance with an exemplary embodiment of the present invention;
[0010] FIG. 2 illustrates the plate of the exemplary printing apparatus, in accordance with an exemplary embodiment of the present invention;
[0011] FIG. 3 illustrates the cup of the exemplary printing apparatus, in accordance with an exemplary embodiment of the present invention;
[0012] FIG. 4 illustrates an exemplary venous access port assembly, in accordance with an exemplary embodiment of the present invention;
[0013] FIG. 5A is a planar view of the bottom of an exemplary venous access port assembly onto which radiopaque indicia have been printed using the exemplary printing apparatus illustrated in FIG. 1 , in accordance with an exemplary embodiment of the present invention; and
[0014] FIG. 5B is an isometric view of the exemplary venous access port assembly of FIG. 5A , in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0015] Referring now to FIG. 1A , there is illustrated an exemplary printing apparatus, generally designated as 100 , in accordance with an exemplary embodiment of the present invention. The printing apparatus 100 comprises a bed 110 for supporting a plate 200 and a bed 130 for supporting a jig 140 that holds a medical device (not illustrated in FIG. 1A ) onto which the exemplary printing apparatus 100 prints indicia.
[0016] Mounted onto the bed 110 is a metal plate 115 onto which the plate 200 is secured. In an exemplary embodiment, the metal plate 115 is pinned to the bed 110 , and the plate 200 is held in place with dowel pins on the metal plate 115 .
[0017] The jig 140 includes bolt holes 143 and 144 through which bolts secure the jig 140 to the bed 130 . The jig 140 also includes recess 141 and 142 into which medical devices are disposed. The recesses 141 and 142 hold the medical devices in place while the printing apparatus 100 prints indicia onto the medical devices. In an exemplary embodiment, a venous access port assembly is disposed into each of the recesses 141 and 142 , with a bottom surface of each access port assembly facing upwards away from the top face of the jig 140 .
[0018] The printing apparatus 100 additionally comprises a cup 300 attached to an arm 120 . Attached to the bottom of the cup 300 is a ring 350 . The cup 300 contains ink that is applied to a top surface 210 of the plate 200 . The printing apparatus 100 also comprises a pad 150 for transferring the ink on the top surface 210 of the plate 200 to the medical devices in the jig 140 .
[0019] FIG. 1A illustrates an idle state of the printing apparatus 100 in which the cup 300 is in a first position atop the plate 200 . Referring now to FIG. 1B , there is illustrated a second position of the cup 300 , in accordance with an exemplary embodiment of the present invention. As is illustrated in FIG. 1B , in the second position, the cup 300 is disposed at an end of the plate 200 away from the jig 140 . In the second position of the cup 300 , etchings 220 and 230 on the top surface 210 of the plate 200 are exposed.
[0020] Referring now to FIG. 2 , there is illustrated a closer view of the top surface 210 of the plate 200 , in accordance with an exemplary embodiment of the present invention. As can be seen in FIG. 2 , the etchings 220 and 230 in the top surface 210 of the plate 200 comprise the letters “CT.” The exemplary plate 200 is used to print “CT” onto the medical devices, e.g., venous access port assemblies, held by the jig 140 .
[0021] In an exemplary embodiment, the exemplary printing apparatus 100 prints a radiopaque marking fluid onto the medical devices held in the jig 140 . An exemplary radiopaque marking fluid comprises a mixture of a clear ink and tungsten particulates in a defined ratio. Generally, the ratio depends upon the substrate, i.e., the material of the medical devices in the jig 140 , on which the radiopaque marking fluid is to be applied. Thus, the ratio depends on the substrate material, the durometer of the substrate, the chemical makeup (compound) of the substrate or the material (substrate) receiving the indicia, and/or processing of the material receiving the indicia. In an exemplary embodiment, the ratio of the mixture is suitable for application to a polysulfone substrate, such as a venous access port assembly formed from polysulfone. Flexible substrates use a radiopaque marking fluid having a clear ink/tungsten ratio that results in the indicia printed onto the medical devices being flexible also to prevent cracking Stiff substrates allow a clear ink/tungsten ratio that results in stiff indicia printed onto the medical device.
[0022] Each of the etchings 220 and 230 have respective depths to accommodate ink applied by the cup 300 . In the embodiment in which the exemplary printing apparatus 100 applies radiopaque marking fluid to a medical device, the depths of the etchings 220 and 230 may be between 0.0001 inch (0.000254 cm) and 0.003 inch (0.00762 cm). The depths depend upon the size of the tungsten particulates in the radiopaque marking fluid. Generally speaking, the depths of the etchings 220 and 230 must be increased to accommodate larger tungsten particulates in the radiopaque marking fluid.
[0023] Radiopacity of the radiopaque marking fluid varies inversely with the size of the tungsten particulates in the radiopaque marking fluid. Smaller particulates have a lower radiopacity than larger particulates. Thus, when using a radiopaque marking fluid having relatively smaller tungsten particulates, the exemplary printing apparatus 100 desirably performs more hits (applications of radiopaque marking fluid) on the subject medical device to transfer the shape or letters defined by the etchings 220 and 230 onto the medical device, as compared to a lower number of hits required for a radiopaque marking fluid having relatively larger tungsten particulates. Desirable sizes of the tungsten particulates are on the order of one to several microns. In an exemplary embodiment, the size of the tungsten particulates is from one to five microns.
[0024] To ensure proper adhesion of the radiopaque marking fluid to the medical devices within the recesses 141 and 142 , the medical devices should be cleaned using a suitable cleaning means. Examples of suitable cleaning means include plasma, solvent, aqueous, etc. The cleaning means are not limited to any one technology.
[0025] Other specifications of the printing apparatus 100 include the material forming the pad 150 , the time for which the radiopaque marking fluid applied in the etchings 220 and 230 are exposed to air before being transferred by the pad 150 to the medical devices, and flash-off time for the radiopaque marking fluid. The firmness of the pad 150 is selected in order to facilitate the transfer of as much radiopaque marking fluid within the etchings 220 and 230 to the medical devices that will adhere to the devices. In a further exemplary embodiment of the printing apparatus 100 , the pad 150 is formed from silicone.
[0026] The flash-off time of the radiopaque marking fluid is selected so that the radiopaque marking fluid achieves a desired level of tackiness while it is exposed to air before being transferred to the medical devices. Such exposure to air may include blowing chilled air, heated air, or air at room temperature onto the radiopaque marking fluid within the etchings 220 and 230 . The temperature and humidity of the air applied to the radiopaque marking fluid within the etchings 220 and 230 is selected to achieve the desired level of tackiness of the radiopaque marking fluid before being transferred to the medical devices.
[0027] Referring now to FIG. 3 , there is illustrated a view of the underside of the cup 300 and the ring 350 , in accordance with an exemplary embodiment of the present invention. The cup 300 comprises an outer rim 305 and an inner riser 310 . Together, the outer rim 305 and inner riser 310 define an interior cavity 330 which contains the ink or radiopaque marking fluid used in the printing process. The ring 350 is secured to the rim 305 of the cup 300 . The ring 350 performs several duties. It seals the ink within the cup 300 , specifically within the interior cavity 330 of the cup 300 , when the cup 300 is disposed on the plate 200 . Further, it acts as a squeegee to wipe ink off the top surface 210 of the plate 200 during the printing process.
[0028] Disposed on the riser 310 is a plurality of magnets 320 . The magnets 320 are attracted to the plate 200 to allow the ring 350 to perform its sealing and wiping functions. Because the magnets 320 are attracted to the plate 200 , the cup 300 compresses the ring 350 against the plate 200 and presses the plate 200 against the metal plate 115 .
[0029] An exemplary method of printing radiopaque marking fluid onto a bottom surface of venous access port assemblies is now described with reference to FIGS. 1A , 1 B, 2 , and 3 . A technician places venous access port assemblies into the recesses 141 and 142 of the jig 140 and attaches the plate 200 to the metal plate 115 . The technician fills the cavity 330 of the cup with a radiopaque marking fluid that will be applied to the venous access port assemblies within the recesses 141 and 142 and subsequent venous access port assemblies that will be placed within the recesses 141 and 142 in subsequent printing operations. The technician then places the printing apparatus 100 in the idle state in which the cup 300 is disposed on the top surface 210 of the plate 200 over the etchings 220 and 230 .
[0030] In the idle state, the radiopaque marking fluid within the cup 300 covers and fills the etchings 220 and 230 and covers the portion of the top surface 210 over which the cup 300 is disposed. The technician then commands the printing apparatus 100 to transfer the radiopaque marking fluid from the etchings 220 and 230 to the medical devices, i.e., to perform a “hit.” The printing apparatus 100 translates the cup 300 away from the etchings 220 and 230 . In the process of such translation, the ring 350 secured to the bottom of the cup 300 acts as a squeegee to wipe any radiopaque marking fluid on the top surface 210 of the plate 200 outside of the etchings 220 and 230 . The cup 300 moves to the second position, and radiopaque marking fluid remains within the etchings 220 and 230 .
[0031] The radiopaque marking fluid within the etchings 220 and 230 is then exposed to air to achieve a desired tackiness. Such air may be at room temperature or heated or chilled. When the radiopaque marking fluid achieves the desired level of tackiness, the pad 150 hits the etchings 220 and 230 and picks up some or all of the radiopaque marking fluid within the etchings 220 and 230 . The pad 150 then hits the medical devices within the recesses 141 and 142 to transfer the radiopaque marking fluid to the medical devices. The printing apparatus 100 returns to its idle state.
[0032] The printing apparatus 100 repeats the process described above to perform additional hits on the medical devices to layer the radiopaque marking fluid on the medical devices to achieve a desired level of radiopacity of the printed indicia. When the desired level of radiopacity is achieved, the medical devices are removed from the jig, and new medical devices are inserted to be printed using the process described above. The deposited radiopaque marking fluid may be allowed to air dry, or the printed medical devices may be placed into an oven to speed the drying process.
[0033] Referring now to FIG. 4 , there is illustrated an exemplary embodiment of a venous access port assembly, generally designated as 400 , in accordance with an exemplary embodiment of the present invention. The venous access port assembly 400 comprises a septum 410 and a housing 420 that includes an interior fluid reservoir (not illustrated). The septum 410 is disposed on the port housing 420 to seal the interior fluid reservoir.
[0034] The venous access port assembly 400 additionally comprises a discharge port 430 extending from a distal end 440 of the port assembly 400 . The discharge port 430 is attached securely and sealingly to the proximal end of a catheter (not illustrated). A passageway (not illustrated) extends from the interior reservoir to a distal tip opening 450 of discharge port 430 . The port assembly further comprises a cap 460 which secures the septum 410 to the port housing 420 to maintain the fluid seal within the interior fluid reservoir.
[0035] In an exemplary embodiment of the printing apparatus 100 , the recesses 141 and 142 formed within the jig 140 are shaped to hold the access port assembly 400 during the printing process. In such an embodiment, an access port assembly 400 is disposed within each of the recesses 141 and 142 such that the septum 410 of each port assembly 400 faces down and a bottom surface of each port assembly 400 face up toward the pad 150 . The printing apparatus 100 applies ink to the bottom surface of each port assembly 400 . In an exemplary embodiment, the printing apparatus 100 applies radiopaque marking fluid to the bottom surface of each port assembly 400 .
[0036] The venous access port assembly 400 is further described in U.S. patent application Ser. No. 11/801,050 filed May 7, 2007 and claiming priority from U.S. Provisional Patent Application Ser. No. 60/801,523 filed May 18, 2006 and in U.S. patent application Ser. No. 12/143,377 filed Jun. 20, 2008 and claiming priority from U.S. Provisional Patent Application Ser. No. 60/936,491 filed Jun. 20, 2007, the contents of all of which applications are hereby incorporated by reference in their entirety for all purposes.
[0037] FIG. 5A illustrates a planar view of a port assembly 500 onto which indicia have been printed, in accordance with an exemplary embodiment of the present invention. FIG. 5B illustrates an isometric view of the port assembly 500 , in accordance with an exemplary embodiment of the present invention.
[0038] Referring now to FIGS. 5A and 5B together, the port assembly 500 comprises a base 510 having a bottom surface 520 onto which indicia have been printed. The indicia include indicia 530 centered on the bottom surface 520 of the port assembly 500 . In the example shown, indicia 530 comprise the letters “CT” representing the term “computed tomography.” The meaning of this term is described in further detail below.
[0039] The indicia on the bottom surface 520 further include a smaller inner circle 540 and a larger outer circle 550 provided on the outermost periphery of bottom surface 520 . The outer circle 550 includes a gap 560 where the port assembly 500 includes a recess to accommodate a stem 570 .
[0040] In an exemplary embodiment of the printing apparatus 100 described above, the printing apparatus 100 applies radiopaque marking fluid to print radiopaque indicia onto the medical devices disposed within the recesses 141 and 142 of the jig. In such embodiment, the medical devices may be formed from radiotransparent material. In a further exemplary embodiment, the printing apparatus 100 prints radiopaque indicia on venous access port assemblies, such as the port assemblies 400 or 500 . In such embodiment, the port assemblies 400 and 500 are formed from a plastic material, such as a silicone elastomer or polysulfone. Thus, in an exemplary embodiment, the indicia 530 , the inner circle 540 , and the outer circle 550 are printed with radiopaque marking fluid.
[0041] A wide variety of medical procedures require infusion of a fluid into a patient. For example, vascular imaging technologies may require use of a contrast media that is injected into the patient. More specifically, computed tomography (CT) is an imaging technology that utilizes a contrast media and may be employed for the noninvasive evaluation and assessment of a vascular system (i.e., CT angiography or CTA). Multidetector computed tomography (MDCT) is one specific type of CT that may be utilized for CTA. For proper imaging of a vascular system via CT, intravenous contrast media injection protocols are coordinated and selected for the anatomic area of interest.
[0042] More particularly, conventionally, a so-called “power injector” system may be employed for injecting contrast media at a high pressure into a peripherally inserted intravenous (IV) line. Because CT procedures are often defined in terms of a desired flow rate of contrast media, such power injection systems are, in general, controllable by selecting a desired flow rate. Accordingly, such power injection systems may develop pressure (within the maximum pressure capability of the power injection system) as is necessary to maintain the selected flow rate.
[0043] The pressure required for contrast injection depends on many factors, including flow rate, contrast viscosity, configuration of infusion tubing, such as tube diameter and length, and any obstruction or restriction to flow (e.g., kinks, curves, fittings, compression). As mentioned above, to maintain the flow rate required for a CT or MRI study, a power injector may generate high pressures. Ruptures can occur when the injection pressure exceeds the tolerance of the vascular access devices, such as venous access ports. Other problems may occur due to timing errors between the scan and the contrast. In order to maximize the rapid scanning capacity of the newer vascular imaging devices, the starting of the scanning process can be delayed a predetermined amount of time after injection of the contrast media has begun. If the scan starts too early, just as the contrast is arriving at the heart, arteries can appear smaller than they really are when the image is post-processed. On the other hand, if scanning is delayed too long, image artifacts can arise from diluted contrast in the cardiac veins. The window of opportunity for optimal scans may be very small, because contrast media circulates quickly through cardiac arteries and into cardiac veins.
[0044] The term “high pressure injection” is understood to mean injections in which pressures within the port assembly 400 or 500 reach pressures generated by power injections having fluid flow rates between about 1 milliliter per second and about 5 milliliters per second. Such pressures may be between about 37 psi (255 kPa) to about 65 psi (448 kPa) within the reservoir of such port assemblies.
[0045] Thus, in an exemplary embodiment, the radiopaque indicia, such as the indicia 530 , 540 , and 550 , indicate that the medical device, e.g., the port assembly 500 , on which such indicia are printed by the printing apparatus 100 , is rated for high pressure injection such as is necessary for infusion into a patient of contrast medium that is used in computed tomography. Hence, in an exemplary embodiment, the indicia 530 comprise the letters “CT.” Other indicia may be used that indicate some other attribute or characteristic of the venous access port assembly.
[0046] By printing radiopaque indicia onto a venous access port assembly rated for high pressure injections, a clinician is able to verify that such venous access port assembly is rated for high pressure injections after being implanted into a patient. Specifically, such clinician may X-ray the implanted port assembly and be able to verify that such port assembly is rated for high pressure injection if “CT” is discernable on the port assembly in the X-ray image. Further, because the radiopaque marking fluid is applied to an exterior surface of the venous access port assembly, the indicia (e.g., “CT”) are viewable to the naked eye prior to implantation. Thus, the surgeon implanting the port assembly is able to verify that such port assembly is rated for high pressure injection by visual inspection of the port assembly prior to implantation. In an exemplary embodiment, the CT indicia appear to be black to the naked eye.
[0047] These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it will be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It should therefore be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention. | A method of printing radiopaque indicia on a medical device. The method includes applying radiopaque marking fluid to a surface of a plate comprising one or more etchings having a depth of at least 0.0001 inches, exposing the radiopaque marking fluid on the surface of the plate to air to allow the radiopaque marking fluid to achieve a sufficient level of tackiness, and transferring the radiopaque marking fluid to a medical device. The radiopaque marking fluid comprises a clear ink and tungsten particulates having a particulate size of more than one micron. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to German Patent Application No. 102015000866.8, filed Jan. 24, 2015, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure pertains to a roof panel particularly for the passenger cabin of a motor vehicle, and more particularly to a roof panel assembly having a composite panel and a metal frame.
BACKGROUND
[0003] In the continuing pursuit of ways to reduce the weight and also the fuel consumption of motor vehicles, it has already been suggested that plastic be used to produce various components of a vehicle body that are conventionally made from metal. A proposal for a roof panel manufactured mainly from a fiber-reinforced plastic is known for example from DE 10 2008 032 334 A1. This roof panel with a substantially flat cross section, at least in the direction transverse to the vehicle, is supported along the side edges thereof by horizontal flanges of two longitudinal lateral roof support members and fixed to the lateral sides of the longitudinal roof support members with adhesive beads.
[0004] Since plastics generally undergo considerably greater thermal expansion than metals, the expansion behavior of these conventional roof panels differs significantly from that of the metal longitudinal support members to which it is fastened. Consequently, significant compression and shearing forces occur in the adhesive beads, and over time these can cause the adhesive bond to fail.
SUMMARY
[0005] The present disclosure provides a roof panel for a motor vehicle, in which the concerns for failure of an adhesive bond with a largely metal body is minimized, despite the fact that the roof panel is primarily made of a plastic or composite material.
[0006] In accordance with one aspect of the present disclosure, the roof panel includes a panel-like composite or plastic body and a metal frame that runs continuously around a border of the plastic body. This border prevents the thermal expansion of the plastic body at high temperatures, so the expansion of the entire roof panel approximates that of an equivalent metal roof panel. Because of its uninterrupted encircling structure, the frame can absorb strong forces from the plastic body. In order to guarantee the high load-bearing capability of the roof panel, one or more of the components may be made from a fiber-reinforced plastic.
[0007] The frame protects the panel from damage by embedding the frame in plastic body, and also makes it easier to bond the roof panel to surrounding supports of the bodies of the frame not exposed, and the surface of the roof panel that comes into contact with the adhesive is made uniformly of plastic. The frame may include a single wire, which should preferably have a cross section without edges defining a simple closed curve such as a circle or an oval, thereby avoiding local concentration of the stresses arising between the plastic body and the frame, and any damage to the plastic body resulting therefrom.
[0008] The plastic body may particularly include two components secured one on top of the other, between which the frame is inserted. The components may be for example panel-like blanks; however, one of the components may also include tabs positioned around the periphery along the edge of the plastic body, which have a groove into which the frame can be inserted.
[0009] In order to prevent the frame from warping due to the effect of thermal tension, connecting wires may cross over an opening in the frame and the two ends thereof may be fastened to the frames. Like the frame itself, the connecting wires themselves are inserted between the components, particularly between two panel-like blanks. The connecting wires may form a braid or a mesh, which preferably fills in the opening in the frame uniformly. If the wires that crossed are fastened to each other at the intersection points of the braid or mesh, a significant fraction of the stress that occurs due to heating of the roof panel can be absorbed directly by the mesh, thereby relieving the frame of this load.
[0010] A groove for adhesive may extend along at least a part of the periphery of the roof panel to hold the adhesive with which it is fastened to the vehicle body. A groove for adhesive having a suitable cross section, which is open both downwardly and toward the respective periphery of the roof panel may be obtained expediently if the lower of the aforementioned components fastened one on top of the other has a shorter peripheral length than the upper component.
[0011] In order to improve the load-bearing capacity of the roof panel, it may be reinforced with ribs extending in the transverse direction. The ribs may be joined to the panel-like plastic body as a separate component during production of the roof panel. A plurality of ribs may expediently be connected as a single part in a roof arch having a comb-like cross section. The production of the roof panel may also be rendered more efficient if the ribs are constructed to form rungs of a ladder-like structural element, the side rails of which extend along lateral edges of the roof panel. The side rails may also serve to delimit the groove for adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements.
[0013] FIG. 1 is a view of the roof panel according to the present disclosure from above;
[0014] FIG. 2 is a view of the roof panel from below;
[0015] FIG. 3 is an expanded view of the components used to assemble the roof panel;
[0016] FIGS. 4 a -4 f illustrate the stages of a manufacturing process for the roof panel;
[0017] FIG. 5 is a cross section through a lateral peripheral area of the roof panel;
[0018] FIG. 6 is a cross section through a front peripheral area of the roof panel and a roof cross member of a vehicle body on which the roof panel is mounted; and
[0019] FIG. 7 is a section view in the lengthwise direction of the vehicle through a central region of the roof panel.
DETAILED DESCRIPTION
[0020] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the present disclosure or the following detailed description.
[0021] FIG. 1 shows the roof panel 1 according to the present disclosure in a view from above. The periphery of roof panel 1 includes a front edge 2 relative to the installed position of the roof panel in a motor vehicle, which is provided to serve as a border with the top edge of a windscreen, a rear edge 3 that may border the rear window or which includes a small cutaway so that it can accommodate the upper edge of a tailgate, as in the case shown here, and longitudinal edges 4 . The top side of roof panel 1 is constructed with a slight convex curvature in both the longitudinal and transverse directions. This curvature limits the pressure that roof panel 1 can exert on adjacent components of the vehicle along the length thereof when it is heated. Protruding connecting elements 5 , 6 extend downward along edges 2 , 3 , 4 on the underside of roof panel 2 visible in FIG. 2 . Groups of ribs 7 extend transversely over the underside of roof panel 1 , from one longitudinal edge 4 to the other.
[0022] FIG. 3 shows components, from which roof panel 1 is constructed in layers. These components include, from top to bottom, an upper blank 8 made from a fiber-reinforced plastic, a perforated metal structure 9 , a lower blank 10 made from fiber-reinforced plastic, and a ladder-like structural element 11 in which two side rails of the ladder structure are formed by the longitudinally aligned connecting elements 6 , and connecting elements 5 and ribs 7 connect connecting elements 6 to each other like the rungs of a ladder.
[0023] Metal structure 9 includes a frame 12 , in this case formed by a strong wire having a circular cross section and extending without interruption about the periphery, and a braid or mesh 13 made of thinner wires 14 , the ends of which are each attached to frame 12 by spot welding or similar methods. The wires preferably have a cross section without edges which define a simple closed curve such as a circle or an oval. In the braid 13 shown in FIG. 3 , wires 14 are all straight and cross each other at right angles. Wires 14 may be fastened to each other at the intersection points, by welding, soldering or winding them around each other, for example.
[0024] Components 8 to 11 are connected to the completed roof panel 1 by placing first blank 8 , followed by the metal structure 9 , blank 10 and structural element 11 in a molding tool lower section 15 , as shown in FIG. 4 a to FIG. 4 f , and compressing and heating them between lower section 15 and an upper section 16 in order to soften the plastic matrices of blanks 8 , 10 , so that they melt and fuse with each other in the interspaces between the wires of braid 13 . When a deep bond between the plastic parts of blank 8 , 10 and the ladder-like structural element 11 has been created in this way, sections 15 , 16 of the molding tool are separated again, and the completed roof panel 1 can be taken out.
[0025] FIG. 5 shows the structure of the roof panel 1 obtained in this way in the form of a sectional view through a longitudinal edge 4 in a direction transverse to the vehicle. In FIG. 4 , boundary lines between the blanks 8 , 10 and structural element 11 have been highlighted to indicate more clearly where the plastic material of roof panel 1 from these various original components came from; in practice, the fusing of components 8 , 10 , 11 should advantageously be so complete that such a boundary line would no longer be clearly visible in a real section.
[0026] A groove for adhesive 17 , open downwardly and to the side, extends along edge 4 and is provided to hold an adhesive bead for retaining roof panel 1 securely on a longitudinal support member (not shown), which member extends over a door of the vehicle and connects the ends of the A, B and C pillars in a manner known per se. In this context, a peripheral member 18 of roof panel 1 extending above the groove for adhesive 17 is formed solely by the original upper blank 8 . A lateral flank 19 that delimits the groove for adhesive 17 on the side closest to the vehicle middle is created by one of the lateral connecting elements 6 of ladder-like structural element 11 . The strong wire of frame 12 is pressed into connecting element 6 from above; or this purpose, connecting element 6 may be provided with a groove that is upwardly open from the start of the process.
[0027] The dimension of blank 10 is selected in this context such that the respective edges thereof are touching frame 12 from the inside. It would also be conceivable to select the dimensioning of blank 10 such that it is pressed into the groove of connecting element 6 together with frame 12 and extends as far as flank 19 , as indicated by a dot-dashed line in FIG. 5 . Under the pressure of the molding tools, the upper sides of ribs 7 are fused with blank 10 , and both blanks 8 , 10 are individually pressed into interspaces 20 between the wires 14 of braid 13 , where they are thoroughly fused with each other.
[0028] The construction of roof panel 1 at front and rear edges 2 , 3 is similar to that of the longitudinal edges 4 , is shown in FIG. 6 for front edge 2 . Here, frame 12 is pressed in a groove on the upper side of cross member 5 , and cross member 5 in turn is fused together with blanks 8 , 10 inside and outside of frame 12 . A steel cross member 21 of the vehicle body, which extends between the top ends of two A pillars (not shown), supports the front edge 2 of roof panel 1 and an upper edge of windscreen 23 with an adhesive bead 22 .
[0029] FIG. 7 is a sectional view in the longitudinal direction of the vehicle body through a central area of roof panel 1 . The sectional plane extends transversely to a group of the ribs 7 . Ribs 7 form the teeth of the comb-like cross-section of a fiber-reinforced plastic roof arch 24 , which in turn forms a rung in ladder-like structural element 11 . A back section 25 of the comb-like cross-section has fused with blank 10 along a dashed line. The neutral fiber in roof panel 1 extends substantially along wires 14 , between the blanks 8 , 10 . The ribs 7 located at a distance from the neutral fiber therefore help considerably to enhance the stiffness of roof panel 1 .
[0030] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents. | A roof panel for the passenger cabin of a motor vehicle includes a composite or plastic panel-like body and a metal frame that runs continuously along a periphery of the plastic body. The metal frame prevents the thermal expansion of the plastic body at high temperatures, so the expansion of the entire roof panel approximates that of an equivalent metal roof panel. Specifically, the uninterrupted encircling structure of the frame absorbs forces resulting from thermal expansion of the plastic body. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to ice cream scoop apparatus, and more particularly pertains to a new and improved heated ice cream scoop apparatus wherein the same is arranged for accommodating heat to heat the ladle head permitting ease of entry of the scoop into an ice cream container and subsequent ease of release of ice cream from within the scoop apparatus.
2. Description of the Prior Art
A heated ice cream scoop device has been utilized in the prior art, wherein the heated ice cream scoop utilizes electrical resistance elements mounted throughout the scoop head operative through a mount to effect heating of the scoop head.
U.S. Pat. No. 3,476,059 to Anderson sets forth another example of an electrically heated ice cream scoop utilizing resistance elements mounted within the scoop structure.
U.S. Pat. No. 3,992,604 to Leddy sets forth a further example of an electrically heated ice cream dispenser organization.
Accordingly, it may be appreciated that there continues to be a need for a new and improved heated ice cream scoop apparatus as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in construction in utilizing a readily replenished butane gas supply in association with the ice cream scoop structure to permit heating of the ice cream scoop ladle and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of ice cream scoop apparatus now present in the prior art, the present invention provides a heated ice cream scoop apparatus wherein the same is arranged for selective heating of the ice cream scoop ladle head portion. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved heated ice cream scoop apparatus which has all the advantages of the prior art ice cream scoop apparatus and none of the disadvantages.
To attain this, the present invention provides an ice cream scoop including a ladle formed with an interior wall and exterior wall defining a heating chamber therebetween. The heating chamber including a vent directed through the exterior wall diametrically opposed to an elongate handle, wherein the handle includes a heating assembly mounting a heating cartridge directing heated air supply between the interior and exterior walls of the scoop.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore an object of the present invention to provide a new and improved heated ice cream scoop apparatus which has all the advantages of the prior art ice cream scoop apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved heated ice cream scoop apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved heated ice cream scoop apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved heated ice cream scoop apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such heated ice cream scoop apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved heated ice cream scoop apparatus 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.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of the instant invention.
FIG. 2 is an orthographic rear view, taken in elevation, of the instant invention.
FIG. 3 is an orthographic view, taken along the lines 3--3 of FIG. 1 in the direction indicated by the arrows.
FIG. 4 is an orthographic cross-sectional illustration of the ladle head utilized by the instant invention taken in cross-section.
FIG. 5 is an orthographic cross-sectional illustration of the butane lighter cartridge mounted within the lower handle shaft portion.
FIG. 6 is an isometric illustration of a modified apparatus utilized by the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 6 thereof, a new and improved heated ice cream scoop apparatus embodying the principles and concepts of the present invention and generally designated by the reference numerals 10 and 10a will be described.
More specifically, the heated ice cream scoop apparatus 10 of the instant invention essentially comprises a concave ladle head 11 including an interior wall 11a spaced from and coextensive an exterior wall 11b to define a ladle head cavity 18 therebetween. The cavity includes a ladle head vent opening 19 directed through the exterior wall 11b diametrically opposed to an associated ladle shaft 15 diametrically aligned with the ladle head 11. The ladle head 11 and associated ladle shaft 15 are mounted to an upper handle shaft 13 that is in turn mounted to a lower handle shaft 14, wherein each of the shafts 13, 14, and 15 are coaxially aligned relative to one another. The ladle shaft 15 includes internal threads 16 cooperative with and securable to an upper handle shaft externally threaded boss 20. The upper handle shaft boss 20 includes an upper handle shaft conduit 21 coaxially directed therethrough. A plurality of windows 22 are directed through the upper handle shaft 20 adjacent an abrasive striker wheel 31 projecting through a wall of the upper handle shaft 13 to provide air flow in flame propagation of a heated flue aligned by the upper handle shaft conduit 21 and the associated ladle head cavity 18. The abrasive striker wheel 31 cooperates with a flint member 33 to effect striking of a spark, wherein a valve lever 32 pivotally mounted below the striker wheel 31 receiving the flint member 33 therethrough includes a valve lever projection 34 selectively projecting within an upper terminal end of a fuel feed channel 29. A retraction spring 36 is arranged to normally bias the valve lever projection 34 into sealing engagement with the upper terminal portion of the fuel feed channel 29. The fuel feed channel 29 projects through the upper handle shaft 13 and externally threaded lower boss 25 formed on a lower portion of the upper handle shaft 13 to be threadedly received within an internally threaded portion of the lower handle shaft 14, in a manner as depicted in FIG. 5. The lower handle shaft 14 is received threadedly about the externally threaded lower face boss 25 into confrontation and sealing relationship with the annular seal 24. The piercing conduit 28 that includes the fuel feed channel 29 directed therethrough pierces the associated butane cartridge 30 to selectively direct fuel through the fuel feed channel 29 for providing a flame through the upper terminal end of the fuel feed channel 29 in association with the abrasive striker wheel 31.
FIG. 6 illustrates a modified apparatus 10a, wherein a handle member 37 mounted to the concave ladle head 11 includes a handle cavity slot 38, with the handle cavity slot receiving an associated butane lighter member 40 therewithin. The butane lighter member 40 includes a flame outlet nozzle 43 operative through a striker wheel 41 and a valve plate 42 to direct a flame into the handle conduit 39 that subsequently directs the flame into the ladle head cavity 18, in a manner as discussed with reference to FIG. 4.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | An ice cream scoop including a ladle formed with an interior wall and exterior wall defining a heating chamber therebetween. The heating chamber including a vent directed through the exterior wall diametrically opposed to an elongate handle, wherein the handle includes a heating assembly mounting a heating cartridge directing heated air supply between the interior and exterior walls of the scoop. | 5 |
FIELD OF THE INVENTION
[0001] This application claims the benefit of U.S. Provisional Application No.60/252,056 filed Nov. 20, 2000.
[0002] The present invention relates to a system for facilitating the use of several appliances, machines, tools from a single work position and without the necessity of removing and replacing a desired sewing machine or tool implement. More particularly, the invention relates to a system comprising a turntable apparatus adapted to the top of any cabinet/workbench/table wherein several appliances, machines, tools are mounted or placed and can be rotated into the work position. Rotating the turntable can be manually or electric motor driven.
SUMMARY OF THE INVENTION
[0003] It is noted that the features of the present invention have application in many fields as noted above. However, the features have particular application to sewing systems.
[0004] In accordance with the present invention, there is provided a sewing system comprising a unique rotating turntable for mounting several sewing implements and a cabinet with drop leaves, drawers and shelves. For space utilization efficiency, equal amounts of the front and back of the turntable rotating mounting platform can be removed so as to form a straight edge on the front and back of the cabinet top. All drawers use all the depth available, some with the use of full extension drawer slides. The remaining available space has adjustable shelves.
[0005] The present invention provides a space-saver model for use in areas where space is at a premium are provided. This sewing system is designed to utilize the cabinet top for mounting several types of machines, such as a sewing machine, and provide adequate storage space in the form of up to five drawers and eight shelves. A minimum of four surge protected outlets are provided with an on/off switch and a heavy-duty electric cord out the back of the table that can be plugged into any household outlet.
[0006] The turntable assembly comprises a turntable attached to the upper plate of a ball bearing metal raceway. The lower plate of the ball bearing race is bolted to the cabinet top. The upper plate and the attached turntable, therefore, are free to rotate on the ball bearing lower plate race. A circular groove in the cabinet top forms a track way for a spring-loaded locking pin that protrudes through the turntable into the circular track way. Locking holes in the circular groove allow the spring-loaded locking pin to drop into the locking holes thereby providing means for locking the turntable in a desired position. A knob-like handle on the spring-loaded locking pin provides the means for manually rotating the turntable.
[0007] A second embodiment provides a motor and gear arrangement to rotate the turntable. The mounting platform, in this embodiment, is attached to a large circular gear whose teeth engage a smaller drive gear attached to the drive shaft of an electric motor. The electric motor is switch activated to rotate the turntable. Stops on the large driven gear engage a switch arrangement to reverse motor current thereby reversing the direction of the turntable and preventing the turntable from continuing to rotate beyond 355°.
[0008] With the above in mind, an object of the present invention is to provide a system for rotating multiple implements into a work position which is characterized by novel features of construction and arrangement including means for plugging in the appliances, machines ,tool, etc., incorporating a surge protection.
[0009] Another object of the present invention is to provide a system for rotating multiple implements into a work position incorporating a turntable which can only be rotated 355° and in this matter preclude any of the cord extensions from becoming entangled.
[0010] Still another object of the present invention is to provide a system of the type disclosed wherein a wire race keeps the cores from interfering with a drawer directly under the turntable.
[0011] Still a further object of the present invention is to provide a system for rotating multiple implements into a work position, incorporating a knee switch for revolving and changing direction of the turn table.
[0012] A still further object of the present invention is to provide a system wherein the stops at the end of the 355° rotation reverses rotation of the switch as well as being able to change direction with turning the switch off and then back on.
[0013] Still another object of the present invention is to provide a system wherein the manual turntable locks into a position with a spring-loaded locking pin at a predetermined location which the electric turntable locks into position wherever it stops and is held by a gearing system.
BRIEF DESCRIPTION OF THE FIGURES
[0014] These and other objects of the present invention and various features and details of the operation and construction thereof are hereinafter more fully set forth with reference to the accompanying drawings, wherein:
[0015] [0015]FIG. 1 is a perspective view of a typical configuration of the present invention with two sewing machines mounted on a rotating table that is integral with a sewing cabinet.
[0016] [0016]FIG. 2 is a top view of the turntable with a sewing machine in the work position and a power cord leading from the sewing machine to a center opening in the turntable and wherein the groove within the rotating turntable is shown in phantom. Only one sewing implement is shown although several machines can be mounted on the turntable.
[0017] [0017]FIG. 3 is a top view similar to FIGS. 1 and 2 and illustrates the process of rotating the sewing machine to another position.
[0018] [0018]FIG. 4 is a top view similar to FIGS. 2 and 3 with a sewing machine rotated 180° from its original position.
[0019] [0019]FIG. 5 is a partial front view of the turntable system with the turntable elevated showing the turntable, locking pin, and groove.
[0020] [0020]FIG. 6 is an enlarged exploded view of the locking pin and track.
[0021] [0021]FIG. 7 is an enlarged, fragment sectional view taken on line 7 - 7 of FIG. 2 with locking pin engaged in a stop position in the track.
[0022] [0022]FIG. 7A is a further enlarged view of FIG. 7 showing details of the locking pin.
[0023] [0023]FIG. 7B is a view similar to FIG. 7A with the locking pin disengaged from its stop position.
[0024] [0024]FIG. 8 is an exploded view of turntable construction elements and assembly.
[0025] [0025]FIG. 8A is a partial section elevation view of the turntable support illustrating the power cord cutout and cutout cap.
[0026] [0026]FIG. 8B is a view taken along line 8 B- 8 B of FIG. 8A showing the power cord cutout and cutout cap.
[0027] [0027]FIG. 9 is a top view of the turntable assembly with the mounting plate removed to show the motorized gear mechanism for rotating the turntable.
[0028] [0028]FIG. 10 is a fragmentary view of the gear mechanism with the drive gear rotating in a counter clockwise direction. The stop projection on the driven gear is approaching the fixed reversing switch.
[0029] [0029]FIG. 11 is a fragmentary view of the drive gear mechanism showing the stop projection depressing the plunger of the reversing switch.
[0030] [0030]FIG. 12 is a fragmentary view with the motor turning the drive gear in a clockwise direction, the stop projection on the driven gear has rotated approximately 355° and is approaching the reversing switch in the opposite direction.
[0031] [0031]FIG. 13 is a sectional front view of the turntable assembly and motor taken along line 13 - 13 of FIG. 9.
[0032] [0032]FIG. 14 is an enlarged view of circled view 14 of FIG. 13 illustrating details of the attachment of ball bearing supported turntable assembly.
[0033] [0033]FIG. 15 is an enlarged view of circled view 15 of FIG. 13 illustrating details of the drive and driven gears of the motorized turntable assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] It will be appreciated by those skilled in the art that the turntable system described hereinafter has application to many different kinds of appliances, machines, and tools. For example, the turntable system of the present invention may find application in a motorized turntable wherein several kitchen appliances are mounted such as a mixer, electric can opener, blender and the like. To illustrate the principles of the present invention, a sewing machine application is described.
[0035] Referring now to FIG. 1, there is shown a sewing system 10 of the present invention comprising a generally rectangular shaped sewing cabinet 11 , turntable 20 , and sewing machines S 1 and S 2 Sewing cabinet 11 is illustrative of one of several sewing cabinet models having a cabinet top 12 , drop leaf 13 on one side of sewing cabinet 11 , drawers 14 for storing sewing accessories and file folders, adjustable shelves 15 , a center kneehole drawer 16 , and a knee activated switch 17 . Shelves (not shown) may also be provided at the form and potion of knee hole. . Sewing system 10 is illustrated in a typical configuration with drop leaf 13 in a down position, sewing machine S 1 on turntable 20 is in the work position and sewing machine S 2 in an idle position. Electrical power cords C 1 and C 2 extending from S 1 and S 2 are routed through spindle opening 19 (see FIG. 2) on turntable 20 to a power receptacle (not shown) attached within kneehole of sewing cabinet 11 . Turntable 20 is positioned in a recessed circular cut out 18 (FIG. 5) on cabinet top 12 of sewing cabinet 11 such that cabinet top 12 and turntable 20 are coplanar with no height discontinuities. Equal amounts of the front and back of turntable 20 are removed so as to form straight edges 27 and 28 on the front and back so as to conform to cabinet 11 width dimension.
[0036] Top views of turntable 20 on cabinet top 12 of cabinet 11 shown in FIGS. 2, 3, and 4 with sewing machine S 2 removed for clarity purposes, illustrate positional accommodation of sewing system 10 . A 355° channel cut into cabinet top 12 of cabinet 11 constitutes a circular track 21 that guides turntable 20 to user desired positions. In FIGS. 5, 6 and 7 rotation handle 31 and locking pin 23 ride on a circular metallic insert 32 embedded in circular track 21 providing means for manually rotating sewing machines S 1 and S 2 from one position to another. Locking holes are formed by drilling through metallic insert 32 and partially into cabinet top 12 within the channel of circular track 21 . Locking holes 24 , 25 , and 26 are typical examples of prepositioned stops on circular track 21 although stops may be positioned anywhere along circular track 21 at the discretion of the user. Spring 30 is compressed when locking pin 23 is riding on metallic insert 32 . When a locking hole is encountered, spring 30 forces locking pin 23 into a locking hole thus preventing further rotation until locking pin 23 is manually lifted out of the locking hole. In FIG. 2, locking pin 23 is engaged in locking hole 24 . Likewise, in FIG. 3, turntable 20 has been rotated 90° and locking pin 23 is engaged in locking hole 25 . In FIG. 4, sewing machine S 1 is shown rotated approximately 180° from its original position with locking pin 23 inserted in locking hole 26 . Electrical power cords C 1 and C 2 are fed through spindle opening 19 in the center of turntable 20 and routed through cutout 40 shown in FIGS. 8A and 8B to electrical receptacle (not shown) on the underside of cabinet top 12 . Closure 41 retains electrical cord C 1 in cutout 40 and prevents electrical cord C 1 from sagging and becoming entangled. This arrangement allows electric power cords C 1 and C 2 to move with sewing machine S 1 an S 2 without constraining rotational motion.
[0037] Details of the manual version of sewing system 10 are illustrated in FIGS. 5, 6, and 7 and is comprised of turntable 20 , spindle shaft 22 , locking pin 23 , circular track 21 , spring 30 , rotation handle 31 , and metallic insert 32 in circular track 21 . FIG. 7 is an enlarged assembly view of locking pin 23 and rotation handle 31 . Spring 30 is compression biased between upper and lower spring retainers 33 and 33 a respectively so that a downward force is continually exerted on locking pin 23 . Cotter pin 34 maintains lower spring retainer 33 a on locking pin 23 while shoulder 20 a in inverted T shaped circumferential groove 20 b in turntable 20 retains upper spring retainer 33 on locking pin 23 . FIGS. 7A and 7B are expanded detail views showing the operation of locking pin 23 . The flanged upper end 23 a of locking pin 23 is retained within an internal slot 31 a of rotation handle 31 such that when rotating turntable 20 , handle 31 is free to rotate on locking pin 23 thereby allowing locking pin 23 to remain in a fixed orientation. In FIG. 7A, it can be seen that locking pin 23 through the action of compression biased spring 30 has been inserted in locking hole 24 while in FIG. 7B a manual upward force has released locking pin 23 from locking hole 24 allowing turntable 20 to be rotated.
[0038] When assembled turntable 20 is secured to cabinet top 12 by ball bearing raceway 42 as shown in FIGS. 13 and 14. To rotate turntable 20 , on ball bearing raceway 42 , locking pin 23 is released from its locking hole 24 with an upward pull on rotation handle 31 compressing spring 30 . Turntable 20 can then be rotated in circular track 21 to a new position. When the new position is reached rotation handle 31 is released forcing locking pin 23 into a new locking hole as shown in FIGS. 3 and 4.
[0039] A motorized embodiment of sewing system 10 is shown in an exploded view in FIG. 8 and is comprised of turntable 20 , spindle shaft 22 , drive gear 35 , drive shaft 35 a , driven gear 36 , ball bearing raceway 42 , reversing switch 38 , and electric motor 39 . Motorized turntable 20 is positioned in a recessed circular cut out 18 on cabinet top 12 such that cabinet top 12 and turntable 20 are coplanar with no height discontinuities. Equal amounts of the front and back of turntable 20 are removed so as to form straight edges 27 and 28 conforming to sewing cabinet 11 width dimension. Electrical Cord C 1 from sewing machine S 1 to electrical outlet (not shown) is routed through cutout 40 on the under surface of cabinet top 12 . Electrical cord C 1 is supported in cutout 40 by closure 41 which snaps into cutout 40 thereby constraining electrical cord C 1 and preventing entanglement as shown in FIGS. 8A and 8B. Referring again to FIG. 8, drive shaft 35 a is connected to electric motor 39 . Driven gear 36 has internal gear teeth 36 a and is attached to the underside of turntable 20 . Referring now to FIG. 9 in conjunction with FIGS. 13, 14, and 15 , top plate 43 of ball bearing raceway 42 and driven gear 36 are bolted to turntable 20 . Bottom plate 44 of ball bearing raceway 42 is bolted to recess 18 of cabinet top 12 . Top plate 43 is free to rotate on ball bearings 45 while bottom plate 44 remains stationary. When power is applied to electric motor 39 , it rotates drive gear 35 whose teeth 35 b are in meshed contact with gear teeth 36 a of driven gear 36 causing driven gear 36 , turntable 20 , and top plate 43 to rotate. Turntable 20 may be stopped at any position within its 355° travel by simply removing power to electric motor 39 . When turntable 20 has reached its travel limit in one direction, means are provided to reverse motor 39 polarities to rotate turntable 20 in the opposite direction. Referring now to FIGS. 10, 11, and 12 , pin 36 b on the outer perimeter of driven gear 36 rides in channel 37 and when in contact with reversing switch 38 , power to motor 39 is reversed turning drive gear 35 in the opposite direction and counter rotating driven gear 36 . In this motorized embodiment, switch 45 prevents rotation beyond 355°. When pin 36 b on the outer perimeter of driven gear 43 as shown in FIGS. 10 and 11, contacts switch 38 , power to motor 39 is reversed turning drive gear 35 in the opposite direction and counter rotating driven gear 36 as shown in FIG. 12.
[0040] Even though particular embodiments of the present invention have been illustrated and described herein, it is not intended to limit the invention and changes and modifications may be made therein within the scope of the following claims. | A system facilitating the use of multiple sewing machines mounted on a sewing cabinet is disclosed. A circular turntable on which multiple sewing machines are mounted can be activated either manually or with an electric motor to rotate a desired sewing implement to the working position. The cabinet is designed for maximum storage space in a minimum of wall space. Different models provide up to five drawers and eight shelve as well as a drop leaf for increased table area. The system has surge protected outlets with an on/off switch and an electric cord that can be plugged into any household outlet. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of co-pending application U.S. Ser. No. 10/855,446 filed May 26, 2004.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates generally to fluid delivery devices. More particularly, the invention concerns an improved apparatus for infusing medicinal agents into an ambulatory patient at specific rates over extended periods of time, which includes a novel bellows reservoir and a unique adjustable flow rate control means for precisely adjustably controlling the rate of fluid flow from the bellows reservoir of the device toward the patient.
[0006] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
[0007] Many medicinal agents require an intravenous route for administration of the medicament. The delivery device for delivering the medicament, while not an active pharmacologic agent, may enhance the activity of the drug by mediating its therapeutic effectiveness. Certain classes of new pharmacologic agents possess a very narrow range of therapeutic effectiveness, for instance, too small a dose results in no effect, while too great a dose results in toxic reaction.
[0008] In the past, prolonged infusion of fluids has generally been accomplished using gravity flow methods, which typically involve the use of intravenous administration sets and the familiar bottle suspended above the patient. Such methods are cumbersome, imprecise and require bed confinement of the patient. Periodic monitoring of the apparatus by the nurse or doctor is required to detect malfunctions of the infusion apparatus. Devices from which liquid is expelled from a relatively thick-walled bladder by internal stresses within the distended bladder are well known in the prior art. Such bladder, or “balloon” type, devices are described in U.S. Pat. No. 3,469,578, issued to Bierman and in U.S. Pat. No. 4,318,400, issued to Perry.
[0009] One of the most versatile and unique fluid delivery apparatus developed in recent years is that developed by one of the present inventors and described in U.S. Pat. No. 5,205,820. The components of this novel fluid delivery apparatus generally includes: a base assembly, an elastomeric membrane serving as a stored energy means, fluid flow channels for filling and delivery, flow control means, a cover, and an ullage which comprises a part of the base assembly.
[0010] Another prior art patent issued to one of the present applicants, namely U.S. Pat. No. 5,743,879, discloses an injectable medicament dispenser for use in controllably dispensing fluid medicaments such as insulin, anti-infectives, analgesics, oncolylotics, cardiac drugs biopharmaceuticals, and the like from a prefilled container at a uniform rate. The dispenser, which is quite dissimilar in construction and operation from that of the present invention, includes a stored energy source in the form of a compressively deformable, polymeric elastomeric member that provides the force necessary to controllably discharge the medicament from a prefilled container, which is housed within the body of the device. After having been deformed, the polymeric, elastomeric member will return to its starting configuration in a highly predictable manner.
[0011] Another important prior art fluid delivery device is described in the U.S. Pat. No. 6,063,059 also issued to one of the present inventors. This device, while being of a completely different construction embodies a compressible-expandable stored energy source somewhat similar to that used in the apparatus of the present invention.
[0012] As will be appreciated from the discussion, which follows, the apparatus of the present invention is uniquely suited to provide precise, continuous fluid delivery management at a low cost in those cases where a variety of precise dosage schemes are of utmost importance. An important aspect of the apparatus of the present invention is the provision a novel, rotatable fluid flow rate control means that includes uniquely formed micro capillary, multichannel flow rate control channels which enable precise control of the rate of fluid flow of the medicament to the patient. More particularly, the apparatus of the present invention includes a novel, adjustable fluid flow rate mechanism which enables the fluid contained within the reservoir of the device to be precisely dispensed at various selected rates.
[0013] The apparatus of the present invention can be used with minimal professional assistance in an alternate health care environment, such as the home. By way of example, devices of the invention can be comfortably and conveniently removably affixed to the patient's body or clothing and can be used for the continuous infusion of antibiotics, such as, for example, an antibiotic sold by Abbott Laboratories under the name and style ANCIF and by Rosche under the name and style ROCEPHIN, analgesics, such as morphine and like medicinal agents.
[0014] By way of summary, the apparatus of the present invention uniquely overcomes the drawbacks of the prior art by providing a novel, disposable dispenser of simple but highly reliable construction. A particularly important aspect of the apparatus of the present invention resides in the provision of a novel, self-contained energy source in the form of a compressible-expandable spring member that provides the force necessary to substantially, uniformly dispense various solutions from the device reservoir. Because of the simplicity of construction of the apparatus of the invention, and the straightforward nature of the energy source, the apparatus can be manufactured at low cost without in any way sacrificing accuracy and reliability.
BRIEF SUMMARY OF THE INVENTION
[0015] It is an object of the present invention to provide a compact fluid dispenser for use in controllably dispensing fluid medicaments, such as, antibiotics, analgesics, and like medicinal agents from the novel bellows-type device reservoir.
[0016] It is another object of the invention to provide a fluid dispenser of the aforementioned character, which is highly reliable and is easy-to-use by laypersons in a non-hospital environment.
[0017] Another object of the invention is to provide a small, compact fluid dispenser that includes novel fill means for filling the bellows type dispenser reservoir with the medicament to be dispensed.
[0018] Another object of the invention is to provide an apparatus which can be factory pre-filled with a wide variety of medicinal fluids or one which can readily be filled in the field shortly prior to use.
[0019] Another object of the invention is to provide a dispenser in which a stored energy source is provided in the form of a constant force spring member of novel design that provides the force necessary to continuously and substantially uniformly expel fluid from the device reservoir.
[0020] Another object of the invention is to provide a device of the aforementioned character which includes novel adjustable flow rate control means disposed intermediate the fluid reservoir outlet and the outlet port of the device for precisely controlling the rate of fluid flow from the outlet port toward the patient.
[0021] Another object of the invention is to provide a dispenser that includes precise variable flow rate selection.
[0022] Another object of the invention is to provide a fluid dispenser of the class described which is compact, lightweight, is easy for ambulatory patients to use, is fully disposable, and is extremely accurate so as to enable the infusion of precise doses of medicament over prescribed periods of time.
[0023] Another object of the invention is to provide a device of the character described which embodies a novel fluid volume indicator that provides a readily discernible visual indication of the volume of fluid remaining in the device reservoir.
[0024] Another object of the invention is to provide a self-contained medicament dispenser which is of very simple construction and yet extremely reliable in use.
[0025] Another object of the invention is to provide a fluid dispenser as described in the preceding paragraphs, which is easy and inexpensive to manufacture in large quantities.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0026] FIG. 1 is a generally perspective view of one form of the fluid dispensing device of the present invention showing one side of the device.
[0027] FIG. 2 is a generally perspective view of the fluid dispensing device shown in FIG. 1 showing the opposite side of the device.
[0028] FIG. 3 is a rear view of the fluid-dispensing device shown in FIGS. 1 and 2 .
[0029] FIG. 4 is a front view of the fluid-dispensing device shown in FIGS. 1 and 2 .
[0030] FIG. 5 is a side view of one of the locking arms of the device.
[0031] FIG. 6 is a cross-sectional view taken along lines 6 - 6 of FIG. 4 .
[0032] FIG. 7 is a cross-sectional view taken along lines 7 - 7 of FIG. 4 .
[0033] FIG. 8 is a cross-sectional view taken along lines 8 - 8 of FIG. 7 .
[0034] FIG. 9 is a cross-sectional view taken along lines 9 - 9 of FIG. 7 .
[0035] FIG. 10 is a cross-sectional view taken along lines 10 - 10 of FIG. 7 .
[0036] FIG. 11 is a cross-sectional view taken along lines 11 - 11 of FIG. 7 .
[0037] FIG. 12 is a generally perspective, exploded view of the rear portion of the fluid dispensing device shown in FIG. 1 .
[0038] FIG. 13 is a generally perspective exploded view of the fluid dispensing device shown in FIG. 1 .
[0039] FIG. 14 is a generally perspective view of the micro rate selector knob assembly of the device.
[0040] FIG. 15 is a fragmentary cross-sectional view of a portion of the flow rate control means of the invention showing the micro rate selector knob assembly in an off condition.
[0041] FIG. 16 is a fragmentary cross-sectional view of a portion of the flow rate control means of the invention showing the micro rate selector knob assembly in a delivery condition.
[0042] FIG. 17 is a generally perspective view of the macro rate selector knob assembly of the fluid dispensing device.
[0043] FIG. 18 is a side elevational view of the outer face of the cover member of the rate control assembly of the invention.
[0044] FIG. 18A is an enlarged cross-sectional view taken along lines 18 A- 18 A of FIG. 18 .
[0045] FIG. 18B is an enlarged cross-sectional view taken along lines 18 B- 18 B of FIG. 18 .
[0046] FIG. 19 is an enlarged cross sectional view taken along lines 19 - 19 of FIG. 18 .
[0047] FIG. 20 is an enlarged cross sectional view taken along lines 20 - 20 of FIG. 18 .
[0048] FIG. 21 is an end view of the flow rate control assembly of this latest form of the fluid delivery device of the invention.
[0049] FIG. 22 is a view taken along lines 22 - 22 of FIG. 21 .
[0050] FIG. 23 is an end view of the inner face of the base member of the rate control assembly of this latest form of the invention.
[0051] FIG. 24 is an enlarged, fragmentary view of the portion identified in FIG. 23 as “ 24 ”.
[0052] FIG. 25 is a generally perspective illustrative view of a portion of the fluid delivery device of the invention showing the fluid flow path during the fill step.
[0053] FIG. 26 is a generally perspective illustrative view of a portion of the fluid delivery device of the invention showing the fluid flow path during the fluid delivery step.
[0054] FIG. 27 is a longitudinal cross-sectional view of an alternate form of the fluid dispensing device of the present invention.
[0055] FIG. 28 is a rear view of the fluid-dispensing device shown in FIG. 27 .
[0056] FIG. 29 is a front view of the fluid-dispensing device shown in FIG. 27 .
[0057] FIG. 30 is a cross-sectional view taken along lines 30 - 30 of FIG. 27 .
[0058] FIG. 31 is a side view of one of the locking arms of the device.
[0059] FIG. 32 is a cross-sectional view taken along lines 32 - 32 of FIG. 29 .
[0060] FIG. 33 is a cross-sectional view taken along lines 33 - 33 of FIG. 27 .
[0061] FIG. 34 is a cross-sectional view taken along lines 34 - 34 of FIG. 27 .
[0062] FIG. 35 is a cross-sectional view taken along lines 35 - 35 of FIG. 27 .
[0063] FIG. 36 is a generally perspective, exploded view of the fluid dispensing device shown in FIG. 27 .
[0064] FIG. 37 is a longitudinal cross-sectional view of still another form of the fluid dispensing device of the present invention.
[0065] FIG. 38 is a rear view of the fluid-dispensing device shown in FIG. 37 .
[0066] FIG. 39 is a front view of the fluid-dispensing device shown in FIG. 37 .
[0067] FIG. 40 is a cross-sectional view taken along lines 40 - 40 of FIG. 37 .
[0068] FIG. 41 is a side view of one of the locking arms of the device.
[0069] FIG. 42 is a cross-sectional view taken along lines 42 - 42 of FIG. 39 .
[0070] FIG. 43 is a cross-sectional view taken along lines 43 - 43 of FIG. 37 .
[0071] FIG. 44 is a cross-sectional view taken along lines 44 - 44 of FIG. 37 .
[0072] FIG. 45 is a cross-sectional view taken along lines 45 - 45 of FIG. 37 .
[0073] FIG. 46 is a generally perspective, exploded view of the fluid dispensing device shown in FIG. 37 .
[0074] FIG. 47 is a longitudinal cross-sectional view of yet another form of the fluid dispensing device of the present invention.
[0075] FIG. 47A is a longitudinal cross-sectional view of a specially designed vial cartridge that enables the intermixing of a lyophilized drug with a suitable diluent prior to the delivery of the mixture of the fluid reservoir of the device.
[0076] FIG. 48 is a rear view of the fluid-dispensing device shown in FIG. 47 .
[0077] FIG. 49 is a front view of the fluid-dispensing device shown in FIG. 47 .
[0078] FIG. 50 is a cross-sectional view taken along lines 50 - 50 of FIG. 47 .
[0079] FIG. 51 is a side view of one of the locking arms of the device.
[0080] FIG. 52 is a cross-sectional view taken along lines 52 - 52 of FIG. 49 .
[0081] FIG. 53 is a cross-sectional view taken along lines 53 - 53 of FIG. 47 .
[0082] FIG. 54 is a cross-sectional view taken along lines 54 - 54 of FIG. 47 .
[0083] FIG. 55 is a cross-sectional view taken along lines 55 - 55 of FIG. 47 .
[0084] FIG. 56 is a generally perspective, exploded view of the fluid dispensing device shown in FIG. 47 .
[0085] FIG. 57 is a longitudinal cross-sectional view of still another embodiment of the fluid dispensing device of the present invention.
[0086] FIG. 58 is a rear view of the fluid-dispensing device shown in FIG. 57 .
[0087] FIG. 59 is a front view of the fluid-dispensing device shown in FIG. 57 .
[0088] FIG. 60 is a cross-sectional view taken along lines 60 - 60 of FIG. 57 .
[0089] FIG. 61 is a side view of one of the locking arms of the device.
[0090] FIG. 62 is a cross-sectional view taken along lines 62 - 62 of FIG. 59 .
[0091] FIG. 63 is a cross-sectional view taken along lines 63 - 63 of FIG. 57 .
[0092] FIG. 64 is a cross-sectional view taken along lines 64 - 64 of FIG. 57 .
[0093] FIG. 65 is a cross-sectional view taken along lines 65 - 65 of FIG. 57 .
[0094] FIG. 66 is a generally perspective, exploded view of the fluid dispensing device shown in FIG. 57 .
DETAILED DESCRIPTION OF THE INVENTION
[0095] Referring to the drawings and particularly to FIGS. 1 through 26 , one form of the apparatus of the present form of the invention is there illustrated and generally designated by the numeral 102 . As best seen in FIGS. 1 , 2 and 13 , the apparatus here comprises a snap together outer housing 104 having first and second portions 104 a and 104 b, respectively. Housing portion 104 a comprises the reservoir portion, while housing portion 104 b comprises the rate control, fill and delivery and control portions. When snapped together the housing portions define a carrying handle 104 c.
[0096] Disposed within first portion 104 a of outer housing 104 is a novel expandable housing 105 having a fluid reservoir 105 a ( FIGS. 7 and 13 ) provided with an inlet passageway 105 b for permitting fluid flow into the fluid reservoir and an outlet 105 c for permitting fluid flow from the fluid reservoir. Expandable housing 105 , which can be constructed from a metal or plastic material and can include a coating of the character presently to be described, comprises a bellows structure having an expandable and compressible, accordion-like, annular-shaped sidewall 105 d, the configuration of which is best seen in FIGS. 7 and 13 . A capture ring 105 e ( FIGS. 7 and 13 ) secures the expandable housing in position.
[0097] Disposed within second portion 104 a of outer housing 104 is the novel stored energy means of the invention for acting upon inner expandable housing 105 in a manner to cause the fluid contained within fluid reservoir 105 a to controllably flow outwardly of the housing, through the dispensing means of the invention and onwardly toward the patient. In the present form of the invention, this important stored energy means comprises a constant force spring member 107 that is carried within the second portion 104 a of the outer housing. Spring member 107 is first extended by fluid flowing into reservoir 105 a and then controllably retracts in the manner shown in FIG. 7 to cause fluid flow from the outer housing through the dispensing means of the invention. Stored energy member or constant force spring 107 , which is a special variety of extension spring, is readily commercially available from several sources including Barnes Group Inc. of Bristol, Conn., Stock Drive Products/Sterling Instrument of Hyde Park, N.Y. and Walker Corporation of Ontario, Canada. Constant force extension spring 107 is basically a high stress, long deflection device that offers great advantages when used in applications where very low or zero gradient is desired, where space is a factor and where very high reliability is required. Constant force springs, such as spring 107 , provide markedly superior constant force loading when compared to conventional helical extension or like springs. Spring 107 , after being expanded, tends to uniformly return toward its starting configuration and in so doing will exert an inward pressure on a pusher means, shown here as pusher member 109 of the character shown in FIG. 7 . Pusher member 109 is operably coupled with the expandable housing 105 and functions to move the expandable housing from an expanded configuration to a contracted configuration. More particularly, as the spring 107 returns toward its starting configuration, it will act on pusher member 109 in a manner to move the expandable housing from an expanded configuration to a contracted configuration and in so doing will cause the fluid contained within the fluid reservoir 105 a to flow outwardly through outlet 105 c and toward the flow rate control means of the invention at a substantially constant rate.
[0098] Forming an important aspect of the apparatus is the fill means, which is carried by the first portion 104 a of outer housing 104 and functions to controllably fill the reservoir 105 a with the fluid to be dispensed. As best seen in FIG. 7 , housing portion 104 b includes a fluid passageway 110 that communicates with inlet 105 b of fluid reservoir 105 a. Fluid passageway 110 also communicates with a cavity 114 formed within first portion 104 b of the housing. Disposed within cavity 114 is a conventional, umbrella type check valve 116 , which permits fluid flow toward fill passageway 110 , but blocks fluid flow in the opposite direction. Passageway 110 also communicates, via a passageway 118 , with a cavity 120 that houses a pierceable septum 122 , which comprises a part of one form of the fill means of the invention. Septum 122 may be a conventional slit septum, the character well understood by those skilled in the art, which is pierceable by the cannula of a filling syringe assembly (not shown) which contains the medicinal fluid to be dispensed and which, in a manner presently to be described, can be used to fill or partially fill reservoir 105 a via passageway 110 .
[0099] First portion 104 a of housing 104 includes a vial receiving portion 124 that is normally closed by a closure cap 126 . Connector portion 124 is provided with a chamber 124 a for telescopically receiving the medicament fill vial assembly of the invention the character of which will presently be described. An elongated support 128 , which is mounted within chamber 124 a includes a threaded end portion 128 a and carries an elongated, longitudinally extending, hollow needle 129 having a central fluid flow passageway.
[0100] Referring particularly to FIG. 12 , the medicament containing fill vial assembly 130 includes a fill vial 132 having a fluid chamber 134 for containing the injectable fluid medicament. Chamber 134 is provided with a first open end 134 a and second closed end 134 b. First open end 134 a is sealably closed by closure means here provided in the form of an externally threaded elastomeric plunger 136 which is telescopically movable within chamber 134 from a first location where the plunger is disposed proximate first open end 134 a to the second, device-fill location where the plunger is disposed proximate second closed end 134 b ( FIG. 7 ).
[0101] After removal of closure cap 126 from connector portion 124 , vial assembly 130 can be inserted into chamber 124 a ( FIGS. 7 and 13 ). As the fill vial assembly is so introduced and the plunger 136 is threadably interconnected with threaded end 128 a of support 128 , the sharp end 129 a of the elongated needle 129 will pierce the central wall 136 a of the elastomeric plunger in the manner shown in FIG. 7 . An inward pressure exerted on the vial assembly will cause the vial to move inwardly of chamber 124 a and will cause the structural support 128 to move the elastomeric plunger inwardly of the vial chamber 134 in a direction toward the second or closed end 134 b of the vial chamber. As the plunger is moved inwardly of the vial, the fluid contained within the vial chamber will be expelled there from into the hollow elongated needle 129 , which has pierced the central wall 136 a of the elastomeric plunger. The fluid will then flow past conventional umbrella type check valve 116 , into passageway 110 and thence into a passageway 140 which communicates with reservoir inlet 105 b.
[0102] As the fluid flows into reservoir 105 a, the bellows 105 d will expand in a manner to exert a rearward pressure on the plunger end portion 109 a of pusher member 109 causing it to move rearwardly. As the pusher member moves rearwardly, it will exert forces on spring member 107 causing it to expand from its retracted configuration shown in FIG. 7 to its expanded configuration. This rearward movement of pusher member 109 can be viewed through the volume indicator window 142 indicating that the reservoir has changed from an empty configuration to a filled configuration ( FIG. 1 ).
[0103] As the reservoir 105 a fills with fluid, any gases trapped within the reservoir will be vented to atmosphere via vent means “V”, mounted in portion 104 b of the housing. This vent means here comprises a gas vent 143 that can be constructed of a suitable hydrophobic porous material such as a porous plastic.
[0104] Upon opening the fluid delivery path to the fluid delivery means of the invention, shown here as a conventional administration set 144 ( FIG. 1 ), the stored energy means, or spring 107 , will tend to return to its starting configuration thereby controllably urging fluid flow outwardly of reservoir 105 a via the flow control means of the invention the character of which will presently be described.
[0105] Administration set 144 is connected to the second portion 104 b of housing 104 by a connector 146 in the manner shown in FIG. 1 of the drawings. The proximal end 148 a of administration line 148 of the administration set is in communication with an outlet fluid passageway 152 which is formed in housing portion 104 b in the manner best seen in FIG. 7 . Disposed between the proximal end 148 a and the distal end of the administration line are a conventional gas vent and filter 154 . Provided at the distal end 148 b, is a luer connector 156 of conventional construction ( FIG. 1 ). Between gas vent and filter 154 and luer connector 156 is a conventional line clamp 158 and disposed between gas vent and filter 144 and the proximal end 148 a of the administration line is a conventional “Y” site 159 .
[0106] A number of beneficial agents can be contained within vial 132 and can be controllably dispensed to the patient including, by way of example, medicaments of various types, drugs, pharmaceuticals, hormones, antibodies, biologically active materials, elements, chemical compounds, or any other suitable material useful in diagnostic cure, medication, treatment or preventing of diseases or the maintenance of the good health of the patient.
[0107] As the fluid contained within reservoir 105 a is urged outwardly thereof by the stored energy means, the fluid will flow under pressure through reservoir outlet 105 c ( FIG. 7 ) and then on toward the flow control means, or flow control assembly of this latest form of the invention. This important flow control means functions to precisely control the rate of fluid flow flowing from the reservoir 105 a toward the patient.
[0108] Referring to FIGS. 18 through 26 , it can be seen that the flow rate control means of the flow control means of this latest form of the invention comprises an assembly which includes a base plate, or rate control member 160 and a mating cover member 162 ( FIG. 21 ). Cover member 162 is provided with a fluid inlet port 164 and a plurality of spaced apart, generally tubular shaped micro rate fluid outlet ports 166 a, 166 b, 166 c, 166 d and 166 e respectively. As illustrated in FIG. 22 , flow rate control member, or base plate 160 is uniquely provided with a plurality of micro rate flow control channels 160 a, 160 b, 160 c, 160 d and 160 e respectively, each having an inlet and an outlet. As indicated in the drawings, the outlets of the micro rate flow control channels are in communication with the spaced apart micro rate outlet ports of the cover member 162 and the inlet port is in fluid communication with reservoir 105 a. Cover member 162 is also provided with a plurality of spaced apart, generally tubular shaped macro rate fluid outlet ports 170 a, 170 b, 170 c, 170 d and 170 e respectively. Flow rate control member, or base plate 160 is also uniquely provided with a plurality of macro rate flow control channels 172 a, 172 b, 172 c, 172 d and 172 e respectively, each having an inlet and an outlet 173 a, 173 b, 173 c, 173 d and 173 e. The outlets of the macro rate flow control channels are in communication with the spaced apart macro rate outlet ports of the cover member 162 .
[0109] As indicated in FIG. 20 , inlet port 164 is provided with a filter member 175 of conventional construction for filtering particulates from the fluid flowing toward the various rate control channels.
[0110] Also forming a part of the flow control means of this latest form of the invention is a micro rate selector knob 180 that is carried within a horizontal bore 182 formed in housing portion 104 b. Selector knob 180 includes a body portion 180 a and an enlarged diameter head portion 180 b. As illustrated in FIG. 14 , selector knob 180 is uniquely provided with a plurality of radially extending flow control channels 184 a, 184 b, 184 c, 184 d and 184 e, each having an inlet port and an outlet port which is in fluid communication with an axially extending passageway 186 . Axially extending passageway 186 is, in turn, in fluid communication with administration line 148 . In a manner presently to be described, micro selector knob, which comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the selector knob with a selected one of the spaced apart micro rate fluid outlets 166 a, 166 b, 166 c, 166 d and 166 e of the rate control cover 162 ( FIG. 18 ).
[0111] Also forming a part of the flow control means of this latest form of the invention is a macro rate selector knob 190 that is carried within a horizontal bore 192 formed in housing portion 104 b. Selector knob 190 includes an enlarged diameter head portion 190 b and a generally cylindrical body portion 190 a. As illustrated in FIG. 17 , selector knob 190 is uniquely provided with a plurality of radially extending flow control channels 194 a , 194 b, 194 c, 194 d and 194 e, each having an inlet port and an outlet port which it is in fluid communication with an axially extending passageway 196 . Axially extending passageway 196 is, in turn, in fluid communication with administration line 148 .
[0112] In a manner presently to be described, selector knob 190 , which also comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the macro selector knob with a selected one of the spaced apart macro rate fluid outlets 170 a, 170 b, 170 c, 170 d and 170 e of the rate control cover 162 ( FIG. 18 ).
[0113] As best seen in FIGS. 7 and 25 , inlet port 164 of the rate control assembly is in communication with the outlet port 105 c of reservoir 105 a via a passageway 197 with which it is in communication. As the pusher assembly 109 is urged forwardly by the stored energy means, the fluid contained within reservoirs 105 a will flow through the outlet port 105 c , through passageway 197 and into inlet 164 of the rate control assembly in a manner to permit each of the micro channels and each of the macro channels of the rate control plate 160 to fill with the medicinal fluid to be dispensed to the patient.
[0114] In using the apparatus, rotation of the micro rate selector knob 180 will permit each of the spaced outlets of the micro channels to selectively be aligned with a selected one of the outlets 166 a, 166 b, 166 c, 166 d and 166 e of the rate control cover 162 . The fluid can then flow into a selected one of the plurality of passages 184 a, 184 b, 184 c, 184 d and 184 e, formed in the micro rate selector knob 180 , into axially extending passageway 186 , into the administration line 148 via a circumferentially extending fluid flow passageway 199 (see FIGS. 7 and 26 ), into the administration line 148 and then on to the patient at a precise micro rate of flow. To assist in rotating knob 180 , the knob is provided with a finger gripping bar 181 ( FIG. 1 ).
[0115] In operation, upon rotation of selector knob 180 a selected one of the micro channels outlets 166 a, 166 b, 166 c, 166 d and 166 e will align with a selected inlet 184 a, 184 b, 184 c, 184 d and 184 e of selector knob 180 (see FIGS. 15 and 16 ). For example, when outlet 166 a is in index with inlet 184 a ( FIG. 16 ), fluid will flow from reservoir 105 a through micro channel 160 a, into selector knob inlet 184 a via cylindrical outlet port 166 a, into central passageway 186 , into annular passageway 199 , into passageway 152 , into the administration line 148 and toward that patient at a precise, predetermined first rate. Similarly, when outlet 166 c of micro channel 160 c is aligned with inlet 184 c of selector 180 , fluid will flow from reservoir 105 a through micro channel 160 c, into selector inlet 184 c via cylindrical outlet port 166 c, into central passageway 186 , into annular passageway 199 , into passageway 152 , into the administration line 148 and toward the patient at a second rate.
[0116] As shown in FIG. 14 , selector knob 180 is provided with a plurality of circumferentially spaced apart indexing cavities 200 that closely receive the end of an indexing finger 202 a of an outwardly extending locking arm 202 , which forms a part of the flow control means of the invention and functions to prevent rotation selector knob 180 . ( FIGS. 6 , 13 and 10 ) Finger 202 a is continuously urged into a selected one of the indexing cavities 200 formed in knob 180 by a coiled spring 204 ( FIGS. 6 and 13 ). In order to permit rotation of knob 180 , arm 202 must be pushed inwardly against the urging of spring 204 .
[0117] In a similar manner, rotation of the macro rate selector knob 190 will permit each of the spaced outlets of the macro channels to selectively be aligned with a selected one of the outlets 170 a, 170 b, 170 c, 170 d and 170 e of the rate control cover 162 . The fluid can then flow into a selected one of the plurality of passages 194 a, 194 b, 194 c, 194 d and 194 e formed in the micro rate selector knob 190 , into axially extending passageway 196 , into the administration line via a circumferentially extending fluid flow passageway 205 , via a passageway 205 a formed in housing portion 104 b (see FIGS. 7 and 17 ) and then on to the patient at a precise macro rate of flow. To assist in rotating knob 190 , the knob is provided with a finger gripping bar 191 ( FIG. 1 ).
[0118] As shown in FIG. 17 , selector knob 190 is provided with a plurality of circumferentially spaced apart indexing cavities 206 that closely receive the end of an indexing finger 208 a of an outwardly extending locking arm 208 , which forms a part of the flow control means of the invention and functions to prevent rotation selector knob 190 ( FIGS. 6 and 13 ). Finger 208 a is continuously urged into a selected one of the indexing cavities 206 formed in knob 190 by a coiled spring 210 ( FIGS. 6 and 13 ). In order to permit rotation of knob 190 , arm 208 must be pushed inwardly against the urging of spring 210 .
[0119] The apparatus of this latest form of the invention also includes disabling means for irrevocably disabling the device and rendering it inert. Referring to FIGS. 1 , 4 and 11 , this disabling means here comprises a disabling shaft 214 that is telescopically movable within a passageway 216 formed within housing portion 104 b. As best seen in FIG. 11 , shaft 214 has a distal end 214 a, which, upon insertion of the shaft distal end into passageway 152 , will block fluid flow through the passageway. A friction fit retainer 216 normally holds shaft 214 in the retracted position.
[0120] The details of the construction of the important rate control plate, or member 160 of the invention and the various methods of making the rate control plate will now be considered. With respect to materials, the most appropriate materials for constructing the rate control plate are medical grade polymers. These types of polymers include thermoplastics, duroplastics, elastomers, polyurethanes, acrylics and epoxies. In other variations, the materials used for the flow control plate may be made of glass or silica. In further variations, the flow control component may be made of metals or inorganic oxides.
[0121] Using the foregoing materials, there are several ways that the flow control channels can be made. These include injection molding, injection-compression molding, hot embossing and casting. The techniques used to make these imbedded fluid channels are now commonplace in the field of microfluidics, which gave rise to the lab-on-a-chip, bio-MEMS and micro-total analysis systems (μ-TAS) industries. Additionally, depending on the size of the fluid channels required for a given flow rate, more conventional injection molding techniques can be used.
[0122] The first step in making the channels using an injection molding or embossing process is a lithographic step, which allows a precise pattern of channels to be printed on a “master” with lateral structure sizes down to 0.5 □m. Subsequently, electroforming is preformed to produce the negative metal form, or mold insert. Alternatively for larger channel systems, precision milling can be used to make the mold insert directly. Typical materials for the mold insert or embossing tool are nickel, nickel alloys, steel and brass. Once the mold insert of embossing tool is fabricated, the polymer of choice may be injection molded or embossed to yield the desired part with imprinted channels.
[0123] Alternatively, channels can be made by one of a variety of casting processes. In general, a liquid plastic resin, for example, a photopolymer can be applied to the surface of a metal master made by the techniques described in the preceding paragraph and then cured via thermal or ultraviolet (UV) means. After hardening, the material is then “released” from the mold to yield the desired part. Additionally, there are similar techniques available that utilize CAD data of the desired channel configuration and direct laser curing of a liquid monomer to yield a polymerized and solidified part with imbedded channels. This process is available by contract, from, by way of example, example MicroTEC, mbH of Duisburg Germany.
[0124] In order to seal the flow control channels, a planar top plate may be used. In this instance, the channel system may be sealed with a cover, or top plate, such as cover 162 , which is here defined as any type of suitable cover that functions to seal the channel. The top plate may be sealably interconnected with the base which contains the flow channels by several means, including thermal bonding, sonic welding, laser welding, adhesive bonding and vacuum application.
[0125] Thermal bonding may be preformed by using a channel base plate material and planar top cover that are made of similar polymeric materials. In this case the two substrates are placed in contact with one another, confined mechanically and heated to 2-5° C. above their glass transition temperature. Following a holding period sufficient enough for the polymer molecules of the two surfaces interpenetrate with one another, the temperature is slowly reduced and a stress free bonded interface with imbedded micro channels is yielded.
[0126] Additionally, the top plate, or cover may be bonded to the base plate through the use of one or more suitable bonding materials or adhesives. The bonding material or adhesive may be of the thermo-melting variety or of the liquid or light curable variety. For thermo-melting adhesives, the adhesive material is melted into the two apposed surfaces, thereby interpenetrating these surfaces and creating a sealed channel structure.
[0127] Further, liquid curable bonding materials or adhesives and light curable bonding materials or adhesives may be applied to one of the surfaces, for example the cover. Subsequently, the other surface is brought into contact with the coated surface and the adhesive is cured by air exposure or via irradiation with a light source. Liquid curable bonding materials or adhesives may be elastomeric, for example, thermoplastic elastomers, natural or synthetic rubbers, polyurethanes, and silicones. Elastomeric bonding materials may or may not require pressure to seal the channel system. They may also provide closure and sealing to small irregularities in the apposed surfaces of the channel system.
[0128] A channel system may also be formed and sealed in cases where two surfaces are being joined and one of the surfaces has one or more apertures. In order to promote bonding between these two surfaces, a vacuum may be applied to the apertures. Bonding may then be accomplished by thermal methods or after previously having applied a bonding material or adhesive.
[0129] While the rate control plate, or base member 160 can be constructed in various sizes, a rate control chip which is rectangular in shape and approximately 11 cm long and approximately 5 cm wide is suitable for the present application. Similarly, while the depth of the channels can vary depending upon the end use of the device, as a general rule the depth of the channels is on the order of approximately 10-100 um.
[0130] As previously mentioned, the cross section of the set of channels may vary in area over the members of the set of individual channels so as to achieve the specified flow rate of a particular channel. The cross section may also vary over the length of any particular channel so as to achieve the specified flow rate for the particular channel. Some examples of typical channel cross sections are square, rectangular, elliptical, circular, semi-circular and semi-elliptical. Channel cross sections may also be more complicated than those noted explicitly here.
[0131] A typical rate control system of the invention will, by way of example, be able to deliver fluid at six specified flow rates as, for example 0.25, 0.5, 1.0, 2.0 and 5.0 ml/hr. For optimum performance, the flow rate should be constant and within 10% of the desired specified value.
[0132] In operation, the flow of fluid through the flow control channels is controlled by taking advantage of the viscous drag imposed on the moving fluid by the walls of the channels. For a given imposed pressure and channel cross section, the longer the channel, the smaller the flow rate. The pressure required to achieve the desired flow rates in the micron channels is preferably in the range of from 0.01 to 1 ATM. However, for some applications it may be desirable to exceed these limits.
[0133] The path that the micro channels take in any given rate control plate, or chip may be straight, a single meander or two or more meanders. The turns of the meanders may be of any angle from approximately 45° to approximately 220°. The runs of straight path between turns of the meanders may be of any length that the chip can accommodate, but these straight runs would typically be from 50 um to 500 um in length.
[0134] Referring particularly to FIG. 7 , reservoir 105 a can also be filled using an alternate form of fill means of the invention that comprises septum fill means which includes the previously identified septum 122 . Septum 122 can be pierced by the piercing needle of a conventional syringe (not shown). In a conventional manner the fluid contained within the syringe can be caused to flow through the piercing needle which has pierced septum 122 , into passageway 118 , thence into passageway 140 . From passageway 140 the fluid will flow into inlet 105 b of reservoir 105 a.
[0135] Turning next to FIGS. 27 through 46 , another form of the apparatus of the present invention is there illustrated and generally designated by the numeral 302 . This apparatus is similar in some respects to the apparatus shown in FIGS. 1 through 26 and like numerals are used in FIGS. 27 through 46 to identify like components. As best seen in FIG. 27 , the primary difference between this latest form of the invention and that shown in FIGS. 1 through 26 concerns the provision of a differently configured reservoir fill means for filling the device reservoir. More particularly, as will presently be described in greater detail, this alternate form of fill means comprises two fill vials or containers, rather than one.
[0136] As best seen in FIG. 27 , the apparatus here comprises an outer housing 304 having first and second portions 304 a and 304 b respectively. Disposed within outer housing 304 a is an inner, expandable housing 105 which is identical in construction and operation to that described in connection with the embodiment of FIGS. 1 through 26 .
[0137] Also disposed within second portion 304 a of the outer housing is the novel stored energy means of the invention for acting upon inner expandable housing 105 in a manner to cause the fluid contained within fluid reservoir 105 a thereof to controllably flow outwardly of the housing. In this latest form of the invention, this stored energy means is also identical in construction and operation to that previously described and comprises a constant force spring 107 .
[0138] With regard to the fill means of this latest form of the invention, which is also carried by first portion 304 a of the outer housing, this important fill means functions to fill the reservoir 105 a with the fluid to be dispensed. This fill means here comprises the previously described septum fill means, which is identical to that previously described and also includes a vial fill means which includes two, rather than the one, fill vial or fill container.
[0139] As to the septum fill means, as illustrated in FIG. 27 , second housing portion 304 b includes a fluid passageway 306 which is in communication with inlet 308 of fluid reservoir 105 a. Proximate its lower end 306 a, fluid passageway 306 communicates with a cavity 309 formed within the second housing portion. Disposed within cavity 309 is a pierceable septum 310 that comprises a part of the septum fill means of this latest form of the invention. As before, septum 310 is pierceable by the needle of the syringe which contains the medicinal fluid to be dispensed and which can be used in a conventional manner to fill or partially fill reservoir 105 a via passageway 306 .
[0140] First portion 304 a of the housing also includes a first chamber 312 for telescopically receiving a first medicament containing fill vial 314 and a second chamber 316 for receiving a second medicament containing vial 318 . The fill vials 314 and 318 are of identical construction to vial 130 of the earlier described embodiment. Telescopically receivable within each of the fluid chambers of the vials are elongated supports 320 . Each of the elongated supports 320 has an integrally threaded end portion 320 a and each carries a longitudinally extending, elongated hollow needle 322 . Each of the hollow needles 322 has a flow passageway that communicates with a fluid passageway 324 provided in housing portion 304 b ( FIG. 27 ). First chamber 312 , second chamber 316 , elongated supports 320 , and hollow needles 322 together comprise the alternate form of the vial fill means of the apparatus of the invention. The method of operation of this alternate form of fill means will presently be described.
[0141] A number of beneficial agents can be contained within vials 314 and 318 and can be controllably dispensed to the patient including, by way of example, medicaments of various types, drugs, pharmaceuticals, hormones, antibodies, biologically active materials, elements, chemical compounds, or any other suitable material useful in diagnostic cure, medication, treatment or preventing of diseases or the maintenance of the good health of the patient.
[0142] Forming another very important aspect of the apparatus of this latest form of the invention is a novel flow control means that are carried by second portion 304 b of outer housing 304 . This flow control means which is identical in construction and operation to that described in connection with the first embodiment of the invention, functions to precisely control the outwardly rate of fluid flow from reservoir 105 a and toward the patient. As before, the flow control means comprises an assembly which includes a base plate, or rate control member 160 and a mating cover member 162 ( FIG. 21 ). As illustrated in FIG. 22 , flow rate control member, or base plate 160 is uniquely provided with a plurality of micro rate flow control channels 160 a, 160 b, 160 c, 160 d and 160 e respectively, which are in communication with the spaced apart micro rate outlet ports of the cover member 162 . Flow rate control member, or base plate 160 is also uniquely provided with a plurality of macro rate flow control channels 173 a, 173 b, 173 c, 173 d and 173 e respectively, which are in communication with the spaced apart macro rate outlet ports of the cover member 162 .
[0143] Also forming a part of the flow control means of this latest form of the invention is a micro rate selector knob 180 that is carried within a horizontal bore 182 formed in housing portion 304 b. Selector knob 180 is of identical construction and operation to the selector knob described in connection with the first embodiment of the invention and is uniquely provided with a plurality of radially extending flow control channels 184 a, 184 b, 184 c, 184 d and 184 e, each having an inlet port and an outlet port which is in fluid communication with an axially extending passageway 186 . Axially extending passageway 186 is, in turn, in fluid communication with administration line 148 , which is also of identical construction and operation to that described in connection with the first embodiment of the invention.
[0144] Micro selector knob 180 , which comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the selector knob with a selected one of the spaced apart micro rate fluid outlets 166 a, 166 b , 166 c, 166 d and 166 e of the rate control cover 162 ( FIG. 18 ).
[0145] Also forming a part of the flow control means of this latest form of the invention is a macro rate selector knob 190 that is carried within a horizontal bore 192 formed in housing portion 304 b. Selector knob 190 is also of identical construction and operation to selector knob 190 as described in connection with the first embodiment of the invention and is uniquely provided with a plurality of radially extending flow control channels 194 a , 194 b, 194 c, 194 d and 194 e, each having an inlet port and an outlet port which it is in fluid communication with an axially extending passageway 196 . Axially extending passageway 196 is, in turn, in fluid communication with administration line 148 .
[0146] Selector knob 190 , which also comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the macro selector knob with a selected one of the spaced apart macro rate fluid outlets 170 a , 170 b, 170 c, 170 d and 170 e of the rate control cover 162 (see FIG. 18 ).
[0147] In using the apparatus of this latest form of the invention, following removal of the vial cover 327 , which forms a part of the first portion of housing 304 ( FIGS. 27 and 36 ), vials 314 and 318 can be inserted into chambers 312 and 316 respectively. As the fill vials are so introduced and the plungers 136 are threadably interconnected with ends 320 a of supports 320 , the sharp ends of the elongated needles 322 will pierce the central walls 136 a of the elastomeric plungers. Continuous movement of the vials into chambers 312 and 316 will cause the structural supports 320 to move the elastomeric plungers inwardly of the vial chambers. As the plungers move inwardly of the vials, the fluid contained within the vial chambers will be expelled therefrom into the hollow elongated needles 322 . As best seen in FIG. 27 , the fluid will then flow past umbrella type check valves 116 and into stub passageways 330 formed in second portion 304 b of the apparatus housing. From passageways 330 the fluid will flow into passageway 324 and then into reservoir 105 a of the bellows component 105 via inlet 308 . It is to be understood that the vials 316 and 318 can contain the same or different medicinal fluids and can be introduced into their respective chambers either one at a time, or simultaneously.
[0148] It is also to be understood that, if desired, the reservoir of the bellows component can also be filled by alternate filling means of the character previously described which comprises a syringe having a needle adapted to pierce the pierceable septum 310 which is mounted within second portion 304 b of the apparatus housing. As the reservoir 105 a fills with fluid either from the fill vials or from the filling syringe, any gases trapped within the reservoir will be vented to atmosphere via vent means “V”, mounted in portion 304 b of the housing.
[0149] As the fluid flows into reservoir 105 a, the bellows 105 d will expand in a manner to exert a rearward pressure on the plunger end portion 109 a of pusher member 109 causing it to move rearwardly. As the pusher member moves rearwardly, it will exert forces on spring member 107 causing it to it to expand from its retracted configuration shown in FIG. 27 to its expanded configuration. This rearward movement of pusher member 109 can be viewed through the volume indicator window 142 indicating that the reservoir has changed from an empty configuration to a filled configuration ( FIG. 1 ).
[0150] As before selector knobs 180 and 190 are provided with a plurality of circumferentially spaced apart indexing cavities that closely receive the ends of the indexing fingers of outwardly extending locking arms 208 , which forms a part of the flow control means of the invention and function to prevent rotation of the selector knobs (see FIGS. 6 and 13 ). Similarly disabling means of the character previously described can be used to disable the apparatus of this latest form of the invention.
[0151] Turning next to FIGS. 37 through 46 , still another form of the apparatus of the present invention is there illustrated and generally designated by the numeral 402 . This alternate form of the apparatus of the invention is also similar in many respects to that shown in FIGS. 1 through 26 and like numerals are used in FIGS. 37 through 46 to identify like components. The primary difference between this latest form of the invention and that shown in FIGS. 1 through 26 is that the vial fill means for filling the device reservoir is of a different configuration from that used in both the first and second, previously described embodiments of the invention. More particularly, as will presently be described in greater detail, this alternate form of vial fill means comprises a vial cartridge having a hollow glass or plastic body portion that defines a fluid chamber that is closed by a pierceable, elastomeric septum.
[0152] As best seen in FIG. 37 , the apparatus here comprises an outer housing 404 having first and second portions 404 a and 404 b respectively. Disposed within outer housing 404 is an inner, expandable housing 105 which is identical in construction and operation to that described in connection with the embodiment of FIGS. 1 through 26 .
[0153] Also disposed within housing 404 is the novel stored energy means of the invention for acting upon expandable housing 105 in a manner to cause the fluid contained within fluid reservoir 105 a thereof to controllably flow outwardly of the housing. In this latest form of the invention, this stored energy means is also identical in construction and operation to that previously described and comprises a constant force spring 107 .
[0154] With regard to the fill means of this latest form of the invention, which is carried by the first portion 404 a of the outer housing, as before, this important fill means functions to fill the reservoir 105 a with the fluid to be dispensed. This fill means here comprises the previously described septum fill means which is identical to that previously described, and also includes the previously mentioned, cartridge type vial fill vial which is of the construction best seen in FIG. 37 of the drawings. As to the septum fill means, as illustrated in FIG. 37 , second portion 404 b includes a fluid passageway 408 which is in communication with inlet 410 of fluid reservoir 105 a. Proximate its lower end 408 a, fluid passageway 408 communicates with a cavity 414 formed within the second portion 404 b of the housing. Disposed within cavity 414 is a pierceable septum 416 that comprises a part of the septum fill means of this latest form of the invention. As before, septum 416 is held in position by a retainer 416 a and is pierceable by the needle of the syringe which contains the medicinal fluid to be dispensed and which can be used in a conventional manner to fill or partially fill reservoir 105 a via passageway 408 .
[0155] First portion 404 a of the housing also includes a first chamber 418 for telescopically receiving the previously mentioned cartridge fill vial, which is generally designated in the drawings by the numeral 420 . As shown in FIG. 37 , cartridge fill vial 420 comprises a hollow glass or plastic body portion 422 that defines a fluid chamber 422 b. Fill vial 420 has an open first end 422 a and a second end 424 that is closed by a pierceable, elastomeric septum 426 . An elastomeric plunger 428 is reciprocally movable within fluid chamber 424 . As shown in FIG. 37 , a hollow needle 430 is mounted within second portion 404 b of the device housing and is located proximate the inboard end of chamber 424 . Hollow needle 430 is adapted to pierce septum 426 when the fill vial is inserted into chamber 418 and pushed into the position shown in FIG. 37 .
[0156] A number of beneficial agents can be contained within vial 420 and can be controllably dispensed to the patient including, by way of example, medicaments of various types, drugs, pharmaceuticals, hormones, antibodies, biologically active materials, elements, chemical compounds, or any other suitable material useful in diagnostic cure, medication, treatment or preventing of diseases or the maintenance of the good health of the patient.
[0157] Forming an important aspect of the apparatus of this latest form of the invention is a novel flow control means that is carried by second portion 404 b of outer housing 404 . This flow control means which is identical in construction and operation to that described in connection with the first embodiment of the invention, functions to precisely control the outwardly rate of fluid flow from reservoir 105 a and toward the patient.
[0158] As before, the flow control means comprises an assembly which includes a base plate, or rate control member 160 and a mating cover member 162 ( FIG. 21 ). As illustrated in FIG. 22 , flow rate control member, or base plate 160 is uniquely provided with a plurality of micro rate flow control channels 160 a, 160 b, 160 c, 160 d and 160 e respectively, which are in communication with the spaced apart micro rate outlet ports of the cover member 162 . Flow rate control member, or base plate 160 is also uniquely provided with a plurality of macro rate flow control channels 173 a , 173 b, 173 c, 173 d and 173 e respectively, which are in communication with the spaced apart macro rate outlet ports of the cover member 162 .
[0159] Also forming a part of the flow control means of this latest form of the invention is a micro rate selector knob 180 that is carried within a horizontal bore 182 formed in housing portion 404 b. Selector knob 180 is of identical construction and operation to the selector knob described in connection with the first embodiment of the invention and is uniquely provided with a plurality of radially extending flow control channels 184 a, 184 b, 184 c, 184 d and 184 e, each having an inlet port and an outlet port which is in fluid communication with an axially extending passageway 186 . Axially extending passageway 186 is, in turn, in fluid communication with administration line 148 , which is also of identical construction and operation to that described in connection with the first embodiment of the invention.
[0160] Micro selector knob 180 , which comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the selector knob with a selected one of the spaced apart micro rate fluid outlets 166 a, 166 b , 166 c, 166 d and 166 e of the rate control cover 162 ( FIG. 18 ).
[0161] Also forming a part of the flow control means of this latest form of the invention is a macro rate selector knob 190 that is carried within a horizontal bore 192 formed in housing portion 404 b. Selector knob 190 is also of identical construction and operation to selector knob 190 as described in connection with the first embodiment of the invention and is uniquely provided with a plurality of radially extending flow control channels 194 a , 194 b, 194 c, 194 d and 194 e, each having an inlet port and an outlet port which it is in fluid communication with an axially extending passageway 196 . Axially extending passageway 196 is, in turn, in fluid communication with administration line 148 .
[0162] Selector knob 190 , which also comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the macro selector knob with a selected one of the spaced apart macro rate fluid outlets 170 a , 170 b, 170 c, 170 d and 170 e of the rate control cover 162 (see FIG. 18 ).
[0163] In using the apparatus of this latest form of the invention, following removal of the vial cover 433 , which forms a part of the first portion of housing 404 ( FIGS. 37 and 46 ), vial 420 can be inserted into chamber 418 . As previously mentioned, plunger 428 is disposed within vial 420 and is moved by a support 436 of a vial cover 433 ( FIG. 46 ) as the vial cover is mated with the apparatus housing. As plunger 428 moves inwardly of vial reservoir 424 , the fluid contained in the reservoir will be forced through hollow needle 430 , passed the umbrella check valve 116 mounted within third housing portion 405 , into a stub passageway 440 , into passageway 408 and finally into reservoir 105 a of the bellows component 105 via inlet 410 .
[0164] It is also to be understood that, if desired, the reservoir of the bellows component can also be filled by alternate filling means of the character previously described which comprises a syringe having a needle adapted to pierce the pierceable septum 416 which is mounted within second portion 404 b of the apparatus housing. As the reservoir 105 a fills with fluid either from the fill vials or from the filling syringe, any gases trapped within the reservoir will be vented to atmosphere via vent means “V”, mounted in portion 404 b of the housing.
[0165] As the fluid flows into reservoir 105 a, the bellows 105 d will expand in a manner to exert a rearward pressure on the plunger end portion 109 a of pusher member 109 causing it to move rearwardly. As the pusher member moves rearwardly, it will exert forces on spring member 107 causing it to expand from its retracted configuration shown in FIG. 37 to its expanded configuration. This rearward movement of pusher member 109 can be viewed through the volume indicator window 142 indicating that the reservoir has changed from an empty configuration to a filled configuration ( FIG. 1 ).
[0166] As before selector knobs 180 and 190 are provided with a plurality of circumferentially spaced apart indexing cavities that closely receive the ends of the indexing fingers of outwardly extending locking arms 208 , which forms a part of the flow control means of the invention and function to prevent rotation of the selector knobs (see FIGS. 6 and 13 ). Similarly disabling means of the character previously described can be used to disable the apparatus of this latest form of the invention.
[0167] Turning next to FIGS. 47 through 56 , still another form of the apparatus of the present invention is there illustrated and generally designated by the numeral 502 . This alternate form of the apparatus of the invention is similar in some respects to the apparatus shown in FIGS. 27 through 46 and like numerals are used in FIGS. 47 through 56 to identify like components. As best seen in FIG. 47 , the primary difference between this latest form of the invention and that shown in FIGS. 27 through 46 concerns the provision of a differently configured reservoir fill means for filling the device reservoir. More particularly, as will presently be described in greater detail, this alternate form of fill means comprises two fill vials or containers, rather than one.
[0168] As best seen in FIG. 47 , the apparatus here comprises an outer housing 504 having first and second portions 504 a and 504 b respectively. Disposed within outer housing 504 a is an inner, expandable housing 105 which is identical in construction and operation to that described in connection with the embodiment of FIGS. 1 through 26 .
[0169] Also disposed within second portion 504 a of the outer housing is the novel stored energy means of the invention for acting upon inner expandable housing 105 in a manner to cause the fluid contained within fluid reservoir 105 a thereof to controllably flow outwardly of the housing. In this latest form of the invention, this stored energy means is also identical in construction and operation to that previously described and comprises a constant force spring 107 .
[0170] With regard to the fill means of this latest form of the invention, which is also carried by first portion 504 a of the outer housing, this important fill means functions to fill the reservoir 105 a with the fluid to be dispensed. This fill means comprises the previously described septum fill means which is identical to that previously described, and also includes a vial fill means which includes two, rather than the one, fill vial or fill container.
[0171] As to the septum fill means, as illustrated in FIG. 47 , second housing portion 504 b includes a fluid passageway 506 which is in communication with inlet 508 of fluid reservoir 105 a. Proximate its lower end 506 a, fluid passageway 506 communicates with a cavity 509 formed within the second housing portion. Disposed within cavity 509 is a pierceable septum 510 that comprises a part of the septum fill means of this latest form of the invention.
[0172] As before, septum 510 is pierceable by the needle of the syringe which contains the medicinal fluid to be dispensed and which can be used in a conventional manner to fill or partially fill reservoir 105 a via passageway 506 .
[0173] First portion 504 a of the housing also includes a first chamber 512 for telescopically receiving the first medicament containing fill vial 420 and a second chamber 516 for receiving a second medicament containing vial 518 . First vial 420 , which is of identical construction to vial 420 of the earlier described embodiment, comprises a vial cartridge having a hollow glass or plastic body portion that defines a fluid chamber that is closed by a pierceable, elastomeric septum. However, the second vial cartridge 518 is of a uniquely different construction from the previously described medicament containing vials. More particularly, as will be discussed in greater detail hereinafter, this second vial cartridge is specially designed to enable the intermixing of a lypholized drug with suitable diluents prior to the delivery of the mixture to the fluid reservoir of the device.
[0174] A number of beneficial agents can be contained within vials 420 and 518 and can be controllably dispensed to the patient, including, by way of example, medicaments of various types, drugs, pharmaceuticals, hormones, antibodies, biologically active materials, elements, chemical compounds, or any other suitable material useful in diagnostic cure, medication, treatment or preventing of diseases or the maintenance of the good health of the patient.
[0175] As in the earlier described embodiments of the invention, another very important aspect of the apparatus of this latest form of the invention is a novel flow control means that are carried by second portion 504 b of outer housing 504 . This flow control means which is identical in construction and operation to that described in connection with the first embodiment of the invention, functions to precisely control the outwardly rate of fluid flow from reservoir 105 a and toward the patient. As before, the flow control means comprises an assembly which includes a base plate, or rate control member 160 and a mating cover member 162 ( FIG. 21 ). As illustrated in FIG. 22 , flow rate control member, or base plate 160 is uniquely provided with a plurality of micro rate flow control channels 160 a, 160 b, 160 c, 160 d and 160 e respectively, which are in communication with the spaced apart micro rate outlet ports of the cover member 162 . Flow rate control member, or base plate 160 is also uniquely provided with a plurality of macro rate flow control channels 173 a, 173 b, 173 c, 173 d and 173 e respectively, which are in communication with the spaced apart macro rate outlet ports of the cover member 162 .
[0176] Also forming a part of the flow control means of this latest form of the invention is a micro rate selector knob 180 that is carried within a horizontal bore 182 formed in member 406 . Selector knob 180 is of identical construction and operation to the selector knob described in connection with the first embodiment of the invention and is uniquely provided with a plurality of radially extending flow control channels 184 a, 184 b, 184 c, 184 d and 184 e, each having an inlet port and an outlet port which is in fluid communication with an axially extending passageway 186 . Axially extending passageway 186 is, in turn, in fluid communication with administration line 148 , which is also of identical construction and operation to that described in connection with the first embodiment of the invention.
[0177] Micro selector knob 180 , which comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the selector knob with a selected one of the spaced apart micro rate fluid outlets 166 a, 166 b , 166 c, 166 d and 166 e of the rate control cover 162 ( FIG. 18 ).
[0178] Also forming a part of the flow control means of this latest form of the invention is a macro rate selector knob 190 that is carried within a horizontal bore 192 formed in member 405 . Selector knob 190 is also of identical construction and operation to selector knob 190 as described in connection with the first embodiment of the invention and is uniquely provided with a plurality of radially extending flow control channels 194 a, 194 b, 194 c, 194 d and 194 e, each having an inlet port and an outlet port which it is in fluid communication with an axially extending passageway 196 . Axially extending passageway 196 is, in turn, in fluid communication with administration line 148 .
[0179] Selector knob 190 , which also comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the macro selector knob with a selected one of the spaced apart macro rate fluid outlets 170 a , 170 b, 170 c, 170 d and 170 e of the rate control cover 162 (see FIG. 18 ).
[0180] With respect to cartridge fill vial 420 , as before, this fill vial comprises a hollow glass or plastic body portion 422 that defines a fluid chamber 424 . Fill vial 420 has an open first end 422 a and a second end 424 that is closed by a pierceable, elastomeric septum 426 . An elastomeric plunger 428 is reciprocally movable within fluid chamber 424 . As shown in FIG. 47 , a hollow needle to 430 is mounted within second portion 504 b of the device housing and is located proximate the inboard end of chamber 424 .
[0181] With respect to second cartridge fill vial 518 , this vial comprises a container of special design that includes a chamber 519 and uniquely contains a lyophilized drug 537 that is separated from a reconstituting fluid 539 by a barrier stopper 542 ( FIG. 47A ). Lyophilized drug 537 can, by way of example, comprise anti-infectives or various other types of beneficial agents. Second fill vial 518 also includes an elastomeric plunger 544 that is reciprocally movable within fluid chamber 519 .
[0182] As illustrated in FIGS. 47 and 56 , the removable cover 523 of the device housing includes a pair of spaced apart pusher members 544 and 546 which engage plungers 428 and 544 respectively to push them forwardly of their respective container chambers.
[0183] Considering in more detail the novel vial assembly 518 , as best seen in FIG. 47A , this vial assembly comprises a vial 545 that is sealed at one end by plunger 544 and at the other end by a pierceable septum 548 ( FIGS. 47 and 47A ). Formed intermediate the ends of vial 545 is a raised outer wall portion 547 which permits fluid 539 to bypass a barrier stopper 542 as the barrier stopper is urged inwardly of the container by pressure exerted thereon by the fluid 539 . Fluid 539 exerts pressure on barrier member 542 as a result of pusher member 546 exerting inward pressure on plunger 544 , which pressure is, in turn, caused by the inward movement of plunger 544 as the cover 523 is mated with the apparatus housing.
[0184] A continued inward pressure exerted on plunger 544 will cause fluid 539 to flow past barrier member 542 via wall portion 547 so as to reconstitute lyophilized drug 537 . Continued pressure exerted on plunger 543 will cause the reconstituted drug formed by the fluid 539 which has been intermixed with drug 537 to flow through a hollow needle 550 which is carried by housing portion 504 b, past a lower check valve 552 , into a stub passageway 554 , then into passageway 506 and finally into the device reservoir 105 a.
[0185] As the vial cover 523 is mated with the apparatus housing, pusher member 544 engages plunger 428 of vial 420 and moves it inwardly of vial reservoir 424 . Continued inward movement of the pusher member causes the fluid contained in the reservoir to be forced through a hollow needle 430 , passed the upper umbrella check valve 556 mounted within second housing portion 504 b, into a stub passageway 558 , into a passageway 506 and finally into the device reservoir.
[0186] As the fluid flows into reservoir 105 a, it will compress the stored energy means, or constant force spring 107 in the manner previously described.
[0187] Upon opening the fluid delivery path to the administration set, the stored energy means, or member 107 , will tend to return to its starting configuration thereby controllably urging fluid flow outwardly of reservoir 105 a via the flow control means of the invention which functions in the manner previously described.
[0188] As in the earlier described embodiments, disabling means of the character previously described can be used to disable the apparatus of this latest form of the invention.
[0189] Turning next to FIGS. 57 through 67 , another form of the apparatus of the present invention is there illustrated and generally designated by the numeral 602 . This apparatus is similar in some respects to the apparatus shown in FIGS. 37 through 46 and like numerals are used in FIGS. 57 through 67 to identify like components. As best seen in FIG. 57 , the primary difference between this latest form of the invention and that shown in FIGS. 37 through 46 concerns the provision of a differently configured reservoir fill means for filling the device reservoir. More particularly, as will presently be described in greater detail, this alternate form of fill means comprises two cartridge type fill vials or containers, rather than one.
[0190] As best seen in FIG. 57 , the apparatus here comprises an outer housing 604 having first and second portions 604 a and 604 b respectively. Disposed within outer housing 604 a is an inner, expandable housing 105 which is identical in construction and operation to that described in connection with the embodiment of FIGS. 1 through 26 .
[0191] Also disposed within second portion 604 a of the outer housing is the novel stored energy means of the invention for acting upon inner expandable housing 105 in a manner to cause the fluid contained within fluid reservoir 105 a thereof to controllably flow outwardly of the housing. In this latest form of the invention, this stored energy means is also identical in construction and operation to that previously described and comprises a constant force spring 107 .
[0192] With regard to the fill means of this latest form of the invention, which is also carried by first portion 604 a of the outer housing, this important fill means functions to fill the reservoir 105 a with the fluid to be dispensed. This fill means comprises the previously described septum fill means, which is identical to that previously described and also includes a vial fill means which includes two, rather than the one, fill vial or fill container.
[0193] As to the septum fill means, as illustrated in FIG. 57 , second housing portion 604 b includes a fluid passageway 606 which is in communication with inlet 608 of fluid reservoir 105 a. Proximate its lower end 606 a, fluid passageway 606 communicates with a cavity 609 formed within the second housing portion. Disposed within cavity 609 is a pierceable septum 610 that comprises a part of the septum fill means of this latest form of the invention. As before, septum 610 is pierceable by the needle of a syringe which contains the medicinal fluid to be dispensed and which can be used in a conventional manner to fill or partially fill reservoir 105 a via passageway 606 .
[0194] First portion 604 a of the housing also includes a first chamber 612 for telescopically receiving a first medicament containing fill vial 420 and a second chamber 616 for receiving a second medicament containing vial 420 . The fill vials 420 are of identical construction and operation to vial 420 of the earlier described embodiment and the details of their construction will not here be repeated.
[0195] A number of beneficial agents can be contained within the two vials 420 and can be controllably dispensed to the patient including, by way of example, medicaments of various types, drugs, pharmaceuticals, hormones, antibodies, biologically active materials, elements, chemical compounds, or any other suitable material useful in diagnostic cure, medication, treatment or preventing of diseases or the maintenance of the good health of the patient.
[0196] Forming another very important aspect of the apparatus of this latest form of the invention is a novel flow control means that are carried by second portion 604 b of outer housing 604 . This flow control means, which is identical in construction and operation to that described in connection with the first embodiment of the invention, functions to precisely control the rate outwardly of fluid flow from reservoir 105 a and toward the patient. As before, the flow control means comprises an assembly which includes a base plate, or rate control member 160 and a mating cover member 162 ( FIG. 21 ). As illustrated in FIG. 22 , flow rate control member, or base plate 160 is uniquely provided with a plurality of micro rate flow control channels 160 a, 160 b, 160 c, 160 d and 160 e respectively, which are in communication with the spaced apart micro rate outlet ports of the cover member 162 . Flow rate control member, or base plate 160 is also uniquely provided with a plurality of macro rate flow control channels 173 a, 173 b, 173 c, 173 d and 173 e respectively, which are in communication with the spaced apart macro rate outlet ports of the cover member 162 .
[0197] Also forming a part of the flow control means of this latest form of the invention is a micro rate selector knob 180 that is carried within a horizontal bore 182 formed in housing portion 604 b. Selector knob 180 is of identical construction and operation to the selector knob described in connection with the first embodiment of the invention and is uniquely provided with a plurality of radially extending flow control channels 184 a, 184 b, 184 c, 184 d and 184 e, each having an inlet port and an outlet port which is in fluid communication with an axially extending passageway 186 . Axially extending passageway 186 is, in turn, in fluid communication with administration line 148 , which is also of identical construction and operation to that described in connection with the first embodiment of the invention.
[0198] Micro selector knob 180 , which comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the selector knob with a selected one of the spaced apart micro rate fluid outlets 166 a, 166 b , 166 c, 166 d and 166 e of the rate control cover 162 ( FIG. 18 ).
[0199] Also forming a part of the flow control means of this latest form of the invention is a macro rate selector knob 190 that is carried within a horizontal bore 192 formed in housing portion 604 b. Selector knob 190 is also of identical construction and operation to selector knob 190 as described in connection with the first embodiment of the invention and is uniquely provided with a plurality of radially extending flow control channels 194 a , 194 b, 194 c, 194 d and 194 e, each having an inlet port and an outlet port which it is in fluid communication with an axially extending passageway 196 . Axially extending passageway 196 is, in turn, in fluid communication with administration line 148 .
[0200] Selector knob 190 , which also comprises a part of the selector means of this latest form of the invention, functions to selectively align one of the inlets of the radially extending flow control channels of the macro selector knob with a selected one of the spaced apart macro rate fluid outlets 170 a , 170 b, 170 c, 170 d and 170 e of the rate control cover 162 (see FIG. 18 ).
[0201] In using the apparatus of this latest form of the invention, following removal of the vial cover 623 , which forms a part of the first portion of housing 604 ( FIGS. 57 and 67 ), vials 420 can be inserted into chambers 612 and 616 . As previously mentioned, plungers 428 are disposed within vials 420 and are moved by supports 626 of a vial cover 623 ( FIGS. 57 and 67 ) as the vial cover is mated with the apparatus housing. As the plungers 428 move inwardly of their respective vial reservoirs 424 , the fluid contained in the reservoirs will be forced through hollow needles 430 , passed the umbrella check valves 116 mounted within housing portion 604 b , into a stub passageways 630 , into passageway 606 and finally into reservoir 105 a of the bellows component 105 via inlet 608 .
[0202] It is also to be understood that, if desired, the reservoir of the bellows component can also be filled by alternate septum filling means of the character previously described. As the reservoir 105 a fills with fluid either from the fill vials or from the filling syringe of the alternate septum filling means, any gases trapped within the reservoir will be vented to atmosphere via vent means “V”, mounted in portion 604 b of the housing.
[0203] As the fluid flows into reservoir 105 a, the bellows 105 d will expand in a manner to exert a rearward pressure on the plunger end portion 109 a of pusher member 109 causing it to move rearwardly. As the pusher member moves rearwardly, it will exert forces on spring member 107 causing it to it to expand from its retracted configuration shown in FIG. 57 to its expanded configuration. This rearward movement of pusher member 109 can be viewed through the volume indicator window 142 indicating that the reservoir has changed from an empty configuration to a filled configuration ( FIG. 1 ).
[0204] As before selector knobs 180 and 190 are provided with a plurality of circumferentially spaced apart indexing cavities that closely receive the ends of the indexing fingers of outwardly extending locking arms 208 , which forms a part of the flow control means of the invention and function to prevent rotation of the selector knobs (see FIGS. 6 and 13 ). Similarly disabling means of the character previously described can be used to disable the apparatus of this latest form of the invention.
[0205] Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims. | A compact fluid dispenser for use in controllably dispensing fluid medicaments, such as, antibiotics, analgesics, and like medicinal agents from the device reservoir which is provided in the form of a novel bellows type assembly. The fluid dispenser includes a unique stored energy mechanism which takes the form of a constant force spring member of novel design that provides the force necessary to continuously and substantially uniformly expel fluid from the device reservoir. The device also includes novel adjustable flow rate control assembly that is disposed intermediate the fluid reservoir outlet and the outlet port of the device for precisely controlling the rate of fluid flow from the outlet port toward the patient. | 0 |
TECHNICAL FIELD
[0001] The application of innovative micro and nano vesicle forming technologies to effect beneficial results through the application of synthetic and natural ingredients to the skin has shown a great potential to significantly benefit the cosmetic formulation practice, offering solutions to many of the current limitations in ingredients, treatment style and management of human skin effected by environmental and physiological impact.
BACKGROUND
[0002] A liposome vesicle encapsulates a region of aqueous solution inside a hydrophobic membrane; dissolved hydrophilic solutes cannot readily pass through the lipids. Hydrophobic chemicals can be dissolved into the membrane, and in this way liposome can carry both hydrophobic molecules and hydrophilic molecules.
[0003] Several CFs (Compressed Fluid) methodologies have been used to generate vesicles, some of them already existed and others were developed for this specific application. Most of the methods involve a mixture between the compressed CO2, the vesicle membrane constituents and an organic solvent for producing the vesicles upon contact with an aqueous phase.
[0004] Depending on the role of the compressed CO2 used in each method, they can be classified as: Process involving the use of CO2 as a solvent (e.g. Supercritical Liposome Method and Rapid Expansion of Supercritical Solutions), Processes involving the use of CO2 as an anti-solvent (e.g. Gas Antisolvent Precipitation and Aerosol Solvent Extraction System) and Processes involving the use of CO2 as a co-solvent or a processing aid (e.g. Depressurization of an Expanded Liquid Organic Solution-Suspension and Supercritical Reverse Phase Evaporation).
[0005] Model hydrophilic and hydrophobic compounds, such as fluorescent dyes, sugars and cholesterol, have been encapsulated into vesicles using these methodologies whereas biomolecules like proteins, anticancer drugs and antibiotic, have been integrated in less extent.
[0006] Transdermal delivery systems (TDS) were introduced onto the US market in the late 1970s), but transdermal delivery of drugs had been around for a very long time. There have been previous reports about the use of mustard plasters to alleviate chest congestion and belladonna plasters used as analgesics. The mustard plasters were homemade as well as available commercially where mustard seeds were ground and mixed with water to form a paste, which was in turn used to form a dispersion type of delivery system.
[0007] Once applied to the skin, enzymes activated by body heat led to the formation of an active ingredient (allyl isothiocyanate). Transport of the active drug component took place by passive diffusion across the skin—the very basis of transdermal drug delivery.
[0008] The epi-dermis undergoes changes in structure and function which result in many of the characteristics of aged skin, including loss of elasticity, formation of wrinkles, loss of water-holding capacity, sagging, and poor microcirculation. At the molecular level, these changes have been correlated with biochemical changes in the content and structure of the extracellular matrix to which the major cells of the epi-dermis (i.e., the fibroblasts) reside. Collagen becomes highly cross-linked and inelastic, elastin is reduced in amounts and is incorrectly distributed, which results in reduced intercellular water for reduction and repair of these changes. Nonsurgical options include chemical peels and chemicals with minor irritant properties (e.g., topical retinoid, salicylic acid, and alpha-hydroxy acids), are based on the principle of wounding the stratum corneum—the skin's primary defense against the transit of exogenous materials into the epidermis and dermis—to allow the penetration of constituents through the disrupted skin, which stimulates the desired response, typically restorative healing. All of these techniques require a wound healing response to the skins being intentionally wounded as a method to initiate the rejuvenation process.
[0009] Owing to the selective nature of the skin barrier, only a small pool of ingredients can be delivered non-systemically or systemically at therapeutically relevant rates. Besides great potency, the physicochemical ingredient characteristics often evoked as favorable for percutaneous delivery include moderate lipophilicity and low-molecular-weight. However, a large number of skin damage mitigating active agents do not fulfill these criteria.
[0010] Chemical permeation enhancers facilitate drug permeation across the skin by increasing drug partitioning into the barrier domain of the stratum corneum, increasing drug diffusivity in the barrier domain of the stratum corneum or the combination of both (2).
[0011] The heterogeneous stratum corneum is composed of keratin ‘bricks’ and intercellular continuous lipid ‘mortar’ organized in multilamellar strata (3)(4)(5). Depending on the nature of the drug or ingredient, either of these two environments may be the rate-limiting milieu (barrier domain) for the percutaneous transport.
[0012] As a consequence, it is anticipated that the magnitude of permeation improvement obtained with a given permeation enhancer will vary between lipophilic and hydrophilic ingredients. Several mechanisms of action are known: increasing fluidity of stratum corneum lipid bilayers, extraction of intercellular lipids, increase of ingredient's thermodynamic activity, increase in stratum corneum hydration, alteration of proteinaceous corneocyte components and others.
[0013] The stratum corneum is a formidable barrier to exogenous agents including cosmeceutical ingredients. Therefore, it is often necessary to add permeation-enhancing chemicals to aid beneficial constituents in passing through the stratum corneum. Permeation-enhancing chemicals include fatty acids, organic solvents (i.e., acetone and ethanol), alcohols, esters and surfactants.
[0014] It is generally understood that for enhancers, increased potency is directly correlated with increased skin irritation. Difficulty in reducing the irritation of these agents has been expressed since the same mechanisms responsible for increasing permeation cause irritation. While potent enhancers are effective at transiently compromising the integrity of the stratum corneum barrier, their action is not entirely limited to the stratum corneum and the interaction with viable epidermis can cause cytotoxicity and irritation. Published methods for reducing the skin irritation of permeation enhancers include combining permeation enhancers (synergistic mixtures) and manipulation of their chemical structures.
[0015] Conventional lipid or niosome vesicle production techniques have drawbacks such as complex and time consuming procedures involving organic solvents. For liposomes, conventional methods can involve harsh conditions that result in denaturation of the lipids and active ingredients, and also cause poor ingredient encapsulation efficiency.
[0016] Since the liposomes were first used as drug carriers in 1970s. Many methods, such as Supercritical fluids (SCFs), for preparing liposomes have been developed, but these methods require large amounts of organic solvents like chloroform, ether, freon, methylenechloride and methanol that are harmful to the environment and the human body, and very few methods have been developed that yield liposomes that have a high trapping efficiency for water soluble substances without using any organic solvent.
[0017] Additionally, all these methods are not suitable for mass production of liposomes because they consist of many steps. With the advent of Green Chemistry in the early 1990s, the surge of supercritical fluids (SCFs) increased vastly.
[0018] The supercritical state of a fluid (SCF) is intermediate between that of gas and liquids. The SCF has been used widely in pharmaceutical industrial operations including crystallization, particle size reduction, drug delivery preparation, coating and product sterilization. In the pharmaceutical field, supercritical carbon dioxide (scCO2) is by far the most commonly used gas, which can become supercritical at conditions that are equal or exceed its critical temperature of 31.1° C. and its critical pressure of 7.38 Megapascals (Mpa).
[0019] The encapsulation degree of any drug into vesicles is influenced by several parameters related to the: a) vesicle composition, b) the nature of the cosmeceutical ingredient and c) the preparation methodology. Regarding the vesicle composition, besides the selection of the lipids forming the membrane and the presence of charges on it, the type of vesicle plays also an important role. Thus, for hydrophilic drugs, such as proteins or peptides, the encapsulation degree appears to increase in the following order: MLV<SUV<LUV. ( FIG. 1.0 ) Nevertheless in the case of hydrophobic drugs, the size and type of liposomes do not seem to play a major role.
[0020] Liposomes with a single bilayer are known as unilamellar vesicles (UV). UVs may be made extremely small (SUVs) or large (LUVs) ( FIG. 3.0 ). Liposomes are prepared in the laboratory by sonication, detergent dialysis, ethanol injection, French press extrusion, ether infusion, and reverse phase evaporation.
[0021] These methods often leave residuals such as detergents or organics with the final liposome. From a production standpoint, it is clearly preferable to utilize procedures which do not use organic solvents since these materials must be subsequently removed.
[0022] Some of the methods impose harsh or extreme conditions which can result in the denaturation of the phospholipid raw material and encapsulated ingredients. These methods are not readily scalable for mass production of large volumes of liposomes.
[0023] Several methods, such as energy input in the form of sonic energy (sonication) or mechanical energy (extrusion), exist for producing MLVs (multilamellar vesicles), LUVs and SUVs without the use of organic solvents.
[0024] MLVs (multilamellar vesicles), free of organic solvents, are usually prepared by agitating lipids in the presence of water. The MLVs are then subjected to several cycles of freeze thawing in order to increase the trapping efficiencies for water soluble ingredients.
[0025] MLVs are also used as the starting materials for LUV and SUV production. One approach of creating LUVs, free of organic solvents, involves the high pressure extrusion of MLVs through polycarbonate filters of controlled pore size. SUVs can be produced from MLVs by sonication,
[0026] French press or high pressure homogenization techniques. High pressure homogenization has certain limitations. High pressure homogenization is useful only for the formation of SUVs. In addition, high pressure homogenization may create excessively high temperatures.
[0027] Contrary to the present embodiment, extremely high pressures are associated with equipment failures. High pressure homogenization does not insure end product sterility. High pressure homogenization is associated with poor operability because of valve plugging and poor solution recycling.
[0028] The use of liposomes for the delivery and controlled release of therapeutic drugs requires relatively large supplies of liposomes suitable for in vivo use ( FIG. 6.0 ). Present laboratory scale methods lack reproducibility, in terms of quantity and quality of encapsulated ingredients, lipid content and integrity, and liposome size distribution and captured volume.
[0029] The multidimensional characteristics of the ingredient and the liposome, as well as potential raw material variability, influence reproducibility. Present state-of-the-art liposome and niosome products are not stable. It is desirable to have final formulations which are stable for six months to two years at room temperature or at refrigeration temperature.
[0030] Present liposome products are difficult to sterilize. Sterility is currently accomplished by independently sterilizing the component parts lipid, buffer, ingredient and watery autoclave or filtration and then mixing in a sterile environment.
[0031] This sterilization process is difficult, time consuming and expensive since the product must be demonstratively sterile after several processing steps. Heat sterilization of the finished product is not possible since heating liposomes or niosomes does irreparable damage. Filtration through 0.22 micron filters may also alter the features of multilayered liposomes and elastic niosomes.
[0032] Gamma ray treatment, not commonly used in the pharmaceutical industry, may disrupt liposome or elastic niosome membranes. Picosecond laser sterilization is still experimental and has not yet been applied to the sterilization of any commercial pharmaceutical.
[0033] In the past two decades, several cosmetic formulations based on ingredient delivery systems have been successfully introduced for the treatment of skin disorders. Many problems exhibited by free active cosmetic ingredients (ACIs), such as poor solubility, toxicity, rapid in vivo breakdown, unfavorable pharmacokinetics, poor bio distribution and lack of selectivity for target tissues can be ameliorated by the use of a VDS (vesicle delivery system) as offered by the current embodiment. Although a whole range of delivery agents exist nowadays, the main components typically include a nanocarrier, a targeting moiety conjugated to the nanocarrier, and a cargo, such as the desired cosmeceutical ingredient.
[0034] In 1846, Gobley separated phospholipids from egg yolk. The term “lecithin” which is derived from the Greek lekithos was first used to describe a sticky orange material isolated from egg yolk. “Lecithin” refers to the lipids containing phosphorus isolated from eggs and brains; (3) from a scientific point of view, “lecithin” refers to PCs (phosphatidylcholine) the most common phospholipid, egg yolks, liver, wheat germ and peanuts contain the phospholipid lecithin.
[0035] Phospholipids ( FIG. 3.0 ) have excellent biocompatibility. In addition, phospholipids are renowned for their amphiphilic structures. The amphiphilicity confers phospholipids with self-assembly, emulsifying and wetting characteristics. When introduced into aqueous milieu, phospholipids self-assembly generates different super molecular structures which are dependent on their specific properties and conditions.
[0036] In the need for synthetic analogs of natural phospholipids, further synthetic phospholipids were for instance designed to optimize the targeting properties of liposomes. Examples are the PEG-ylated phospholipids and the cationic phospholipid 1,2-diacyl-P—O ethylphosphatidylcholine. Also attempts were made to convert by organic chemical means phospholipids into pharmacological active molecules (for instance ether phospholipids or to make phospholipid pro-drugs.
[0037] DPPC is the major constituent of stratum corneum surfactants which controls the dynamic surface tension (DST) and helps maintaining the epi-dermis health. It is also one of the most popular phospholipids used for preparing lipid or niosome bilayers and model biological membranes.
SUMMARY
[0038] The present embodiment features methods and apparatus for producing liposomes and niosomes containing hydrophobic and hydrophilic ingredients know to be beneficial to the repair and rejuvenation to the stratum corneum and underlying epi-dermis with the ability to effect non-systemic drug absorption and transportation are influenced by various factors. The methods and apparatus are suitable for large scale production of pharmaceutical grade liposomes which are sterile, of a predetermined size, and are substantially free of organic solvents. The present embodiment features a method of making liposomes and elastic niosomes using low pressure fluids.
[0039] As constructed according to the present embodiment example, nano and macro carriers can be either unimolecular (i.e.: dendrimers, carbon nanotubes, polymer-conjugate drug/protein, etc.) or multimolecular carries, based on molecular self-assemblies (nanoshells, vesicles, etc.). Their major constituents are either lipids or polymers and they all have in common that the final arrangement is governed by the nature of the initial components and the methodology used in their preparation. Some of the advantages are the incorporation of ACIs (active cosmeceutical ingredients).
[0040] One method of the example embodiment comprises the steps of forming a solution or mixture of a phospholipid, a hydrophobic or hydrophilic cosmeceutical ingredient, an aqueous phase and a low pressure fluid. The solution or mixture is decompressed to separate the low pressure, critical fluid, from the phospholipid and aqueous medium, to form one or more liposomes. This method is referred to as the decompression method of forming liposomes in the embodiment. Preferably, the rate of depressurization influences the size of the liposomes formed.
[0041] According to the procedure of the example embodiment, schematically represented in FIG. 4.0 , operating always under mild conditions to preserve the activity of the labile biomolecules. The general method consists in loading a solution of the membrane lipid components and the desired hydrophobic bio-actives in an organic solvent (e.g. ethanol), into the high-pressure reactor previously driven to the preferred working temperature ( FIG. 4.0 A). The reactor is then pressurized, in a second stage, with a large amount of compressed CO2 until reaching the working pressure (10 MPa) ( FIG. 4.0 B).
[0042] Finally in the third stage, the vesicular conjugates are formed by depressurizing the resulting CO2-expanded solution over an aqueous phase, which might contain water soluble surfactants and hydrophilic bio-actives ( FIG. 4.0 C). In this step a flow of N2 at the working pressure is used in order to push down the CO2-expanded solution and to keep constant the pressure inside the reactor. It is worth to note that no further energy input is required for achieving the desired SUVs (small unilamellar vesicles) structural characteristics, neither for increasing the loading or functionalization.
[0043] In applications utilizing the example embodiment with low pressure fluids, the properties of the coating material and particularly the interactions of coating materials with low pressure low temperature fluids are especially important.
[0044] These interactions may be important for enabling the incorporation of cosmeceutical essential oils into carrier materials, for example by facilitating the diffusion of the essential oil due to the swelling and opening of the pores of carrier material particles.
[0045] One method comprises the steps of (1) forming a solution or mixture of a phospholipid, (2) an aqueous phase and low pressure low temperature methodologies. (3) The solution or mixture is decompressed to separate the fluid, from the phospholipid and aqueous media, to form one or more liposomes.
[0046] In some embodiments, the aqueous, or addition phase, has a therapeutic cosmeceutical agent included. As used herein, the term “therapeutic cosmeceutical agent” means a chemical or ingredient capable of effecting a desirable response in an individual subject. This embodiment is ideally suited for therapeutic cosmeceutical agents which are not shear sensitive.
[0047] Preferably the compressed fluid is recycled. To the extent that phospholipids and aqueous phase are carried over with the CF, such components may also be recycled. For convenience, liposomes formed with CF fluid in the current embodiment are referred to as “LPLTVs.”
[0048] An example embodiment features an apparatus for forming liposomes/niosomes (non-ionic) vesicles. The apparatus comprises a first vessel wherein a phospholipid, an aqueous phase and a CF are combined to form a mixture or solution. The apparatus further comprises a second vessel in communication with the first vessel for expansion.
[0049] The apparatus of the embodiment further comprises a third vessel for depressurization as a means capable of reducing the pressure of the solution or mixture. Depressurization means may be interposed between the first and second vessels or may be integral with a third vessel. The third vessel receives the solution or mixture of phospholipids and an aqueous phase which form liposomes upon depressurization.
[0050] Preferably, the CF is removed from depressurization means and/or the third vessel and recycled.
[0051] One example embodiment comprises the steps of forming a solution or mixture of a phospholipid and a compressed fluid. The solution or mixture is then decompressed through a tip or orifice into an aqueous phase to form one or more liposomes. As a result of the decompression, the CF is separated from the phospholipids and the aqueous phase. The released CF is either vented or recycled to form a solution or mixture of phospholipid.
[0052] A further example embodiment features a method of making liposomes or niosomes comprising the steps of forming a solution or mixture of a phospholipid and a CF. The solution or mixture is injected into an aqueous phase to form one or more liposomes or niosomes as the phospholipids and CFs are decompressed.
[0053] Preferably, the aqueous phase or phospholipids contain a cosmeceutical therapeutic agent which is incorporated into the liposome or niosomes.
[0054] Embodiments of the present method are ideally suited for skin rejuvenating agents which are shear sensitive such as botanicals, proteins and peptides. Embodiments of the present method do not subject botanicals, proteins and peptides to extreme shear forces or temperatures.
[0055] Example embodiments are ideally suited to form unilamellar liposome or niosome vesicles. The size of the liposome or niosome is determined by the rate of decompression.
[0056] A preferred method uses a CF selected from the group of compositions capable of forming a critical fluid comprising carbon dioxide; nitrous oxide; halo-hydrocarbons, such as FREON; alkanes such as propane and ethane; and alkanes such as ethylene.
[0057] One example embodiment features an apparatus for forming liposomes and niosomes. The apparatus comprises a first vessel for containing a solution or mixture of a phospholipid and a compressed fluid. The apparatus further comprises a second vessel for containing an aqueous phase. The first vessel and the second vessel are in communication by means of injection means for injecting the phospholipid and CF fluid mixture into the aqueous phase. Upon injection into the aqueous phase in the third vessel, liposomes are formed.
[0058] Preferably, the aqueous phase contains a cosmeceutically therapeutic agent which cosmeceutical therapeutic agent is encapsulated within the liposome.
[0059] Conjugation of cosmeceutical bio-beneficial ingredients to nano carriers can offer over the free ingredient the protection from premature degradation, a higher stability, an enhance permeability through biological membranes, a higher control of the pharmacokinetics, a better ingredient tissue distribution profile, and an improvement of intracellular, intercellular, and intra-follicular penetration and the ability to control whether the nano-carrier goes systemic or non-systemic.
BRIEF DESCRIPTION OF THE DRAWINGS:
[0060] For a better understanding of the example embodiments, reference should be made to the following detailed description disclosed in conjunction with the accompanying drawings, in which:
[0061] FIG. 1.0 illustrates the classification of vesicles regarding size and lamellarity.
[0062] FIG. 2.0 illustrates the construction and composition of phospholipids
[0063] FIG. 3.0 illustrates the major classifications of liposomes as vesicular systems according to their size and membrane lamellarity.
[0064] FIG. 4.0 (A, B, C) is a representation of the steps of forming a solution or mixture of a phospholipid, an aqueous phase and low pressure low temperature methodologies.
[0065] FIG. 5.0 is a TEM image of liposomes produced in the LPLTVs process.
[0066] FIG. 6.0 is an image of the appearance of small spheres aggregating into larger spheres or captured within larger spheres in the LPLTVs liposomal forming process.
[0067] FIG. 7.0 shows rod or coffee-bean morphology observed in the liposomes samples produced by the LPLTVs process.
[0068] FIG. 8.0 is a schematic representation of the LPLTV process method.
[0069] FIG. 9.0 shows a solubility curve of hyaluronic acid and cholesterol, in ethanol/CO2 at 10 MPa and 308 K.
[0070] FIG. 10.0 is a schematic illustration of the formation of (a) the hyaluronic acid cholesterol/CTAB bimolecular amphiphile and (b) their self-assembling into bilayer vesicles based on the packing parameter concept.
[0071] FIG. 11.0 is a chart showing Hyaluronic Acid levels in active and control samples.
DETAILED DESCRIPTION
[0072] The present embodiment features methods and apparatus for producing cosmeceutically benevolent ingredient content liposomes and niosomes. The methods and apparatus are suitable for large scale production of pharmaceutical and cosmeceutical grade vesicles for the treatment of skin anomalies created as a result of aging skin or chronic environmental insult which are sterile, of a predetermined size, and are substantially free of organic solvents.
Definitions
[0073] As used herein, the word “hydrophilic” in relation to the material means that that material is above 10% soluble in water by weight at standard temperature and pressure (STP).
[0074] As used herein, the word “hydrophobic” as used in relation to a material means that that material is less than 0.1% soluble in water by weight at standard temperature and pressure (STP).
[0075] As used herein, the term (IDS) as used in relation to the explanation of the current embodiment means Ingredient Delivery Systems.
[0076] As used herein, the word “micelle” as used in relation to a material means “molecules having both polar or charged groups and non-polar regions (amphiphilic molecules) formed aggregates”.
[0077] As used herein, the word “vesicle” as used in relation to one prepared artificially, in which case they are called liposomes. If there is only one phospholipid bilayer, they are called unilamellar liposome vesicles; otherwise they are called multilamellar.
[0078] As used herein, the word “niosome ” as used in relation to a non-ionic surfactant-based Vesicle formed mostly by non-ionic surfactant and cholesterol incorporation as an excipient.
[0079] As used herein, the term “LPLTVs as used means Low Pressure Low Temperature alternative construction of Vesicles based on milder conditions of pressure (<10 MPa) and temperature (<308 K) than the previously described methodologies based on CFs (Compressed Fluids).
[0080] As used herein, the term Active Cosmetic Ingredients (ACIs) as used means but is not limited to such substances as synthetic or natural skin rejuvenating ingredients, sunscreen ingredients, skin-lightening agents, and anti-acne ingredients.
[0081] As used herein, the term CFs as used means such substances made from compressed fluids based technologies to produce niosomes or vesicles.
[0082] As used herein, the term phospholipids as used means lipids containing phosphorus, a polar potion and non-polar potion in their structures.
[0083] As used herein, the term niosomes are microscopic lamellar vesicular structures, which are formed on the admixture of non-ionic surfactant and cholesterol with subsequent hydration in aqueous media.
[0084] One example embodiment features an apparatus for forming liposomes and niosomes. The apparatus comprises a first vessel or mixing the organic phase, a second vessel for containing a mixture of multi-lamellar vesicles and a compressed fluid and a third vessel for decompressing into the aqueous phase. The first vessel is in communication with a second vessel which second vessel is in communication with a third vessel capable of decompressing the mixture to remove the compressed fluid. During decompression, one or more liposomes or niosomes are formed.
[0085] Another embodiment further comprises a third vessel for forming multilamellar vesicles by hydrating phospholipids in an aqueous phase.
[0086] In the embodiment, the aqueous phase or the phospholipids may contain a therapeutic agent to impart special qualities to the liposome for beneficial partitioning of the stratum corneum to aid in transiting cosmeceutically beneficial liposomes or niosomes to the epi-dermis.
[0087] An embodiment further features control means for determining the rate of decompression. The rate of decompression determines the size of liposomes or niosomes.
[0088] Preferably, compressed fluid removed from the liposome preparation in the decompression vessel is recycled to the first vessel to form additional mixtures of multilamellar vesicles and compressed fluid.
[0089] Contact with compressed fluid may cause destruction of the cellular structures particularly upon rapid decompression. Thus, embodiments are, for the most part, self-sterilizing.
[0090] Methods and apparatus of the example embodiment are capable of forming liposomes or niosomes which carry a cosmeceutical therapeutic agent. The cosmeceutical therapeutic agent can be incorporated into ingredients which are used to form the liposome or niosome or the liposome or niosome can be loaded with the cosmeceutical therapeutic agent after the liposome or niosome is formed.
[0091] Embodiments allow the recovery of raw materials, lipids and solvents which are not incorporated into the final liposome or niosome product. Example embodiments feature efficient cosmeceutical ingredient entrapment and recovery of un-encapsulated cosmeceutical ingredient. The operating parameters of the apparatus and method are consistent with other industrially applied processes. The method and apparatus are capable of operating continuously.
[0092] These and other features, aspects, and advantages of the embodiment will become evident to those of ordinary skill in the art from a reading of the present disclosure.
[0093] During the depressurization step of the example embodiment, the expanded organic solution experiences a large, abrupt and extremely homogenous temperature decrease produced by the CO2 evaporation from the expanded solution. This is the reason that explains the obtaining of homogenous vesicles regarding size, lamellarity and morphology compared with the same system but prepared by a conventional mixing method.
[0094] However, changes in the procedures and equipment, as in the present embodiment, result in vesicular systems with differentiated characteristics. The processes can also be distinguished by the latter hydration step that can occur either during the pressurization or the depressurization step.
[0095] These lipid or niosome vesicles of the present embodiment allow the physicochemical properties of ingredient molecules, of a higher molecular weight in excess of 700 kDa, in a liposomal system to be changed, which facilitates crossing of the stratum corneum barrier into the epi-dermis.
[0096] The size of the liposome can be controlled by the rate of decompression to form liposomes or niosomes of predetermined size to control the volume and depth of penetration.
[0097] Among the various approaches for exploiting developments in nano and micro technology for cosmetic applications, ingredient delivery systems (IDS) have already had an enormous impact on cosmetic formulation technology, improving the performance of many existing ingredients and enabling the use of entirely new therapies. The fact that IDSs can protect sensitive molecules, such as hormones, enzymes and proteins, from degradation and the in-vivo attack of the immune system providing longer resident times, have been used to improve the effectiveness and delivery of these ingredients. Although nano and micro particulate carriers can be made from a variety of organic and inorganic materials, vesicle and polymer based-nanocarriers are perhaps the most widely used for ingredient delivery purposes.
[0098] Particularly vesicles, liposome and noisome, have served as convenient delivery vehicles for biologically active compounds because they are non-toxic, biodegradable and non-immunogenic. Contrary to products where the active substance is in simple solution, the pharmacological properties of vesicle-based delivery systems strongly depend on the structural characteristics of the conjugates. Indeed, a high degree of structural homogeneity regarding size, morphology and vesicle organization in the membrane is crucial, for their optimum performance as functional entities.
[0099] Liposomes and niosomes are vesicles in which, in the current embodiment, cosmeceutical ingredients can be trapped and administered more efficiently. However, these vesicles, micelle, liposome and niosome, are not similar to each other. In a comparison, micelles vs. liposomes, and or elastic niosomes, the differences between the two are explained as; Micelles are structures composed of a monolayer of amphipathic molecules. In a biological system, the molecules tend to arrange themselves in such a manner that the inner core of these structures are hydrophobic and the outer layers are hydrophilic in nature.
[0100] Liposomes as in the present embodiment, are composed of a bilayer of amphipathic molecules, the molecules are arranged in two concentric circles, such that the hydrophilic heads of the outer layer are exposed to the outer environment, and the hydrophilic heads of the inner layer make the inner hydrophilic core. The hydrophobic tails are tucked between the two layers.
[0101] In the present embodiment, elastic liposomes are microscopic vesicles having single or multiple phospholipid bilayers which can entrap hydrophilic compounds within their aqueous cores.
[0102] Elastic niosomes are composed of nonionic surfactants, ethanol and water. They are superior to conventional niosomes because they enhance penetration of a drug through intact skin by passing through pores in the stratum corneum, which are smaller than the vesicles. In fact, their elasticity allows them to pass through channels that are less than one tenth of their own diameter. Thus they can deliver ingredients or compounds of both low and high molecular weight. Furthermore, they can provide prolonged action and demonstrate superior biological activity compared to conventional niosomes. The transport of these elastic vesicles is concentration independent and driven by trans-epidermal hydration.
[0103] To deliver the molecules to sites of action, the lipid or niosome bilayer can fuse with other bilayers such as the cell membrane, thus delivering the liposome contents. By making liposomes in a solution of natural or synthetic ingredients that can effect a beneficial change to the skin, (which would normally be unable to diffuse through the membrane) they can be (indiscriminately) delivered past the lipid bilayer. A liposome or niosome vesicle does not necessarily have lipophobic contents, such as water, although, in the case of the present embodiment, it usually does.
[0104] The preferred phospholipid in the current process embodiment is naturally derived, for example phospholipids obtained from plant or animal sources. Natural phospholipids are purified from, e.g., soybean, rapeseed, and sunflower seed. The phospholipid may be salted or desalted, hydrogenated or partially hydrogenated or natural, semi-synthetic or synthetic.
[0105] Liposomes, niosomes and in general vesicles, are undoubtedly one of the most promising carriers in nano and micro cosmeceutical ingredient delivery. They are particularly important in the stratum corneum percutaneous transit field due to their great versatility respect to size, composition, surface characteristics, biocompatibility, biodegradability, low toxicity, capacity for entrapping and/or integrating hydrophilic and/or hydrophobic molecules and possibility of surface functionalization. Vesicles of the present process embodiment are spherical objects enclosing a liquid compartment, with a diameter ranging from 20 nm to a few thousand of nanometers, separated from its surroundings by at least one thin membrane consisting of a bilayer (unilamellar) or several layers (multilamellar) of amphiphilic molecules.
[0106] Sometimes the terms liposome, niosome and vesicle are used interchangeably, although a liposome is a type of vesicle composed mainly by phospholipids, a niosome as a non-ionic surfactant-based vesicle formed mostly by non-ionic surfactant and cholesterol incorporation as an excipient. Vesicles can be formed also by non-lipid building blocks, such as block co-polymers or cationic or non-ionic surfactants.
[0107] A liposome or niosome is an artificially-prepared vesicle composed of a lipid bilayer. The liposome or niosome can be used as a vehicle for administration of percutaneous skin nutrients and pharmaceutical drugs. Liposomes and niosomes are composed of natural phospholipids, and may also contain mixed lipid chains with surfactant properties (e.g., egg phosphatidylethanolamine). According to the present process embodiment, a liposome design may employ surface ligands for attaching to unhealthy tissue.
[0108] In the present embodiment, phospholipids have a propensity to form liposomes and niosomes, which can be employed as the cosmetic ingredient carriers. Phospholipids have good emulsifying property which can stabilize the cosmetic serum emulsions. In addition, phospholipids as surface-active wetting agents which can coat on the surface of crystals to enhance the hydrophilicity of hydrophobic ingredients. The above properties are successfully employed in the LPLTVs design.
[0109] As used herein, in the current embodiment example, the term “phospholipid” refers to compositions which are esters of fatty acids in which the alcohol component of the molecule contains a phosphate group as an integral part ( FIG. 2.0 ).
[0110] In order to extend LPLTVs (Low Pressure Low Temperature alternative construction of Vesicles) to the preparation of other kinds of vesicle systems taking full advantage of the possibilities offered by this process were also undertaken. Phospholipids-based formulations are widely used for delivery purposes and for this reason 1,2-dipalmitoyl-sn-glycero-3-phosphocholine (DPPC) was selected as a membrane component for the liposome preparation with LPLTVs.
[0111] Phospholipids comprise the glycerol-phosphatides, containing glycerol, and the sphingomyelins containing sphingosine.
[0112] According to the alcohols contained in the phospholipids, they can be divided into glycerophospholipids and sphingomyelins.
[0113] For the present embodiment, the use of Glycerophospholipids, which are the main phospholipids in eukaryotic cells, refer to the phospholipids in which glycerol is the backbone are preferred. All naturally occurring glycerophospholipids possess a-structure and L-configuration.
[0114] Preferred phospholipids used in the embodiment comprise phosphatidylcholine, phosphatidylethanolamine, phosphatidylserine and sphingomyelin; and although not preferred, in the present embodiment, synthetic phospholipids comprising dimyristoyl phosphatidylcholine, dipalmitoyl phosphatidylcholine, distearoyl phosphatidylcholine, distearoyl phosphatidylglycerol, dipalmitoyl phosphatidylglycerol, dimyristoyl phosphatidylserine, distearoyl phosphatidylserine, and dipalmitoyl serine.
[0115] In the case of the present method embodiment, liposomes or niosomes are used as carriers for beneficial ingredients for the treatment of skin anomalies. Liposomes and niosomes can be made with different features can enhance an ingredients efficacy, reduce an ingredients toxicity, restriction from going systemic and prolong the ingredients therapeutic effect.
[0116] Niosomes are self-assembled vesicles composed primarily of synthetic surfactants and cholesterol. They are analogous in structure to the more widely studied liposomes formed from biologically derived phospholipids.
[0117] The type of epi-dermal activity resulting from the application of the current embodiment's content of natural or synthetic ingredients to be beneficial includes: Hydration•Skin lightening•Anti-wrinkle/skin smoothing•Antioxidant activity/free radical scavenger•Anti-inflammatory/anti-irritant•Collagen stimulation•Cell regeneration/stimulation•Sebum regulation•Anti-cellulite•Antimicrobial•Antibacterial.
[0118] With chronological age and chronic exposure to adverse environmental factors, (notably UVA, UVB, and IR radiation) the visual appearance, physical properties, and physiological functions of skin change in ways that are considered cosmetically undesirable. The most notable and obvious changes include the development of fine lines and wrinkles, loss of elasticity, increased sagging, loss of firmness, loss of color evenness (tone), coarse surface texture, and mottled pigmentation.
[0119] Less obvious, but measurable changes which occur as skin ages or endures chronic environmental insult include a general reduction in cellular and tissue vitality, reduction in cell replication rates, reduced cutaneous blood flow, reduced moisture content, accumulated errors in structure and function, and a reduction in the skin's ability to remodel and repair itself
[0120] Many of the above alterations in appearance and function are caused by changes in the outer epidermal layer of the skin, while others are caused by changes in the lower dermis.
[0121] Regardless of the stimulus for skin damage, when damage occurs, numerous natural and complex biochemical mechanisms are set into motion in attempts to repair the damage.
[0122] The present embodiment relates generally to construct a process for a vesicle-driven treatment method and composition for improving the skin's visual appearance, function, and clinical/biophysical properties which have been changed by factors such as chronological age, chronic sun exposure, adverse environmental pollutants, household chemicals, disease pathologies, smoking, and malnutrition. In particular, the present embodiment relates to a process to create a method of treating skin by increasing the skin's stratum corneum transit of known beneficial ingredients through dynamic infusion of vesicles (DIV) generated from natural and biocompatible phospholipids with an aqueous volume enclosed within a lipid or niosome membrane.
[0123] The result of the present process embodiment is to deliver larger molecular weight, longer lasting, beneficial ingredients to areas of the epi-dermis depleted of needed vitamins, hydration, nourishment and complimentary ingredients need for the rejuvenation of elastin and collagen.
[0124] Now, in the current embodiment, comes the development of a new, single process, ingredient vesicle methodology based on a Low Pressure Low Temperature alternative construction of liposome or niosome Vesicles process (LPLTVs) for the direct, robust and scalable encapsulation of biomolecules in vesicles. The development of reproducible and scalable methodologies in order to functionalize those vesicles with targeting/protective units enabling greater selectivity of the therapeutic epidermal targets and therefore more effective treatments.
[0125] The use of the biomolecules-vesicles conjugates prepared by LPLTVs can be used in the treatment of different skin anomalies. The embodiments process uses milder conditions of pressure (<10 MPa) and temperature (<308 K) than previous methodologies based on CFs, allowing the processing of heat labile compounds and reducing the investment cost of a high pressure plant when the process is scaled-up.
[0126] The present embodiment encompasses compressed fluid-based methodologies (CF), also called dense gas technologies, for the production of lipid-based ingredient carrier systems with structural characteristics not reachable by already existing procedures using liquid organic solvents. In the present embodiment, we have improved the processing of vesicles and niosomes because they provide the ability to reduce the amount of organic solvent required by conventional methods and allow a better control over the final vesicle structural characteristics. Moreover compressed fluid processing offers sterile operating conditions and the ability for one-step production processes, which is convenient in transferring the technology to larger scale operations.
[0127] The present embodiment's compressed fluid technology was developed as a platform for producing lipid and niosome-based cosmetic ingredient carrier systems that can address most of the limitations of conventional methods.
[0128] LPLTVs methodology allows an easy and direct preparation of different liposome-biomolecule conjugates with micro and nano scopic sizes and great degrees of unilamelarity.
[0129] The stability time of the liposome-based conjugates is somewhat smaller than those of LPLT Vesicle-based conjugates. This stability is improved by the addition of stabilizing/targeting units to the formulation.
[0130] Bioactivity of the integrated biomolecules is unaffected under the processing conditions with CO2-expanded solvents.
[0131] Liposomes and Niosomes prepared by the current embodiment's process of LPLTVs, fulfill the structural and physio-chemical requirements to be a platform for the percutaneous delivery of synthetic or natural ACIs (active cosmeceutical ingredients).
[0132] Major advantages of the embodiment's application of CFs technology are that sterile and stable liposomal and niosomal formulations can be produced with minimum amounts of organic solvents.
[0133] In the case of blemished or compromised complexion of the skin the following properties could be desirable: •Sebum regulating•Anti-bacterial•Anti-inflammatory/anti-irritant•Soothing/calming•Skin healing and regeneration•uniform complexion•lightening and brightening.
[0134] These and other advantages will be apparent to individuals skilled in the art in view of the drawings and detailed description which follow.
[0135] Examples of some preferred preparation ingredients in the present embodiment include natural botanicals, those ingredients that that originates from plants, herbs, roots, flowers, fruits, leaves or seeds such as: aloe vera, almond oil, avocado oil, coconut oil, hazelnut oil, jojoba oil, olive oil, palm oil, pumpkin seed oil, sesame oil, sunflower oil, tamanu oil, candeia oil, arnica,
[0136] chamomile, oat extract, hibiscus flower, boswellia serratta, cocoa powder, green and white tea, gotu kola, chamomile extract, L-arginine, glutamine, pantothenic acid, white willow bark extract, tetrahydrocurcuminoids, alpha-arbutin, aloesin, alpha glucosyl hesperidin, niacinimide, fucoidan, magnesium asorbyl phosphate, azelaic acid, N-acetyl-D-glucosamine, glutathione, mulberry, pomegranate seed oil, cyprus rotund root extract, licorice, licorice-glabrin root extract, kojic acid, panax ginseng root extract, ginko bilbao, salicylic acid, Lauric acid, glycerin, caffeine, tocopheryl acetate, copper peptide, retinyl palmitate, asorbyl palmitate, wakame, dimethylethanolamine, beta glucan, triglyceride as well as hyaluronic acid (Hyaluronic acid is a natural and sugar-like biopolymer in the human body that alternately consists of D-glucuronic acid and N-acetyl-D-glucosamine-units).
[0137] Additionally, preferred natural polymers for the current embodiment such as starch, starch, xanthan or guar gum, carrageenan, alginates, polysaccharides, pectin, gelatin, agar, and cellulose derivatives can be used to this end. On the synthetic side, polyacrylate derivatives and polyacrylamide polymers can be incorporated in to the carrier system of the present embodiment. More recent developments include combining hydrophobic and hydrophilic polymers into block and star copolymers and thermally responsive systems.
[0138] Polymers are particularly susceptible to the construction of vesicle that can physically entrap the active component, preserving its biological stability, or the bioactive component can be incorporated chemically into a polymer chain or pendant group, then released through hydrolysis. For example, salicylic acid (an anti-acne ingredient) can be incorporated into the main chain of polyanhydride ester and released within a short time.
[0139] The current example embodiment also applies to the construction of vesicle encapsulated polymers that are routinely used in many personal care and cosmetic products.
[0140] The current embodiment takes advantage of the various properties of these polymers to impart unique benefits to their formulations. The range of properties is as varied as the class of polymers that have been utilized. Using polymers, cosmetic chemists can create high performance products. Broad spectrums of polymers; natural polymers, synthetic polymers, organic polymers as well as silicones are used in a wide range of cosmetic and personal care products as film-formers, emulsifiers, thickeners, modifiers, protective barriers, and as aesthetic enhancers.
[0141] A further embodiment features a method of making liposomes comprising forming a mixture of multilamellar vesicles and a CF. The mixture is decompressed to remove the CF to form one or more liposomes or niosomes.
[0142] Preferably, multilamellar vesicles are made by hydrating phospholipids in an aqueous phase. Preferably, the aqueous phase or the phospholipids contain a cosmeceutical therapeutic agent.
EXAMPLE 1
Phase Behavior Studies for the Low Pressure Low Temperature Alternative Construction of a Liposome and Niosome Vesicles (LPLTVs)—CO2-Solvent System
[0143] Prior to liposome or niosome formation, the phase behavior and solubility of the chosen lipid in dense CO2 were investigated to verify the suitability of the lipid for dense gas processing and, in particular LPLTVs processing.
[0144] Knowledge of the threshold pressure for precipitation of lipid from solution is also a key factor for design of the LPLTVs process in order to determine the maximum pressure for the technique so that yield is enhanced and loss of lipid in the expansion chamber minimized. The solid state of 1,2 distearoyl-sn-glycero-3-phosphocholine (DSPC) was maintained when the lipid was exposed to CO2 below 350 bar at 50° C. and 150 bar at 70° C. The solubility of DSPC in pure CO2 at 50° C. and pressures up to 280 bar was considered negligible. The addition of 5 mol % ethanol co-solvent did not significantly improve the solubility of DSPC in CO2 at 50° C. and 250 bar. Use of higher pressures or larger amounts of organic solvent are undesirable, thus the results of the solubility study are in agreement with the literature in concluding that effects arising from poor solubility of lipids in dense CO2 are not easily overcome.
[0145] In prior art, at 50° C. and 250 bar, DSPC required the addition of 4.8% v/v ethanol as well as the use of a recycling system for homogeneous dissolution of the lipid in CO2. In the current embodiment, the use of the LPLTVs process eliminates the current limitations of dense gas techniques associated with solubilizing lipids using a supercritical fluid and simply utilizes a dense gas as an aerosolization aid. The threshold pressure for the precipitation of DSPC from a 10 mg/mL ethanol solution at 22° C. was 55 bar.
[0146] Precipitation was first observed at 58, 55, and 56 bar for the 5, 10, and 20 mg/mL solutions of DSPC and cholesterol (70:30 lipid to cholesterol weight ratio) in ethanol at 22° C., respectively. Therefore it can be seen that cholesterol had negligible effect on the threshold pressure. When the pressurization rate for the 5 mg/mL lipid/cholesterol solution was dramatically increased, precipitation was not observed until 60 bar was reached. A faster pressurization rate is preferable for the embodiments LPLTVs process in order to minimize the time requirement for each experiment. During this experiment, noticeable expansion only started to occur after 50 bar was reached. Solution expansion is desired to maximize the effect of utilizing CO2 as an aerosolization aid to disperse the lipid solutions throughout the aqueous phase. Therefore, the expansion pressure used in the LPLTVs experiments to avoid solute precipitation and enhance the yield for or niosome formation from ethanol solutions was between 50 and 55 bar at 22° C.
[0147] The threshold pressure for the precipitation of a 20 mg/mL DSPC/cholesterol chloroform solution (90:10 lipid/cholesterol weight ratio) at 22° C. was 41 bar. The solvent volume had significantly expanded (doubled) by the time 40 bar was reached in the chloroform experiments. Therefore, expansion pressures between 38 and 40 bar were used for the LPLTVs chloroform experiments to achieve maximum expansion without lipid precipitation.
EXAMPLE 2
Effects of Process Variables on LPLTVs Operation
[0148] The effects of solute composition, solute concentration, type of solvent, nozzle diameter, type of aqueous media, temperature of vesicle formation chamber, and volume of dense gas used for spraying on both the ease of operation of the embodiments LPLTVs process and the product were investigated. The results obtained for liposome formation are summarized in Table 1. Preliminary trials were conducted to establish viable nozzle options for the LPLTVs system. A variety of nozzles were tested including 102, 178, 254, 508, and 1016 μm i.d. stainless steel tubing and 100 μm i.d. Peeksil tubing (polymer tubing with fused silica lining). The most suitable nozzle for the LPLTVs apparatus, to control the flow rate and prevent blockages, was the 178 μm i.d. stainless steel tubing. The 254 μm nozzle was used in Set 1 (Table 1); however, there were difficulties in controlling the flow rate and maintaining constant pressure in the expansion chamber. Other nozzle dimensions may be selected depending on the pump capacity and vessel dimensions.
[0149] The LPLTVs process of the present example embodiment is robust and, within the range examined, variation of solute concentration and composition, type of solvent, type of aqueous media, and volume of CO2 used for spraying had minimal effect on the operation of the LPLTVs process. The temperature of the vesicle formation chamber did, however, significantly affect the process since a smaller amount of liposomal product was obtained at 90° C. (Set 5) compared with 75° C. The smaller volume can be attributed to the aqueous medium being closer to its boiling point at 90° C., and thus some of the water was lost to the solvent trap via evaporation.
EXAMPLE 3
Characterization of Liposomes Produced by the LPLTVs Process
The Liposome Morphology.
[0150] TEM (Transmission electron microscopy) was used to investigate the morphology of the particles produced in the embodiments LPLTVs process. At all conditions studied, submicron spheres were observed that possessed a similar structure to liposomes previously reported in the literature. The image shown in FIG. 5.0 indicates that spherical particles, generally ranging in size from 35 to 200 nm and more commonly 35-100 nm, were formed using the LPLTVs process. Images collected suggest that the liposomes were unilamellar. Not only were the spheres of a size range common to unilamellar liposomes, but in many images a single, thin wall can be seen at the edge of each particle. However, the arguments against positive identification of lamellarity using negative staining and TEM have been well documented in the literature.18 Staining artifacts are difficult to identify and are often interpreted as unexpected morphologies. Confirmation that the particles formed were in fact liposomes was found by utilizing SANS (Small-Angle Neutron Scattering) to identify an aqueous core, as discussed below. The spherical particles shown in FIG. 5.0 are a general indication of the liposomes formed; however, some other features have also been observed. In several samples, a large quantity of smaller spherical particles (10-20 nm) was observed, which are at or below the lower size limit at which liposomes can be formed and may be considered as micelles. In some samples, small vesicles appear to be aggregated into or contained within a larger liposome vesicle, as shown in FIG. 6.0 .
[0151] A vesicle-in-vesicle structure may be formed in the last stage of the LPLTVs process due to liposomes forming in the presence of existing vesicles. However, the lipid vesicles are more likely to have formed into aggregate structures during the negative staining process in order to minimize any deleterious effects when the aqueous phase was removed or to minimize the interactions of the lipid with the stain. The artifact of these aggregated systems could also result from a larger vesicle superimposed upon smaller vesicles, which is a common feature in TEM analysis. The particle size and morphology of the LPLTVs liposomes was not significantly changed within the range of process parameters varied. However, rods or coffee bean morphology (liposomes exhibiting a characteristic ‘coffee-bean’ appearance due to the presence of an inner structure apparently separating the LUV into two sections) appeared in a few samples in addition to spherical particles, as shown in FIG. 7.0 . It is suggested that the coffee bean morphology was formed due to the collapse of vesicles, predominantly for the smaller particles. This effect can be attributed to the lower stability of small vesicles due to the high curvature of the membrane.
[0152] The unilamellar liposomes produced using a conventional technique were stained with ammonium molybdate with and without the presence of protein. The images of the liposomes stained without protein showed “cup-like structures” and vesicles consisting of two lipid membranes. When protein was included in the staining process, the images showed vesicles consisting of a single lipid bilayer.
[0153] In the present embodiment, it is concluded that the liposomes in both images were unilamellar and that the vesicles had collapsed in the absence of protein. The double membrane feature can therefore be explained by the thick edge of the collapsed sphere, and the “cup-like structures” can be observed if the collapsed spheres are rotated.
[0154] The correct choice of vesicle or niosome preparation method in the current embodiment depends on the following parameters: the physicochemical characteristics of the material to be entrapped and those of the liposomal or niosomal ingredients; the nature of the medium in which the vesicles are dispersed; the effective concentration of the entrapped substance and its potential toxicity; additional processes involved during application/delivery of the vesicles; optimum size, polydispersity and shelf-life of the vesicles for the intended application; and, batch-to-batch reproducibility and possibility of large-scale production of safe and efficient liposomal products.
[0000]
TABLE 1
Summary of the Conditions Investigated and the Results Obtained for Producing
Liposomes via the embodiments of the LPLTVs Process.
set
1
2
3
4
5
6
7
8
9
nozzle diameter
254
178
178
178
178
178
178
178
178
(μm)
solute lipid content
70
70
90
90
90
90
90
90
90
(% w/w)
solute conc.
20
20
20
5
20
20
20
20
20
(mg/mL)
VFC temp.
75
75
75
75
90
75
75
75
75
(° C. ± 2.5)
CO 2 spraying vol.
200
200
200
200
200
50
200
200
200
(mL)
aqueous media
RO H 2 O
RO H 2 O
RO H 2 O
RO H 2 O
RO H 2 O
RO H 2 O
DI H 2 O
TBS
RO H 2 O
organic solvent
EtOH
EtOH
EtOH
EtOH
EtOH
EtOH
EtOH
EtOH
Chlfm
effective diameter
156 ± 2
166 ± 5
121 ± 1
162 ± 23
207 ± 75
122 ± 2
119 ± 3
143 ± 5
357 ± 64
(nm)
polydispersity
0.27 ± 0.01
0.27 ± 0.01
0.15 ± 0.01
0.19 ± 0.01
0.18 ± 0.01
0.15 ± 0.01
0.17 ± 0.02
0.18 ± 0.02
0.29 ± 0.03
product lipid content
75.2 ± 1.9
77.3 ± 1.8
82.4 ± 0.4
76.1 ± 0.1
81.5 ± 0.5
80.5 ± 0.2
80.9 ± 0.3
80.1 ± 0.6
81.8 ± 1.3
(% w/w)
residual solvent
3.1 ± 0.4
1.6 ± 0.8
1.4 ± 0.4
2.2 ± 0.3
1.9 ± 0.7
3.9 ± 0.2
1.8 ± 0.4
2.0 ± 0.8
0.4 ± 0.3
(% v/v)
*VFC: vehicle formation chamber; RO H 2 O: water purified via severse ; DI H 2 O: water; TBS: TRIS buffered saline; EtOH: ethanol; Chlfm: chloroform
indicates data missing or illegible when filed
[0155] Collapsed spheres were present in all LPLTVs samples; however, rods or “coffee bean” particles were rare except in those samples from Sets 1 and 2, where a higher proportion of cholesterol was used compared with other samples.
[0000]
TABLE 2
The calculated SLD for the components
LPLT Vs of the LPLT Vs liposome samples
material
SLD (×10 − Å − )
H 2 O
−0.56
D 2 O
6.33
hydrocarbon chain (CH 2 )
−0.44
cholesterol (C H OH)
0.21
lipid headgroup (C H O NP)
1.12
indicates data missing or illegible when filed
[0000]
TABLE 3
SANS Fitted parameters for the LPLT liposome sample
fitted parameter (Å − )
value
core SLD
6.30 × 10 −
shell SLD
3.85 × 10 −
solvent SLD
6.82 × 10 −
indicates data missing or illegible when filed
[0156] Cholesterol was incorporated in order to improve stability, and it has been reported in the literature that the incorporation of cholesterol causes larger liposomes or niosomes to form.
[0157] However, the rod-shaped particles were at the smaller end of the size range for the LPLTVs. Comparison of images from a number of samples indicated that the presence of rods may be promoted by the level of stain as well as the size of the vesicles. It is therefore also possible that the relative proportion of rods found in Sets 1 and 2 was amplified by the staining process. Because of the improved spherical morphology observed in Set 3, the experiments were carried out using a preferred lipid/cholesterol ratio of 90:10.
[0000] Advantages of the current embodiments LPLTVs Process for Bulk Liposome or Niosome Vesicle Formation.
[0158] The LPLTVs process has many advantages over conventional liposome or niosome formation techniques. These advantages include the fact that it is a simple and rapid process for bulk production of unilamellar liposomes or niosomes. A conventional liposome standard was produced, and the formation process took almost 24 h and multiple stages to complete. The embodiments LPLTVs process produced a greater volume of the same formulation in less than half an hour, clearly demonstrating the dramatic reduction in processing time.
[0159] The conventional ethanol and ether injection methods exhibit some similarities to the embodiments LPLTVs process since they involve the dissolution of a lipid into an organic phase, followed by the injection of the lipid solution into aqueous media forming liposomes. The drawbacks of the ethanol injection method as opposed to the examples of the present embodiment, are the poor homogeneity of the vesicles if there is not adequate mixing and the residual solvent levels in the product.
[0160] Either injection method eliminates the residual solvent issue by having a heated aqueous phase, but is a time-consuming technique. It has been suggested that injecting the ether solution at a rate faster than 0.2 mL/min can cause cooling of the aqueous phase due to evaporation, and that pre-evaporation of ether can cause nozzle blockages and the formation of multilamellar vesicles. The LPLTVs process of the present embodiment for the formation of liposomes or niosomes formed around cosmeceutically benevolent ingredients has significant advantages over both the ethanol and ether injection methods since the depressurization from a high pressure environment creates outstanding dispersion of the lipid solution and mixing with the aqueous environment. The incorporation of both heating and dense gas washing enables the solvent to be efficiently removed. The LPLTVs process can also produce an equivalent volume of product in a significantly reduced time span. Compared with other dense gas processes developed for liposome formation, the LPLTVs process is beneficial due to its simplicity and the incorporation of residual solvent removal measures into the method. The LPLTVs process also operates at pressures generally less than 60 bar and moderate temperatures, therefore making the process more cost-effective and avoiding the concerns of uncontrollable foam formation present in the low pressure liposome method. A significant advantage of the LPLTVs process is that it can be used to process a broad range of materials since there is no requirement for the compound to be solubilized in the dense gas and there are no high shear forces. Furthermore, time-consuming solubility studies and recycling loops for lipid solubilization are not needed. The only preliminary investigation required is the determination of the threshold pressure for precipitation of the solutes from expanded solution, such that the solution expansion can be carried out without precipitation.
[0161] In the LPLTVs process of the current embodiment, the entrapment of hydrophilic compounds may be achieved through the dissolution of the target compound into the aqueous media prior to release of the lipid solution. The liposomes or niosomes would then form, entrapping the hydrophilic or hydrophobic compound within the aqueous interior of the vesicle.
[0162] To entrap a hydrophobic, hydrophilic, lipophilic, or amphipathic compound into liposomes or niosomes using the LPLTVs process, the compound is dissolved along with the phospholipid and other solutes in the liquid solvent.
[0163] The compound then becomes entrapped within the phospholipid membrane as a result of the affinity of the compound for the membrane rather than the aqueous phase.
[0164] The suitability of the LPLTVs process for entrapping hydrophobic compounds has already been demonstrated through incorporating up to 25% w/w cholesterol into the liposome formulation. The LPLTVs technique can also be applied to the formation of structures other than liposomes. Micro particles of hydrophobic compounds could be produced through precipitation into aqueous media in the LPLTVs process.
[0165] Liposomal Particle Size Distribution and Stability. Photon correlation spectroscopy (PCS) was used to assess the particle size distribution of the liposomal population using the Brookhaven ZetaPlus. Each liposomal sample was diluted in RO or DI water and placed in a disposable polypropylene cuvette. Ten runs, each of 1 min duration, were conducted at 23-25 oC for each sample. A laser wavelength of 678 nm was used with a destination angle of 90o. The dust cutoff was set between 20 and 50 μm. The instrument calculates an effective diameter for each run and an overall effective diameter for the 10 runs combined. The effective diameter is the mean diameter that is calculated by the following equation:
[0000]
Effective
diameter
=
(
1
d
k
)
-
1
=
∑
i
N
i
d
i
6
P
i
∑
i
N
i
d
i
5
P
i
[0166] Where Ni refers to the number per scattering volume of the ith particle, and Pi accounts for angular scattering effect for particles larger than λ/20. Pi is calculated using Mie theory and requires the particle refractive index; however, for Rayleigh scatters and at sufficiently low angles, Pi=1 is used in the program.
EXAMPLE 4
A Formulation for the Treatment of Acne Made using the Current LPLTVs Embodiment
[0167] A solution for treating Acne vulgaris or Propionibacterium acnes containing lipids formed of the following ingredients utilizing the science of the present embodiment may be formulated using the constructed phospholipids of the following volumes;
[0168] D.I. water 50% to 95% (preferably 60 to 90%, ethanol 15 to 40% (preferably 25 to 30%), hyaluronic acid 5 to 50% (preferably 12 to 18%) propanediol 10 to 80% (preferably 20 to 25%), aloe vera 0.2 to 20% (preferably 0.5 to 5%), azelaic acid 2 to 50% (preferably 4 to 8%), salicylic acid 0.2 to 20% (preferably 0.5 to 5.0%), lauric acid 0.2 to 20% (preferably 0.5 to 5.0%), asorbyl palmitate 0.1 to 20% (preferably 0.2 to 8%) niacinimide 0.2 to 20.0% (preferably 0.5 to 5%),lecithin 0.2 to 10% (preferably 0.5 to 5.0%), glycerin 0.5 to 25% (preferably 2 to 10%), caffeine 0.2 to 20% (preferably 0.5 to 10%)
EXAMPLE 5
A Formulation for the Enhanced Hydration and the Reduction of Fine Lines and Wrinkles Made using the Current Embodiment
[0169] A solution for treatment of lack of skin hydration and the reduction of fine lines and wrinkles containing lipids formed of the following ingredients utilizing the science of the present embodiment may be formulated using the constructed phospholipids of the following volumes;
[0170] D.I. water 50% to 95% (preferably 60 to 90% ethanol 15 to 40% (preferably 25 to 30%), hyaluronic acid 5 to 50% (preferably 12 to 18%) propanediol 10 to 80% (preferably 20 to 25%), aloe vera 0.2 to 20% (preferably 0.5 to 5%), hexa-peptide 8 2% to 50% (preferably 5% to 20%), caffeine 0.2 to 20% (preferably 0.5 to 10%), glycerin 0.5 to 25%(preferably 2 to 10%), tocopheryl acetate 0.1 to 10% (preferably 0.5 to 8%), retinyl palmitate 0.1 to 10%(preferably 0.5 to 8%), asorbyl palmitate 0.1 to 20% (preferably 0.2 to 8%), Copper tri-peptide GHK-Cu 0.1 to 20% (preferably 0.2 to 8%), hesperidin 0.1 to 20% (preferably 0.2 to 8%), dimethylethanolamine (DMAE) 0.05 to 20% (preferably 0.08 to 8%), sesame oil 2 to 50% (preferably 3 to 20%) beta glucan 0.1 to 20% (preferably 0.2 to 8%)
Test 1
LPLTVs Method for the Preparation of Hyaluronic Acid-Rich Vesicles
[0171] The present embodiment is based on the use of compressed CO2 in a process called LPLTVs for the production of micron-sized and submicron-sized crystalline particles from an organic solution. As novelty the process used the CO2 as co-solvent being completely miscible at a given pressure and temperature with a specific solution of an organic solvent containing the solute to be crystallized. In order to take full advantage of compressed fluid processing without using severe working conditions a novel and improved procedure based on the LPLTVs process was developed. This method, named as LPLTVs (Low Pressure Low Temperature alternative construction of Liposome Vesicles), enabled the preparation of cholesterol rich-hyaluronic acid vesicles. The process uses milder conditions of pressure (<10 MPa) and temperature (<308 K) than the previously described methodologies based on CFs, allowing the processing of heat labile compounds and reducing the investment cost of a high pressure plant when the process is scale-up. Using this procedure, homogeneous nanovesicles composed of hyaluronic acid, cholesterol and the cationic surfactant CTAB (cetyltrimethylammonium bromide, in a molar ratio 1:1, were prepared by depressurizing a volumetric expanded organic solution containing the cholesterol and hyaluronic acid over a flow of an aqueous solution containing the CTAB surfactant ( FIG. 5.0 ). An alternate non-ionically formed elastic noisome can be constructed using the same apparatus.
[0172] During the depressurization step, the expanded organic solution experiences a large, abrupt and extremely homogenous temperature decrease produced by the CO2 evaporation from the expanded solution. This explains the obtaining of homogenous vesicles regarding size, lamellarity and morphology.
[0173] In order to prepare any vesicular system using LPLTVs is necessary that the lipids forming the membrane are completely soluble in the CO2-expanded organic solvent , presenting one phase at the working conditions of pressure, P w, temperature, T w and CO2 molar fraction, X2. Therefore for the preparation of cholesterol rich-hyaluronic acid vesicles by LPLTVs method is always necessary to analyze the solubility behavior of the used sterol in CO2-expanded solvents, by means of a detailed phase diagram study, like the one showed in FIG. 6.0 .
[0174] An important prerequisite for the effective use of vesicles as a cosmeceutical ingredient carrier as described above is to control their stability, which can be defined as the extent to which the carrier retains its ingredient contents either in vitro or in vivo studies. One of the major disadvantages when using classical vesicles based on phospholipids, is the leakage of the encapsulated ingredient during their storage. One variant that can enhance the retention of drugs and promote the stability of liposomes or niosomes is the presence of hyaluronic acid in the formulation. Another variant is the preparation of liposomes from non-phospholipid amphiphiles, such as surfactants or polymers.
[0175] This kind of vesicular formulations show low passive leakage in comparison to liposomal systems based only on phospholipids and therefore a higher retention of the encapsulated materials, as for example epi-dermal therapeutically active molecules.
[0176] In the present example embodiment for the preparation of positively charged vesicles composed by cholesterol, hyaluronic acid and the cationic surfactant hexadecyltrimethylammonium bromide (CTAB). More recently nanoscopic vesicles, composed by different sterols and other quaternary ammonium surfactants have been also successfully prepared. This is why it was decided to name this kind of formulations as LPLTV (low pressure low temperature vesicles) that are stable for periods as long as several years, their morphology do not change upon rising the temperature or by dilution and they show a great homogeneity regarding size and morphology.
[0177] Studies at molecular level of the self-assembling of cholesterol hyaluronic acid and CTAB molecule in aqueous medium showed that a pure vesicular phase is only formed at equimolar ratios of both components. Moreover molecular dynamic (MD) simulations revealed that the cholesterol, hyaluronic acid and the CTAB self-assemble in a unique bimolecular synthon that can be considered as a single entity which further self-assembles in particularly stable vesicles ( FIG. 7.0 ) ( FIG. 10 ). Moreover, MD simulations have provided a theoretical support to justify the experimental high thermal stability and the exceptional morphological properties attributed to cholesterol, hyaluronic acid/CTAB vesicles at 1:1 molar ratio.
Test 2
Analysis of Active and Placebo Tape Strips from an In-Vivo Study of Skin Permeation of 800 KDa Hyaluronic Acid using the embodiments LPLTVs Formation Process Introduction
[0178] The test was to extract and analyze tape strips and blanks from an in vivo tape stripping study of 800 KDa Hyaluronic Acid skin penetration transport.
[0179] HA distribution in stratum corneum (SC) layer was investigated. Distribution in SC was studied using a tape-stripping method.
Methods:
[0180] Each tape sample will be extracted individually by extraction solvent: 1× PBS with 0.2% NaN3/acetonitrile (50/50 v). Samples with extraction solvent were vortexed at high speed for 1 minute followed with centrifugation at 12,000 rpm for 10 minutes (chill the samples on ice at 4 oC and then centrifuge). The supernatant solution was then collected from each tube/container and stored at 4 oC and ready for analysis.
Outcome:
[0181] See the chart in FIG. 11.0 showing Hyaluronic Acid levels in active and control samples.
[0182] Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. | The skin serves as a barrier that protects the body from the external environment and prevents water loss. This barrier function also prevents most hydrophilic or hydrophobic and large molecular weight ingredients (>500 kDa) from penetrating intact skin. Until recently, methods to increase stratum corneum permeability were generally not effective enough to make the stratum corneum so permeable that the barrier posed by the viable epidermis mattered. However, that has now changed with the development of the present embodiment's physical methods and highly optimized chemical formulations, such that we revisited the permeability of the full epidermis with the example embodiment's constructs and not focus only on the stratum corneum. This example embodiment therefore tests the hypothesis that the viable epidermis offers a significant permeability barrier to both small molecules and macromolecules that becomes the rate limiting step. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of co-pending and commonly-owned U.S. patent application Ser. No. 12/686,433, entitled “BIOPSY DEVICE WITH ROTATABLE TISSUE SAMPLE HOLDER,” filed Jan. 13, 2010, which is a continuation of U.S. Pat. No. 7,854,707, entitled “TISSUE SAMPLE REVOLVER DRUM BIOPSY DEVICE,” issued Dec. 21, 2010, the disclosures of which are hereby incorporated by reference in their entirety.
U.S. Pat. No. 7,854,707 is a continuation-in-part of commonly-owned U.S. Pat. No. 7,867,173, entitled “BIOPSY DEVICE WITH REPLACEABLE PROBE AND INCORPORATING VIBRATION INSERTION ASSIST AND STATIC VACUUM SOURCE SAMPLE STACKING RETRIEVAL,” issued Jan. 11, 2011, the disclosure of which is hereby incorporated by reference in its entirety.
U.S. Pat. No. 7,854,707 also claims priority to U.S. Pat. Appln. Ser. No. 60/874,792, entitled “BIOPSY SAMPLE STORAGE” to Hibner et al., filed Dec. 13, 2006, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates in general to biopsy devices, and more particularly to biopsy devices having a cutter for severing tissue, and even more particularly to biopsy devices for multiple sampling with a probe remaining inserted.
BACKGROUND OF THE INVENTION
When a suspicious tissue mass is discovered in a patient's breast through examination, ultrasound, MRI, X-ray imaging or the like, it is often necessary to perform a biopsy procedure to remove one or more samples of that tissue in order to determine whether the mass contains cancerous cells. A biopsy may be performed using an open or percutaneous method.
An open biopsy is performed by making a large incision in the breast and removing either the entire mass, called an excisional biopsy, or a substantial portion of it, known as an incisional biopsy. An open biopsy is a surgical procedure that is usually done as an outpatient procedure in a hospital or a surgical center, involving both high cost and a high level of trauma to the patient. Open biopsy carries a relatively higher risk of infection and bleeding than does percutaneous biopsy, and the disfigurement that sometimes results from an open biopsy may make it difficult to read future mammograms. Further, the aesthetic considerations of the patient make open biopsy even less appealing due to the risk of disfigurement. Given that a high percentage of biopsies show that the suspicious tissue mass is not cancerous, the downsides of the open biopsy procedure render this method inappropriate in many cases.
Percutaneous biopsy, to the contrary, is much less invasive than open biopsy. Percutaneous biopsy may be performed using fine needle aspiration (FNA) or core needle biopsy. In FNA, a very thin needle is used to withdraw fluid and cells from the suspicious tissue mass. This method has an advantage in that it is very low-pain, so low-pain that local anesthetic is not always used because the application of it may be more painful than the FNA itself. However, a shortcoming of FNA is that only a small number of cells are obtained through the procedure, rendering it relatively less useful in analyzing the suspicious tissue and making an assessment of the progression of the cancer less simple if the sample is found to be malignant.
During a core needle biopsy, a small tissue sample is removed allowing for a pathological assessment of the tissue, including an assessment of the progression of any cancerous cells that are found. The following patent documents disclose various core biopsy devices and are incorporated herein by reference in their entirety: U.S. Pat. No. 6,273,862 issued Aug. 14, 2001; U.S. Pat. No. 6,231,522 issued May 15, 2001; U.S. Pat. No. 6,228,055 issued May 8, 2001; U.S. Pat. No. 6,120,462 issued Sep. 19, 2000; U.S. Pat. No. 6,086,544 issued Jul. 11, 2000; U.S. Pat. No. 6,077,230 issued Jun. 20, 2000; U.S. Pat. No. 6,017,316 issued Jan. 25, 2000; U.S. Pat. No. 6,007,497 issued Dec. 28, 1999; U.S. Pat. No. 5,980,469 issued Nov. 9, 1999; U.S. Pat. No. 5,964,716 issued Oct. 12, 1999; U.S. Pat. No. 5,928,164 issued Jul. 27, 1999; U.S. Pat. No. 5,775,333 issued Jul. 7, 1998; U.S. Pat. No. 5,769,086 issued Jun. 23, 1998; U.S. Pat. No. 5,649,547 issued Jul. 22, 1997; U.S. Pat. No. 5,526,822 issued Jun. 18, 1996; and US Patent Application 2003/0199753 published Oct. 23, 2003 to Hibner et al.
At present, a biopsy instrument marketed under the trade name MAMMOTOME is commercially available from DEVICOR MEDICAL PRODUCTS, INC. for use in obtaining breast biopsy samples. This device generally retrieves multiple core biopsy samples from one insertion into breast tissue with vacuum assistance. In particular, a cutter tube is extended into a probe to cut tissue prolapsed into a side aperture under vacuum assistance and then the cutter tube is fully retracted between cuts to extract the sample.
With a long probe, the rate of sample taking is limited not only by the time required to rotate or reposition the probe but also by the time needed to translate the cutter. As an alternative to this “long stroke” biopsy device, a “short stroke” biopsy device is described in the following commonly assigned patents and patent applications: U.S. Pat. No. 7,419,472, entitled “Biopsy Instrument with Internal Specimen Collection Mechanism,” issued Sep. 2, 2008 in the name of Hibner et al.; and U.S. Pat. No. 7,740,597, entitled “Biopsy Device with Sample Tube,” issued Jun. 22, 2010 in the name of Cicenas et al. The cutter is cycled across the side aperture, reducing the sample time. Several alternative specimen collection mechanisms are described that draw samples through the cutter tube, all of which allow for taking multiple samples without removing the probe from the breast.
In particular, in the cross referenced U.S. Pat. Pub. No. 2006/0074345, entitled “BIOPSY APPARATUS AND METHOD”, these tissue samples are drawn by vacuum proximally through the cutter tube into a serial tissue stacking assembly that preserves the order of sample taking, can be visually observed through a transparent lumen, and can serve as a transport container for samples taken during a pathology examination.
While these known tissue storage approaches have a number of advantages, it is believed that further improvements may be made in tissue storage and transport for core biopsy procedures.
SUMMARY OF THE INVENTION
The present invention addresses these and other problems of the prior art by providing a biopsy device that has a probe cannula that is inserted into tissue to obtain a core biopsy sample by translating a cutter with the probe cannula. A pneumatic pressure differential is used to draw a severed tissue sample proximally from the probe cannula into an individual sample container. Thereafter, another empty sample container is moved into position to accept the next tissue sample.
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 DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will be better understood by reference to the following description, taken in conjunction with the accompanying drawings in which:
FIG. 1 is an isometric view of a biopsy device with an attached sample revolver drum assembly consistent with the present invention.
FIG. 2 is an isometric view of the biopsy device of FIG. 1 with a disposable probe assembly that includes the sample revolver drum assembly disengaged from a reusable handpiece that has a lower tray removed to expose a carriage frame assembly and a motor drive assembly.
FIG. 3 is an isometric view of the reusable handpiece of FIG. 1 with a top cover detached with a left half cut away and with the lower handle tray detached to expose the motor drive assembly operatively engaged to the carriage frame assembly.
FIG. 4 is an isometric view of the motor drive assembly removed from the carriage frame assembly of FIG. 3 .
FIG. 5 is a bottom isometric view of the top cover of the reusable handpiece of FIG. 2 .
FIG. 6 is a top, left and aft isometric view of the carriage frame assembly of FIG. 4 .
FIG. 7 is a top, left and forward view of the carriage frame assembly of FIG. 4 with an upper frame disassembled.
FIG. 8 is a top, left and front isometric view of the carriage frame assembly of FIG. 4 with the upper frame removed.
FIG. 9 is a bottom isometric view of the carriage frame assembly of FIG. 8 with the upper frame removed.
FIG. 10 is a top, left and front isometric exploded view of the carriage frame assembly of FIG. 4 .
FIG. 11 is a right front view of a transmission section of the motor drive assembly of FIG. 4 with a distal bulkhead removed.
FIG. 12 is a front left exploded view of the transmission section of the motor drive assembly of FIG. 4 .
FIG. 13 is a left front isometric view of the disposable probe assembly of FIG. 1 with a hand-held distal portion partially disassembled from the sample revolver drum assembly.
FIG. 14 is an isometric view from below and to the left of the hand-held distal portion of the disposable probe assembly of FIG. 13 with cover components omitted.
FIG. 15 is an isometric view of an exploded portion of the disposable probe assembly.
FIG. 16 is an isometric view of the sample revolver drum assembly of FIG. 1 .
FIG. 17 is an exploded view of the sample revolver drum assembly of FIG. 16 .
FIG. 18 is an isometric detail view of an indexer gear cover of the sample revolver drum assembly of FIG. 16 .
FIG. 19A is a left side diagrammatic view of a left cyclic arm shown in phantom down for engagement during a proximal stroke engaged to the indexer gear cover of FIG. 18 .
FIG. 19B is a left side diagrammatic view of the left cyclic arm shown in phantom at a proximal most position on the indexer gear cover of FIG. 18 .
FIG. 19C is a left side diagrammatic view of the left cyclic arm shown in phantom during a return distal stroke rotated upward for disengagement.
FIG. 20 is an isometric view of a revolver cylindrical drum assembly of the sample revolver drum assembly of FIG. 16 .
FIG. 21 is an isometric view of the revolver cylindrical drum of the revolver cylindrical drum assembly of FIG. 20 .
FIG. 22 is an isometric view of a revolver drum belt with a couple of removed sample vials of the revolver cylindrical drum assembly of FIG. 20 .
FIG. 23 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with both carriages advanced for closing a side aperture in a probe cannula for insertion into tissue.
FIG. 24 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with an aft carriage retracted to vent the probe cannula to the atmosphere to begin a new sample taking cycle.
FIG. 25 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with a front carriage beginning to retract, opening the side aperture and beginning to switch to supplying vacuum to the probe cannula.
FIG. 26 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with both carriages retracted supplying vacuum pressure to the side aperture to prolapse tissue into the probe cannula.
FIG. 27 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with the front carriage being distally advanced to sever tissue.
FIG. 28 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with the front carriage fully distally translated to complete severing of a tissue sample with atmosphere pressure supplied to the side aperture through a lateral lumen.
FIG. 29 is a diagrammatic view of the hand-held distal portion of the disposable probe assembly of FIG. 1 with the aft carriage distally advanced to retract the tissue sample with vacuum pressure.
DETAILED DESCRIPTION OF THE INVENTION
Turning to the Drawings, wherein like numerals denote like components throughout the several views, in FIGS. 1-2 , a biopsy device 10 includes a reusable handpiece 12 , and a disposable probe assembly 14 . A lower handle tray 16 is disassembled from upper portions of the reusable handpiece 12 to expose portions that operably engage the disposable probe assembly 14 . A sample revolver drum assembly 18 is prepared to receive the next tissue sample by an indexing assembly 19 attached to a hand-held distal portion 21 of the disposable probe assembly 14 that mounts to and is actuated by the reusable handpiece 12 . Tissue that is drawn by vacuum assistance into a side aperture 20 of a probe cannula 22 of the disposable probe assembly 14 is severed by a DC motor 24 ( FIG. 3 ) in the reusable handpiece 12 that also powers rotation and staging of the sample revolver drum assembly 18 to segregate and store the tissue samples in the order received.
With particular reference to FIG. 1 , insertion of the probe cannula 22 into tissue is integrally supported by a piercing tip 26 attached at a distal end as well as a longitudinal jack hammer motion to the probe cannula 22 selected by positioning a slide button 28 distally and depressing a forward motor button 30 . In response, the DC motor 24 drives a transmission section 31 ( FIG. 2 ) grounded to a top cover 34 of the reusable handpiece 12 to longitudinally reciprocate an internal carriage frame assembly 32 ( FIG. 2 ) that is engaged for movement with the probe cannula 22 ( FIG. 3 ). With the slide button 28 proximally positioned, depression of the forward motor button 30 causes the DC motor 24 to advance and rotate a cutter tube 36 , depicted in FIG. 1 as having been fully distally translated, closing the side aperture 20 . Depression of a reverse motor button 38 causes the cutter tube 36 to retract. Depression of a mode button 40 may cause other functions to be performed. An external conduit 42 extends from the disposable probe assembly 14 and is terminated by a filter/tube fitting 43 . Vacuum assistance passes through a lateral lumen 44 of the probe cannula 22 and distally communicates via internal vent holes 47 ( FIG. 23 ) and then enters a cutter lumen 46 that encompasses the cutter tube 36 and includes the side aperture 20 . An additional feature contemplated but not depicted includes using the mode button 40 to selectively communicate a saline supply to lateral lumen 44 to flush the probe cannula. It should be appreciated that the biopsy device 10 includes a minimum of “tethers” that would impede use, pose a tripping hazard, or extend set-up time.
Alternatively, instead of “hard-walled” lateral lumen 44 separated from the cutter lumen 46 along its length, applications consistent with the present invention may have a cylindrical probe cannula wherein the cutter tube 36 is positioned off-center to translate across a side aperture. A “soft-walled” lateral lumen may then be defined as a space between an outer diameter of the cutter tube and an inner diameter of the cylindrical probe cannula.
In FIG. 2 , the disposable probe assembly 14 has a bottom cover 48 with a distal probe mount cover 50 that assists in supporting the probe cannula 22 while allowing the longitudinal jack hammer motion. A plurality of locking tabs 52 with locking edges 54 extend upwardly through pass-through slots 56 formed in the periphery of the lower handle tray 16 to resiliently extend outwardly into engaging contact with the slots 56 . Relieved areas 58 are formed behind each locking tab 52 in a top extension member 59 that surrounds a probe support body 60 . The combination covers a cavity defined by the bottom cover 48 , which allows depression of the locking tabs 52 to unlock the disposable probe assembly 14 to install another identical or similar assembly.
A proximal end of the cutter tube 36 receives a cutter gear 62 having distal and proximal reduced diameter bearing surfaces 64 , 66 on each longitudinal side of a rotation spur gear section 68 , which engage the reusable handpiece 12 for rotation and for longitudinal translation through a distally open longitudinal aperture 70 formed in the lower handle tray 16 .
Reusable Handpiece.
In FIGS. 3-13 , the reusable handpiece 12 is depicted in various states of disassembly to illustrate its operation. The transmission section 31 is part of a rigidly mounted motor drive assembly 76 that includes the motor 24 in between a planetary gearbox 78 and an encoder 80 . The battery or other power source and control circuitry are omitted in the depictions. The motor drive assembly also includes a right guide pin 82 and a left guide pin 84 . The motor drive assembly 76 is shown operably engaged to the longitudinally reciprocating carriage frame assembly 32 in FIG. 3 and is disassembled from the longitudinally reciprocating carriage frame assembly in FIG. 4 . In FIG. 4 , the right guide pin 82 is inserted proximally through a right front pin guide 86 and then through a right rear pin guide 88 , both part of an upper frame 90 of the carriage frame assembly 32 . A proximal end of the right guide pin 82 resides within a distally projecting right pin receptacle 92 ( FIG. 12 ) formed as part of a distal bulkhead 94 of the transmission section 31 . A distal end of the right guide pin 82 is received by a right pin recess 96 ( FIG. 5 ) formed in the top cover 34 . Similarly, the left guide pin 84 is inserted proximally through a left front pin guide 98 and then through a left rear pin guide 100 , both part of the upper frame 90 of the carriage frame assembly 32 . A proximal end of the left guide pin 84 resides within a distally projecting left pin receptacle 102 , respectively formed as part of the distal bulkhead 94 of the transmission section 31 . A distal end of the left guide pin 84 is received by a left pin recess 104 ( FIG. 5 ) formed in the top cover 34 .
With particular reference to FIGS. 3 , 4 , 6 , 7 and 12 , a right front ring bearing 106 is inserted over a distal portion of the right guide pin 82 and is received within a cylindrical recess 108 formed on a distal side of the right front pin guide 86 . A right aft ring bearing 109 is inserted over a proximal portion of the right guide pin 82 and is received within a cylindrical recess 111 ( FIG. 6 ) formed on a proximal side of the right aft pin guide 88 . A left front ring bearing 110 is inserted over a distal portion of the left guide pin 84 and is received within a cylindrical recess 112 formed on a distal side of the left front pin guide 98 . A left aft ring bearing 113 ( FIG. 9 ) is inserted over a proximal portion of the left guide pin 84 and is received within a left cylindrical recess 115 ( FIG. 6 ) formed on a proximal side of the left rear pin guide 100 A right compression spring 114 is proximally received over the right guide pin 82 between the right front and rear pin guides 86 , 88 . More particularly, the right compression spring 114 is distally positioned against the right front pin guide 86 and at its proximal end by a right downwardly projecting structure 116 ( FIG. 5 ) formed on an interior of the top cover 34 that closely encompasses a top portion of the right guide pin 82 without contacting other portions of the carriage frame assembly 32 . A left compression spring 118 is proximally received over the left guide pin 84 between the left front and rear pin guides 98 , 100 . More particularly, the left compression spring 118 is distally positioned against the left front pin guide 98 at its distal end by a left downwardly projecting structure 120 ( FIG. 5 ) formed on the interior of the top cover 34 that closely encompasses a top portion of the left guide pin 84 without contacting other portions of the carriage frame assembly 32 . Thereby, the carriage frame assembly 32 is biased to a distal position relative to the top cover 34 and lower handle tray 16 .
In FIGS. 3-5 , a forward projecting cylindrical resilient member 122 fastened to the upper frame 90 reduces noise by contacting the front interior of the top cover 34 slowing distal movement of the carriage frame assembly 32 prior to reaching full travel. The distal bulkhead 94 is restrained by being proximal to a top ridge 123 , a right ridge 125 , and a left ridge 127 ( FIG. 5 ) formed in the interior of the top cover 34 and to a bottom ridge 129 formed on an upper surface of the lower handle tray 16 .
Returning to FIGS. 3-4 and 7 , the upper frame 90 has right and left front shaft apertures 124 , 126 that respectfully receive for rotation a distal end of a rotation shaft 128 and a translation shaft 130 . The right front shaft aperture 124 is closed by the front portion of a right lower frame 131 of the carriage frame assembly 32 . The left front shaft aperture 126 is closed by the front portion of a left lower frame 132 of the carriage frame assembly 32 . A front (cutter) carriage 134 and an aft (straw) carriage 136 are received on the translation shaft 130 and are encompassed by the upper and lower frames 90 , 132 . In FIG. 6 , a proximal beveled and slotted end 138 of the rotation shaft 128 extends out of right aft shaft aperture 140 formed in the upper frame 90 for engagement to the transmission section 31 and is closed by an aft portion of the right lower frame 131 . A proximal slotted end 142 of the translation shaft 130 extends out of a left aft aperture 144 formed in the upper frame 90 for engagement to the transmission section 31 and is closed by the lower frame 132 . A threaded receptacle 146 on the aft end of the upper frame 90 receives a proximally projecting bolt 148 having an upwardly directed strike pin 148 at its proximal end.
In FIGS. 7-10 , the carriage frame assembly 32 sequences translation of the front and aft carriages 134 , 136 . With particular reference to FIG. 10 , the front and aft carriages 134 , 136 respectively include lower longitudinal grooves 152 , 154 that slide upon a lower rail 156 upwardly presented on the left lower frame 132 . The front and aft carriages 134 , 136 respectively include an upper longitudinal groove 158 , 160 that slides upon a rail (not shown) downwardly presented on the upper frame 90 . The translation shaft 130 has a distal overrun portion 162 and a center overrun portion 164 separated by a front threaded portion 166 that a threaded bore 168 of a front main body portion 169 of the front carriage 134 traverses in response to rotation of the translation shaft 130 . A front translation compression spring 170 on the translation shaft 130 distal to the front carriage 134 compresses to allow the front carriage 134 to free wheel when being distally advanced and then biases the front carriage 134 aft to engage the front threaded portion 166 for being retracted upon reversal of rotation of the translation shaft 130 .
With particular reference to FIGS. 8 and 10 , proximal to the center overrun portion 164 is an aft threaded portion 172 and then a proximal overrun portion 174 that a threaded bore 176 of a back main body portion 177 of the aft carriage 136 traverses in response to rotation of the translation shaft 130 as well as in response to a connection to the front carriage 134 . In particular, a front bracket 178 mounted on a right side of the front carriage 134 has a rightward front pin guide 180 that receives a distal end of a longitudinally aligned carriage limiting rod 182 . A distal threaded end 184 of the carriage limiting rod 182 extends distally out of the rightward front pin guide 180 and is prevented from backing out by a front nut 186 . A long compression spring 188 is received over a shaft 190 of the carriage limiting rod 182 proximal to the rightward front pin guide 180 . An aft bracket 192 is attached to a right side of the back main body portion 177 of the aft carriage 136 to extend a rightward aft pin guide 194 that receives the carriage limiting rod 182 , which extends a proximal threaded end 196 proximally out of the rightward aft pin guide 194 to receive an aft nut 198 that limits forward movement. The long compression spring 188 biases the aft carriage 136 away from the front carriage 134 , delaying retraction of a tissue sample until cutting is complete when full distal translation of the front carriage 134 pulls the aft carriage 136 onto the aft threaded portion 172 .
With particular reference to FIG. 9 , a lengthwise engagement aperture 200 , defined between the right and left lower frames 131 , 132 , presents engaging structures that actuate the disposable probe assembly 14 and the revolver drum assembly 18 . The rotation (spur) gear 128 exposes its left side to the lengthwise engagement aperture 200 for engagement with the rotation spur gear section 68 of the cutter gear 62 to impart a rotation. The front bracket 178 has a downward distal half cylinder recess 202 sized to grip the distal reduced diameter bearing surface 64 of the cutter gear 62 ( FIG. 2 ). The front bracket 178 further has a downward proximal half cylinder recess 204 proximally spaced and sized to grip the proximal reduced diameter bearing surface 66 of the cutter gear 62 ( FIG. 2 ) as well as a downwardly projecting front actuation finger 206 to the left side and below of the cutter gear 62 for effecting atmospheric pressure to the probe cannula 22 . Similarly, the aft bracket 192 has a downward distal half cylinder recess 208 and a downward proximal half cylinder recess 210 proximally spaced and sized to nonobstructively translate overtop of a tissue retraction tube 211 , as well as a downwardly projecting aft actuation finger 212 that selects vacuum pressure for communicating to the probe cannula 22 .
In FIGS. 2-3 and 11 - 12 , the motor drive assembly 76 rotates rotation and translation shafts 128 , 130 at a fixed ratio to optimize cutting performance of the cutter tube 36 when the slide button 28 is back. Alternatively, the motor drive assembly 76 imparts a jackhammer vibration to the carriage frame assembly 32 when the slide button 28 is forward. With particular reference to FIGS. 11-12 , the planetary gearbox 78 extends proximally a keyed motor drive shaft 214 ( FIG. 12 ) through a drive shaft hole 216 formed in the distal bulkhead 94 . A slide spur gear 218 is received upon the keyed motor drive shaft 214 remaining engaged for rotation between a first distal (jack hammer) position and a second proximal (translation) position in accordance with a position of the slide button 28 whose distal and proximal feet 220 , 222 straddle the slide spur gear 218 . In FIG. 11 , the slide spur gear 218 is close to a proximal bulkhead 224 of the transmission section 31 , engaging a small spur 226 of a multiplier gear assembly 228 . The multiplier gear assembly 228 includes a longitudinal shaft 230 centrally attached to the small spur gear 226 . Proximal thereto, a cylindrical hub 232 is pinned to the longitudinal shaft 230 and in turn is encompassed by and pinned to a large spur gear 234 that rotates within a correspondingly sized, distally open recess 236 formed in proximally projecting container 237 integral to the proximal bulkhead 224 . A front cylinder bearing 238 received on a distal portion of the longitudinal shaft 230 is received by the proximal surface of the distal bulkhead 94 .
A first output drive shaft 240 distally presents a right angle prismatic end 242 shaped to engage the beveled and slotted end 138 of the rotation shaft 128 that passes through a lower right hole 244 in the distal bulkhead 94 . A cylindrical spacer 246 is received over a distal cylindrical portion 248 of the first output shaft 240 , taking up the space between the rotation shaft 128 and the proximal bulkhead 224 . A distally open recess 250 , formed as part of the container 237 that communicates from below with the recess 236 , is shaped to receive a proximal cylindrical end 252 of the first output drive shaft 240 and encompasses cylindrical bearing 254 as well as a small spur gear segment 256 , which is distal thereto and engages the large spur gear 234 of the multiplier gear assembly 228 .
A second output drive shaft 258 distally presents a right angle prismatic end 260 to engage the proximal slotted end 142 of the translation shaft 130 that extends through a low left hole 262 in the distal bulkhead 94 . A cylindrical spacer 264 is received over a distal cylindrical portion 266 of the second output drive shaft 258 proximal to the right angle prismatic end 260 and distal to a wider diameter hub segment 268 that is encompassed by and pinned to a large spur gear 270 that engages the small spur gear 226 of the multiplier gear assembly 228 . Proximal to the hub segment 268 is a wide spacer segment 272 and then a narrow cylindrical end 274 that receives a cylindrical bearing 276 that resides within a correspondingly-sized, distally open recess 278 that communicates from the left with the recess 236 and is formed as part of the same container 237 .
The distal and proximal bulkheads 94 , 224 are structurally attached to one another in parallel alignment traverse to the longitudinal axis of the biopsy device 10 by cylindrical legs 280 molded to and proximally projecting from rectangular corners of the distal bulkhead 94 and fastened to the proximal bulkhead 224 . In addition, a pin 282 passes through holes 281 , 283 longitudinally aligned in the distal and proximal bulkheads 94 , 224 respectively along a top surface.
When the slide button 28 is moved distally to the jackhammer position, the sliding spur gear 218 disengages from the small spur gear 226 and engages a large spur gear 284 of a rotary camming gear assembly 286 . A camming shaft 286 from distal to proximal includes a distal cylindrical end 288 , a cam wheel 290 , a mid-shaft portion 292 that receives the upwardly directed strike pin 150 of the proximally projecting bolt 148 , a wide diameter hub 294 that is encompassed by and pinned to the large spur gear 284 , and a proximal cylindrical end 296 . A distal cylindrical bearing 298 is received within a proximally open container 300 projecting distally from the distal bulkhead 94 and in turn receives the distal cylindrical end 288 of the camming shaft 286 . A proximal cylindrical bearing 302 is received within a distally projecting and open cylinder 304 formed on the proximal bulkhead 224 and in turn receives the proximal cylindrical end 296 of the camming shaft 286 .
As the camming shaft 286 rotates clockwise as viewed from behind, the cam wheel 290 presents a proximal surface to the distal edge of the strike pin 150 that is more proximal until the interrupted portion of the camming wheel 290 is presented, allowing the strike pin 150 to return to a distal position under the urging of the distal biasing of the right and left compression springs 114 , 118 .
Disposable Probe Assembly.
In FIGS. 13-29 , the disposable probe assembly 14 has movable components that respond to the actuating motions of the reusable handpiece 12 . With particular reference to FIGS. 13-15 , the distal portion 21 of the disposable probe assembly includes the probe cannula 22 that is supported by the probe support body 60 . The probe support body 60 includes a distal probe mount 306 that is received within the distal probe mount cover 50 of the bottom cover 48 . The front carriage 134 controls a vacuum valve 307 . In particular, proximal to and underlying a longitudinal axis of the disposable probe assembly 14 defined by a probe guide hole 308 passing through the distal probe mount 306 , a vertically open longitudinal trough 310 is formed into a necked portion 312 of the probe support body 60 . A cutter carriage-driven vacuum valve driver 313 has an elongate driver body 314 that longitudinally translates within the longitudinal trough 310 and upwardly presents an elongate slot 315 for being indirectly moved by the downwardly projecting front actuation finger 206 of the front carriage 136 .
With reference also to FIG. 23 , a proximal block portion 316 is attached to the necked portion 312 of the probe support body 60 . A lower mounting 317 extends from the elongate driver body 314 distal to and longitudinally aligned with a distally open, longitudinally aligned vacuum valve bore 318 ( FIG. 23 ) formed in proximal block portion 316 of the probe support body 60 . Central and proximal ports 320 , 321 communicate with the vacuum valve bore 318 from an underside of the proximal block portion 316 and a distal port 322 communicates laterally from a right side of the proximal block portion 316 . A right distal 90-degree fitting 319 communicates between the distal port 322 and an intake filter 323 within an outer hose fitting 324 .
A vacuum valve control rod 325 has a distal actuating portion 326 extending distally out of the valve bore 318 with a distal end positionable under the downwardly open portion of the longitudinal trough 310 and attached to the lower mounting 317 of the vacuum valve driver 313 . The vacuum valve control rod 325 also has a valve spool portion 327 that longitudinally translates within the valve bore 318 to selectively position between a first position and a second position. A proximal O-ring 328 near a proximal end of the valve spool portion 327 and a distal O-ring 329 are spaced such that the first position entails the O-rings 328 , 329 bracketing the central and distal ports 320 , 322 and the second position entails the O-rings 328 , 329 bracketing the proximal and central ports 321 , 320 , respectively.
The aft carriage 136 controls an air valve 351 . In particular, an air valve body 330 is attached to a left side of the proximal block portion 316 and includes a distally open longitudinal air valve bore 331 ( FIG. 23 ) depicted in FIG. 14 as accessed by a distal left port 332 , a left center port 333 , and a left proximal port 334 . An air valve control rod 335 has a distal actuating portion 336 extending distally out of the air valve bore 331 . The valve control rod 335 also has a valve spool portion 337 that longitudinally translates within the air valve bore 331 to selectively position between a first position and a second position. A proximal O-ring 338 near a proximal end of the valve spool portion 337 and a distal O-ring 339 are spaced such that the first position entails the O-rings 338 , 339 bracketing the central and distal ports 333 , 332 and the second position entails the O-rings 338 , 339 bracketing the proximal and central ports 334 , 333 , respectively.
A valve connecting vacuum conduit 340 has one end attached to a lower center ninety-degree fitting 341 attached to the central port 320 of the vacuum valve bore 318 and the other end attached to an aft left ninety-degree fitting 342 that communicates with the left proximal port 334 of the air valve bore 331 . A distal conduit 343 is attached at one end to a center ninety-degree fitting 344 that communicates with the left center port 333 and at the other end at a probe union ninety-degree fitting 345 that communicates with the lateral lumen 44 . A vacuum supply conduit 346 is attached at one end to a distal ninety-degree fitting 347 that communicates with the proximal port 321 and at the other end to a vacuum supply (not shown). An air supply conduit 348 is attached at one end to a distal ninety-degree fitting 349 that communicates with the distal left port 332 and the other end to an air supply (not shown).
The front actuation finger 206 of the front carriage 136 ( FIGS. 9-10 ) is received within an upwardly open socket 350 formed on a left side of a cutter carriage-driven indexing shuttle 352 having a lateral concave recessed band 354 shaped to encompass with a clearance a lower portion of the rotation spur gear section 68 of the cutter gear 62 . An indexing arm 355 attached to the indexing shuttle 352 includes a proximally directed portion that proximally terminates in a rightward portion that terminates in an upward portion. In FIG. 14 , a downwardly projecting vacuum actuator lug 356 ( FIG. 14 ) attached to an underside of the indexing shuttle 352 is received within the elongate slot 315 of the vacuum valve driver 314 to selectively communicate the vacuum supply to the probe cannula 22 . An air shuttle 358 longitudinally rides on a left edge of the necked portion 312 of the probe support body 60 and upwardly projects an air valve tab socket 360 positioned to receive the aft actuating finger 212 of the aft carriage 138 . A downward mounting arm 362 of the air shuttle 358 is attached to the distal actuating portion 336 of the air valve control rod 335 extending distally out of the air valve bore 331 .
A straw hook wire 364 supports a midpoint of a sample retraction tube 363 in place upon the probe support body 60 prior to engagement with the reusable handpiece 12 . A curled lower right end passes into leftwardly opening 365 along the top right surface of the proximal block portion 316 of the probe support body 60 into a small mounting block 366 extending upwardly from a right side with a downwardly inserted pin 368 passing through the curled lower right end to hold the straw hook wire 364 in place. The straw hook wire 364 has a horizontal portion attached to the curled end that passes under the sample retraction tube 363 , bending upward and then bending leftward and horizontally again through a lateral slot 370 in a vertical wire support member 372 formed onto a left side of the top surface of the proximal block portion 316 . It should be appreciated that engagement of the reusable handpiece 12 forces the left portions of the straw hook wire 364 out of engagement with the midpoint indented feature 350 as a rib feature 373 ( FIG. 9 ) deflects the left portion of the straw hook wire 364 . This facilitates commonality with disposable probe assemblies in which the straw hook wire 364 keeps a translating sample retraction straw in place prior to mounting to the reusable handpiece 12 (not shown).
With particular reference to FIGS. 16-17 , the sample revolver drum assembly 18 includes a revolver cylindrical drum 380 encompassed by a detachable revolver drum belt 382 that in turn holds removable sample vials 384 forming a revolver cylindrical drum assembly 386 ( FIG. 20 ). A drum base 388 includes a half cylinder recess 389 which holds the sample revolver drum assembly 386 for rotation about the longitudinal axis and is closed by a top drum cover 390 , which may be transparent for monitoring progress in tissue collection or opaque. An indexer support base 392 of the indexing assembly 19 has a proximal surface fastened to a distal surface of the drum base 388 and extends a mounting flange 394 distally to attach to a proximal end of the hand-held distal portion 21 of the disposable probe assembly 14 . The sample retraction tube 363 passes over the mounting flange 394 and is gripped within a longitudinal groove 396 formed along a top, left side of the indexer support base 392 and passes through a hole 398 on a top left corner of a distal face of the drum base 388 .
A slotted distal drum axle 400 of the revolver cylindrical drum 380 is received within a smaller distal portion of the half cylinder recess 389 and a proximal drum axle 401 ( FIG. 21 ) is received within a smaller proximal portion of the half cylinder recess 389 . The slotted distal drum axle 400 receives an angled proximal end 402 of a shaft 404 that passes through a shaft hole 406 in the drum base 388 . A distal portion of the shaft 404 is received within a shaft recess 408 across the top of the indexer support base 392 that communicates with a half cylindrical gear recess 410 that encompasses a lower half of a large bevel gear 412 mounted on the shaft 404 . A small half cylindrical gear recess 414 receives a transversely oriented small bevel gear 416 that engages the large bevel gear 412 . A transverse shaft 418 has a left end mounted to the small bevel gear 416 and a right end mounted to a dual spur gear assembly 420 that rotates within a rightward transverse half cylindrical recess 422 formed in the indexer support base 392 .
With particular reference to FIG. 18 , a top indexer gear cover 424 mounts overtop of the indexer support base 392 that contacts the top surfaces of the shaft 404 and left and right axle ends 426 , 428 of the dual spur gear assembly 420 with a leftward slot 430 that exposes a top portion of the large bevel gear 412 and distally open left and right vertical slots 432 , 434 that expose top surfaces of a left and right spur gear 436 , 438 of the dual spur gear assembly 420 . In FIG. 17-18 , a central beam 440 , defined between the left and right vertical slots 432 , 434 , has a T-shaped hold down spring 442 mounted on top with its narrow end 444 mounted to a proximal end of the central beam 440 . A laterally wider end 446 extends overtop of both vertical slots 432 , 434 . A cyclic spring gate 448 extends laterally to the left and right from a proximal end of the T-shaped hold down spring 442 and ramps downwardly and proximally.
With particular reference to FIG. 18 , each side of the central beam 440 has a respective left and right lower pin guides 462 , formed as an upper surface of a wider lower portion. An upper pin guide 449 extends laterally out from the central beam 440 on each side and is spaced respectively above the lower pin guides 462 , 470 to form a lower pin channel 451 . Although only the left upper pin guide 449 is depicted, it should be appreciated that the right side includes a mirror image upper pin guide. A rear ramped portion 453 of the upper pin guide 449 underlies and supports the cyclic spring gate 448 .
Left and right cyclic arms 450 , 452 have distal ends mounted on respective ends of a transverse cyclic axle 454 whose central portion passes through a top end 456 of the index arm 355 . Left fore and aft cyclic pins 458 , 460 extend rightward out of the left cyclic arm 450 . Right fore and aft cyclic pins 466 , 468 extend leftward out of the right cyclic arm 452 . Each cyclic arm 450 , 452 includes a respective left and right bottom rack segment 472 , 474 close to the distal rotating end positioned to engage a respective spur gear 436 , 438 under the downward urging of the laterally wider distal end 446 of the T-shaped hold spring 442 .
With reference to FIG. 16 , the left cyclic arm 450 is at its distal most position. It should be appreciated that the left aft cyclic pin 460 is distal to the upper pin guide 449 . In FIG. 19A , proximal movement of the right cyclic arm 450 presents the rack segment 472 to rotate the left spur gear 436 (not shown in FIG. 19A ) top aft, held in engagement by the T-shaped hold down spring 442 . Proximal movement of the cyclic arms 450 , 452 causes the dual spur gear assembly 420 and thus the small bevel gear 416 to rotate top aft, which in turn causes the large bevel gear 412 and revolver cylindrical drum assembly 386 to rotate top right, indexing the sample vial 384 to the sample retraction tube 363 in the hole 398 . In FIG. 19B , the right cyclic arm 450 has reached its proximal most position, wherein the left aft pin 460 has pushed through the cyclic spring gate 448 and out of the lower pin channel 451 . In FIG. 19C , upon distal movement of the right cyclic arm 450 , the left aft pin 460 rides up the cyclic spring gate 448 , rotating the right cyclic arm 450 out of engagement with the left spur gear 436 . It should be appreciated that the left aft pin 460 will drop off of the front of the upper pin guide 449 as the distal most position is reached and be positioned to enter again the lower pin channel 451 under the downward urging the T-shaped hold down spring 442 .
In FIGS. 20-22 , the revolver cylindrical drum 380 includes radially spaced longitudinal recesses 476 shaped to receive respective cylindrical vial holders 478 formed in the revolver drum belt 382 that hold the sample vials 384 . Each vial holder 478 includes an elongate outward aperture 480 so that contents of the retained vial 384 may be viewed. In order that pathology may ascertain which sample vial 384 received the first and subsequent tissue samples, the revolver drum belt 382 terminates in first and second belt retaining ears 482 , 484 that are drawn into longitudinal abutment and inserted into a longitudinal indexing and retention slot 486 formed in the revolver cylindrical drum 380 as the circled revolver drum belt 382 is slid longitudinally onto the revolver cylindrical drum 380 . A V-shaped slot 488 of the slotted distal drum axle 400 assures that the angled proximal end 402 of the shaft 404 is in an initial condition with a narrow aspect upward to receive the open side of the V-shaped slot 488 , which registers the retaining ears 482 , 484 to a known position prior to commencing sampling.
In FIGS. 23-29 , the operation of the reusable handpiece 12 and the hand-held distal portion 21 of the disposable probe assembly 14 are depicted sequentially in diagrammatic form to illustrate how the indexing assembly 19 and revolver drum assembly 18 are operated in conjunction with the taking of vacuum assisted core biopsy samples. In FIG. 23 , the hand-held distal portion 21 of the disposable probe assembly 14 has both carriages 134 , 136 distally advanced in an initial state for closing the side aperture 20 in the probe cannula 22 for insertion into tissue. The front carriage 134 also advances the cutter carriage-driven vacuum valve driver 313 to its distal position, switching the vacuum valve 307 distally to provide atmospheric pressure to the air valve 351 (i.e., atmosphere in distal port 322 and out center port 320 to left proximal port 334 ). The aft carriage 136 positions the air valve 351 to shut off the input from the vacuum valve 307 , instead causing the air supply conduit 348 to communicate through the left distal port 332 to the left center port 333 to the distal conduit 343 to pressurize the lateral lumen 44 .
In FIG. 24 , the aft carriage 136 has proximally retracted, switching the air valve 351 so that the atmospheric pressure provided by the vacuum valve 307 now communicates through the left proximal port 334 to the left center port 334 to the distal conduit 343 to the lateral lumen 44 , venting the probe cannula 22 to begin a new sample taking cycle.
In FIG. 25 , the front carriage 134 has begun to proximally retract while the aft carriage 136 remains at its proximal most position. The cutter tube 36 retracts exposing a portion of the side aperture 20 of the probe cannula 22 while the vacuum and air valves 307 , 351 remain in the same state with the probe cannula 22 vented to the atmosphere.
In FIG. 26 , the front carriage 134 has reached its proximal most position, fully retracting the cutter tube 36 to expose the side aperture 20 of the probe cannula 22 , which is now under vacuum pressure to prolapse tissue by having the front carriage 134 position the vacuum valve 307 to pass vacuum supply from the proximal port 321 through the center port 320 to the left central port 330 to the left distal port 332 to the lateral lumen 44 , drawing air through the internal vent holes 47 .
In FIG. 27 , the front carriage 134 has begun to distally advance, severing tissue, while the vacuum valve 307 remains switched to vacuum supply and the air valve 351 remains in the state of passing the vacuum pressure through to the lateral lumen 44 .
In FIG. 28 , the front carriage 134 has been fully distally advanced, causing the cutter tube 36 to completely sever the prolapsed tissue into a tissue sample and switching the vacuum valve 307 to vent to the atmosphere. With the aft carriage 136 still back, the air valve 351 passes the atmospheric pressure to the lateral lumen 44 to vent the probe cannula 46 .
In FIG. 29 , the aft carriage 136 has been distally advanced, switching the air valve 351 to pass air pressure from the left distal port 332 to the left center port 333 to the lateral lumen 44 . The increased air pressure passes through the holes 47 to the distal end of the cutter lumen 47 causing the tissue sample to be blown proximally back up the cutter tube 36 out of the distal hand-held portion 21 of the biopsy device 10 into the sample revolver drum assembly 18 .
The clinicians benefit from being able to visually or diagnostically image the tissue samples while still being able to maintain the probe cannula 22 in tissue to take additional samples, insert therapeutic agents, deposit a marker, etc. Thus, a minimum of reinsertions and verifications of position are necessary, yet the clinician is reassured that proper samples are being taken. Moreover, avoidance of biohazards is provided by encasing the tissue samples for convenient transport for pathology assessment. Further, the individual storage allows correlating a particular sample taken at a specific position in the patient's breast. In addition, the apparatus is portable with a minimum of needed interconnections.
It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art, given the benefit of the present disclosure, 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 spirit and scope of the appended claims.
For example, while a rotating drum assembly provides an efficient means to capture a plurality of tissue samples, applications consistent with the present invention may include an uncircled belt that is drawn into a proximal portion of a biopsy device and then indexed to a next sample container with the filled sample containers on the belt moved out.
As another example, while automatically registering the next of a plurality of sample containers (e.g., vials) provides an efficient way of segregating tissue samples, applications consistent with the present invention may selectively uncouple the indexing of the next sample container. Instead, a manual selection may be made when the next sample container is to be positioned to receive the next sample. Alternatively, a separate control may be selected for the motor to drive the indexing arm or similar reciprocating element.
As another example, while a sample revolver drum assembly attached for movement with the proximal portions of the biopsy device has certain advantages, applications consistent with the present invention may include a revolver drum assembly coupled by flexible attachments, such as communicating a flexible drive capable for indexing motion.
As yet another example, while a detachable belt and detachable sample vials provide clinical flexibility, it should be appreciated that applications consistent with the present invention may include vials or similarly shaped sample containers that are immovably attached to a belt or a rigid outer cylinder wall structure.
As yet a further example, while a mechanical linkage is described herein for automatically indexing the samples, it should be appreciated that electromechanical positioning and control may be employed to sequencing sample storage. | A biopsy device comprises a probe body, a cannula extending distally from the probe body, a cutter moveable relative to the cannula to sever tissue, and a tissue sample holder coupled with the probe body. The tissue sample holder comprises a rotatable member having a plurality of recesses to receive tissue samples. The rotatable member can be operable to successively index each recess relative to a lumen defined by the cutter. A cover portion may be associated with the rotatable member and permits one or more recesses to be viewable through the cover. The recesses may be configured to carry one or more tissue samples as the rotatable member is rotated. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. National Phase Application of PCT International Application No. PCT/EP2009/063509, filed Oct. 15, 2009, which claims priority to German Patent Application No. 10 2008 052 202.3, filed Oct. 17, 2008, the contents of such applications being incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to a driving dynamics control system for vehicles.
BACKGROUND OF THE INVENTION
[0003] Active, electrically operable chassis and drive train components with independently operable actuators are making increasing in-roads into modern automobile technology, since they may be used to influence the driving behavior of a motor vehicle in a targeted fashion. A driving dynamics control system is now faced with the task of needing to divide the stabilization interventions it has calculated between one or more actuators as control specifications.
[0004] There are known from the prior art systems that, in coexistence with other systems, independently influence the driving behavior of a motor vehicle by virtue of the fact that each system operates that actuator for which it is responsible. In this case there is no integrated driving dynamics controller, but individual control systems that attempt independently of one another to attain a desired driving behavior by operating an actuator.
[0005] In the case of systems comprising a central driving dynamics controller, the prior art has disclosed rule-based division algorithms of the control specification of the driving dynamics controller. Either the division of the control specification of the driving dynamics controller between the manipulated variables of the actuators is carried out via empirically determined distribution factors or via a sequential concatenation of the individual manipulated variables. In the case of a method with empirically determined distribution factors, it is customary to determine the distribution factors in simulation studies or directly by trial series in the vehicle. A sequential concatenation also takes account of the fact that the actuators satisfy different comfort requirements. Consequently, in the case of sequential concatenation the first step is to take account of those actuators that can most comfortably implement the control requirement. If their potential is insufficient, the more uncomfortable actuators come into use.
[0006] WO 2004/101337 A1, incorporated herein by reference, discloses a driving dynamics control system for vehicles that has a signal distribution that is fed vehicle data, environmental data and data relating to the driver's wishes as input data. In this process, a plurality of subsystems that can be controlled and/or regulated and modify the dynamics of the vehicle, such as steering adjustable independently of the driver, a chassis adjustable independently of the driver, a brake adjustable independently of the driver, and a drive train adjustable independently of the driver are provided. In the case of the previously known driving dynamics control system, the data from the signal distribution are fed to a central determination unit, and the central determination unit determines a central control objective from the data of the signal distribution. The central control objective is fed to a central manipulated variable distribution or a central driving state controller that, in an interactive communication with the subsystems, drives said subsystems in such a way that the control objective is implemented by the subsystems on the vehicle. This method is, however, less suitable in the normal driving range and in the limit range in terms of driving dynamics.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the invention to improve a driving dynamics control system of the generic type described above so that the driving characteristics of a motor vehicle with reference to longitudinal, lateral and vertical dynamics are improved.
[0008] The present invention relates to a driving dynamics control system for vehicles, comprising at least one driving dynamics controller that is fed setpoint specifications, on the one hand, and driving state variables on the other hand, as input data, and comprising a plurality of actuators that can be controlled and/or regulated and modify the dynamics of the vehicle, such as steering, adjustable independently of the driver, on a front and/or rear axle of the vehicle, a chassis adjustable independently of the driver, a brake adjustable independently of the driver, and a drive train adjustable independently of the driver, the driving dynamics controller determining a central control specification from the setpoint specifications and the driving state variables and feeding it to a distribution algorithm that distributes the control specification into manipulated variables for driving the actuators.
[0009] Here, a driving dynamics control system is for optimally dividing manipulated variables of the actuators between any desired active chassis components. To this end, the distribution algorithm is fed the state of the actuators when generating the manipulated variables to take account of the current control potential and the current actuating speed of the actuators and their possible contribution to the implementation of the control specification.
[0010] The control specifications of the driving dynamics controller consist of physical variables of the longitudinal, lateral and vertical dynamics, and is a vectorial function of the driving state variables and the manipulated variables of the actuators. In a particularly advantageous development, it is provided that the distribution algorithm minimizes the deviation between the control specifications of the vehicle dynamics controller and the manipulated variables in order to improve the driving behavior of a motor vehicle both in the normal driving range and in the limit range in terms of driving dynamics.
[0011] The following system of equations is applied in order to minimize the deviation between the control specifications and the manipulated variables:
[0000]
min
u
_
J
=
γ
W
v
(
B
u
_
-
v
_
)
+
W
u
(
u
_
-
u
_
d
)
u
_
min
<=
u
_
<=
u
_
max
;
u
_
.
min
<=
u
_
.
<=
u
_
.
max
dim
(
B
)
=
(
m
×
n
)
;
dim
(
u
_
)
=
(
m
×
1
)
;
dim
(
v
_
)
=
(
n
×
1
)
[0012] A further advantageous development provides that the distribution algorithm includes a matrix with the aid of which the manipulated variables are multiplied in order to obtain the control specification. The matrix includes for each operating point the current control potential actuators in order to ensure an optimum distribution of the control specification into the manipulated variables of the actuators.
[0013] Here, the matrix is designed as a Jacobi matrix whose entries are formed from partial derivatives of the vectorial function of the driving state variables and the manipulated variables of the actuators. The matrix is determined with the aid of the following relationship:
[0000]
B
=
(
∂
g
i
∂
u
j
)
i
=
1
,
…
,
n
;
j
=
1
,
…
,
m
.
[0014] For a control specification consisting of the physical variable of the yaw moment, the distribution algorithm calculates and distributes an additional steering angle for front wheel steering, an additional steering angle for rear wheel steering, and a distribution parameter for dividing the roll support forces between two stabilizers of the chassis operable independently of the driver.
[0015] For a control specification consisting of the physical variables of the global longitudinal force, the global lateral force and the global yaw moment, the distribution algorithm calculates and distributes a steering angle for front wheel steering, a steering angle for rear wheel steering and individual wheel brake or wheel drive torques as well as a distribution parameter for dividing the roll support forces between the two stabilizers of the chassis operable independently of the driver.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention is best understood from the following detailed description when read in connection with the accompanying drawings. Included in the drawings is the following figures:
[0017] FIG. 1 shows a simplified illustration of the basic structure of the inventive driving dynamics control system;
[0018] FIG. 2 shows a schematic of the vehicle model used for calculating the yaw moment;
[0019] FIG. 3 shows a diagram of the tire model used in which the lateral force is plotted against a slip angle for various vertical forces given a fixed friction value; and
[0020] FIG. 4 shows a schematic of the parameters influencing the inventive distribution algorithm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The driving dynamics control system is illustrated in its basic structure in FIG. 1 as a control loop. A driving dynamics controller A calculates a control specification v of the driving dynamics controller from a setpoint specification w and a driving state variable x . As is illustrated in FIG. 1 , the control specification v of the driving dynamics controller includes the three global force components F xG , M zG and F zG in the case of longitudinal, lateral and vertical dynamics. The force component F xG in this case denotes the longitudinal force of the motor vehicle, while the force component M zG denotes the yaw moment and the force component F zG the support force of the vehicle body. Further components such as, for example, the lateral force of the motor vehicle F yG , the longitudinal moment M xG or the lateral moment M yG can be added if required. Depending on the application, the manipulated variables serve to stabilize the motor vehicle in the driving dynamics limit range or to increase the vehicle agility in the normal driving range.
[0022] The distribution algorithm C described in this invention divides the control specification v of the driving dynamics controller A in accordance with the optimization function specified in equation I between the actuators 1 to m, and produces therefor the corresponding manipulated variables u . This requires a solution of an underdetermined system of equations with secondary conditions for the control range and the actuating speed of the actuators 1 to m, this being done with the aid of the method of least error squares:
[0000]
min
u
_
J
=
γ
W
v
(
B
u
_
-
v
_
)
+
W
u
(
u
_
-
u
_
d
)
u
_
min
<=
u
_
<=
u
_
max
;
u
_
.
min
<=
u
_
.
<=
u
_
.
max
dim
(
B
)
=
(
m
×
n
)
;
dim
(
u
_
)
=
(
m
×
1
)
;
dim
(
v
_
)
=
(
n
×
1
)
(
I
)
[0023] In the first summand, the function describes the deviation between the control specification v and the manipulated variables u . In order to be able to compare the manipulated variables u with the control specification v , they are multiplied by the (m×n)-matrix B. The matrix B represents a linear relationship between the physical manipulated variables of the actuators and the control specification v that was calculated by the driving dynamics controller A. The matrix B therefore describes the linearized actuator potential at the current operating point. The distribution algorithm C now attempts to minimize the deviation between the manipulated variables u and the control specification v . The control specifications v can be weighted individually via the weighting matrix W v .
[0024] Assuming that the control specification v and the manipulated variables u can be mapped via the vector function g : → in accordance with
[0000] v = g ( x , u ) (II)
the matrix B can be calculated as a Jacobi matrix via the following relationship:
[0000]
B
=
(
∂
g
i
∂
u
j
)
i
=
1
,
…
,
n
;
j
=
1
,
…
,
m
(
III
)
[0026] The following exemplary embodiment shows the control of the lateral dynamics of a motor vehicle by the application of the previously described method. What is considered is a vehicle having the following active, electronically drivable chassis components: front wheel steering with angle superposition, rear wheel steering and roll stabilizer. Here, for a control specification v comprising the physical variable of the yaw moment M zG the distribution algorithm C calculates an additional steering angle for front wheel steering Δδ v , an additional steering angle for rear wheel steering Δδ h , and a distribution parameter λ for dividing the roll support forces between two stabilizers of the chassis operable independently of the driver and distributes these appropriately.
[0027] The yaw moment M zG is regarded as the control specification v . The manipulated variables of the actuators are an additional steering angle for front wheel steering Δδ v , an additional steering angle for rear wheel steering Δδ h , and a distribution parameter λ for dividing the roll support forces between the two stabilizers.
[0028] FIG. 2 illustrates the vehicle model under consideration together with the longitudinal and lateral forces acting on the wheels. As is expressed in equation IV, the yaw moment M zG acting on the vehicle can be determined as a function of the additional steering angles Δδ v and Δδ h by balancing the moments.
[0000]
M
zG
=
[
-
s
2
l
v
]
T
[
F
xvl
C
F
yvl
C
]
+
[
s
2
l
v
]
T
*
[
F
xvr
C
F
yvr
C
]
+
[
-
s
2
-
l
h
]
T
*
[
F
xhl
C
F
yhl
C
]
+
[
s
2
-
l
h
]
T
*
[
F
xhr
C
F
yhr
C
]
=
[
-
s
2
l
v
]
T
·
[
cos
(
δ
v
+
Δ
δ
v
)
-
sin
(
δ
v
+
Δδ
v
)
sin
(
δ
v
+
Δδ
v
)
cos
(
δ
v
+
Δδ
v
)
]
·
[
F
xvl
F
yvl
]
+
[
s
2
l
v
]
T
·
[
cos
(
δ
v
+
Δδ
v
)
-
sin
(
δ
v
+
Δδ
v
)
sin
(
δ
v
+
Δδ
v
)
cos
(
δ
v
+
Δδ
v
)
]
·
[
F
xvr
F
yvr
]
+
[
-
s
2
-
l
h
]
T
·
[
cos
(
Δδ
h
)
-
sin
(
Δδ
h
)
sin
(
Δδ
h
)
cos
(
Δδ
h
)
]
·
[
F
xhl
F
yhl
]
+
[
s
2
-
l
h
]
T
·
[
cos
(
Δδ
h
)
-
sin
(
Δδ
h
)
sin
(
Δδ
h
)
cos
(
Δδ
h
)
]
·
[
F
xhr
F
yhr
]
(
IV
)
[0029] The lateral forces F y are yielded from the tire model specified in equation V. The model may be used for the analytical calculation of the lateral forces as a function of the slip angle α, and the longitudinal forces F x and the wheel vertical forces F z as well as some tire model parameters. The tire model also includes a slip stiffness C αo dependent on F z .
[0000]
F
y
=
{
(
C
α
0
F
Z
α
-
sign
(
α
)
C
α0
2
F
Z
2
4
μ
F
Z
α
2
)
1
-
(
F
x
μ
0
F
Z
)
2
,
α
<
2
μ
0
C
α0
sign
(
α
)
μ
0
F
Z
1
-
(
F
x
μ
0
F
Z
)
2
,
α
≥
2
μ
0
C
α
0
where
C
α0
=
C
α1
+
C
α
2
*
F
z
F
z
0
and
α
v
=
δ
v
-
β
-
l
v
v
ψ
.
+
Δδ
v
;
α
h
=
-
β
+
l
h
v
ψ
.
+
Δδ
h
(
V
)
[0030] FIG. 3 illustrates the tire characteristics as a lateral force/slip angle diagram for selected vertical forces F z and a fixed coefficient of friction.
[0031] The longitudinal forces F x are determined by the braking torque exerted during braking and, on the driven axle, additionally by the driving torque. They can be calculated approximately by using equation VI:
[0000]
F
x
=
{
-
P
wheel
·
C
PM
r
dyn
(
non
-
driven
wheel
)
M
eng
·
i
drive
2
·
r
dyn
-
P
wheel
·
C
PM
r
dyn
(
driven
wheel
)
(
VI
)
P wheel =brake pressure
C PM =conversion factor from brake pressure to brake torque
r dyn =dynamic tire radius
M eng =engine torque
i drive =transmission ratio of the drive train
[0037] The distribution parameter λ for dividing the roll moments between the two vehicle axles acts as follows on the vertical force F z of the individual wheels:
[0000]
F
zvl
=
m
·
g
l
h
2
(
l
v
+
l
h
)
-
2
·
m
·
v
·
ψ
.
·
h
·
λ
s
F
zvr
=
m
·
g
l
h
2
(
l
v
+
l
v
)
+
2
·
m
·
v
·
ψ
.
·
h
·
λ
s
F
zhl
=
m
·
g
l
v
2
(
l
v
+
l
h
)
-
2
·
m
·
v
·
ψ
.
·
h
·
(
1
-
h
)
s
F
zhr
=
m
·
g
l
v
2
(
l
v
+
l
h
)
+
2
·
m
·
v
·
ψ
.
·
h
·
(
1
-
λ
)
s
(
VII
)
m=vehicle mass
g=gravitational constant
v=vehicle (longitudinal) speed
h=centroid height
s=track
I v =distance from centroid to front axle
I h =distance from centroid to front axle
ψ=yaw rate
[0046] The distribution parameter λ varies in the range between 0 and 1, the value λ=0 signifying that the total roll moment of the rear axle is applied. Correspondingly, the total roll moment is supported via the front axle given the value λ=1.
[0047] Substituting equations V, VI and VII in equation IV yields a closed representation between the virtual yaw moment M zG and the actuator manipulated variables Δδ v , Δδ h and λ. The following relationship results by analogy to equation II:
[0000] v =M zG = g (Δδ v ,Δδ h ,λ) (VIII)
[0048] After the calculation of the B-matrix in accordance with equation III, the optimization algorithm specified in equation I can be applied directly and the optimum manipulated variables can be calculated.
[0049] In a second exemplary embodiment, the global longitudinal force, the lateral force and the yaw moment are used as control specification. The second exemplary embodiment shows the control of the lateral dynamics of a motor vehicle by application of the above described method. What is considered is a vehicle having the following active, electronically drivable chassis components: front wheel steering with angle interface, rear wheel steering, roll stabilizer and brake system with wheel torque interface or, alternatively, a system with monitoring of the wheel torques or with wheel hub motors. For a control specification v comprising the physical variable of the global longitudinal force F xG , the global lateral force F yG and the global yaw moment M zG , the distribution algorithm C calculates a steering angle for front wheel steering Δδ v , a steering angle for rear wheel steering Δδ h and individual wheel brake or wheel drive torques M wheel,v1 , M wheel,vr , M wheel,hl , M wheel,hr , as well as a distribution parameter λ for dividing the roll support forces between the two stabilizers of the chassis that can be operated independently of the driver.
[0050] The following relationship results for manipulated variables u and control specification v :
[0000]
u
_
=
[
u
1
u
2
u
3
u
4
u
5
u
6
u
7
]
=
[
Δδ
v
Δδ
h
M
wheel
,
vl
M
wheel
,
vr
M
wheel
,
hl
M
wheel
,
hr
λ
]
,
_
_
v
_
=
[
F
xG
F
yG
M
zG
]
=
[
g
1
(
u
_
)
g
2
(
u
_
)
g
3
(
u
_
)
]
,
(
IX
)
[0051] The global forces and moments/torques are determined for a two-dimensional vehicle model from the equations below:
[0000]
F
xG
=
(
F
x
,
vl
+
F
x
,
vr
)
cos
(
δ
v
+
Δδ
v
)
-
(
F
y
,
vl
+
F
y
,
vr
)
sin
(
δ
v
+
Δδ
v
)
+
(
F
x
,
hl
+
F
x
,
hr
)
cos
(
Δδ
h
)
-
(
F
y
,
hl
+
F
y
,
hr
)
sin
(
Δδ
h
)
F
yG
=
(
F
x
,
vl
+
F
x
,
vr
)
sin
(
δ
v
+
Δδ
v
)
+
(
F
y
,
vl
+
F
y
,
vr
)
cos
(
δ
v
+
Δδ
v
)
+
(
F
x
,
hl
+
F
x
,
hr
)
sin
(
Δδ
h
)
-
(
F
y
,
hl
+
F
y
,
hr
)
cos
(
Δδ
h
)
M
zG
=
F
x
,
vl
(
-
s
2
cos
(
δ
v
+
Δδ
v
)
+
l
v
sin
(
δ
v
+
Δδ
v
)
)
+
F
y
,
vl
(
s
2
sin
(
δ
v
+
Δδ
v
)
+
l
v
cos
(
δ
v
+
Δδ
v
)
)
+
F
x
,
vr
(
s
2
cos
(
δ
v
+
Δδ
v
)
+
l
v
sin
(
δ
v
+
Δδ
v
)
)
+
F
y
,
vr
(
-
s
2
sin
(
δ
v
+
Δδ
v
)
+
l
v
cos
(
δ
v
+
Δδ
v
)
)
+
F
x
,
hl
(
-
s
2
cos
(
Δδ
h
)
-
l
h
sin
(
Δδ
h
)
)
+
F
y
,
hl
(
s
2
sin
(
Δδ
h
)
-
l
h
cos
(
Δδ
h
)
)
+
F
x
,
hr
(
s
2
cos
(
Δδ
h
)
-
l
h
sin
(
Δδ
h
)
)
+
F
y
,
hr
(
-
s
2
sin
(
Δδ
h
)
-
l
h
cos
(
Δδ
h
)
)
(
X
)
[0052] The lateral forces F y in equation X follow from the tire model specified in equation V. The following relationship is used for F x in equation V and equation X:
[0000]
F
x
,
i
=
M
wheel
,
i
r
dyn
(
XI
)
[0053] The inequalities
[0000]
-
k
μ
0
F
z
,
i
≤
M
wheel
,
i
r
dyn
≤
0
(
XII
)
with the application parameter k, the coefficient of friction μ 0 and the vertical forces from equation VII, resulting from the Kamm's circle can be further supplemented in the case of the secondary conditions in equation I. The Jacobi matrix B is yielded in accordance with equation III as
[0000]
B
=
[
∂
g
1
∂
u
1
∂
g
1
∂
u
2
∂
g
1
∂
u
3
∂
g
1
∂
u
4
∂
g
1
∂
u
5
∂
g
1
∂
u
6
∂
g
1
∂
u
7
∂
g
2
∂
u
1
∂
g
2
∂
u
2
∂
g
2
∂
u
3
∂
g
2
∂
u
4
∂
g
2
∂
u
5
∂
g
2
∂
u
6
∂
g
2
∂
u
7
∂
g
3
∂
u
1
∂
g
3
∂
u
2
∂
g
3
∂
u
3
∂
g
3
∂
u
4
∂
g
3
∂
u
5
∂
g
3
∂
u
6
∂
g
3
∂
u
7
]
(
XIII
)
[0055] For the purpose of explanation, FIG. 4 illustrates schematically the influence of the input parameters inventive distribution algorithm C. The distribution algorithm C is fed the control specification v , and the distribution algorithm C produces the manipulated variables u taking account of the actuator states, in order to take account of their current control potential, their current actuating speed and their possible contribution to the implementation of the control specification v . The distribution algorithm C has the matrix B by which the manipulated variables u are multiplied in order to obtain the control specification v . Featured in the matrix B are data of the tire model, which is represented in equation V and illustrated in FIG. 3 , the driving state of the motor vehicle and the coefficient of friction together with the vertical force of the wheels of the motor vehicle. On the other hand, the control range, and thus the bounds of the manipulated variables u and their speed depend on the driven actuator type, on the power limits of the driven actuator type and, in turn, on the coefficient of friction together with the vertical force of the wheels of the motor vehicle.
[0056] As is further illustrated in FIG. 4 , the distribution algorithm C is influenced by the weighting matrix W v of the control specification v , the weighting matrix W v being dependent on the invoking function. The weighting matrix W u of the manipulated variables u depends on the invoking function, the actuator configuration and further comfort parameters that enable a comfortable drive with the motor vehicle. | A driving dynamics control system for vehicles. The control system including at least one driving dynamics controller that is fed setpoint specifications and driving state variables as input data. The control system also includes a plurality of actuators that can be controlled and/or regulated to modify the dynamics of the vehicle, such as steering, adjustable independently of the driver, on a front and/or rear axle of the vehicle, a chassis adjustable independently of the driver, a brake adjustable independently of the driver, and a drive train adjustable independently of the driver. The driving dynamics controller determines a central control specification from the setpoint specifications and the driving state variables and sends it to a distribution algorithm that distributes the control specification into manipulated variables for driving the actuators. | 1 |
BACKGROUND
[0001] Cooking vessels such as pots and pans that have upstanding side walls surrounding upwardly opening cooking chambers in which foods are heated and cooked typically contain cooking fluids that can bubble over or boil over, especially when the cooking chambers are fully covered, which can cause cooking temperatures within the cooking chambers rising to inappropriate magnitudes. Leaving the upwardly opening cooking chambers completely uncovered can also permit cooking fluids to splatter about. Accordingly, in many situations, neither fully covered nor fully uncovered cooking chambers provide desirable results.
[0002] A technique commonly used by cooks to eliminate bubble-over, and to regulate or control temperature within the cooking chamber of a cooking vessel being heated is to adjustably position the cover or lid of the cooking vessel off-center, so that, during heating or cooking, only a selected portion of the upwardly opening cooking chamber of the vessel is covered, and a remaining portion of the cooking chamber is deliberately left uncovered. This technique, when used during cooking, provides a simple and straightforward technique for regulating and controlling the temperature within the cooking chamber, and permits bubble-over or boil-over to be minimized.
[0003] A problem with positioning a cover or a lid off-center (which term is used herein to mean “extending substantially horizontally atop only a portion of the rim or top edge of a vessel's cooking chamber”) is that the portion of the cover or lid that extends outside and beyond the periphery of the vessel's cooking chamber is entirely unsupported—meaning that it extends in a cantilevered fashion—whereby the cantilevered and off-center cover or lid may fall off, or can easily be accidentally knocked or brushed completely off of the associated cooking vessel, which may cause hot cooking fluid such as hot cooking grease and the like to be splattered or spilled onto a floor and/or near to a stove or cooktop that is being used to heat the cooking vessel.
[0004] U.S. Pat. No. 2,879,915 which issued Mar. 31, 1959 to Joseph R. Medor (the disclosure of which us uncorporated herein by reference) recognizes the need for providing underlying support for an off-center lid situated atop a cooking vessel. However, the Medor patent addresses this need by proposing a metal clip that is designed to extend into, and to overlie an interior portion of the cooking chamber of a cooking vessel. The proposed clip of Medor underlies and is designed to offer added support for only the part of and off-center cover or lid that overlies the vessel's cooking chamber, and does nothing to underlie and support the part of an off-center cover or lid that extends in a cantilevered fashion beyond the perimeter of the vessel's cooking chamber.
[0005] A significant drawback of the Medor clip is that it overlies only an inside portion of a cooking chamber of the cooking vessel on which it is installed. The clip is not intended to underlie and support any part of a off-center cover or lid that extends outside of and beyond the perimeter of the cooking chamber of a cooking vessel—which is the part of a off-center cover of lid that is most likely to be accidentally struck and unintentionally brushed off the associated cooking vessel.
[0006] A further drawback of the Medor clip is that it is not intended to aid in adjustably positioning an off-center lid through a wide range of movement so that a significant portion of the area of a cover or lid can extend outside the perimeter of the cooking chamber of a cooking vessel while the cover or lid is still being supported by the relatively short Medor clip.
[0007] Inasmuch as the Medor clip is intended to be used to overlie a cooking chamber where hot grease and cooking fluids are likely to be bubbling and splattering about, clearly the clip is intended to be grasped, repositioned and adjusted only when the associated cooking vessel is out of service, not while cooking fluids are being heated and are bubbling about—i.e., not while cooking is underway.
[0008] Another drawback of the Medor clip is its likelihood of becoming covered with grease and other splatter, necessitating that the clip frequently be removed to be cleaned.
[0009] Still another drawback of the Medor clip is that it in no way makes use of the handle of the cooking vessel on which the clip is installed to underlie and to provide support for an off-center cover or lid. Further, the clip proposed by Medor is designed to take a rigid form that offers no resilience and no capability to adjustably grip cooking vessel portions of differing size, and having no memory for returning to an initial shape after being deformed temporarily to grip a cooking vessel handle or the like.
[0010] Neither recognized in nor appreciated by the Medor patent is the fact that the significant degree of temperature control can advantageously be obtained by modifying and adjusting the covered and uncovered areas of the cooking chamber of a cooking vessel. The patent neither recognizes nor suggest taking advantage of the fact that, by increasing the size of an uncovered area of a cooking chamber, cooking temperature can easily be decreased because more heat is permitted to escape; or that, by decreasing the size of the uncovered area of a cooking chamber, an increase in cooking temperature can easily be obtained.
SUMMERY
[0011] In preferred practice, a lid support and positioner is provided that is configured for versatility in that it can be used in cooperation with cooking vessel handles of a wide variety of types and shapes to support and off-center cover or lid so temperature can be regulated within the vessel's cooking chamber.
[0012] In preferred practice, a lid support and positioner is provided that is designed to overlie a selected portion of a handle of a cooking vessel, and to underlie, engage and provide support for a peripheral region of an off-center cover or lid that extends beyond the periphery of the cooking chamber of the vessel—namely a portion of the off-center cover or lid that overlies a part of the vessels handle.
[0013] In preferred practice, a lid support and positioner is provided that easily can be adjustably positioned along the length of an elongate handle of a cooking vessel to underlie, engage and support at various selected locations a peripheral region of an off-center cover or lid that extends beyond the periphery of the cooking chamber of the cooking vessel and overlies a part of the vessel's elongate handle.
[0014] In preferred practice, a lid support and positioner is formed from resilient material and is configured to resiliently grip, and to thereby be retained on, a handle of a cooking vessel—which renders the lid support and positioner particularly versatile when used with cooking vessels that have elongate handles along which a lid support and positioner can be adjusted to underlie, engage and support portions of off-center covers or lids that may extend significantly different distances while being adjustably positioned to overlie different lengths of the elongate handle of a cooking vessel.
[0015] In preferred practice, a lid support and positioner is configured 1) to engage, underlie and provide auxiliary support to a cantilevered portion of a cover or lid that is positioned off-center atop the rim or top edge of a cooking vessel, and 2) to resiliently grip and thereby be retained on an elongate handle of a cooking vessel as the lid support and positioner is adjustably positioned along an elongate handle of the cooking vessel.
[0016] In preferred practice, a lid support and positioner is provided that renders it quite easy to set and adjust throughout a wide range of movement the extent to which a cover or lid is positioned off-center while resting atop a rim or top edge of an upstanding sidewall of a cooking vessel, whereby the temperature within a cooking chamber of the vessel can be easily regulated to minimize or prevent bubble-over, boil over and grease splatter.
[0017] In some embodiments, a lid support and positioner is a one-piece member in the form of non-planar endless ring to annular loop of resilient material that is shaped to be installable one a wide variety of cooking vessel handles to receive or even to adjustably grip the elongate handle of the cooking vessel while overlying the handle to provide underlying support for a portion of an off-center cover or lid that extends beyond the perimeter of an upwardly opening cooking chamber of the cooking vessel.
[0018] In some embodiments, a lid support and positioner provides and upwardly extending projection suited to underlie and/or engage a portion of an off-center cover or lid that extends in a cantilevered fashion beyond the perimeter of an upwardly opening cooking chamber of a cooking vessel, to assist in positioning the off-center cover or lid so the temperature within the cooking chamber can be regulated by controlling the extent to which the off-center cover or lid over lies and leaves uncovered selected areas of the cooking chamber.
[0019] In preferred practice, a lid support and positioner is configured 1) to engage, underlie and provide auxiliary support to a cantilevered portion of a cover or lid that is positioned off-center atop the rim or top edge of a cooking vessel, and 2) to resiliently grip and thereby be retained on an elongate handle of a cooking vessel as the lid support and positioner is adjustably positioned along an elongate handle of the cooking vessel.
[0020] In preferred practice, a lid support and positioner is provided that renders it quite easy to set and adjust throughout a wide range of movement the extent to which a cover or lid is positioned off-center while resting atop a rim or top edge of an upstanding sidewall of a cooking vessel, whereby the temperature within a cooking chamber of the vessel can be easily regulated to minimize or prevent bubble-over, boil over and grease splatter.
[0021] In some embodiments, a lid support and positioner is a one-piece member in the form of non-planar endless ring to annular loop of resilient material that is shaped to be installable on a wide variety of cooking vessel handles to receive or en to adjustably grip the elongate handle of the cooking vessel while overlying the handle to provide underlying support for a portion of an off-center cover or lid that extends beyond the perimeter of an upwardly opening cooking chamber of the cooking vessel.
[0022] In some embodiments, a lid support and positioner provides and upwardly extending projection suited to underlie and/or engage a portion of an off-center cover or lid that extends in a cantilevered fashion beyond the perimeter of an upwardly opening cooking chamber of a cooking vessel, to assist in positioning the off-center cover or lid so the temperature within the cooking chamber can be regulated by controlling the extent to which the off-center cover or lid over lies and leaves uncovered selected areas of the cooking chamber.
[0023] In some embodiments, a lid support and positioner takes the form of a non-planar endless ring or annular loop of resilient material which extends about a central opening that is configured to permit an elongate handle of a cooking vessel to extend therethrough, with the lid positioner be adapted to permit spreading of its opposed portions to resiliently grip opposed surfaces of the handle aid in retaining the lid support and positioner at desired locations along the length of the handle, with the lid positioner also having an elongate portion projecting therefrom that can be oriented to extend generally upwardly from a exterior surface of the annular ring for engaging a perimetrically extending region of a cover or lid in an off-center position supported atop and partially overlying a portion of the handle of the associated cooking vessel.
DESCRIPTION OF DRAWINGS
[0024] These and other features, and a fuller understanding of the present inventions may be had by referring to the following description and claims, taken in conjunction with the accompanying drawings wherein:
[0025] FIG. 1 is a perspective view of a lid support and positioner depicting one possible embodiment of the present invention;
[0026] FIG. 2 is a left side view thereof, it being understood that a right side view is a left-to-right reversed mirror image thereof;
[0027] FIG. 3 is a sectional view as seen from a plane indicated by a line 3 - 3 in FIG. 2 ;
[0028] FIG. 4 is a front elevation view thereof;
[0029] FIG. 5 is a sectional view as seen from a plane indicated by line 5 - 5 in FIG. 3 ;
[0030] FIG. 6 is a rear elevation view thereof;
[0031] FIG. 7 is a top plan view thereof;
[0032] FIG. 8 is a bottom plan view thereof;
[0033] FIG. 9 is a perspective view showing the lid support and positioner in one possible orientation on a handle on a first type of a cooking vessel;
[0034] FIG. 10 is a perspective view similar to FIG. 8 showing the lid support and positioner underlying and assisting to support a cover or lid in an off-center position atop the first type of cooking vessel in FIG. 9 ;
[0035] FIG. 11 is a perspective view that also similar to FIG. 8 showing the lid support and positioner an another possible orientation on a handle of the first type of a cooking vessel;
[0036] FIG. 12 is a perspective view similar to FIG. 11 showing the lid support and positioner and yet another possible orientation on a handle of the first type a cooking vessel underlying and assisting to support a cover or a lid in an off-center position atop the first type of cooking vessel;
[0037] FIG. 13 is a perspective view showing the lid support and positioner in one possible orientation on a handle of a second type of cooking vessel; and
[0038] FIG. 14 is a perspective view similar to FIG. 13 showing the lid support and positioner in an alternate orientation underlying and assisting to support a cover or lid in an off-center position atop the second type of cooking vessel.
DESCRIPTION
[0039] Referring to FIGS. 1-2, 4 and 6-8 , a one piece lid support and positioner 100 is shown that depicts one possible and preferred embodiment of the invention. As will be readily apparent to and understood by those who are skilled in the art, a lid support and positioner that embodies features of the present invention may take any of a wide variety of forms and configurations that offer such features and versatility as is described herein. The depicted lid support and positioner embodiment 100 is primarily formed by continuos, endless ring or annular loop of material indicated generally by the 150 which extends about in circles a central opening 175 which is best shown in FIGS. 4 and 6 .
[0040] In preferred practice, the material forming the whole of the one piece lid support and positioner 100 is selected to be a relatively resilient material having a memory that tends to return the endless ring or annular loop 150 to the configuration shown in FIGS. 1-2, 4 and 6-8 if forced is released that has been applied to the lid support and positioner 100 to cause the continuous, endless ring annular loop of material 150 to take slightly a different form, configuration or shape such as may occur if the lid support and positioner 100 is slightly stretched to receive, or to grip opposed surfaces of a handle of a cooking vessel, as may take place when the lid support and positioner is installed on a handle of a cooking vessel as depicted in FIGS. 9-11 hereof.
[0041] The endless ring or annular loop 150 that forms a majority of the lid support and positioner 100 is defined by contiguously extending set or sequence of four nonplanar, generally c-shape portions 110 , 120 , 130 , 140 that (referring only to FIG. 1 ) can perhaps be said to be separated from one another by four imaginary lines that are labeled by the letters A,B, C and D.
[0042] If the imaginary lines A, B, C, and D can be thought of as designating imaginary “ends” of the C-shaped portions 110 , 120 , 130 , 140 , then the C-shaped top portion 110 can perhaps be said to have a first “end” 111 that joins along the imaginary line A with the first “end” 121 of the C-shaped left side portion 120 ; the C-shaped left side portion can perhaps be said to have a second “end” 122 that joins smoothly along the imaginary line B with a first “end” 131 of the C-shaped bottom portion 130 ; the C-shaped bottom portion 130 can perhaps be said to have a second “end” 132 that joins smoothly along the imaginary line D with a first end 141 of the C-shaped right side portion 140 ; and the C-shaped right side right side portion 140 can perhaps be said to have a second end region 142 that joins smoothly with a second end region 112 of the C-shaped top portion 110 . As such, the four C-shaped portions 110 , 120 , 130 , 140 complete the contiguous endless ring or annular loop 150 that forms the majority of the lid support and positioner 100 . Moreover, the contiguously extending C-shape top, left side, bottom and right side portions 110 , 120 , 130 , 140 , respectively, that form the endless ring or annular loop 150 cooperate to encircle the open central area or opening 175 best shown in FIGS. 4 and 6 .
[0043] As can best been seen in a side view provided by FIG. 2 and the rear view provided by FIG. 6 , the top and bottom C-shaped portions 110 , 130 overlie each other and extend in substantially parallel, substantially horizontally extending planes 109 , 139 . As can be seen in the front and rear views provided by FIGS. 4 and 6 , respectively, the left and right side C-shaped portions 120 , 140 , respectively, extend in spaced, substantially vertically extending, non-parallel planes 129 , 149 ,—which is to say that the C-shaped side portions 120 , 140 are more widely spaced near the front of the lid support and positioner 100 than near the rear of the lid support and positioner 100 .
[0044] The top, left side, bottom, and right side C-shaped portions 110 , 120 , 130 , 140 , respectively, of the endless loop or annular ring of the lid support or positioner 100 all have cross-sectional areas that are substantially equal, but the shape or configuration of the various cross-sections of the resilient material that forms the C-shaped portions 110 , 120 , 130 , 140 differ somewhat along the length of the endless loop or annular ring 150 . For example, as viewed in FIG. 3 , the C-shaped left and right side portions 120 , 140 have substantially identically sized cross-sectional areas 125 , 145 , respectively, that are of different substantially trapezoidal shape. And, as viewed in FIG. 5 , the C-shaped bottom portion 130 has a cross-section that is substantially rectangular in shape (with slightly rounded corners), but has an area 135 that is substantially the same as that of the trapezoidal cross-sectional areas 125 , 145 shown in FIG. 3 .
[0045] As can easily be seen in FIGS. 1, 2, 4 and 5 , the lid support and positioner embodiment 100 has a elongate projection 160 that extends upwardly but at a forwardly inclined angle from a centrally located part 118 of the C-shaped top portion 110 . The projection 160 is of substantially uniform, generally cylindrical cross-section, and has a rounded upper end region 170 . Other possible embodiments of the present invention may have more projections, or none at all, as maybe appropriate for use with particular cooking vessels.
[0046] The resilient character of the material from which the lid positioner 100 is fabricated permits various opposed parts and portions of the positioner 100 to move toward and away from each other. For example, the opposed C-shaped top and bottom portions 110 , 120 , respectively, and the opposed left and right portions 130 , 140 , respectively, can move short distances toward and away from each other to permit and object such as a handle of a particular cooking pan to be inserted therebetween even if the size of the handle is slightly larger than the spacings between the top and bottom portions 110 , 130 , respectively, or between the left and right side portions 120 , 140 , respectively. Stated in another way, the configuration of the resilient lid support and positioner 100 can be modified to enlarge or adjust the shape and size of the central opening 175 .
[0047] Referring to FIGS. 9-12 , cooking vessels 200 of identical form are shown. In FIGS. 13-14 , differently configured but identical coking vessels 300 are shown. As will become apparent of the following discussion of what is depicted in FIGS. 10-14 , the lid support and positioner 100 may be installed in a wide variety of ways on the handles of cooking vessels of a wide variety of types to provide support for, and to assist in the off-center positioning lids or covers of a wide variety of configurations.
[0048] Each of the identical cooking vessels 200 depicted in FIGS. 9-12 has an upstanding sidewall 210 that surrounds an upwardly opening cooking chamber 220 . The sidewalls 210 each have top surfaces or rims 230 that encircle an associated cooking chambers 220 . Elongate handles 240 connect at one end with an exterior surface of each of upstanding sidewalls 210 of the cooking vessels 200 shown in FIGS. 9-12 .
[0049] Shown in each of FIGS. 10-12 is the lid support and positioners 100 which installed on or draped over an associated one the elongate handles 240 . In FIGS. 10 and 11 , the depicted handle 240 extends through the center opening 160 of the depicted lid support and positioner 100 . In FIG. 12 the lid support and positioner is draped over the associated handle 240 . In each of FIGS. 10, 11 and 12 the lid support and positioner 100 serves to underlie, engage, support and position a portion of a off-center lid 250 that extends outside the perimeter of the associated upwardly opening cooking chamber 220 .
[0050] In FIG. 10 , the depicted upstanding projection 160 of the depicted lid support and positioner 100 can be seen to extend upwardly inside a peripheral region 270 of the associated lid or cover 250 . In FIG. 11 , the depicted upstanding projection 160 depends downwardly in an out-of-the-way position. In FIG. 12 , the upstanding projection 160 can be seen to extend leftwardly relative to the handle 240 , in an out-of-the-way position.
[0051] Each of the identical cooking vessels 300 depicted in FIGS. 13-14 has an upstanding sidewall 310 that surrounds an upwardly opening cooking chamber 320 . The sidewalls 310 each have tops surfaces or rims 330 that encircle an associated cooking chambers 320 . Variously configured handles 340 connect with an exterior surface of each of the upstanding sidewalls 310 of the cooking vessels 300 shown in FIGS. 13-14 .
[0052] In FIGS. 13 and 14 , the lid support and positioner 100 is shown installed at different locations on one of the handles 340 . In FIG. 13 , the upstanding projection 160 of the lid support and positioner 100 extends upwardly inside a peripheral region of the associated lid or cover 350 . In FIG. 14 , the projection 160 is shown extending downwardly in an out-of-the-way position.
[0053] As those skilled in the art will readily understand and appreciate, a significant feature of the present invention resides in providing a simple, easy to use form of lid support and positioner that can be used with cooking vessel handles of many configurations to underlie and provide support, and possibly also to aid in positioning a an off-center lid or cover of the vessel so that the lid or cover will be better supported than if an off-center lid were attempted to be held in balance without form of over-the-handle support for portions of lids or covers that extend beyond the perimeter of the cooking chambers of cooking vessel.
[0054] Although the invention has been described in a preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example, and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. It is intended to protect whatever features of patentable novelty exist in the invention disclosed. | The present invention relates to a lid support and positioner that is quite versatile in how it can cooperate with the handle of cooking vessels to overly the handle, and to underly, engage and provide support for a cover or lid of the cooking vessel that is positioned off center relative to an upward opening cooking chamber of the vessel to permit the cooking chamber to breathe so as to minimize or prevent bubble-over or boil-over of cooking fluids. When used with cooking vessels that have elongate handles, the lid support and positioner may be adjustable positioned on the length of the handle to underly, engage and support a peripheral portion of an off-center cover or lid at a range of locations where the lid selectively covers/uncovers different proportions of the cooking chamber to thereby regulate and control the cooking temperature within the cooking chamber. | 0 |
TECHNICAL FIELD
[0001] The present disclosure relates to optical devices and modules, and in particular to photonic integrated circuits.
BACKGROUND
[0002] Photonic integrated circuits include multiple optical components integrated on a common substrate, typically a semiconductor substrate. The optical components may include arrays of elements such as waveguides, splitters, couplers, interferometers, modulators, filters, etc., and may have similar or different optical processing functions. Photonic integrated circuits may be built by bonding together several optical, electro-optical, or optoelectronic chips. Electrical driver chips may also be attached to optoelectronic chips and electrically coupled by solder bumps or wirebonds.
[0003] Structurally, photonic integrated circuits resemble electronic integrated circuits, with optical waveguides for conducting optical signals between different optical components. Due to integrated character of optical components and connections, photonic integrated circuits may be suitable for mass production to a similar degree integrated electronic circuits are, potentially allowing significant economy of scale. Silicon-based photonic integrated circuits in particular may benefit from a well-developed material, technological, and knowledge base of silicon-based microelectronics industry.
[0004] It may be desirable to reduce size of photonic integrated circuits to fit more circuits on a same semiconductor wafer. To achieve size reduction, individual circuit components need to be more densely packed. There is, however, a limit on how densely the components may be packed. When distances between the components are too small, optical crosstalk may result. The optical crosstalk occurs because light scattered from one component may be coupled to a nearby component, impacting that component's optical performance. Amplifiers, lasers, and photodetectors may be particularly sensitive to optical crosstalk caused by stray light from neighboring components.
[0005] One typical example of a light-scattering component is a Mach-Zehnder interferometer of an optical modulator. When light modes in two arms of the Mach-Zehnder interferometer are in counter phase, a Y-junction combiner combining the two arms does not couple light into the output waveguide of the Y-junction combiner. Instead, the light is coupled into a radiative mode, causing the light to scatter throughout the photonic integrated circuit. Another typical example of a light-scattering component is an in-coupler of light. An in-coupler disposed near an edge of a photonic integrated circuit may scatter light escaped the core of an input waveguide due to an optical misalignment, imperfection of the input optical mode, etc. The scattered light may become guided by various layers of the photonic integrated circuit, causing extensive “ringing”, i.e. optical crosstalk.
[0006] Thus, not only is optical crosstalk a limiting factor of miniaturization of photonic integrated circuits, it may also be a performance-degrading factor, and a significant design constraint. In prior-art photonic integrated circuits, the optical components are spaced apart to reduce the effect of optical crosstalk. This increases the overall dimensions of photonic integrated circuits, raising manufacturing costs.
SUMMARY
[0007] In accordance with an aspect of the present disclosure, a light shield structure may be formed between integrated optical devices of a photonic integrated circuit. Preferably, a light shield structure is formed using the very materials used to build the photonic integrated circuit, i.e. the materials already present in the circuit and compatible with the material system of the circuit. Metal layers, metal vias, and doped semiconductor regions may be used to surround light-sensitive and/or light-emitting integrated optical components or modules. Thus, a light shield may be integrally built in.
[0008] In accordance with an aspect of the disclosure, there is provided a photonic integrated circuit comprising a substrate, first and second integrated optical devices over the substrate, and a light shield structure between the first and second integrated optical devices. The light shield structure is configured to suppress optical crosstalk between the first and second integrated optical devices. For example, the light shield structure may include an opaque structure for suppressing i.e. absorbing, reflecting, scattering light propagating between the first and second integrated optical devices, such as a light emitting device and a photodetector. In a preferred embodiment, the opaque structure has optical transmission of less than 10%.
[0009] In one exemplary embodiment, the opaque structure may include a first opaque wall fully or partially surrounding the first integrated optical device, e.g. on all four sides, or on three sides when the first integrated optical device is disposed near an edge of a photonic integrated circuit. Openings may be provided in the first opaque wall for optical waveguides to extend through the openings. For silicon-based systems, the first opaque wall may include heavily doped silicon, e.g. doped at a carrier concentration of at least 10 18 cm −3 .
[0010] In one embodiment, the opaque structure is not coplanar with the first or second integrated optical devices. The opaque structure may include a metal structure disposed farther away from the substrate than the first integrated optical device, or closer to the substrate. The light shield structure may include a second opaque wall extending from the first opaque wall and surrounding the first integrated optical device. The light shield structure may also include a photonic crystal, a plasmonic structure, a random or semi-random scatterer, etc.
[0011] In accordance with another aspect of the disclosure, the light shield structure may include a dielectric layer and a channel or trench extending through the dielectric layer from the first opaque wall and surrounding the first integrated optical device. The channel or trench may be filled e.g. with metal or semiconductor, forming a second opaque wall extending from the first opaque wall. Furthermore, a light-shielding metal or semiconductor layer may be disposed over the first integrated optical device. The light-shielding metal or semiconductor wall may extend to the metal or semiconductor layer, thus providing a nearly complete integrated enclosure for the first integrated optical device. Similar light shielding structures may be provided around the second integrated optical device as well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Exemplary embodiments will now be described in conjunction with the drawings, in which:
[0013] FIG. 1A is a plan view of a photonic integrated circuit of the present disclosure;
[0014] FIG. 1B is a side cross-sectional view of the photonic integrated circuit of FIG. 1A , taken in a plane B-B shown in FIG. 1A ;
[0015] FIG. 2 is a three-dimensional partial cut-out view of a photonic integrated circuit including a metal light shield;
[0016] FIG. 3 is a three-dimensional partial cut-out view of a photonic integrated circuit including a semiconductor light shield;
[0017] FIG. 4A is a frontal cross-sectional view of a shielded waveguide-coupled photodetector according to the present disclosure, wherein electrodes of the photodetector perform the light shielding function;
[0018] FIG. 4B is a plan view of the shielded waveguide-coupled photodetector of FIG. 4A ;
[0019] FIG. 5 is a top view of a shielded waveguide Y-junction according to the present disclosure;
[0020] FIG. 6 is a top view of a shielded edge coupler according to the present disclosure;
[0021] FIG. 7 is a top view of a shielded grating coupler according to the present disclosure, featuring an optional shielded serpentine waveguide;
[0022] FIG. 8 is a top view of a shielded optical device, the light shielding structure including a Bragg grating structure;
[0023] FIG. 9 is a frontal cross-sectional view of a shielded integrated optical device according to another aspect of the present disclosure; and
[0024] FIG. 10 is a frontal cross-sectional view of a photonic integrated circuit of the disclosure including and an opaque wall extending between the two integrated optical devices for reducing optical crosstalk between them.
DETAILED DESCRIPTION
[0025] While the present teachings are described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments. On the contrary, the present teachings encompass various alternatives and equivalents, as will be appreciated by those of skill in the art.
[0026] Referring to FIGS. 1A and 1B , a photonic integrated circuit 100 of the present disclosure includes a substrate 150 , first 101 and second 102 integrated optical devices over the substrate 150 , and a light shield structure 108 between the first 101 and second 102 integrated optical devices. By way of a non-limiting example, the first integrated optical device 101 may include a slab optical waveguide section 121 coupled to input 151 and output 152 waveguides. The light shield structure 108 may include any opaque structure, e.g. a metal structure, configured to suppress optical crosstalk between the first 101 and second 102 integrated optical devices. In the embodiment shown in FIGS. 1A and 1B , the light shield structure 108 includes a first opaque wall 131 surrounding the first integrated optical device 101 . An optional second opaque wall 132 may extend from the first opaque wall 131 , surrounding the first integrated optical device 101 as shown in FIG. 1B . In one embodiment, a metal or semiconductor shield layer (not shown for brevity) may extend over the first integrated optical device 101 such that the second opaque wall 132 extends to the metal or semiconductor shield layer.
[0027] The first opaque wall 131 and/or second opaque wall 132 may include an optically absorbing material. Furthermore, the first opaque wall 131 and/or second opaque wall 132 may be at least partially reflecting, and/or scattering, to ensure that the first opaque wall 131 effectively functions as a light shield. In one embodiment, the first opaque wall 131 and/or second opaque wall 132 has optical transmission of less than 10%, and more preferably less than 5%, of the incoming and/or outgoing stray light.
[0028] Referring specifically to FIG. 1A , the first opaque wall 131 may surround the first integrated optical device 101 , while leaving an opening for at least one waveguide, e.g. openings 141 , 142 for the input 151 and output 152 waveguides, respectively. The term “surrounds” is understood herein as allowing for openings in a surrounding structure if required, e.g. the openings 141 , 142 are provided in the first opaque wall 131 for the input 151 and/or output 152 waveguides.
[0029] Referring specifically to FIG. 1B , the light shield structure 108 may be not coplanar with the first integrated optical device. In the embodiment shown, the light shield structure 108 does not extend to the plane of the first integrated optical device, being farther away from the substrate 150 than the first integrated optical device. This may be advantageous in embodiments where the light shield structure 108 includes a metal structure, and the first integrated optical device 101 includes a semiconductor structure under the metal. The light shield structure 108 may also be closer to the substrate 150 than the first integrated optical device 101 . The light shield structure 108 may include not only an opaque absorptive structure but also nano- and microstructures such as a photonic crystal, a plasmonic structure, or a random or semi-random scatterer, for example.
[0030] In some embodiments of the present disclosure, at least one of the first 101 and/or the second 102 integrated optical device may be manufactured on additional substrates bonded to the substrate 150 . Alternatively, at least one of the first 101 and/or the second 102 integrated optical device may be monolithically fabricated on the substrate 150 . Furthermore, in some embodiments, the first integrated optical device 101 may include a light emitting device such as a laser or a semiconductor optical amplifier (SOA) e.g. a reflective SOA and/or traveling-wave SOA, while the second integrated optical device 102 may include a receiver, a photodetector, etc.; or the other way around. The first 101 and/or second 102 integrated optical devices may be comprised of Si, SiO 2 , doped glass, SiON, SiN, InP, AlGaAs, GaAs, InGaAsP, InGaP, InAlAs, and InGaAlAs. By way of a non-limiting example, the substrate may include Si, GaAs and InP.
[0031] Referring to FIG. 2 , a photonic integrated circuit 200 is a variant of the photonic integrated circuit 100 of FIGS. 1A and 1B , and includes similar elements. The photonic integrated circuit 200 of FIG. 2 includes a metal wall 231 . The metal wall 231 (only one half is shown in FIG. 2 for clarity) may be disposed on the same layer as the first integrated optical device 101 and may surround the first integrated optical device 101 . A metal layer 113 may be disposed on top of the metal wall 231 over the first integrated optical device 101 , for extra protection against stray light.
[0032] In accordance with one aspect of the present disclosure, an integrated photodetector of a photonic integrated circuit may be optically shielded using an opaque wall structure made of the very material a photosensitive layer of the integrated photodetector is made of, although a doping level may be adjusted for better absorption of light. Referring to FIG. 3 , a photonic integrated circuit 300 is a variant of the photonic integrated circuit 100 of FIGS. 1A and 1B , and includes similar elements. The photonic integrated circuit 300 of FIG. 3 includes an optically absorbing wall, e.g. a semiconductor opaque wall 331 surrounding the first integrated optical device 101 and shielding the first integrated optical device 101 from exterior light 309 . In one embodiment, the semiconductor opaque wall 331 is made of germanium. In another embodiment, the semiconductor opaque wall 331 is made of silicon doped to a carrier concentration of at least 10 18 cm −3 . Preferably, the semiconductor opaque wall 331 should have optical transmission of less than 10%, and more preferably less than 5% of the incoming stray light 309 .
[0033] Turning now to FIGS. 4A and 4B , an integrated photodetector 400 of the present disclosure includes an isolating silicon substrate 402 including a buried oxide layer 403 on a silicon underlayer 401 , a slab optical waveguide 421 , and a photosensitive slab 422 optically coupled to the slab optical waveguide 421 . A first electrode 431 may be electrically coupled to the photosensitive slab 422 for conducting a photoelectric signal provided by the photosensitive slab 422 upon illumination with light guided by the slab optical waveguide 421 . The first electrode 431 may encircle or surround the photosensitive slab 422 as shown in FIG. 4B , thus functioning as a light shield for absorbing or reflecting stray light 409 propagating towards the photosensitive slab 422 . A second electrode 432 may be disposed on top of the photosensitive slab 422 , thus shielding the photosensitive slab 422 from ambient light 488 .
[0034] FIGS. 4A and 4B illustrate but one example of an electrode structure having direct current (DC) or radio frequency (RF) electrodes configured for usage as light shields. More generally, an optical device may be shielded by surrounding light-emitting or light-sensitive portions of the optical device with an electrode structure of the optical device, e.g. photodetector electrodes, modulator electrodes, etc.
[0035] Referring to FIG. 5 , a photonic integrated circuit 500 is an embodiment of the photonic integrated circuit 100 of FIGS. 1A and 1B , and includes similar elements. The photonic integrated circuit 500 of FIG. 5 includes a substrate 502 and a first opaque wall 531 . The photonic integrated circuit 500 further includes a waveguide Y-junction 521 ( FIG. 5 ) as an embodiment of the first integrated optical device 101 ( FIG. 1B ). The first opaque wall 531 ( FIG. 5 ) of the photonic integrated circuit 500 may surround the waveguide Y-junction 521 , e.g. by repeating the shape of the waveguide Y-junction 521 to capture any light coupled into radiative modes.
[0036] Turning to FIG. 6 , a photonic integrated circuit 600 is another embodiment of the photonic integrated circuit 100 of FIGS. 1A and 1B , and includes similar elements. The photonic integrated circuit 600 of FIG. 6 includes a substrate 602 and a first opaque wall 631 . The photonic integrated circuit 600 further includes an edge coupler 621 . The edge coupler 621 ( FIG. 6 ) may be disposed proximate an edge 607 of the substrate 602 . The first opaque wall 631 partially surrounds the edge coupler 621 , leaving the edge 607 available for coupling an optical beam 680 to the edge coupler 621 via an optional external lens 682 . A waveguide 651 is coupled to the edge coupler 621 . The waveguide 651 extends through an opening 641 in the opaque wall 631 for outputting the coupled optical beam 680 .
[0037] Referring to FIG. 7 , a photonic integrated circuit 700 is yet another embodiment of the photonic integrated circuit 100 of FIGS. 1A and 1B , and includes similar elements. The photonic integrated circuit 700 of FIG. 7 includes a substrate 702 and a first opaque wall 731 . The photonic integrated circuit 700 further includes a grating coupler 721 for optically coupling to an external optical fiber or waveguide, not shown. The grating coupler 721 ( FIG. 7 ) corresponds to the first integrated optical device 101 ( FIG. 1B ). The first opaque wall 731 surrounds the grating coupler 721 . The first opaque wall 731 has an opening 741 to pass through a waveguide 751 optically coupled to the grating coupler 721 . In the embodiment shown, the waveguide 751 includes serpentine structure including a plurality of alternating turns 781 . At least one turn 781 may be provided.
[0038] First 771 opaque side walls and second 772 opaque side walls may be provided, as a part of an optical shield structure. The first 771 opaque side walls and second 772 opaque side walls run on both sides of the serpentine structure, so that first 771 opaque side walls and second 772 opaque side walls may absorb or redirect scattered light emitted by the waveguide 751 . The first 771 opaque side walls and second 772 opaque side walls may provide better stray light capturing than straight walls. Furthermore, a second opaque wall, not shown, may be disposed on the first opaque wall 731 , and/or on the first 771 and second 772 opaque side walls.
[0039] Referring now to FIG. 8 , a photonic integrated circuit 800 is yet another embodiment of the photonic integrated circuit 100 of FIGS. 1A and 1B , and includes similar elements. The light shield structure of the photonic integrated circuit 800 of FIG. 8 includes a Bragg structure 871 on a substrate 802 . The Bragg structure 871 is configured for out-coupling stray light. The Bragg structure 871 may include a plurality of concentric or parallel walls in the first layer surrounding an integrated optical device 820 , as shown.
[0040] Turning to FIG. 9 , a photonic integrated circuit 900 is yet another embodiment of the photonic integrated circuit 100 of FIGS. 1A and 1B , and includes similar elements. The photonic integrated circuit 900 includes a substrate 902 , which includes a first dielectric layer 911 , such as silicon oxide, for example, on the substrate 902 . The photonic integrated circuit 900 further includes of an integrated optical device 908 . The integrated optical device 908 is disposed between the first dielectric layer 911 and a second dielectric layer 912 . A channel 990 extends through the second dielectric layer 912 , surrounding the integrated optical device 908 for absorbing or redirecting stray light. To improve stray light rejection, a metal wall 991 may be formed in the channel 990 . The metal wall 991 may extend through the second dielectric layer 912 running around the integrated optical device 908 . To further suppress optical crosstalk and reject stray light, a metal overlayer 992 may be disposed over the integrated optical device 908 . For better stray light rejection, the metal wall 991 may extend upwards to the metal overlayer 992 .
[0041] Referring now to FIG. 10 , a photonic integrated circuit 1000 is a variant of the photonic integrated circuit 100 of FIGS. 1A and 1B , and includes similar elements. The photonic integrated circuit 1000 of FIG. 10 may include a SOI substrate 1002 including a buried oxide layer 1003 on a silicon underlayer 1001 , and first 1021 and second 1022 integrated optical devices fabricated on the SOI substrate 1002 . An opaque wall 1031 extends between the first and 1021 second 1022 integrated optical devices for suppressing optical crosstalk between the first 1021 and second 1022 integrated optical devices. Similar to the photonic integrated circuit 900 of FIG. 9 , the photonic integrated circuit 1000 of FIG. 10 , may include a metal overlayer 1092 over the integrated optical device 1021 and 1022 . For better stray light rejection, the opaque wall 1031 may extend from the substrate 1002 to the metal overlayer 1092 .
[0042] The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments and modifications, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Further, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein. | A light shield may be formed in photonic integrated circuit between integrated optical devices of the photonic integrated circuit. The light shield may be built by using materials already present in the photonic integrated circuit, for example the light shield may include metal walls and doped semiconductor regions. Light-emitting or light-sensitive integrated optical devices or modules of a photonic integrated circuit may be constructed with light shields integrally built in. | 6 |
BACKGROUND
Often times, global temporary or volatile tables, referred to generally as “temporary tables” are used in a session, i.e., a series of database interactions with a user between a login and a logoff, or a stored procedure, i.e., a collection of SQL statements associated with a named identifier and saved in a dictionary, to hold the intermediate results of some operation, or to split large queries into manageable and re-usable small chunks. Generally, these temporary tables are used or reused in the subsequent “selects” of the main queries.
Database optimizers use column demographics and histograms to produce optimal plans. Collecting such statistics for temporary tables is a challenge.
SUMMARY
In general, in one aspect, the invention features a method for using statistics for temporary tables in optimizing the execution of a database request. The method includes creating a first temporary table using data from a data source as the result of performing an operation while executing the request. The method further includes saving a subset of the demographics of the data source in a session level memory as the demographics of the first temporary table. The method further includes using the saved demographics in optimizing the execution of the portion of the request involving the first temporary table.
Implementations of the invention may include one or more of the following. The data source may be a single table without any filtering conditions and saving a subset of the demographics of the data source in a session level memory as the demographics of the first temporary table may include saving histograms from the single table as the demographics of the first temporary table. The data source may be a single table with filter conditions and saving a subset of the demographics of the data source in a session level memory as the demographics of the first temporary table may include saving the summary demographics of the columns of the table as the demographics of the first temporary table. The data source may be a plurality of tables accessed when executing the database request and saving a subset of the demographics of the data source in a session level memory as the demographics of the first temporary table may include saving the summary demographics of the columns of the plurality of the tables as the demographics of the first temporary table. The data source may be a plurality of sources for inserts and/or selects and saving a subset of the demographics of the data source in a session level memory as the demographics of the first temporary table may include merging the individual demographics from the plurality of sources as the demographics of the first temporary table. The method may further include creating a second temporary table using data from the second temporary table as the result of performing an operation on the first temporary table while executing the request. The method may further include saving a subset of the demographics of the first temporary table in a session level memory as the demographics of the second temporary table. The method may further include using the saved demographics in optimizing the execution of the portion of the request involving the second temporary table.
In general, in another aspect, the invention features a database system. The database system includes one or more nodes; a plurality of CPUs, each of the one or more nodes providing access to one or more CPUs; a plurality of virtual processes, each of the one or more CPUs providing access to one or more virtual processes; each virtual process configured to manage data, including rows from the set of database table rows, stored in one of a plurality of data-storage facilities; and a process configured to use statistics for temporary tables in optimizing the execution of a database request. The process creates a first temporary table using data from a data source as the result of performing an operation while executing the request. The process further saves a subset of the demographics of the data source in a session level memory as the demographics of the first temporary table. The process further uses the saved demographics in optimizing the execution of the portion of the request involving the first temporary table.
In general, in another aspect, the invention features a computer program, stored in a tangible medium, for using statistics for temporary tables in optimizing the execution of a database request. The program includes executable instructions that cause a computer to create a first temporary table using data from a data source as the result of performing an operation while executing the request. The program further includes executable instructions that cause the computer to save a subset of the demographics of the data source in a session level memory as the demographics of the first temporary table. The program further includes executable instructions that cause the computer to use the saved demographics in optimizing the execution of the portion of the request involving the first temporary table.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is one example of a block diagram of a node of a database system.
FIG. 2 is one example of a block diagram of a parsing engine.
FIG. 3 is a flow chart of a parser.
FIG. 4 is a flow chart showing session level demographic infrastructure.
FIG. 5 is a flow chart showing the creation of temporary table demographics.
DETAILED DESCRIPTION
The database row storage technique disclosed herein has particular application, but is not limited, to large databases that might contain many millions or billions of records managed by a database system (“DBS”) 100 , such as a Teradata Active Data Warehousing System available from the assignee hereof. FIG. 1 shows a sample architecture for one node 105 1 of the DBS 100 . The DBS node 105 1 includes one or more processing modules 110 1 . . . N , connected by a network 115 , that manage the storage and retrieval of data in data-storage facilities 120 1 . . . N . Each of the processing modules 110 1 . . . N may be one or more physical processors or each may be a virtual processor, with one or more virtual processors running on one or more physical processors.
For the case in which one or more virtual processors are running on a single physical processor, the single physical processor swaps between the set of N virtual processors.
For the case in which N virtual processors are running on an M-processor node, the node's operating system schedules the N virtual processors to run on its set of M physical processors. If there are 4 virtual processors and 4 physical processors, then typically each virtual processor would run on its own physical processor. If there are 8 virtual processors and 4 physical processors, the operating system would schedule the 8 virtual processors against the 4 physical processors, in which case swapping of the virtual processors would occur.
Each of the processing modules 110 1 . . . N manages a portion of a database that is stored in a corresponding one of the data-storage facilities 120 1 . . . N . Each of the data-storage facilities 120 1 . . . N includes one or more disk drives. The DBS may include multiple nodes 105 2 . . . N in addition to the illustrated node 105 1 , connected by extending the network 115 .
The system stores data in one or more tables in the data-storage facilities 120 1 . . . N . The rows 125 1 . . . Z of the tables are stored across multiple data-storage facilities 120 1 . . . N to ensure that the system workload is distributed evenly across the processing modules 110 1 . . . N . A parsing engine 130 organizes the storage of data and the distribution of table rows 125 1 . . . Z among the processing modules 110 1 . . . N . The parsing engine 130 also coordinates the retrieval of data from the data-storage facilities 120 1 . . . N in response to queries received from a user at a mainframe 135 or a client computer 140 . The DBS 100 usually receives queries and commands to build tables in a standard format, such as SQL.
In one implementation, the rows 125 1 . . . Z are distributed across the data-storage facilities 120 1 . . . N by the parsing engine 130 in accordance with their primary index. The primary index defines the columns of the rows that are used for calculating a hash value. The function that produces the hash value from the values in the columns specified by the primary index is called the hash function. Some portion, possibly the entirety, of the hash value is designated a “hash bucket”. The hash buckets are assigned to data-storage facilities 120 1 . . . N and associated processing modules 110 1 . . . N by a hash bucket map. The characteristics of the columns chosen for the primary index determine how evenly the rows are distributed.
In an example system, the parsing engine 130 is made up of three components: a session control 200 , a parser 205 , and a dispatcher 210 , as shown in FIG. 2 . Session control 200 provides a logon and logoff function. It accepts a request for authorization to access the database, verifies it, and then either allows or disallows the access.
Once session control 200 allows a session to begin, a user may submit a SQL request, which is routed to parser 205 . As illustrated in FIG. 3 , parser 205 interprets the SQL request (block 300 ), checks it for proper SQL syntax (block 305 ), evaluates it semantically (block 310 ), and consults a data dictionary to ensure that all of the objects specified in the SQL request actually exist and that the user has the authority to perform the request (block 315 ). Finally, the parser 205 runs an optimizer (block 320 ), which develops, for example, the least expensive plan to perform the request.
A technique for capturing and using demographics for the temporary tables without the need to re-collect the statistics helps produce optimal plans and improves performance of subsequent selects involving these temporary tables.
A derived statistics infrastructure in a database can derive and propagate single column or multi-column demographics while doing necessary adjustments, across joins/aggregations/analytical functions, etc. Using this infrastructure, as illustrated in FIG. 4 , the demographics of the final spool file or a base table which is being inserted or merged into the target temporary table can be captured. The captured demographics are saved in a session level memory pool which survives across the requests of the same session. These demographics are retrieved and used to optimize the subsequent “selects” involving these temporary tables.
Referring to FIG. 4 , when a new request (e.g., a new utility or query) is received (block 405 ), the system determines the request type (block 410 ).
If the request is an INSERT/SELECT or CREATE AS, the system determines if the target temporary table is empty (block 415 ). If it is, the session level demographics (“SLDS”) are picked up, as described below with respect to FIG. 5 , and saved (block 420 ). The system then returns to block 405 . If the target temporary table is not empty (block 415 ), the system determines if SLDS already exist for the target temporary table (block 425 ). If they do not this is an indication that the previous demographics have been invalidated and should not be further updated. In that case, the system moves on to process the next request (block 430 ) and returns to block 405 . If SLDS already exist for the target temporary table (block 425 ), the new SLDS is merged with the previous SLDS and the result is saved (block 435 ). The system then moves to the next request (block 430 ) and returns to block 405 .
If the request is a select, the system picks up SLDS for all temporary tables for which such data exists (block 440 ). The system first picks up user collected demographics (i.e., demographics collected by way of a system command, such as a COLLECT STATISTICS command, after the data population) (block 445 ) and then “cleans up” the SLDS entries (i.e., uses the user collected demographics to remove inconsistencies and conflicts, if any) (block 450 ). The system then augments the user collected demographics with SLDS for columns that are missing user collected demographics (block 455 ). The system then optimizes the join plan, cardinality, etc. (block 460 ) and moves to the next request (block 430 ), returning to block 405 .
If the request is an UPDATE, DELETE, or DROP TABLE, the system destroys the SLDS for the temporary table involved in the request (block 465 ).
If the request is a LOGOFF, the system destroys the SLDS for all tables (block 470 ) and the session is complete (block 475 ).
The following are examples of two forms of data population are supported to capture session level demographics for temporary tables:
Create Table <Target Temp Table> AS <Source Table> or <Select query block>
Insert into <Target Temp Table><Select query block>
The derived statistics assigned to a temporary table depend on the source of the data when the temporary table is created or when data is inserted into the temporary table (block 505 ), as shown in FIG. 5 . Thus, when creating SLDS for a temporary table, the system considers the source of the data (block 510 )
If the source is a single table without any filtering conditions, the HISTOGRAMS from the source are automatically propagated and saved for the temporary table (block 515 ).
For example, given the statement “Create volatile table t_orderstbl AS OrdersTbl WITH DATA;” all the available source demographics including the HISTOGRAMS are propagated to “t_orderstbl”.
If the source is a complex query with multiple tables or a single table with filtering conditions, only the summary demographics such as (min distinct values, best distinct values, max distinct values, high mode frequency, num nulls) are propagated (block 520 ).
If the target temporary table is populated using multiple insert/selects, the individual demographics from multiple sources are merged and the final demographics are derived (block 525 ).
If the data is populated and the target table is used in a subsequent “select” in the same multi-statement request, the target derived statistics and estimated row count saved are available and used to optimize subsequent “select”.
For example, given the multi-statement request,
insert into t_orderstbl select * from orderhdr where businessid in (10, 20); ; select * from t_orderhdr, orders where t_orderhdr.ordernum=orders.ordernum ;
The derived statistics and estimated row count from the source “select” of insert/select are available to optimize the subsequent “select” statement.
Once the temporary table is populated and the derived statistics are captured, any subsequent data manipulation statement such as delete/update invalidates the saved session level derived statistics for this table.
The session level derived statistics don't override the statistics that are collected after the data is populated but augment for the column(s) which have missing statistics.
The session level derived statistics are destroyed if the table is dropped or the session is logged off.
This enhancement can also be easily extended and applied to the permanent tables, but this is more suitable for temporary tables.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. | Statistics for temporary tables are used in optimizing the execution of a database request. A first temporary table is created using data from a data source as the result of performing an operation while executing the request. A subset of the demographics of the data source is saved in a session level memory as the demographics of the first temporary table. The saved demographics are used in optimizing the execution of the portion of the request involving the first temporary table. | 6 |
PRIORITY NOTICE
[0001] The present application claims priority, under 35 USC §199(e) and under 35 USC §120, to the U.S. Provisional Patent with Application Ser. No. 61/409,963 filed on Nov. 4, 2010, the disclosure of which is incorporated herein by reference in its entirety.
GOVERNMENT INTEREST
[0002] This invention was made with Government support under Contract No. HDTRA1-10-C-0088 awarded by the Defense Threat Reduction Agency. The Government has certain rights in the invention.
COPYRIGHT & TRADEMARK NOTICE
[0003] A portion of the disclosure of this patent document contains material, which is subject to copyright protection. The owner has no objection to the facsimile reproduction by any one of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever.
[0004] Certain marks referenced herein may be common law or registered trademarks of third parties affiliated or unaffiliated with the applicant or the assignee. Use of these marks is by way of example and shall not be construed as descriptive or to limit the scope of this invention to material associated only with such marks.
REFERENCES CITED
US Patent Documents
[0000]
U.S. Pat. No. 5,239,820 August 1993 Leifer et al.
Other Publications
[0000]
Anderson et al., “Fullerene Propellant Research for Electric Propulsion,” AIAA 96-3211, 32nd AIAA/ASME/SAE/ASEE Joint Propulsion Conference and Exhibit, Lake Buena Vista, Fla., 1996.
Leifer, S. D., “Characterization of Fullerenes for Electrostatic Propulsion Applications,” Ph.D. Dissertation, California Institute of Technology, 1995.
Leifer et al., “Thermal Decomposition of a Fullerene Mix,” Physical Review B 51, 9973-9978, 1995.
Leifer et al., “Developments in Fullerene Ion Propulsion Research,” AIAA/SAE/ASEE 30″ h Joint Propulsion Conference, Indianapolis, Ind., 1994.
Leifer, et al., “Effect of the Thermal Stability and Reactivity of Fullerenes on Ion Engine Propellant Applications,” 25th AIAA Plasmadynamics and Lasers Conference, Colorado Springs, Co., 1994.
Anderson, et al., “Design and Testing of a Fullerene RF Ion Engine,” AIAA-95-2664, 31st Joint Propulsion Conference, San Diego, July 1995.
Anderson et al., “Fullerene Propellant Research for Electric Propulsion,” AIAA 96-3211, 32nd Joint Propulsion Conference, Lake Buena Vista, July 1996.
Takegahara et al., “C60 Molecule as a Propellant for Electric Propulsion,” IEPC-93-032, 23rd International Electric Propulsion Conference, September 1993.
Nakayama et al., “Fundamental Experiments of C60 Application to Ion Thruster,” IEPC-95-88, 24th International Electric Propulsion Conference, September 1995.
Takegahara et al., “C60 Feasibility Study on Application to Ion Thruster Preliminary Experiments Using Electron Bombardment Thruster,” AIAA 95-2665, 31 st Joint Propulsion Conference, San Diego, July 1995.
Nakayama et al. “Study on C60 Application to Ion Thruster-Evaluation of Ion Production,” 32nd Joint Propulsion Conference, Lake Buena Vista July 1996.
Tones, “Prediction of the Performance of an Ion Thruster Using Buckminsterfullerene as the Propellant,” Master of Science Thesis, MIT, February 1993.
Hruby, et al., “A High Thrust Density, C60 Cluster, loon Thruster,” AIAA 94-2466, 25th Plasmadynamics and Lasers Conference, Colorado Springs, June 1994.
Hruby, et al., “Fullerene Fueled Electrostatic Thrusters—Feasibility and Initial Experiments,” AIAA 94-3240, 30th Joint Propulsion Conference, Indianapolis, June 1994.
Hruby, et al., “A High Thrust Density, C 60 Cluster Ion, Thruster,” AFOSR Final Report No. 49620-94-C-0006, September 1996.
TECHNICAL FIELD OF THE INVENTION
[0021] The present invention relates in general to ion thrusters for space propulsion.
BACKGROUND OF THE INVENTION
[0022] Ion thrusters or engines have played vital role in space propulsion for wide ranges of applications, such as low thrust precision attitude control, orbit transfer and interplanetary flights. One of crucial parameters of ion thrusters, which determine its applicability to specific missions, is the thrust density, the ratio of the thrust to the area of the exit nozzle/electrode. The high thrust density correlates with a smaller accelerator grid area that is essential in minimizing the construction, operation and lifting costs of the ion thrusters. Although the power to thrust conversion efficiency and I sp of ion thrusters can be much higher than conventional chemical thrusters, the ion thrusters currently are not used for missions requiring large thrusts in the order of multi megawatts, because their construction and lifting costs are prohibitive. Therefore, the methods of increasing thrust density of ion thrusters can significantly broaden their application scopes have been extensively sought for.
[0023] The operation of the ion thruster relies on acceleration of ions. Thus, the space-charge limitation of the ion acceleration process limits the thrust density. Currently, most of ion thrusters use atomic species, such as Xe or Hg making the ion thruster practical for only a limited range of missions. Extensive research efforts have attempted to increase thrust density to levels that would lead to an attractive ion thruster with wider applicability with the use of heavier ion species than Xe or Hg without success. The method of increasing thruster density can be guided by a physical theory by Child-Longmuir law, and according to this law, the thrust density, T a , of an ion thruster can be given by:
[0000] T a ∝m i 2 I sp 4 , (1)
[0000] where I sp is the specific impulse and m i is the ion mass of the propellant. For a specific mission with a fixed I sp , the higher the ion mass is, the higher is the thruster density. Because the thrust density is proportional to square of the ion mass, even small change in ion mass can increase the thrust density significantly. For example, the atomic mass of the most popular propellant Xe is 131, and any fuels with atomic or molecular mass greater than 131 would increase the thrust density over the current limit.
[0024] Molecular or cluster ions can potentially increase ion mass significantly, however, with highly increased probability of fragmentation, which negates the effect of increased ion mass on thrust density. Therefore, the usage of molecular or cluster ions for ion thrusters has not been successful until now. Fullerene clusters, such as C 60 , have much larger masses than Xe, yet under favorable thermodynamic conditions, they behave like atoms in terms of resisting fragmentation. In addition to their larger mass than that atomic species, fullerene clusters have lower ionization potentials, thus require lesser energy for ionization than atomic species. Fullerene clusters can be sublimated at relatively low temperatures without fragmentation, and their vapors behave like atomic vapors. Therefore, the usage of C 60 for propellant for ion thrusters has been extensively investigated by researchers over two decades.
[0025] For example, C 60 clusters, cardinal clusters among fullerenes, have a mass of 720. If thrust operation conditions are kept the same, the thrust density of C 60 ions would be greater than Xe ions by a factor of (720/131) 2 ˜30 according to Eq. 1. For example, a high thrust mission with a thruster beam power of 10 MW and I sp -5,000 with Xe as propellant would need a grid area of 18 m 2 , which is too large for economically viable construction and lift into space. If a similar ion thruster can be operated with C 60 fuel, the required grid area decreases to 0.60 m 2 , which is economically viable for a wide range of space missions. The heavier fullerenes, such as C 72 or C 84 would have better size-reduction effects. The chemistry of fullerenes has recently produced extensive classes of fullerene derivatives, fullerene nanotubes, and fullerene nanotube derivatives. Successful usages of these large stable clusters will further increase the thruster density. Therefore, fullerene-family fuels may open new doors for electrostatic propulsion, if they can be successfully used in ion thrusters.
[0026] Extensive research and development efforts for fullerene ion thrusters have at best produced engines with undesirably low fuel usage efficiency due to serious propellant deposition and other problems resulting from premature fragmentation before full electrostatic acceleration. Previous state-of-the-art fullerene ion thrusters have used traditional ionization methods including DC and RF discharge plasmas. An example C 60 -based ion thruster system is described in U.S. Pat. No. 5,239,820, entitled “Electric Propulsion Using C 60 Molecules,” issued Aug. 31, 1993, to Leifer et al., the disclosure of which is incorporated herein by reference. The prior usage of such ion thruster structures and operation methods with cathodes and hot filaments in DC or RF discharge chambers has not successful in realizing efficient and practical fullerene ion thrusters. A number of publications similar to the above mentioned C 60 ion thruster system reported a failure of obtaining sufficiently high efficiency of fullerenes for rendering C 60 ion thruster practically and economically viable, which have been incorporated herein by reference. Other methods include the usage of charge exchange of fullerene with rare gas ions generated in discharge chambers in a modified configuration of Hall thrusters. An example such ion thruster system is described in Hruby, et al., “A High Thrust Density, C 60 Cluster Ion, Thruster,” AFOSR Final Report No. 49620-94-C-0006, September 1996, the publication of which is incorporated herein by reference. Such approach also resulted in similar inefficiency of fullerene usage to the above mentioned references.
[0027] None of the existing approaches so far resulted in a practical fullerene ion thruster, mainly because their ionization methods for generating fullerene cluster ions induce extensive fragmentation of fullerene clusters resulting in very low efficiency fullerene usage. Therefore, other innovative ion thruster structures and operation methods have been sought for. The present invention solves these problems in existing fullerene ion thrusters with the use of VUV photoionization followed by thermal effusion of fullerene clusters, which has negligible fragmentation during ionization process, thus promises cost effective and practical fullerene ion thrusters for a wide range of space propulsion applications.
SUMMARY OF THE INVENTION
[0028] The inventor realized that the fundamental problem in the existing fullerene ion thrusters is in the ionization process of fullerenes and transportation process of the fullerene ions ant that the problem can be avoided by using a much gentler ionization method than the ones used in previous works or inventions. The present state-of-the-art fullerene ion thrusters use either electron impact ionization or charge exchange with other rare gases in hot filament environment as used in existing methodologies. Such ionization processes can deposit large internal energy into fullerenes after ionization. The hot filament discharge environment can also rapidly destroy fullerenes. These hot fullerene ions can readily fragment in very short time during acceleration even without collision with rare gas atoms. To make the situation worse, in the traditional fullerene thrusters, transportation of fullerene ions is performed in the mixture of fullerene and rare gas atom vapors at relatively high pressure resulting in further extensive collisional fragmentation.
[0029] The salient feature of the present invention lies in the usage of VUV photoionization of molecular beams of fullerene clusters generated by molecular beam sources, including but not limited to Knudsen cells. The photoionization with controlled photon energy can softly ionize fullerenes without depositing extensive internal energy that can fragment fullerene ions. The photoionization cross sections above the ionization potential of fullerene are well investigated. For example, the ionization potential of C 60 is 7.58 eV, and its photoionization cross section at 10 eV is ˜ 10 −16 cm 2 , which is sufficient for efficient and soft photoionization with minimal fragmentation. The reason for this is that during photoionization at photon energy close to the photoionization threshold, the thermal energy, which induces fragmentation, imparted to fullerenes is minimal, and most of photon energy is used for expelling electrons.
[0030] The present invention can also minimize fragmentation during evaporation of fullerenes, because the present invention does not require enclosed structures for ionization process, which are required for containing DC or RF energies in prior arts. Since the present invention does not require such heavy enclosed structures for ionization, in principle, the ionization area can be arbitrarily large without increasing the overall weight of the thruster. This advantage allows to lower evaporation temperature of fullerenes sufficiently below the fragmentation threshold temperature resulting in minimal thermal fragmentation. For example, if the photoionization region has a diameter of 30 cm, the unit ionization efficiency can be achieved with fullerene densities in the order of 3×10 14 /cm 3 . Such a fullerene number density can be achieved by heating the fullerene solid to 650 C well below the thermal fragmentation temperature of 750 C by molecular beam sources including but not limited to Knudsen cells. With such configuration, almost all fullerenes can be efficiently ionized and accelerated together, thus the collisional fragmentation can be minimized as well. These advantages can not be found in prior art.
[0031] The photoionization of fullerenes require intense VUV photon sources with photon energies in excess of 10 eV, well above the photoionization threshold energy, 7.58 eV, of fullerenes. The ideal VUV photons should have high enough photon energy to have reasonably large photoionization cross sections, but low enough photon energy not to fragment fullerenes. The ideal photon energy thus is ˜10-20 eV. Such photon energy can be readily achieved by the above mentioned VUV photon source technologies. The new development in VUV photon lamps, including but not limited to, rare gas resonance lamps, rare gas excimer lamps, now provides the required high flux of VUV photons with high efficiency. Furthermore, the scaling up of such VUV photon source seems straightforward. For example, a 10 MW ion thruster for interplanetary mission with 10 kV (I sp ˜5,000 sec) acceleration would require a cluster ion beam of 1 kA with a ion flux of 6.3×10 21 ions/sec. This would require at least 6.3×10 21 VUV photons per second. With a photon energy of 10 eV, the required photon source power is 10 kW, which is well within reach of near-future VUV source technologies.
[0032] Another advantage of the present invention is that it does not use rare gas for ion transportation in addition to fullerene fuel. Therefore, the structure of the present invention can be considerably simpler and lighter than the exiting fullerene ion thrusters that use conventional discharge plasma technologies. Furthermore, the thrust efficiency of the present invention is significantly high because does not require mixing with rare gas, which reduces the overall thrust efficiency of fullerene-based ion thrusters. Qualitatively, the summary of the advantages of the present invention over the conventional exiting ionization method for fullerene ioni thrusters is presented in Table 1.
[0000]
TABLE 1
Comparison of exiting ionization method and the present
invention for fullerene ion thrusters.
Existing Ionization Method
Present Invention
Ionization Physics
Electron Impact Ionization or
Photoionization
Charge Exchange
Internal Energy
Much Higher than
Lower than
Deposition due to
Fragmentation Threshold
Fragmentation
Ionization
Threshold
Gas Required In
Yes
No
Addition to Fullerene
Fuel
Scaling Up
Difficult
Easy
Structure
Complicated
Simple
Thrust Efficiency
Low
High
Fullerene Fuel Usage
Very Low
High
Usage of Fullerene
Not Possible
Possible
Derivatives
Usage of Fullerene
Not Possible
Possible
Nanotubes and Their
Derivatives
[0033] Another important aspect of the present invention is in its ability of ionizing with minimal fragmentation of functionalized fullerenes, fullerene nanotubes, and fullerene nanotube derivatives, which have larger mass than fullerenes and can be tailored for mission specificities. Currently, chemists in the world have successfully produced bulk quantities of varieties of functionalized fullerenes (fullerene derivatives), such as C 60 -F 48 , which was recently shown to be evaporable without fragmentation. For example, C 60 -F 48 , has a mass of is 1632.
[0034] The thrust density of C 60 -F 48 can be 5 times higher than that of C 60 alone, and 150 times higher than that of Xe. The potential usage of other heavier functionalized fullerene, fullerene derivatives, fullerene nanotubes, and fullerene nanotube derivatives can further increase the thruster density. Therefore, the successful usage of such fullerene derivatives in the present invention will result in more compact and lighter ion thrusters, thus can greatly expand the usage of ion thrusters for unprecedented space mission applications further beyond ion thrusters using fullerene ions. The ionization with minimal fragmentation of such large fullerene derivatives can be readily achieved by the present invention that uses VUV photoionization.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Elements in the figures have not necessarily been drawn to scale in order to enhance their clarity and improve understanding of these various elements and embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the invention.
[0036] FIG. 1 illustrates schematically a high thruster density ion thruster based on photoionization of fullerene, fullerene derivative, nanotubes, or nanotube derivatives clusters generated by an effusion source with an aperture showing the fundamental principle of the present invention.
[0037] FIG. 2 illustrates schematically a high thruster density ion thruster with plural apertures based on ion beams of the fullerene, fullerene derivative, nanotubes, or nanotube derivatives generated by an effusion source (or plural effusion sources) and single or plural VUV photon sources.
[0038] FIG. 3 illustrates schematically an example of a high thruster density ion thruster with plural slit apertures based on ion beams of the fullerene, fullerene derivative, nanotubes, or nanotube derivatives generated by an effusion source (or plural effusion sources) and single or plural VUV photon sources.
[0039] FIG. 4 illustrates schematically an example of a high thruster density ion thruster with plural annular apertures based on ion beams of the fullerene, fullerene derivative, nanotubes, or nanotube derivatives an effusion source (or plural effusion sources) and single or plural VUV photon sources.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying drawings that form a part hereof, in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the present invention.
[0041] The fundamental principle of the present invention lies in the usage of photoionization for ionizing fullerene-family clusters, including but not limited to fullerene clusters, fullerene derivatives, nanotubes, and nanotube derivatives, generated by a molecular beam source, including but not limited to various effusion sources, such as Knudsen cells. In the following descriptions, fullerene clusters can represent fullerene-family clusters or molecules without departing from the scope of the present invention.
[0042] FIG. 1 illustrates schematically a fundamental aspect of the present invention, which is a high thruster density ion thruster based on VUV photoionization of fullerene clusters, 102 , generated in a thermal effusion source, 101 . The thermal effusion source is a molecular beam source activated by thermal heating, energized by radiation, electrical or other means. Fullerene, 102 , are evaporated from a bulk fullerene solid, 103 , exiting an aperture, 105 , forming a thermal fullerene molecular beam, 104 , ionized by a VUV photon beam, 111 , which is generated by a VUV photon source, 110 . The VUV photon source, 110 , includes, but limited to, resonance line sources and excimer sources that can be energized by energizing mechanisms, including but not limited to, electron beams, DC or RF discharge, or their combinations. The photoionized fullerene ions are accelerated first between the first electrode, 120 , and the second electrode 121 . In some cases, the first electrode can be the frontal surface of the thermal effusion source without departing from the scope of the present invention. The photon flux and the fullerene density are maintained such that the fullerene clusters are fully ionized with minimal multiple ionization and internal energy deposition. The photoionized fullerene ions are further accelerated by the third electrode, 122 , to a full exit velocity. The fully accelerated fullerene ions form an ion beam, 140 , which produces thrust.
[0043] The number of electrodes can be varied depending on applications and preferred thruster configuration. The voltages between electrodes can be varied depending on applications and preferred thruster configuration. The electrodes can be solid plates, apertures or grids, or their combinations, depending on applications and preferred thruster configuration. Other components that are not shown in FIG. 1 are electrostatic focusing and steering elements, and electron sources that neutralize the spacecraft. The number of these elements can vary depending on applications and preferred thruster configuration. Other units that are not shown in FIG. 1 are power sources, control units, and structural elements that attach the thruster to the space vehicle.
[0044] FIG. 2 illustrates schematically a high thruster density ion thruster based on photoionization of fullerene clusters, 202 , generated in a thermal effusion source, 201 . Fullerene clusters, 202 , are evaporated from a bulk fullerene solid, 203 , exiting plural apertures, 205 , forming a thermal fullerene beam, 204 , ionized by a VUV photon beam, 211 , which is generated by plural VUV photon sources, 210 . The thermal effusion source is a molecular beam source activated by thermal heating, energized by radiation, electrical or other means. The VUV photon sources, 210 , include, but limited to, resonance line sources and excimer sources that can be energized by energized by energizing mechanisms, including but not limited to, electron beams or DC or RF discharge. The photoionized fullerene ions are accelerated first between the first electrode, 220 , and the second electrode 221 . In some cases, the first electrode can be the frontal surface of the thermal effusion source without departing from the scope of the present invention. The photon flux and the fullerene density are maintained such that the fullerene clusters are fully ionized. The photoionized fullerene ions are further accelerated by the third electrode, 222 , to a full exit velocity. The fully accelerated fullerene ions form ion beams, 240 , which produce thrust.
[0045] The number of thermal effusion sources can be greater than one without departing from the scope of the present invention. The number of electrodes can be varied depending on applications and preferred thruster configuration. The voltages between electrodes can be varied depending on applications and preferred thruster configuration. The electrodes can be solid plates, apertures or grids, or their combinations, depending on applications and preferred thruster configuration. Other components that are not shown in FIG. 2 are electrostatic focusing and steering elements, and electron sources that neutralize the spacecraft. The number of these elements can be depending on applications and preferred thruster configuration. Other units that are not shown in FIG. 2 are power sources, control units, and structural elements that attach the thruster to the space vehicle.
[0046] FIG. 3 illustrates schematically a multiplexed example of the present invention, a high thruster density ion thruster based on photoionization of fullerene clusters generated in a thermal effusion source, 301 . Fullerene are evaporated from a bulk fullerene solid exiting plural slit apertures, 305 , forming a thermal fullerene beam, 304 , ionized by VUV photon beams, 311 , which are generated by plural VUV photon sources, 310 . The VUV photon sources, 310 , include, but limited to, resonance line sources and excimer sources that can be energized by energized by energizing mechanisms, including but not limited to, electron beams or DC or RF discharge. The photoionized fullerene ions are accelerated first between the first electrode, 320 , and the second electrode 321 . In some cases, the first electrode can be the frontal surface of the thermal effusion source without departing from the scope of the present invention. The photon flux and the fullerene density are maintained such that the fullerene clusters are fully ionized. The photoionized fullerene ions are further accelerated by the third electrode, 322 , to a full exit velocity. The fully accelerated fullerene ions form ion beams, 340 , which produce thrust.
[0047] The number of thermal effusion sources can be greater than one without departing from the scope of the present invention. The number of electrodes can vary depending on applications and preferred thruster configuration. The voltages between electrodes can vary depending on applications and preferred thruster configuration. The electrodes can be solid plates, apertures or grids, or their combinations, depending on applications and preferred thruster configuration. The VUV sources can be of a point, planar, slit, annular or combination source configuration. Other components that are not shown in FIG. 3 are electrostatic focusing and steering elements, and electron sources that neutralize the spacecraft. The number of these elements can vary depending on applications and preferred thruster configuration. Other units that are not shown in FIG. 3 are power sources, control units, and structural elements that attach the thruster to the space vehicle.
[0048] FIG. 4 illustrates schematically a multiplexed example of the present invention, a high thruster density ion thruster based on photoionization of fullerene clusters generated in a thermal effusion source, 401 . Fullerene are evaporated from a bulk fullerene solid exiting plural annular apertures, 405 , forming a thermal annular fullerene beam, 404 , ionized by VUV photon beams, 411 , which are generated by plural VUV photon sources, 410 . The VUV photon sources, 410 , include, but limited to, resonance line sources and excimer sources that can be energized by energized by energizing mechanisms, including but not limited to, electron beams or DC or RF discharge. The photoionized fullerene ions are accelerated first between the first electrode, 420 , and the second electrode 421 . In some cases, the first electrode can be the frontal surface of the thermal effusion source without departing from the scope of the present invention. The photon flux and the fullerene density are maintained such that the fullerene clusters are fully ionized. The photoionized fullerene ions are further accelerated by the third electrode, 422 , to a full exit velocity. The fully accelerated fullerene ions form ion beams, 440 , which produce thrust.
[0049] The number of thermal effusion sources can be greater than one without departing from the scope of the present invention. The number of apertures on the thermal effusion source can vary depending on applications and preferred thruster configuration. The number of VUV photon sources can vary depending on applications and preferred thruster configuration. In some situations, the VUV sources can be arranged in a circular fashion with the VUV photon beams directed to the center of the fullerene cluster beams. The number of electrodes can be varied depending on applications and preferred thruster configuration. The voltages between electrodes can be varied depending on applications and preferred thruster configuration. The electrodes can be solid plates, apertures or grids, or their combinations, depending on applications and preferred thruster configuration. The VUV sources can be of point, planar, slit or annular source configuration. Other components that are not shown in FIG. 4 are electrostatic focusing and steering elements, and electron sources that neutralize the spacecraft. The number of these elements can be depending on applications and preferred thruster configuration. Other units that are not shown in FIG. 4 are power sources, control units, and structural elements that attach the thruster to the space vehicle. In some cases, plural ion thrusters can be used in a single space vehicle.
[0050] More specifically, the fullerene clusters used in the present invention can be replaced with fullerene derivatives or functionalized fullerenes, including but not limited to fluorinated, hydrogenated, hydroxylated, chlorinated, and brominated fullerenes without departing from the scope of the present invention. The examples of fluorinated fullerene derivatives include but not limited to C 60 F 36 , C 60 F 48 , and C 60 F 60 . The examples of hydroxylated fullerene derivatives include but not limited to C 60 (OH) n with n can be 1-60. The examples of hydrogenated fullerene derivatives include but not limited to C 60 H n with n can be 1-60. The examples of chlorinated fullerene derivatives include but not limited to C 60 Cl n with n can be 1-60. The fullerene derivatives may have attachment of other organic and inorganic molecules without departing from the scope of the present invention.
[0051] The fullerene clusters used in the present invention can be replaced with fullerene nanotubes or their functionalized forms, including but not limited to fluorinated, hydrogenated, hydroxylated, chlorinated, and brominated fullerene nanotubes without departing from the scope of the present invention. The fullerene nanotube derivatives may have attachment of other organic and inorganic molecules without departing from the scope of the present invention. | The present invention is for a system and a method of VUV photoionization of fullerene and derivative clusters followed by their thermal effusion for a practical energy-efficient and economically-viable high thrust density ion thruster. By taking advantage of the state-of-the-art high intensity VUV photon sources, present invention is able to provide much softer ionization with minimal internal energy deposition than the ionization in the electron impact or charge exchange type ionization in plasma environment used in conventional ion thrusters. Because the invention eliminates the need of additional gas for forming discharge plasma, it permits simpler and lighter structures than the conventional fullerene thrusters with significantly enhanced propellant-usage efficiencies, thrust to power ratios, and thrust to weight ratios. Because the present invention employs softer VUV photoionization, it permits the usage of heavier and more complex fullerene derivatives, nanotubes, and nanotube derivatives than fullerene clusters for fuels without significantly fragmenting them. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Generally, the present disclosure relates to integrated circuits, and, more particularly, to the design of Built-In Self-Test (BIST) circuits for testing components of a microcircuit design.
2. Description of the Related Art
Built-in self-test (BIST) is a technique that allows integrated circuits to test their own operation functionally and/or parametrically. Like other Design-for-Test (DFT) techniques, it makes difficult-to-test circuits easier to test by adding test circuitry to a microcircuit design for such things as test pattern generation, timing analysis, mode selection, and go-/no-go diagnostic tests. BIST includes control circuits to initiate tests and to collect and report the results, even externally to the chip.
BIST circuits often connect to scan logic. Scan logic is another DFT technique that facilitates testing of a microcircuit chip by, for example, replacing traditional sequential elements, such as flip flops, with scannable sequential elements, called scan cells. A scan cell is a traditional latch or flip-flop with an additional input called the scan input and an additional output called the scan output. The portion of the scan cell that comprises the traditional latch or flip-flop remains part of the functional core logic. The scan output of one scan cell, however, connects to the scan input of the next scan cell to form a scan chain. The scan chain allows test patterns to be serially injected into the core logic so that they appear at the outputs of the latches, or flops. Testing is accomplished by shifting test patterns into the scan chains, cycling the system clock one or more times, and capturing the test results within the latches or flops. The results may then be shifted out through the scan chain for analysis by external test equipment or internal BIST logic.
BIST circuits also typically connect to boundary-scan elements. Boundary-Scan (also known as the Joint Test Action Group (JTAG) standard, or IEEE 1149.1) adds boundary-scan cells to each pin on a microcircuit device so that test and control data can be injected into the microcircuit device, tests initiated, and the results shifted out, even when the microcircuit is encased in a package. Boundary-scan test circuits are frequently used to initiate BIST and to report BIST results through, for example, a JTAG interface.
BIST logic does not come without a cost, however. The logic added to a microcircuit design for BIST testing typically intrudes into the critical timing paths of functional signals. BIST logic typically causes functional signals to propagate through additional gates that couple BIST test data onto the functional data paths, reducing the maximum speed of the microcircuit's operation and increasing its power consumption. While BIST makes device testing more efficient, it typically degrades device performance.
SUMMARY OF EMBODIMENTS OF THE INVENTION
The apparatuses, systems, and methods in accordance with the embodiments of the present invention improve device performance while maintaining the effectiveness of BIST. The apparatuses, systems, and methods described herein achieve improved performance by removing BIST intrusion logic from critical timing paths. Functional data, i.e., signals that propagate through the core logic of a microcircuit design, no longer need to pass through additional circuitry for BIST.
One apparatus in accordance with an exemplary embodiment of the invention comprises a plurality of scan cells connected into one or more scan chains, wherein a scan data input of at least one scan cell is configured to receive built-in test data during BIST testing and scan test data during scan testing. The test data may be supplied through a multiplexer that multiplexes the BIST test data and scan test data onto the scan data input pin of the scan cell. The apparatus may be microprocessor having a memory array, such as a cache memory, and an execution unit.
The apparatus may further comprise a memory array having at least one global bitline coupled to functional logic, the functional logic having a functional data input, a functional data output, and a test data input, wherein the test data input is coupled to the functional data output through a bypass circuit, the functional logic configured to cause a signal to propagate from the functional data input to the functional data output without passing through the bypass circuit.
The microprocessor may further comprise at least one execution unit having at least one multi-cycle ALU, at least one single-cycle ALU, at least one physical register file (PRF), and a multiplexer configured to couple test data onto the result path of the multi-cycle ALU. Test data may be written into the PRF through the execution of an opcode in one of the ALUs.
One method in accordance with an exemplary embodiment of the invention comprises multiplexing BIST data with scan test data on a scan data input circuit of a scan cell and selecting between the scan test data and the BIST data during testing of the microcircuit. The method may further comprise providing test data on a test data input of a bypass circuit coupled to functional logic, the functional logic having a functional data input and a functional data output, the test data input being coupled to the functional data output through the bypass circuit, wherein the functional logic is configured to allow a signal on the functional data input to propagate to the functional data output without passing through logic comprising the bypass circuit. The bypass circuit may comprise a multiplexer having one input coupled to the test data input and another input coupled to a feedback signal representing the functional data output. The method may further include injecting a test pattern into a physical register file (PRF) of an execution unit through the result path of a multi-cycle ALU and executing an operation that results in a known pattern being written into the PRF.
In other embodiments, the apparatuses described above may be formed on semiconductor material and configured to operate in the manner described above, or they may be designed using a hardware descriptive language and stored on a computer readable storage device encoded with data that, when implemented in a manufacturing facility, adapts the manufacturing facility to create the apparatuses. Though described in the context of a microprocessor design, the invention may be used in any type of integrated circuit and is not therefore limited to a microprocessors.
BRIEF DESCRIPTION OF THE FIGURES
The disclosed subject matter will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a simplified block diagram of a microprocessor design containing BIST and scan test elements in accordance with an exemplary embodiment of the invention.
FIG. 2 is a simplified block diagram of a portion of the microcircuit design shown in FIG. 1 in accordance with an exemplary embodiment of the invention.
FIG. 3 is a simplified schematic diagram illustrating BIST intrusion logic in the critical timing path of an address line supplied to a memory array typically found in the prior art.
FIG. 4 is a simplified schematic diagram of the circuit of FIG. 3 configured in accordance with an exemplary embodiment of the invention.
FIG. 5 is a simplified schematic diagram of a typical S-R latch having BIST intrusion logic located in a feedback path via a bypass circuit rather than the functional path in accordance with an exemplary embodiment of the invention.
FIG. 6 is a simplified block diagram of an execution unit having at least one multi-cycle ALU with BIST intrusion logic coupled to the result path of the ALU, in accordance with an exemplary embodiment of the invention.
While the disclosed subject matter is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the disclosed subject matter to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosed subject matter as defined by the appended claims.
DETAILED DESCRIPTION
FIG. 1 is a simplified block diagram of a general purpose microprocessor 10 in accordance with an exemplary embodiment of the invention. Microprocessor 10 performs basic arithmetic operations, moves data from one memory location to another, and makes decisions based on the quantity of certain values contained in registers or memory. To accomplish these tasks, microprocessor 10 incorporates a number of execution units 70 , such as a floating point unit or an integer execution unit, functional logic 50 , and control logic 15 . The functional logic 50 , control logic 15 , and execution units 70 may be designed, for example, using scannable sequential elements connected into one or more scan chains. Microprocessor 10 may also include one or more memory arrays 60 , such as a cache memory and/or a translation look-aside buffer, to facilitate operation of the device. Microprocessor 10 also includes a type of memory array typically found in an execution unit 70 , called a physical register file (PRF) 80 . A PRF stores the intermediate results of an executed instruction, such as a floating point operation, for later use or storage in main memory.
For testing, microprocessor 10 contains BIST & Scan Test Control 30 circuitry for generating test patterns and/or shifting test patterns through scan chains that may comprise part of the functional logic 50 , control logic 15 , execution units 70 , and memory arrays 60 . Microprocessor 10 may include a Test Interface 40 that comprises, for example, a JTAG interface containing boundary scan elements, and/or a scan test interface for receiving test patterns and control data from scan test equipment external to the device. Test Interface 40 connects to Power-Up Reset & Control 20 to reset, configure, control, and/or initiate BIST and/or scan testing. Test patterns may be generated internally to microprocessor 10 by BIST & Scan Test Control 30 for BIST testing and injected into the core logic by shifting through the scan chains. The results may be shifted out and compared to expected results within BIST & Scan Test Control 30 or externally through Test Interface 40 .
FIG. 2 is a simplified block diagram of a portion of the microcircuit design shown in FIG. 1 . As shown, BIST & Scan Test Control 30 includes a master control unit 120 that connects to one or more slave units 130 A, 130 B, and 130 N for communicating test patterns and/or control data, to initiate scan or BIST testing, and to collect and/or report the results. BIST & Scan Test Control 30 also connects to Power-Up Reset and Control 20 and Test Interface 40 to coordinate power-up reset testing, JTAG testing, and scan testing and report the test results, including, for example, to report a go/no-go diagnostic test result. Each slave unit controls the testing of one functional unit of microprocessor 10 . As shown, slave unit 130 A connects to memory array 60 , 130 B connects to functional logic 50 , and 130 N connects to execution unit 70 . Each is designed specifically for testing a particular unit or collection of units.
FIG. 3 is a simplified schematic diagram of a scan cell circuit comprising Mux-D flop 220 , as typically found in the prior art. As understood by one of ordinary skill in the art, Mux-D flop 220 has two data inputs, Scan_Data_In 260 and Read_Address_In 245 , and two data outputs, Read_Address_Out 290 and Scan_Data_Out 295 . The next state of Read_Address_Out 290 and Scan_Data_Out 295 is determined by one of the two inputs. For example, if Scan_Enable 270 is high on the next rising edge of clock 280 , Scan_Data_In 260 determines the next state of Read_Address_Out 290 and Scan_Data_Out 295 . If Scan_Enable 270 is low on the next rising edge of clock 280 , Read_Address_In 245 determines the next state of Read_Address_Out 290 and Scan_Data_Out 295 . Clock 280 may be a system clock supplied internally by microprocessor 10 during the functional operation of microprocessor 10 , a clock under the control of BIST & Scan Test Control 30 , or supplied through Test Interface 40 during BIST or scan testing, or a clock generated and/or controlled by all three, depending on the design and operational state of microprocessor 10 .
In a typical microprocessor design, there are many such scan cells connected into one or more scan chains. To form a scan chain, the scan output pin (SDO) of one scan cell is connected to the scan input pin (SDI) of the next. In the context of FIG. 3 , the Scan_Data_In 260 signal of Mux-D flop 220 is typically connected to the scan data output pin of the previous scan cell, and the Scan_Data_Out 295 pin of Mux-D flop 220 is typically connected to the scan data input pin of the next scan cell. Scan chains facilitate shifting test patterns into and out of the core functional logic. By activating the scan enable pin of each scan cell of the scan chain (i.e., Scan_Enable 270 , in the instant example) and cycling clock 280 until the entire test pattern has been serially shifted into the scan chain, the scan test pattern will appear on the outputs of the scan cells. Scan testing may then commence by deactivating the scan enable pin of each scan cell, enabling the functional data input pin of each scan cell to determine the next state of each scan cell's outputs, and cycling clock 280 the required number of times for the test. The results of the scan tests are captured inside the scan cells and may then be serially shifted out of the scan chain in the same manner the test pattern was serially shifted in. The test results may then be compared to expected results. In one embodiment, the comparisons for both scan and BIST testing may be done in slave units 130 A, 130 B, and 130 N and the results reported to master unit 120 . In other embodiments, the comparisons may be done in master unit 120 or in BIST & Scan Test Control 30 and report internally or externally, or shifted out through Test Interface 40 and compared externally to microprocessor 10 .
As shown in FIG. 3 , BIST data enters Mux-D flop 220 through multiplexer 210 . In normal operation of microprocessor 10 , both BIST_Read_Enable 230 and Scan_Enable 270 will remain inactive. This allows Read_Address line 240 to propagate through multiplexer 210 and determine the logical state of Read_Address_Out 290 on the next rising edge of clock 280 . Read_Address 240 is an address line supplied by the core functional logic of microprocessor 10 during a memory read access cycle of memory array 60 , for example. During Memory Built-In Self-Testing (MBIST), BIST Control 30 activates BIST_Read_Enable 230 , sources BIST_Read_Address 250 , and causes clock 280 to pulse one or more times. Multiplexer 210 acts as the insertion point for BIST data and constitutes BIST intrusion logic into the functional path of Read_Address 240 . When BIST intrusion logic is inserted into critical timing paths like this, the maximum clocking frequency of the circuit is degraded and the constant cycling of the intrusion logic during normal functional operation of the microcircuit design consumes additional power. Removing BIST intrusion logic from critical timing paths increases the maximum speed of the microcircuit design and reduces normal power consumption.
FIG. 4 is a simplified schematic diagram of the circuit of FIG. 3 configured in accordance with an exemplary embodiment of the invention. In FIG. 4 , multiplexer 210 multiplexes Scan_Data_In 260 with BIST_Read_Address 250 , Read_Address 240 connects directly to the functional data input pin of Mux-D flop 220 , and the output of multiplexer 210 connects to the scan input pin of the Mux-D flop 220 to select between scan test data and BIST data during testing of the microprocessor 10 . Both BIST_Read_Enable 230 and Scan_Enable 270 select between the scan data input and functional data input of Mux-D flop 220 through OR gate 315 . Because Read_Address 240 connects directly to Mux-D flop 220 , Read_Address 240 no longer propagates through or cycles the logic contained in multiplexer 210 during normal microprocessor 10 operation, making the critical timing path of Read_Address 240 faster and more efficient.
Though FIG. 3 and FIG. 4 illustrate the effect of BIST intrusion logic on read address lines, any data or control line could have been selected. For example, the circuits illustrated in FIG. 3 and FIG. 4 may be used for any data or control line in control logic 15 , functional logic 50 , memory array 60 , or execution unit 70 of microprocessor 10 where BIST and scan test data injection points are made. A read address line is shown for illustration purposes only.
FIG. 5 illustrates another example of avoiding BIST intrusion logic into the critical timing path of a functional data signal. In FIG. 5 , global bitline circuit 310 is coupled to SR latch 320 . Bitline circuit 310 may be any bitline circuit of memory array 60 , for example. Scan or MBIST test data enters latch 320 as Bypass_Data 410 through bypass circuit 330 and appears as Dout 460 of latch 320 , as described in more detail below. In the prior art, Dout 460 of latch 320 would be multiplexed with Bypass_Data 410 on the output side of inverter 414 , and the multiplexer that multiplexes Bypass_Data 410 with Dout 460 (not shown) would constitute intrusion logic along the critical path of Dout 460 .
In the exemplary embodiment of FIG. 5 , the signal path between Global_Bitline 404 and Dout 460 is not encumbered by BIST intrusion logic. During BIST testing, ArrBypassEn 408 is forced high, driving the output of NOR gate 470 low and allowing Bypass_Data 410 to appear on the output of Selector 420 . Selector 420 acts as a multiplexer that multiplexes between Dout* 461 and Bypass_Data 410 , based on the logic level of ArrBypassEn 408 . A logic low on the output of NOR gate 470 closes (turns on) transistor 442 , pulling Global_Bitline 403 high. A high on Global_Bitline 403 and a low on NOR gate 470 closes transistors 444 and 447 , respectively, and opens (turns off) transistor 445 , allowing the bypass data on the output of Selector 420 to determine the state of Dout* 461 by either closing transistor 446 when Bypass_Data 410 is high or transistor 448 when Bypass_Data 410 is low. Inverter 414 inverts Dout* 461 so that Bypass_Data 410 appears with the proper logic level on Dout 460 .
When ArrBypassEn 408 is low, Precharge 405 selects which circuit, i.e., the global bitline circuit 310 or bypass circuit 330 , determines the logic state of Dout* 461 . When Precharge 405 is high, bypass circuit 330 latches the current state of Dout* 461 . Specifically, when Precharge 405 is high, the output of NOR gate 470 is driven low, causing Global_Bitline 403 to be driven high through transistor 442 and closing transistor 447 in bypass circuit 330 . A high on Global_Bitline 403 , in turn, closes transistor 444 and opens transistor 443 . Because ArrBypassEn 408 is low during normal operation of microprocessor 10 , Dout* 461 controls the output of Selector 420 . When Dout* 461 is low, the output of Selector 420 is high, opening transistor 448 and closing transistor 446 . Because both transistor 444 and 446 are now closed, Dout* 461 is pulled low, its current state, and remains a logic low. When Dout* 461 is high, the output of Selector 420 is low, turning on transistor 448 . In this condition, both transistor 448 and 447 are turned on, which pulls Dout* 461 high. Thus, bypass circuit 330 holds the current state of Dout* 461 during a precharge state.
When Precharge 405 is low, global bitline circuit 310 determines the state of Dout* 461 . The output of NOR gate 470 is driven high, turning transistor 445 on and transistors 442 and 447 off. If both Local_Bitline 0 401 and Local_Bitline 1 402 are high, the output of gate 403 turns transistor 440 off and Global_Bitline 403 is driven high by the action of inverter 413 and transistor 441 . When Global_Bitline 403 is high, transistor 443 turns off and transistor 444 turns on. Because transistors 445 and 444 are both on, Dout* 461 is pulled low and Dout 460 assumes a logic high through inverter 414 . When either Local_Bitline 0 401 or Local_Bitline 1 402 is low, transistor 440 turns on and Global_Bitline 403 is pulled low, turning transistor 443 on and transistor 444 off. Because transistor 443 is turned on, Dout* 461 is pulled high and Dout 460 assumes a logic low through inverter 414 . The circuit of FIG. 5 allows Dout 460 to be controlled by either Bypass_Data 410 or bitline data 401 and 402 without the bitline data having to propagate through BIST intrusion logic.
FIG. 6 illustrates yet another example of how to avoid BIST intrusions in the critical timing paths of functional logic. FIG. 6 is a simplified block diagram of an execution unit 70 having two Arithmetic Logic Units (ALU) ( 510 and 512 ), two PRFs ( 570 and 571 ), and two Address Generation Logic Units (AGLUs) ( 511 and 513 ). ALU 0 510 is a multi-cycle ALU, while ALU 1 512 may be a single- or multi-cycle ALU. Each ALU and AGLU contains a result path (i.e., R 00 560 , R 01 561 , R 10 562 , and R 11 563 ) for writing the results of the respective operations into PRF 1 570 and/or PRF 2 571 . Execution Unit 70 contains execution control unit 530 for generating read and write addresses for PRF 1 570 and PRF 2 571 during normal microprocessor 10 operation, or BIST operation under the control of BIST Slave 30 . Note that execution control unit 530 comprises a single control unit, though it is shown in two places in FIG. 6 to facilitate description. Result path R 00 560 contains multiplexer 550 for multiplexing BIST data onto result path R 00 560 . Execution unit 500 also contains four bypass multiplexers ( 540 , 541 , 542 , and 543 ) for multiplexing result path data and source operand data (e.g., S 00 A and S 00 B to the respective logic units. BIST Slave unit 30 connects to execution control unit 530 and BIST Master 20 for BIST testing and control and to multiplexer 550 for injecting test patterns into PRF 1 570 and PRF 2 571 . In the prior art, there would be one multiplexer coupled to each result path (i.e., R 00 560 , R 01 561 , R 10 562 , and R 11 563 ) for multiplexing BIST data with result data and for writing the BIST data into each array. Test patterns and control data may be received by BIST Slave 30 from BIST Master 20 either serially or in parallel over 525 or developed internally to BIST Slave 30 in response to control information from BIST Master 20 . Test results may be received by BIST Slave 30 through ALU 0 510 from Bypass Multiplexer 540 , as described in more detail below, and compared internally to expected results or passed on to BIST Master 20 for comparison with expected results and/or further disposition.
BIST slave 30 writes test pattern data into each memory location of each PRF 570 and 571 by outputting BIST write data on R 00 560 through multiplexer 550 , which may be under the control of BIST Slave 30 or execution unit control 530 , and sending control information to execution control unit 530 , instructing it, for example, to execute an ADD operation, such as add zero to the BIST write data on R 00 560 , via ALU 1 512 . The ADD operation will cause execution control unit 530 to select R 00 560 data on bypass multiplexer BP 10 542 , thereby supplying the BIST write data to ALU 1 512 , to send the proper opcode 531 to ALU 1 512 to execute the ADD operation, and to write result data that would appear on R 10 562 back into PRF 1 570 , for example. As one of skill in the art will understand, BIST Slave 30 and execution control unit 530 may be designed and configured to cause any various types of opcodes 531 to be executed that result in known values being written into either PRF 1 570 or PRF 2 571 . The BIST write data may then be read out of either PRF 1 570 or PRF 2 571 by, for example, executing a second add operation to, for example, add zero to the previous result and to output the result through bypass multiplexer 540 to BIST Slave 30 through 580 and/or 581 for comparison to expected results in the manner described above. One advantage provided by the exemplary embodiment illustrated in FIG. 6 is allowing testing of an execution unit, including its PRFs, through a single BIST intrusion point, i.e., multiplexer 550 . Because the selected result path is a result path of a multi-cycle ALU rather than a single-cycle ALU, the described embodiment does not intrude on a critical timing path.
All elements described herein, including the functional logic 50 , functional control 15 , execution units 70 , memory arrays 60 , and scannable sequential elements, may be formed on a semiconductor material by any known means in the art. Forming can be done, for example, by growing or deposition, or by any other means known in the art. Different kinds of hardware descriptive languages (HDL) may be used in the process of designing and manufacturing microcircuit devices. Examples include VHDL and Verilog/Verilog-XL. In one embodiment, the HDL code (e.g., register transfer level (RTL) code/data) may be used to generate GDS data, GDSII data and the like. GDSII data, for example, is a descriptive file format and may be used in different embodiments to represent a three-dimensional model of a semiconductor product or device. Such models may be used by semiconductor manufacturing facilities to create semiconductor products and/or devices. The GDSII data may be stored as a database or other program storage structure. This data may also be stored on a computer readable storage device (e.g., data storage units, RAMs, compact discs, DVDs, solid state storage and the like) and, in one embodiment, may be used to configure a manufacturing facility (e.g., through the use of mask works) to create devices capable of embodying various aspects of the instant invention. As understood by one or ordinary skill in the art, it may be programmed into a computer, processor or controller, which may then control, in whole or part, the operation of a semiconductor manufacturing facility (or fab) to create semiconductor products and devices. These tools may be used to construct the embodiments of the invention described herein.
The particular embodiments disclosed above are illustrative only, as the disclosed subject matter may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the disclosed subject matter. Accordingly, the protection sought herein is as set forth in the claims below. | Methods, systems, and apparatuses are presented that remove BIST intrusion logic from critical timing paths of a microcircuit design without significant impact on testing. In one embodiment, BIST data is multiplexed with scan test data and serially clocked in through scan test cells for BIST testing. In another embodiment, BIST data is injected into the feedback path of one or more data latches. In a third embodiment, BIST data is injected into the result data path of a multi-cycle ALU within an execution unit. In each embodiment, BIST circuitry is eliminated from critical timing paths. | 6 |
BACKGROUND OF THE INVENTION
It is known to perform regeneration of activated coal or activated coke by the thermal process in which, for example, activated coke is contacted with a heat carrier medium which is at a temperature of more than 500° C. as described in DE-PS No. 1 719 554. The spent activated coke and the hot sand are fed separately to a desorber. The desorber is equipped with means to ensure good mixing of the two material streams. This method makes use of the phenomenon that gas is liberated during desorption, said gas contributing to the formation of an autogenous fluidized bed in the mixing zone. The means to ensure good mixing are stationary, not mobile. Consequently, optimum mixing and utilization of the heat carrier medium can be achieved under design conditions only.
At part-load--referred to the hourly throughput of activated coke--an irregular distribution of activated coke and hot sand might be encountered. Therefore, the flow rate of recycle sand will generally achieve the process requirements under part-load conditions.
Further known measures, such as the installation of weirs beneath the concentric feed pipes according to OS No. 25 39 266 do not reduce the segregating effect to any appreciable extent and are not fully effective under part-load conditions or require an increased sand flow rate. During their downward flow, the activated coke particles are more and more heated by the surrounding sand, but are at the same time increasingly encapsulated by the sand because the bulk density above the particles rises with increasing depth. Louver-type circumferential guide vanes provide additional gas space, but require enlargement of the desorber.
SUMMARY OF THE INVENTION
The object of the invention is to provide an improvement of the process according to the preamble of the application so that it can be performed in a simpler way and more efficiently while reducing equipment requirement.
The problem is solved by a process generally including the steps of mixing a cold spent solid absorbent medium with a heat carrier medium, immediately tumbling the mixture in a revolving path as it moves along an inclined carrier and subjecting the revolving mixture to periodical linear vibrating forces.
Typically, the process may be achieved by apparatus including an elongate, inclined tubular carrier having a lower semicircular cross-sectional portion which is resiliently supported, together with a mechanism for imparting vibratory forces to the inclined carrier.
The invention utilizes the favourable effects of a revolving flow, preferably in a vertical to slightly inclined plane, for creating an advantageous and effective transfer and desorption.
The excellent mixing provides a rapid and uniform transfer of heat from, for example sand to an activated coke; therefore, desorption is initiated rapidly and completed with a short time. Consequently, the entire desorption process--mixing, preliminary degassing, principal degassing, final degassing--can take place within the material stream because the residence time for final degassing is markedly reduced.
In addition, it was found that the quantity of sand can be reduced in relation to the quantity of activated coke, which means further saving of energy and equipnment volume.
BRIEF DESCRIPTION OF THE DRAWING
The characteristics of the invention and their added technical benefits will be noted from the following description to be read in conjunction with the accompanying drawings in which:
FIG. 1 is a side elevational view of a device for implementing the process; and
FIG. 2 is a cross-sectional view taken substantially along line 2--2 of FIG. 1 of a preferred flow configuration of the sand/activated coke mixture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to FIG. 1 and 2 the spent activated coke and the hot sand are joined and are forced into the flow configuration as shown in FIG. 1 immediately at the point of mixing.
Referring to a material carrier 2, preferably of the tubular type, resting resiliently of four spring elements 1 and 1' the sand inlet is marked 3, the activated-coke inlet is marked 4. The carrier 2 is inclined with respect to a horizontal plane and its inclination may be adjustable such as by changing the height of the springs 1 with respect to the height of the springs 1'. The sand leaves the tubular body at its lower end through said outlet 5, the desorbed activated coke through outlet 6. Screen 7 ensures the separation of the sand from the activated coke. The SO 2 -rich gas liberated by the desorption process exits through waste gas nozzle 8 and is discharged. A rigid supporting saddle 9 attached to material carrier 2 holds two unbalanced motors 10 and 10' whose unbalance disks 11 and 11' rotate in opposite directions as indicated by an arrow.
In a system of this design, the two unbalance disks 11 and 11' are subject to self-synchronization so that the sum of the two centrifugal forces yields a linear vibrating force which is perpendicular to the two motor centerlines in the plane of the centrifugal forces.
Supporting saddle 9 is attached to material carrier 2 so that the direction of the resulting vibration-generating force is located in a plane which is perpendicular to the centerline of the tubular body and inclined to the vertical plane. The force is applied to the center of gravity of the total system so that the latter is induced to perform translatory vibrations whose direction is the same as the direction of the resulting vibration-generating force. Under the influence of the vibration-generating forces, material components fed into the system are enduced to move in a manner which effects upward migration of the sand and activated coke particles on the inside surface of the tubular material carrier. Migrating particles of the bottom layer finally cause surface particles to slide back so that the material performs a continuous revolving motion in the direction of arrow. Moreover, thorough mixing of several material components is achieved by causing the forces to act directly on the individual material particles so that they perform a relative mixing motion in addition to the revolving motion because of friction and particle surface serration as well as different particle inertia. These phenomena combine to cause an ascension of the activated coke 13 across the specifically heavier sand 12 on the inclined surface of the mixture stream in the material carrier. This permits good degassing of the coke particles 13 which are moving freely for a short period.
The activated coke particles 14 which are sliding down along the material surface are drawn again into the sand at re-entry 15, heated and entrained into the near-circular route. The repeated mixing of the activated coke particles with the sand, their heating, degassing, segregation and re-heating result in a surprisingly short process route and desorption time for the spent activated coke.
The inclined position of the longitudinal centerline of the tubular body provides a helical revolving motion of the material towards sand outlet 5 and coke outlet 6, said motion ensuring a continuous throughput.
The invention is not limited to the device as described, but includes any device that permits achieving the flow configuration represented in FIG. 2 for mixing and segregation. | This invention relates to a process for the desorption of spent solid adsorbent through heating the latter to desorption temperature by means of a hot granular heat carrier medium; particularly of activated coal or activated coke used for flue gas purification by adsorption in power plants, for example. | 2 |
RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 10/099,044 filed on Mar. 13, 2002, and incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to optical fibers, and in particular to a hollow core photonic bandgap optical fiber.
BACKGROUND OF THE INVENTION
[0003] Optical fibers are long, thin waveguide strands. They are used in a variety of applications involving the reception, transmission and detection of radiation, ranging from optical telecommunications to scientific instrumentation to ornamental displays. Conventional optical fibers have a high-index core surrounded by a low-index cladding, a geometry that results in the total internal reflection of radiation entering the fiber over a select range of angles. Other forms of conventional optical fibers are referred to as “light tunnels” and use reflection from reflective walls rather than total internal reflection. Conventional optical fibers can have a variety of core geometries, including elliptical cores, double cores, polarization-maintaining cores, and hollow cores.
[0004] Hollow core optical fibers are desirable where transmission losses need to be minimized, since in conventional optical fibers most of the radiation loss in an optical fiber occurs from absorption in the solid core. However, conventional optical fibers that depend on total internal reflection for waveguiding and confinement need to have a core with a higher dielectric constant than that of the cladding. Such a structure is at odds with an optical fiber having a hollow central core, since air has a dielectric constant lower than all known practical cladding materials. Thus, hollow core optical fibers generally require specialized design considerations.
[0005] There are a number of different types of hollow core optical waveguides that operate on the either principle of total internal reflection or the principles of conventional reflection. For example, hollow optical waveguides through silicon wafers with highly reflective coatings on the side of the hollow core are disclosed in U.S. Pat. No. 6,090,636 to Geusic et al. An optical fiber interconnect through a silicon wafer with a hole filled with two different dielectric materials is disclosed in U.S. Pat. No. 6,150,188 to Geusic et al. A hollow optical fiber or hollow core waveguide consisting of a dielectric material coated with a highly reflective exterior coating is disclosed in U.S. Pat. No. 5,815,627 to Harrington, wherein the hollow core can contain one guided wave and the annular ring another guided wave. A hollow core optical waveguide having a highly reflective coating on the inside of a glass tube is disclosed in U.S. Pat. No. 6,141,476 to Matsuura.
[0006] As mentioned above, a desirable property for an optical fiber is minimal transmission loss. Accordingly, there has been significant effort to form optical fibers from materials that have high transmission and high reflection. Some of this effort has been directed to forming optical fibers from quasi-two-dimensional photonic crystals. A photonic crystal is a substrate within which is formed an array of period structures through which radiation of a particular wavelength or energy is forbidden to propagate. The result is a material with a very high reflectivity. Two-dimensional photonic bandgap crystal structures have been reported not only at optical wavelengths but at acoustic wavelengths as well.
[0007] It is well known in the semiconductor industry that a series of cylindrical holes judiciously formed in a solid semiconductor material can be used to form a quasi-two-dimensional photonic bandgap crystal. FIG. 1 is a plan view of a conventional two-dimensional photonic crystal formed from a substrate 110 patterned with an triangular array of cylindrical holes 120 .
[0008] An example prior art quasi-two-dimensional photonic bandgap optical fiber 210 is illustrated in FIGS. 2A and 2B. The optical fiber 210 includes an array of holes 220 formed within a cylindrical substrate 226 . The fiber includes an outer cladding 228 . A solid core 232 , referred to as a “core defect,” is at the center of the substrate. Radiation 242 is reflected within the bandgap of the photonic crystal produced by the periodic array of holes surrounding the core and is confined to the core. The radiation travels down the length of the solid core by total internal reflection made possible by the low average index of refraction of the cladding as compared to that of solid core 232 . Though optical fiber 210 is photonic crystal based, it utilizes total internal reflection like a conventional optical fiber and is relatively lossy because the solid core absorbs radiation.
[0009] Accordingly, what is needed is a photonic crystal optical fiber with a hollow core that allows for low-loss radiation propagation down the fiber by virtue of highly reflectivity walls as a result of the photonic bandgap of the crystal.
SUMMARY OF THE INVENTION
[0010] A hollow core photonic crystal optical fiber formed from several smaller hollow core optical fibers layered around a hollow core is shown. The fiber works on the principle of quasi-two-dimensional photonic crystals to confine radiation in a guided wave. The fiber has a true photonic bandgap in which radiation of a particular frequency (or equivalently, energy or wavelength) is totally forbidden, thereby providing a very high reflection coefficient to radiation incident the walls of the hollow core.
[0011] The present invention includes an array of hollow core optical fibers arranged longitudinally about an axis to define a central hollow core about the axis. The array is formed so as to act as a quasi-two-dimensional photonic crystal with a photonic bandgap that allows radiation of a select frequency range to propagate down the central hollow core.
[0012] The present invention further includes a plurality of hollow core optical fibers arranged longitudinally in an array having a two-dimensional triangular lattice structure so as to form a quasi-two-dimensional photonic crystal having a photonic bandgap, and a central hollow core sized to accept radiation corresponding to the photonic bandgap. The hollow core optical fibers are, for example, conventional silica fibers.
[0013] The present invention also includes a system that includes a hollow core photonic bandgap optical fiber having an input end and an output end. The photonic bandgap optical fiber is made up of an array of hollow core optical fibers arranged longitudinally to form a two-dimensional photonic crystal lattice having a photonic bandgap. The array of optical fibers has at least one omitted optical fiber so as to leave a longitudinal central aperture that forms the hollow core in the array. The hollow core in the array is capable of guiding light having a frequency within the photonic bandgap of the array. The system further includes a radiation source optically coupled to the input end, and a photodetector optically coupled to the output end.
[0014] The present invention also includes a method of guiding radiation. The method includes forming a two-dimensional array of hollow core optical fibers to form a quasi-two-dimensional photonic crystal. The crystal has a photonic bandgap. In forming the array of fibers, at least one hollow core optical fiber is omitted. This creates a central hollow core in the array through which light of a select frequency that falls within the photonic bandgap is guided. The method further includes introducing radiation into the central hollow core having a frequency within the photonic bandgap.
[0015] 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
[0016] [0016]FIG. 1 is a plan view of a conventional two-dimensional photonic crystal formed from a substrate and having triangular an array of cylindrical holes formed therein;
[0017] [0017]FIG. 2A is a front-end view of a prior art photonic-crystal-based optical fiber having a plurality of holes surrounding a solid core;
[0018] [0018]FIG. 2B is a cross-sectional view of the prior art optical fiber of FIG. 2A taken along the line 2 B- 2 B;
[0019] [0019]FIG. 3A is a front-end view of an embodiment of the hollow core photonic bandgap optical fiber of the present invention;
[0020] [0020]FIG. 3B is a close-up front end view of the optical fiber of FIG. 3A showing the individual conventional hollow core optical fibers making up the hollow core photonic bandgap optical fiber;
[0021] [0021]FIG. 3C is a partial cross-sectional view of the optical fiber of FIG. 3A as taken along the line 3 C- 3 C;
[0022] [0022]FIG. 4A is a plot of the optimal filling factor F OPT versus the background dielectric constant ε B for a triangular lattice structure;
[0023] [0023]FIG. 4B is a plot of the width of the photonic bandgap as fraction of the center frequency of the bandgap versus the background dielectric constant ε B for a triangular lattice structure;
[0024] [0024]FIG. 5 is a face-on view of an alternate embodiment of the hollow core photonic bandgap optical fiber of the present invention that includes a cladding with a polygonal outer surface;
[0025] [0025]FIG. 6A is a face-on view of an apparatus for forming the hollow core photonic bandgap optical fiber of the present invention, showing first spools of fiber used to form the first layer of fibers on a rod;
[0026] [0026]FIG. 6B is a side view of the apparatus of FIG. 6A, showing second spools of fiber used to form the second fiber layer along with two of the heating units used to melt the fiber when it is pulled longitudinally off of the rod; and
[0027] [0027]FIG. 7 is a side view of a system employing the hollow core photonic bandgap optical fiber of the present invention.
[0028] In the Figures, the first digit of the reference number corresponds to the Figure number. Accordingly, like elements in different Figures have reference numbers that differ only in the first digit that identifies the Figure number.
DETAILED DESCRIPTION OF THE INVENTION
[0029] In the following detailed description of the embodiments of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
[0030] [0030]FIG. 3A is a full front-end view of an embodiment of a hollow core photonic bandgap optical fiber 310 of the present invention. Optical fiber 310 includes an array 314 of coventional hollow core optical fibers 320 each longitudinally arranged about a central axis A 1 . Optical fibers 320 each having an endface 322 , a hollow core 326 with a dielectric constant ε 0 =1, and an annular cladding 330 surrounding the hollow core and having a thickness T and a dielectric constant ε B >1. Note that the dielectric constant of hollow core 326 is taken as the free-space dielectric constant ε 0 , which differs from that of air by only about six parts in ten-thousand. In an example embodiment, hollow core 326 is circular in cross-section and has a radius R 2 . For the sake of discussion, optical fibers 320 are presumed hereinafter to have a circular hollow core.
[0031] [0031]FIG. 3B is a close-up front end view of optical fiber 310 of FIG. 3A. The total radius R 1 of each fiber 320 is given by R 1 =R 2 +T. The total diameter of each fiber is thus D 1 =2R 1 . The triangularly layered arrangement of fibers 320 omits at least one fiber from central axis A 1 , thereby leaving a longitudinal aperture or hollow core 340 centered on the central axis. Hollow core 340 is not exactly circular in cross-section, but has an effective circular cross-section 342 (dashed line). Also, hollow core 340 is also referred to hereinafter as a “central” hollow core to distinguish it from hollow cores 326 of the conventional optical fibers 320 . Here, the word “central” is not intended to limit the location of the hollow core to the exact center of array 314 .
[0032] Where optical fibers 320 have a circular cross-section, their arrangement in in array 314 forms small gaps 350 . For fibers arranged in a triangular arrangement (FIG. 3B), the gaps occur by virtue of the cusps 354 formed by placing two fibers together, and then adding a third fiber to the first two fibers at the cusps.
[0033] In an example embodiment, fiber array 314 constitutes a two-dimensional photonic crystal with a triangular lattice structure and a lattice constant a=2R 1 . The center wavelength and size of the bandgap of the photonic crystal depends on a number of factors, including the lattice constant a, and the difference (contrast) between dielectric constants ε 0 and ε B . It is convenient to define single parameter called the “filling factor,” which is the ratio of the volume of empty space in the crystal to the total volume of the crystal.
[0034] [0034]FIG. 3C is a partial cross-sectional view of optical fiber 310 of FIG. 3A taken along the line 3 C- 3 C. FIG. 3C illustrates how radiation 367 is guided in central hollow core 340 . In example embodiments, central hollow core 340 has an effective diameter D ranging anywhere from 0.5 microns to 5 microns, depending on the wavelength of radiation 367 to be guided. As a general rule, the longest wavelength of radiation capable of being accepted by the central hollow core is about twice the central core diameter D. Thus, to form a hollow core photonic bandgap optical fiber capable of guiding infrared radiation of 1.5 microns for example, the diameter D of central hollow core 340 should be approximately 0.75 microns.
[0035] Because the photonic crystal formed by fiber array 314 is two-dimensional, the associated bandgap is in the directions orthogonal to radiation propagation down hollow core 330 . For large incident angles θ (e.g., near degrees) measured relative to the central axis, the bandgap remains complete. For smaller angles, the bandgap width is reduced, and for increasingly large angles, the bandgap width is reduced and becomes incomplete. Thus, optical fiber 310 has a limited range of acceptance angles.
[0036] [0036]FIGS. 4A and 4B are plots adapted from FIGS. 4 and 6 of the article by M. Plihal et al., entitled “Photonic band structure of two-dimensional systems: The triangular lattice,” Phys. Rev. B, 44 (16), 8565-8571, Oct. 15, 1991, which article is incorporated by reference herein. FIG. 4A plots a curve 410 of the optimal filling factor F OPT as a function of background dielectric constant ε B (also called the CcontrastC) for a two-dimensional triangular lattice structure of cylindrical holes, such as shown in FIG. 1. The optimal filling factor F OPT is that which yields the widest bandgap for the lowest frequency. The results are applicable to the triangular lattice structure of fiber array 314 (FIG. 3B). In an example embodiment, optical fibers 320 (FIGS. 3A-3C) are made of silica, which has a dielectric constant ε B ˜4. From curve 410 , it is seen that the corresponding optimum filling factor F OPT is about 0.55 or 55%.
[0037] In an example embodiment, optical fibers 320 are selected and assembled to provide the optimum filling factor for optical fiber array 314 , as described below. FIG. 4B plots a curve 420 of the normalized width W=(ω G a)/(2πc) of the photonic bandgap (i.e., the width of the bandgap as a fraction of the center frequency ω G ) versus the background dielectric constant ε B . Here, c is the speed of light. It can be seen from curve 420 that for a background dielectric constant ε B =4, the normalized width W of the bandgap is 0.08, or 8% of the center frequency ω G .
[0038] Note also that the normalized width W of the bandgap depends directly on the lattice constant a, which is given by a=2R 1 . Thus, the bandgap is determined by the radius R 1 of optical fibers 320 used to form the optical fiber array/photonic crystal 314 . Further, the frequency of radiation capable of being guided in hollow core 340 of optical fiber 310 is determined by diameter D of the central hollow core. Thus, the lattice constant a of optical fiber array 314 and the diameter D of central hollow core 340 formed therein are selected so that the frequency of radiation accepted by central hollow core 340 overlaps the photonic bandgap associated with the fiber array 314 .
[0039] Designing Fiber for a Select Filling Factor
[0040] The design of optical fiber array 314 as shown in FIGS. 3A-3C is now described. The design process includes selecting a desired filling factor F.
[0041] To this end, first an imaginary triangle 364 of area A T with vertices at the centers of three adjacent optical fibers 320 is formed (FIG. 3B).
[0042] The area A T of the imaginary triangle is given by:
A T =½(2 R 1 )( R 1 )(3) 1/2 =1.73( R 1 ) 2 Equation 1
[0043] The area A C occupied by optical fibers 320 in area A T (i.e., the total area A T minus the area of gaps 350 ) is given by:
A C =3(⅙)π( R 1 ) 2 =1.57( R 1 ) 2 Equation 2
[0044] The area A A of air due to hollow cores 326 of optical fibers 320 in area A T is given by:
A A =(π/2)( R 2 ) 2 =1.57( R 2 ) 2 Equation 3
[0045] The filling factor F is then defined as:
F=A A /A T =[1.57( R 2 ) 2 ]/[1.73( R 1 ) 2 ]0.91[( R 2 ) 2 /( R 1 ) 2 ] Equation 4
[0046] Equation 4 is used to choose the radii R 1 and R 2 to obtain a select filling factor F. For example, filling factor F may be selected to be the optimum filling factor F OPT . Using the example embodiment discussed above, F=F OPT =0.55, so that R 2 = 0 . 78 (R 1 ).
[0047] It is worth noting that the area associated with gaps 350 is small (e.g., about 10%), whereas the filling factor F needed to create a significant bandgap is generally in excess of 50%. Accordingly, gaps 350 generally do not constitute a significant perturbation to the photonic crystal lattice.
[0048] Other embodiments of hollow core photonic bandgap optical fiber similar to that of optical fiber 310 are possible with the present invention. For example, with reference to FIG. 5, there is shown a hollow core photonic bandgap optical fiber 510 made up of an array of optical fibers 520 each having an elliptical cross-section hollow core 526 surrounded by a cladding 528 having a outer surface 538 with a polygonal cross-section ( e.g., hexagonal, as shown). A polygonal hollow core 540 is centered on central axis A 1 . In an alternative embodiment to optical fiber 510 , hollow cores 526 each have a circular cross-section. This alternate embodiment can be considered a special case of the elliptical cross-section hollow core embodiment.
[0049] The polygonal cross-sections can be selected so that the filling factor in cases where gaps 350 are determined to be undesirable. Also, polygonal cross-section fibers may in some instances prove easier to stack when forming the hollow core optical fiber array.
[0050] Method of Fabrication
[0051] A method of forming the hollow core photonic bandgap optical fiber of the present invention is now described. For the sake of illustration, the method is described in connection with forming optical fiber 310 as shown in FIGS. 3A-3C, though the method applies equally to other example embodiments.
[0052] [0052]FIG. 6A shows front-end view of a fiber-forming apparatus 601 having a number (e.g., nine) of first spools 603 of conventional hollow core optical fiber 620 . Each optical fiber 620 has an endface 622 . First spools 603 are arranged radially outward from a central axis A 2 of a forming rod 615 . The forming rod has an outer surface 617 , an end 619 and a radius R R . In an example embodiment, radius R R =R 1 , or alternatively, R R ˜R 1 .
[0053] [0053]FIG. 6B is a side view of apparatus 601 of FIG. 6A, showing a number of second spools 627 of optical fiber 620 . Second spools 627 are also arranged radially outward from rod central axis A 2 but are located closer to rod end 619 so that optical fiber can be arranged over the forming rod or over existing layers of optical fiber placed onto the forming rod. Apparatus 601 includes a number of heat sources 643 are provided adjacent axis A 2 in a position to provide heat to the optical fibers surrounding the forming rod.
[0054] The technique of forming the hollow core photonic bandgap optical fiber of the present invention is similar to the method of forming a wound electrical cable. Thus, optical fibers 620 from first spools 603 are arranged so that a portion of each optical fiber lies along rod outer surface 617 . These fibers form a first optical fiber layer 653 . Next, more optical fibers 620 from second spools 627 are arranged so that a portion each fiber lies over the fibers in the first layer in cusps 654 formed by adjoining fibers (FIG. 3B). This forms a second optical fiber layer 657 .
[0055] The process of layering opticcal fibers 620 from additional spools (not shown) is repeated until a desired number of layers is formed. Heat is then applied to the layered optical fibers via heat sources 643 . When heated to the point where the fibers begin to melt, the layers of optical fibers are pulled off of the forming rod along the direction of the rod axis A 2 . Optical fibers 620 unwind from the spools during the pulling (arrows 662 ), thereby forming a continuous optical fiber with a hollow core 640 centered on axis A 1 coaxial with forming rod axis A 2 .
[0056] Optical system with hollow core photonic bandgap optical fiber
[0057] With reference to FIG. 7, there is shown an optical system 705 . The system includes, in order along an axis A 3 , a radiation source 707 , a first optional optical coupler 709 , and a hollow core photonic bandgap optical fiber 710 according to the present invention. Optical fiber includes an input end 711 , an output end 713 , and a hollow core 760 . System 705 also includes a second optional optical coupler 727 adjacent output end 713 , and a photodetector 737 .
[0058] Radiation source 707 is capable of outputting radiation 767 of a frequency within the photonic bandgap of optical fiber 710 . In one example embodiment, radiation source 707 is a laser, such as a laser diode. In another example embodiment, radiation source 707 is an incoherent radiation source, such as a light-emitting diode or a conventional lamp.
[0059] First optical coupler 709 is an optical system designed to facilitate the coupling of radiation from radiation source 707 to hollow core 760 at input end 711 of optical fiber 710 . Likewise, second optical coupler 727 is an optical system designed to facilitate the coupling of radiation from hollow core 760 at output end 713 of optical fiber 710 to photodetector 737 . First and second optical couplers can include any number or type of optical components, such as lenses, prisms and gratings.
[0060] In operation, radiation source 707 outputs a radiation signal 767 having a frequency or range of frequencies within the photonic bandgap of optical fiber 710 . Radiation source 707 may also output radiation at frequencies different than the photonic bandgap, but such radiation will not be guided as effectively, if at all, by optical fiber 710 . In this sense, optical fiber 710 acts as a radiation filter.
[0061] Radiation signal 767 is coupled into hollow core 760 of optical fiber 710 over within a range of input angles by optical coupler 709 . The radiation signal is confined to the hollow core by virtue of the photonic bandgap of the surrounding hollow core fiber array and propagates down the optical fiber. At the output end, the radiation signal exits the hollow core and is collected by optical coupler 727 , which directs the radiation signal to photodetector 737 . The latter receives and detects the radiation signal and outputs a corresponding electrical signal 771 , such as a photocurrent, which is further processed by an electronic device 777 downstream of the photodetector. In an example embodiment, electronic device 777 is a transimpedance amplifier that converts a photocurrent signal to a voltage signal.
[0062] Conclusion
[0063] The present invention is a hollow core photonic bandgap optical fiber and method of forming same. The hollow core photonic bandgap optical fiber of the present invention utilizes the advantages of a quasi-two-dimensional bandgap structure to provide a high reflectivity over a select radiation frequency range, while also providing a hollow core that minimizes radiation loss due to absorption. The photonic bandgap is formed by combining conventional hollow core optical fibers in an array along an axis but not on the axis, leaving a hollow core centered on the axis. The diameter of the hollow core is sized to allow for the propagation of select radiation frequencies corresponding to the frequencies of the bandgap associated with the fiber array making up the hollow core photonic bandgap optical fiber.
[0064] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations of the present invention. It is to be understood that the above description is intended to be illustrative, and not restrictive. Combinations of the above embodiments, and other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention includes any other applications in which the above structures and fabrication methods are used. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | A photonic crystal optical fiber made up of an array of conventional hollow core optical fibers is disclosed. The array of optical fibers omits at least one fiber to form a central hollow core. The fiber works on the principle of two-dimensional photonic crystals to confine the radiation in a guided wave within the central hollow core. The fiber has a true photonic bandgap in which radiation of a particular energy or wavelength is totally forbidden, thereby providing a very high reflection coefficient to radiation incident the walls of the central hollow core over a select range of angles. The central hollow core allows for radiation propagation with minimal absorption. | 2 |
This is a division of application Ser. No. 548,417 filed Jul. 5, 1990, now U.S. Pat. No. 5,116,924.
CROSS REFERENCE TO RELATED APPLICATION
The present disclosure relates to the subject matter disclosed in application No. 89112252.5 filed in the European Patent Office on Jul. 5th, 1989, the entire specification of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the production of the novel dispersants and the sizing agent dispersions produced therefrom which are advantageously employed for sizing paper. The invention further relates to cationic dispersants for the dispersion of sizing agents, for example rosins and/or derivatives thereof, and reactive sizing agents, for example alkyl ketene dimers, as well as cationic sizing agent dispersions containing these dispersants and possibly also aluminum sulfate.
2. Technology Review
Aqueous resin dispersions for sizing paper are known. Resin dispersions based on natural resins, e.g. rosin resins, possibly containing polymers such as starches that have been crosslinked, possibly under alkali conditions, with methyl cellulose, casein or other proteins are disclosed in many patents. For example, resin dispersions made according to the Bewoid process, are mentioned in German Pat. No. 1,131,348. U.S. Pat. No. 3,955,654 describes resin dispersions produced by high pressure homogenization.
Also known are cationic dispersions of paper sizing agents in water in which cationic starches or cationic, synthetically produced polymers are usually employed as the cationically active substances. The presence of the cationically active substances considerably accelerates the sizing process.
U.S. Pat. No. 3,966,654 discloses aqueous dispersions of paper sizing agents in water which are composed of 5 to 50 weight percent of a fortified resin, 0.5 to 10 weight percent of a water-soluble cationic dispersant and water. The fortified resins employed here are primarily wood and tall oil rosins which have been reacted with compositions containing the group >C═C--C═O. The cationic dispersant may be polyamine epichlorohydrin resins, alkylene polyamine epichlorohydrin resins or polydiallylamine epichlorohydrin resins. The disadvantages of these dispersions are that their shelf life stability still leaves something to be desired.
Aqueous dispersions of finely dispersed and fortified resin sizing agents are the subject matter of U.S. Pat. No. 4,374,673 which is related to European Patent 0,056,876. Instead of the dispersants disclosed in U.S. Pat. No. 3,966,654, this process employs cationic starches as the water-soluble dispersants. Moreover, they also contain an anionic surfactant. The remainder of the dispersion is water. The dispersions employed for sizing paper can be produced either by homogenization of a solution or melt of the fortified resin in a homogenizer under pressure or according to the so-called inversion process. In the firstmentioned process, the fortified resin is initially dissolved in an organic solvent that is not water-miscible. Thereafter, the aqueous solution of a cationic dispersant and an anionic surfactant are dispersed in the solution. By homogenization in a homogenizer under pressures of 50 to 400 bar, the unstable emulsion becomes a stable emulsion. Finally, the organic solvent is removed by vacuum distillation.
Paper sizing agents based on rosin dispersions are also disclosed in European Patent Publication 200,002. In addition to rosin, which may be modified with maleic acid anhydride, fumaric acid, or a modified hydrocarbon resin, these sizing agents contain commercially available protective colloids or surfactants, polyaluminum hydroxychlorides and possibly retention, fixing agents, and/or wet-strength imparting agents. Because of their poor electrolyte stability, these dispersions tend to undergo phase separation and to thicken.
Laid-open application DE 3,737,615 discloses a resin emulsion sizing agent which is composed of a fortified resin and an at least partially quaternary copolymer composed primarily of a monomer of a (meth)acrylic acid alkyl amino alkyl ester or amide and water. An alleged advantage of this sizing agent is that, at a higher pH, in harder water and at a higher temperature (that is, under conditions in which the conventional anionic sizing agents no longer perform efficiently) it has a good sizing effect. This sizing agent is, however, incompatible with acid aluminum salts.
It is therefore an object of the present invention to provide stable sizing agent dispersions for sizing in the neutral and weakly alkali range which are suitable for internal sizing or only the surface, are additionally well compatible with aluminum sulfate and can be manufactured economically without the need for an expensive stirring assembly or other apparatus.
SUMMARY OF THE INVENTION
It was possible to solve this problem in a surprising manner with new sizing agent dispersions containing a novel cationic dispersant, preferably in the form of an aqueous colloidal polymer salt produced from monomers (a) through (f):
(a) 10 to 30 weight % N,N-dimethylaminoethyl acrylate and/or methacrylate;
(b) 5 to 30 weight % of an acrylic and/or methacrylic acid ester of a C 11 to C 22 fatty alcohol;
(c) 10 to 60 weight % methyl acrylate and/or methacrylate;
(d) 0 to 60 weight % butyl acrylate and/or butyl methacrylate;
(e) 0 to 60 weight % isobutyl acrylate and/or isobutyl methacrylate;
(f) 3 to 15 weight % acrylic acid and/or methacrylic acid; with the sum of components (a) through (f) always being 100 %.
The novel cationic dispersant, which disperses the rosin and/or its derivatives or the alkyl ketene dimer, is a copolymer which is able to also function solely as a sizing agent, if required.
The cationic dispersant may also be present as a polymer salt in the form of an aqueous colloidal solution. This form is preferred for the manufacture of the novel sizing agent dispersions.
The nitrogen content of the copolymer is 100 to 250 mMole per 100 g of the sum of the weights of monomers (a) through (f). The salt of the copolymer may be the salt of either an inorganic or an organic acid. Formic acid and acetic acid are particularly suitable for the salt formation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The novel cationic dispersant can be obtained by a radically initiated polymerization in solvent of monomers (a) through (f). The solvent is an organic solvent that is miscible with water, in which monomers (a) through (f) as well as the resulting copolymer dissolve. Preferably, isopropanol is employed. The solvent polymerization is performed in a reactor into which monomers (a) through (f) are fed at room temperature. The monomer mixture of the examples is stirred at 120 to I60 rpm. Stirring continues for about 10 minutes in an inert gas atmosphere. Thereafter, the radical initiator dispersed in isopropanol is added. The reaction temperature is set to reach about 80° C. within 20 minutes and then the influx of inert gas is interrupted. After about 70 minutes, the polymerization is completed. Neutralization with acid is advantageously performed immediately after the end of polymerization. The resulting salt of the copolymer can be converted to a colloidal solution by the addition of demineralized water.
The novel cationic sizing agent dispersion is composed of the dispersant and a sizing agent and possibly aluminum sulfate. The sizing agent according to the present invention is understood to include a reactive sizing agent of the alkyl ketene dimer type as well as a rosin resin or a derivative thereof. The known rosin resins employed are primarily natural rosins, such as wood rosin, gum rosin and tall oil rosin and the rosin derivatives employed are natural rosins modified with maleic acid anhydride and/or fumaric acid, also known as fortified resins. These rosin derivatives may also be mixed with non-fortified resins. Or, rosin derivatives resulting from the esterification of rosin with polyalcohols, such as glycerin and pentaerythritol can be employed.
In a particular manner, the novel sizing agent dispersion may also be combined with aluminum salts. Surprisingly this does not result in flocculation or precipitation if aluminum salts are added to the finished dispersion. According to the present invention, solid or dissolved aluminum salts are added to the finished dispersion while stirring slowly. The quantity of aluminum salts added to the sizing agent dispersion in solid or dissolved form ranges from 0 to 15 weight %, preferably from 5 to 10 weight %, relative to the finished dispersion.
Suitable aluminum salts according to the invention are, for example, aluminum sulfate, aluminum formate, aluminum chloride and polyaluminum chloride and other basic aluminum salts.
The sizing agent dispersions according to the present invention can advantageously also be produced by the inversion method in such a manner that the polymer dispersant is reacted directly with the respective sizing agent in the same reactor in which it was produced. A solution or a melt of, for example, the rosin is added, according to the present invention, to the alcoholic solution of the dispersant under intensive stirring at elevated temperature, particularly at 75° to 85° C. A homogeneous mixture is formed which is converted into an oil-in-water emulsion by the gradual addition of warm water having a temperature from 75° to 85° C. If required, aluminum salts dissolved in water or solid aluminum salts may be added to this emulsion. The weight ratio of dispersant to sizing agent is 1:1 to 1:20, particularly 1:7 to 1:12.
This sizing agent dispersion, containing, for example, aluminum sulfate, can be used immediately for sizing paper. A separate addition of aluminum sulfate is no longer necessary.
The dispersing effect of the novel cationic dispersant on rosin and alkyl ketene dimer, and its compatibility with aluminum salts could not be derived from the prior art and was therefore even more surprising.
During the so-called phase reversal emulsification, a spontaneous decrease in viscosity occurs. After cooling of the oil-in-water emulsion, a white, thin-flowing dispersion is available. Its average particle size is less than 0.5 microns.
Another procedure for producing the cationic sizing agent is that the dispersant is added to the sizing agent, present as a melt or a solution, in the form of a colloidal, aqueous solution and is converted by the subsequent addition of demineralized water and stirring into an oil-in-water emulsion and is thereby dispersed. Solid or dissolved aluminum salts are then added to the resulting sizing agent dispersion. Thus, a stable sizing agent dispersion results from which the organic solvent can be removed by distillation under reduced pressure.
In this process variation, the ratio of dispersant to sizing agent is from about 1:1 to about 1:20, and particularly from about 1:7 to about 1:12.
The examples below serve to demonstrate the production of the novel cationic dispersant and then the production of the sizing agent dispersions according to the present invention and their use for sizing paper. The examples are given for illustrative purposes only and they are not intended to limit the scope of the invention.
EXAMPLE 1
An externally heatable double-wall flask having a 500 ml volume is used as the reaction vessel. It is equipped with a stirrer, reflex condenser, thermometer, gas inlet, bubble counter and drip funnel with gas equalization. At room temperature, the following are successively added to the flask:
20.0 g isopropanol
32.0 g methyl methacrylate (0.32 Mole)
16.5 g methacrylic acid ester of a C 16 -C 18 fatty alcohol (0.05 Mole)
15.7 g N,N-dimethylaminoethyl methacrylate (0.01 Mole)
2.5 g acrylic acid (0.035 Mole)
The homogeneous mixture is stirred at a stirrer rate of 150 rpm and is rinsed for 10 minutes in an inert gas, e.g. nitrogen.
Then 0.25 g azobisisobutyronitrile, dispersed in 5 g isopropanol, are added. The temperature is raised to 80° C. over 20 minutes and once this temperature has been reached, the supply of nitrogen is cut off. Copolymerization of the monomers begins and reaches the desired degree of polymerization after about 70 minutes (K-value of 12 in dimethylformamide at 25° C. and 1.0 g per 100 ml).
The substance is neutralized with 10 g of a 98% formic acid solution. The polymer salt can be dispersed within 10 minutes by the addition of 315 g hot, demineralized water. The temperature of the water is around 80° C.
If the dispersion was made in water, an almost colorless, weakly opalescent colloidal solution results which has a solids content of 16.0 weight %. The viscosity of the solution, measured according to a Brookfield viscometer with an H-1 spindle rotating at 50 rpm is 15 mPa.s. The content of neutralized nitrogen is 150 mMole per 100 g copolymer.
EXAMPLE 2
The procedure is the same as in Example 1, but instead of formic acid, 10.25 g of a 32% hydrochloric acid solution (0.09 Mole) are employed for the neutralization. The resulting solution is light, weakly opalescent and has a viscosity of 20 mPa.s. The pH of this polymer solution is 4.0.
Examples 3 to 5 which are listed in Table 1 below relate to further copolymer compositions which were produced according to the method described in Example 1.
TABLE 1______________________________________ ExampleComponent* 3 4 5______________________________________isopropanol 25 20 20methyl methacrylate 25.1 28 32C.sub.12 -C.sub.14 methacrylate 57.6 -- --C.sub.16 -C.sub.18 methacrylate -- 18.5 16.5N,N-dimethyl amino 21.5 18 15.7ethyl methacrylateacrylic acid 10.8 -- 2.5methacrylic acid -- 7.0 --azobisisobutyronitrile 0.30 0.25 0.25formic acid 17.0 -- 4.6hydrochloric acid, 32% -- 11.8 --water, demineralized 585 294 325solids (weight %) 16 18 16mMole/100 g copolymer 135 160 150appearance slightly bright & slightly turbid clear turbidviscosity (mPa · s) 45 10 20______________________________________ *Unless otherwise indicated, all values are given in grams.
Examples 6 and 7 show the advantages which are realized if the copolymer of the invention is employed as the sole sizing agent.
Regarding the measured values employed, the following explanations:
(1) The degree of sizing is determined relative to ink with a sizing tester of type PLG-e made by Schroder, Weinheim, as specified in its operating instructions. What is measured is the time, in seconds, that expired after contact with the testing ink until remission drops to 80% and 50%, respectively, of the remission value of the paper being tested.
Testing ink: paper testing ink, blue, according to DIN (German Industrial Standard) 53126.
(2) The Cobb value according to DIN 53132 indicates the water absorption of the paper or cardboard in grams per square meter after contact with distilled water for a certain period of time (1 minute, 5 minutes or 30 minutes). The better the sizing effect, the lower the Cobb value.
EXAMPLE 6
An unsized raw paper, produced from 100 weight % bleached coniferous wood sulfate cellulose having a grams per square meter (gsm) substance value of 50 is impregnated in a laboratory sizing press made by Einlehner with a sizing liquid which is composed of 5 % enzymatically decomposed wheat starch and 8 g sizing agent per liter of this starch solution, with the sizing agent being produced according to Example 1 or 3. The paper is then dried for 2 minutes at 100° C. in a photodryer type 64/60 J made by Gerster, Bruchsal. In the sizing press, the paper takes up 4.5 weight % of dry substance.
Under the same conditions, surface sizing is performed with a sizing liquid composed of a commercially available sizing agent based on a copolymer of styrene, butyl acrylate and vinylimidazole having a solids content of 20.5 weight %.
The properties measured in the paper are compiled in Table 2.
TABLE 2______________________________________ Polymer solution Commercially according to the available invention** product* Example 1 Example 3______________________________________Degree of sizing 154 804 1150Water 1 minute 29 25 21(Cobb value)______________________________________ *20.5 wt % solids **16 wt % solids
This compilation shows the improved sizing effect of the products according to the present invention. Also, the improved sizing effect occurs with smaller percentages of active substances.
EXAMPLE 7
A filter paperboard made by Macherey & Nagel of Duren according to DIN 53106 and having a gsm substance value of 270 is impregnated with a sizing liquid composed of 5 % enzymatically decomposed wheat starch and 0.06, 0.08 or 0.1 weight % atro, respectively, of polymer solution produced according to Example 1 to 5 "% atro" pertains to the absolute content of active ingredients in the aqueous dispersion of the sizing agent and indicates the amount of dispersion absolutely present in a given amount of dry pulp. The temperature of the sizing liquid is 60° C. The commercially available sizing agent based on a copolymer of styrene, butylacrylate and vinylimidazole listed in Table 2, is used for comparison. The impregnation is effected as follows: The paperboard cut to DIN A4 size is saturated with the sizing liquid for 10 seconds in a tray having a capacity of 1.5 liter, is then pressed between other filter paperboard by means of a hard rubber roller and then dried for 4 minutes at 100° C. in a photodryer made by Gerster/Bruchsal. The increase in weight of the cardboard was 5.7 % (starch+polymer). The following values, listed in Table 3, were measured at the thus sized cardboard:
TABLE 3__________________________________________________________________________ Commercially Polymer solution according to available the invention product Example 1 Example 5__________________________________________________________________________quantity % 0.06 0.08 0.1 0.06 0.08 0.1 0.06 0.08 0.1atro**Cobb value* 320 94 92 108 95 87 100 90 83__________________________________________________________________________ *active period of water: 30 minutes **% size based on the dry weight of the pulp
EXAMPLE 8
The copolymerization is performed as in Example 1. The following ingredients are added in succession:
125.6 g isopropanol
50.8 g N,N-dimethylaminoethyl acrylate
67.0 g methyl methacrylate
46.0 g methacrylester of a C 16 -C 18 fatty alcohol
5.8 g acrylic acid
0.6 g azobisisobutyronitrile
The temperature during the polymerization is round 82° C. and the reaction time is 90 minutes. The viscosity of the solution at the end of the polymerization is 6000 mPa.s.
Neutralization is effected with 26.2 g of a 98% formic acid solution. Then 678 g demineralized water having a temperature of 80° C. is added to the resulting copolymer salt during a period of 15 minutes. A homogeneous colloidal solution results which has a solids content of 16.8 weight %. The viscosity of the solution, measured with a Brookfield viscometer with an H-1 spindle rotating at 50 rpm, is 260 mPa.s and the density of the solution is 1.02 g/cm 3 .
The following examples describe the production of dispersions according to the invention and their advantageous uses.
EXAMPLE 9
The container described in Example 1 is employed as reactor. The vessel is supplied with 250 g molten wood rosin and this is heated to 100° C. Stirring for a maximum period of 10 minutes, 170 g of the colloidal dispersant produced in Example 8 are added in measured quantities to the heated wood rosin. The result is a slightly yellow water-in-oil emulsion. Then, within 15 minutes, 380 g demineralized water are added to the water-in-oil emulsion with a stir rate of 600 to 800 rpm. During the addition of the water, a phase reversal occurred and an oil-in-water emulsion was formed. Finally, 200 g of an aluminum sulfate solution having an equivalent Al 2 O 3 content of 8 weight % was added to the emulsion.
The end product is a stable, dispersion of fine particulates which is particularly suitable for the overall sizing the entire paper substance as will be demonstrated below.
The properties of the sizing agent dispersion according to the present invention were the following:
______________________________________solids content: 35.0 weight %viscosity: 15 mPa · spH: 3.0particle size: 320 nm______________________________________
EXAMPLE 10
An indirectly heatable double-wall flask having a 1000 ml volume is used as the reaction and dispersion vessel. It is equipped with a stirrer, reflux condenser, thermometer, gas inlet and drip funnel. The following are successively filled into this vessel at room temperature:
35.0 g isopropanol
15.7 g N,N-dimethylaminoethyl acrylate
32.0 g methyl methacrylate
16.6 g methacrylic acid ester of a C 16 to C 18 fatty alcohol
2.5 g acrylic acid
The mixture is stirred at about 150 rpm and is rinsed with nitrogen. Next, 0.25 g azobisisobutyronitrile are added. The mixture is heated to 80° C. in 20 minutes. Then the supply of nitrogen is shut off. The copolymerization of the monomers begins spontaneously and reaches the desired degree of polymerization after about 70 minutes. The resulting solution is neutralized with 6.9 g formic acid.
Next, 250 g wood rosin heated to 90° C., in the molten state, and 20 g isopropanol are stirred into the polymer salt solution. The polymer salt solution and the natural resin form a homogeneous mixture. 675 g of demineralized water that has a temperature range of 80° to 85° C. is slowly and continuously added. The addition of water is completed after 20 minutes. The end product is an oil-in-water emulsion. During the addition of water, an increase in viscosity is initially noted. After the addition of about two thirds of the intended quantity of water, the primarily produced water-in-oil emulsion is converted to an oil-in-water emulsion. A spontaneous drop in viscosity is noted at the point of reversal. It is advisable for the rate of stirring to be adapted to the change in viscosity. At the end of the addition of water, the emulsion is cooled to room temperature over a period of 20 minutes.
The resulting product is a white, thin-flowing rosin dispersion which has an average particle size of 300 nm and a total solids content of 30.2 weight %, with a pH of 5.0 and a viscosity of 28 mPa.s.
According to a special process variation, part of the remaining quantity of water at the end of the phase reversal may also be exchanged for solutions of salts, polyelectrolytes and other substances. Type and quantity of the exchange liquid are always adapted to the desired effect. For example, in rosin dispersions, the remaining quantity of water may be exchange for an aluminum sulfate solution or, in ketene dimer dispersions, for a cationic polyelectrolyte solution.
Table 4 below lists Examples 10 to 17, which describe the subject matter of the present invention in even greater detail.
TABLE 4__________________________________________________________________________Component Example(grams) 10 11 12 13 14 15 16 17__________________________________________________________________________isopropanol 70 55 13.5 27 30 55 27 45N,N'-dimethylaminoethyl 16 20.4 8.1 9.1 16.3 15.7 10.2 15.7acrylateacrylic acid 2.5 2.5 0.9 1.2 2.1 2.5 1.3 2.5C.sub.16 -C.sub.18 methacrylate 16.5 16.5 7.3 8 13.2 16.5 8.3 16.5methylmethacrylate 32 32 10.7 15.4 25.6 32 16 32azobisisobutyronitrile 0.25 0.25 0.10 0.12 0.20 0.25 0.12 0.25hydrochloric acid 98% 11.4 8.9 11.4 8.6formic acid 98% 9 3.5 4 4.5demineralized water 1030 600 618 591 640 314 545 1033wood rosin 300 250 250 250 250rosin ester* 160stearyl ketene dimer 120 200aluminum sulfate solution 300 300(including 8% Al.sub.2 O.sub.3)solids content in weight % 25 32.5 30.8 31.8 24.2 33 31.5 20pH 3 3 3.4 3.4 2.8 2.9 2.8 3.2particle size in nm 220 170 340 370 190 320 320 440viscosity in mPA · s 5 10 10 8 5 25 12 18__________________________________________________________________________ *glycerin ester of a wood rosin having an acid number of 8
EXAMPLE 18
A cardboard was fabricated of 100 % recycled paper (50% newsprint and 50% department store waste) on a Kammerer experimental paper machine to a gsm substance value of 200. The stock consistency was 1.2 weight %. The dilution of the dispersion before applying it to the stock goes up to 0.48%. The dilution was done with backwater. In the machine tub, 0.35 % (with reference to the dry substance of the recycled paper) of a cationic starch (Hi-cat 100® made by Roquette) were added to the suspension. The sizing agents were continuously added to the substance stream in measured quantities. The pH of the system was measured at the headbox. The temperature of the substance at the headbox was about 35° C. Test samples taken from the dried paper panel had a residual moisture content of 4 to 5% and were examined, after 24 hours of exposure to 23° C. and 55% relative humidity, as to their degree of sizing. Type and quantity of the added auxiliary substances and the resulting sizing values are compiled in Table 5.
TABLE 5__________________________________________________________________________ Commercial product**Sizing Agent Example 10 Example 8 Comparison Example 1* as in Example__________________________________________________________________________ 18starting weight 0.5 0.5 0.75 0.75 0.5 0.5 0.75 0.75 0.5 0.5 0.75 0.75 0.5 0.5 0.75 0.75% atro.sup.+retention agent*** 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.5 0.5 0.75 0.75aluminum sulfate -- 0.03 -- 0.3 -- 0.3 -- 0.3 -- 0.3 -- 0.3 -- 0.3 -- 0.3(weight %)****pH (point of 7.6 7.4 7.6 7.3 7.4 7.2 7.2 7.0 7.6 7.4 7.6 7.4 7.6 7.4 7.5 7.3contact)Cobb value water 170 125 120 95 92 83 58 46 260 190 210 145 260 250 260 22060 sec__________________________________________________________________________ *according to Example 18 of DEOS 3,737,615 **commercially available rosin dispersion including casein as a protectiv colloid ***cationic polyacrylamide, type 4632 SC made by Nalco ****commercially available product containing 17-18% Al.sub.2 O.sub.3 .sup.+ % size based on the dry weight of the pulp
EXAMPLE 19
In the same manner as described for Example 18, a paper is produced which has the following composition:
40 weight % pine sulfate cellulose
40 weight % beech sulfite cellulose
20 weight % calcium carbonate of type DX 1, made by Omya GmbH
Manufacturing conditions were:
concentration of solids in machine tub: 1.2%
concentration of solids upon contact with substance: 0.28%
gsm basis weight value: 80
stock temperature: 35° C.
Type and quantity of the added auxiliary agents and the resulting sizing values are listed in Table 6.
TABLE 6__________________________________________________________________________ Example 18 of Commercially availableSizing agent Example 10 Example 13 DE-OS 3,737,615 product as in Example__________________________________________________________________________ 18starting weight 0.6 0.6 0.75 0.75 0.6 0.6 0.75 0.75 0.6 0.6 0.75 0.75 0.6 0.6 0.75 0.75% atro*starch % 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3retention agent % 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015cationicpolyarylamidealuminum sulfate -- 0.4 -- 0.4 -- 0.4 -- 0.4 -- 0.4 -- 0.4 -- 0.4 -- 0.4(weight %)17-18% Al.sub.2 O.sub.3pH 7.3 7.1 7.2 7.0 7.3 7.1 7.2 7.0 7.5 7.3 7.5 7.3 7.5 7.3 7.5 7.3Cobb value water 36 31 28 23 38 32 27 23 115 95 115 86 120 115 120 10060 sec.sizing degree, ink 210 405 450 600 200 320 470 580 1 10 2 25 0 1 0 6seconds__________________________________________________________________________ *based on the dry weight of the pulp
EXAMPLE 20
A paper was produced under otherwise the same conditions as in Example 19, except ketene dimer dispersions according to the invention were employed as sizing agents. Type and quantity of the added auxiliary agents as well as the resulting sizing values are compiled in Table 7.
TABLE 7
The other listed auxiliary agents correspond to those of Table 6.
TABLE 17______________________________________The other listed auxiliary agents correspondto those of Table 6. CommercialSizing agent Example 15 Example 17 Product*______________________________________starting 0.15 0.20 0.15 0.20 0.15 0.20weight %atro***starch % 0.35 0.35 0.35 0.35 0.35 0.35retention 0.02 0.02 0.02 0.02 0.02 0.02agent %filler content 17.4 17.0 17.3 16.9 17.3 17.0in paper %Cobb value 29 24 31 25 47 38A**Cobb value 21 19 22 19 23 19B**degree of 720 980 640 940 200 280sizing A -80%remissiondegree of 2400 3300 1800 2950 2050 3000sizing B -80%remission______________________________________ *Commercially available merchandise including 6% ketene dimer, total solids including emulsifying agents (starch, tenside) 7.2 weight %. **Test result A was directly after manufacture of the paper. Test result was determined after 96 hours of acclimatization at 23° C. and 55% relative humidity. ***based on the dry weight of the pulp.
From the results listed in the above table it is clearly evident that the sizing agent according to the present invention produce a significantly improved instant sizing. Thus, the manufactured paper is available for further processing after a shorter storage time, resulting in a significant economic advantage.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be included within the meaning and range of equivalents of the appended claims. | A cationic dispersant composed of a copolymer made of the monomers N,N-dimethylamino acrylate and/or methacrylate, the acrylic acid ester and or methacrylic acid ester of a C 10 to C 22 fatty alcohol, methyl acrylate and/or methyl methacrylate, acrylic and/or methacrylic acid and optionally n-butyl acrylate and/or methacrylate and isobutyl acrylate and/or methacrylate. It is equally suitable for the production of stable sizing agent dispersions intended for internal or surface sizing. | 3 |
[0001] This application claims priority to U.S. Provisional Applications Ser. Nos. 61/385,539, filed Sep. 22, 2010; 61/422,776, filed Dec. 14, 2010; and 61/513,378, filed Jul. 29, 2011.
BACKGROUND
[0002] Sharps containers are used in hospitals, doctor offices and other areas for the safe disposal of needles and other sharp objects. Some sharps containers inhibit the ability of a person to reach a hand into the container where the hand could come into contact with the sharps.
[0003] Some sharps containers may simply include an opening too small for a hand; however these sharps containers cannot accommodate the occasional large object.
SUMMARY
[0004] Several different embodiments of sharps containers are disclosed herein. In a first embodiment, the sharps container includes a sub-lid that normally defines an opening into the container that is too small for a hand. Upon closure of the sub-lid, the opening is enlarged so that larger objects can be placed in the container while the closure of the sub-lid continues to prevent a hand from reaching into the container interior.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is an exploded view of a sharps container according to a first embodiment.
[0006] FIG. 2 is a rear perspective view of the assembled container of FIG. 1 .
[0007] FIG. 3 is a top view of the body portion of the container of FIG. 1 .
[0008] FIG. 4 is a perspective view of the container of FIG. 2 in the open, use position.
[0009] FIG. 5 is a perspective view of the assembly of FIG. 4 , with the insert 26 and sub-lid 24 removed from the body portion
[0010] FIG. 6 shows the sub-lid 24 and insert 26 snap-fit into the body portion
[0011] FIG. 7 shows the connection of the lid 20 to the insert
[0012] FIG. 8 is a section view of the container 10 of FIG. 7
[0013] FIG. 9 shows the container of FIG. 8 with the sub-lid rotated forward.
[0014] FIG. 10 shows the container of FIG. 8 with the sub-lid rotated forward to a locked position.
[0015] FIG. 11 shows the container of FIG. 10 with the lid closed.
[0016] FIG. 12 is a perspective view of a container according to a second embodiment in a closed position.
[0017] FIG. 13 is a perspective, exploded view of the container of FIG. 12 .
[0018] FIG. 14 is a bottom perspective view of the exploded container of FIG. 13 .
[0019] FIG. 15 shows the container of FIG. 12 with the sub-lid pivoted to an open position.
[0020] FIG. 16 is a section view through the container of FIG. 15 .
[0021] FIG. 17 shows the container of FIG. 12 with the lid assembly pivoted to an open position.
[0022] FIG. 18 shows the container of FIG. 12 stacked with an identical container.
[0023] FIG. 19 shows the container of FIG. 12 nested with an identical container.
[0024] FIG. 20 is a perspective view of a container according to a third embodiment.
[0025] FIG. 21 is an exploded view of the container of FIG. 20 .
[0026] FIG. 22 is a section view through the container of FIG. 20 in the open position.
[0027] FIG. 23 shows the container of FIG. 20 with the sub-lid rotated to the closed position.
[0028] FIG. 24 shows the container of FIG. 23 with the lock arm rotated down to the locked position.
[0029] FIG. 25 is a perspective view of a container according to a fourth embodiment in the closed position.
[0030] FIG. 26 shows the container of FIG. 25 in the open position.
[0031] FIG. 27 is an exploded view of the container of FIG. 25 .
[0032] FIG. 28 is a section view through the container of FIG. 26 .
[0033] FIG. 29 shows the container of FIG. 25 with the lid assembly pivoted to the open position for cleaning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] An exploded view of a sharps container 10 according to one embodiment of the present invention is shown in FIG. 1 . The sharps container 10 includes a body portion 12 having a side wall 14 extending upwardly from the perimeter of a base wall 16 . A lip 15 protrudes outwardly and then downwardly from an upper edge of the side wall 14 . The container 10 further includes a lid assembly 18 selectively enclosing the opening to the body portion 12 . The lid assembly 18 includes a lid 20 , a sub-lid 24 and an insert 26 .
[0035] The sub-lid 24 includes a concave upper wall 28 and a rear wall 29 between two side walls 30 having pivot pins 32 projecting outwardly therefrom. Crenulated or corrugated handle portions 34 project outwardly from a front edge of the side walls 30 . A flange 36 projects forward from the concave upper wall 28 .
[0036] The insert 26 includes a peripheral wall 40 and a lip 42 projecting outwardly from an upper edge of the peripheral wall 40 . Recesses 44 are formed on the interior of the insert 26 for pivotably receiving the pivot pins 32 of the sub-lid 24 . Brackets 46 project upwardly from lateral edges of the insert 26 toward the rear of the insert 26 . Each bracket 46 includes a guide track 48 having a narrow portion spaced away from an open end. Connectors 50 project downwardly at each lateral end of the insert 26 for connecting the insert 26 to the body portion 12 .
[0037] The body portion 12 includes complementary recessed connectors 54 for receiving the connectors 50 of the insert 26 . The body portion 12 may optionally be molded from a translucent polymer so that it can be determined whether the container 10 is full. Indentations 70 are formed in each lateral portion of the side wall 14 of the body portion 12 so that the body portion 12 can be locked to a counter top.
[0038] A handle 56 may be integrally molded with the lid 20 . Hinge pins 76 are formed along a rearward edge of the lid 20 for connection to the body portion 12 .
[0039] FIG. 2 is a rear perspective view of the assembled container 10 in a closed position. Hinge pin receivers 72 are formed along a rearward side of the lip 15 for hingeably connecting the hinge pins 76 of the lid 20 to the body portion 12 . A bracket 78 across the rear of the body portion 12 can be used to lock the container 10 to a wall mount.
[0040] FIG. 3 is a top view of the body portion 12 . As shown, the base 16 includes a plurality of soft bumps 86 that keep waste from sticking to the base 16 .
[0041] FIG. 4 shows the assembled container 10 in the open position. The insert 26 includes an apron 80 angling downwardly from an upper front edge of the insert 26 . The apron 80 has upwardly angled side edges 82 . The handles 34 and side walls 30 of the sub-lid 24 are disposed outwardly of the side edges 82 of the apron 80 of the insert 26 . The pivot pins 32 of the sub-lid 24 are received in the recesses 44 of the insert 26 so that the sub-lid 24 is pivotably mounted in the insert 26 . The front edge of the lid 20 includes a pair of latch openings 60 for interlocking with tabs 62 on the lip 15 of the body portion 12 to lock the lid 20 to the body portion 12 . A gasket (not shown) may optionally be secured to the lid 20 to seal liquids within the container 10 .
[0042] FIG. 5 is a perspective view of the assembly of FIG. 4 , with the insert 26 and sub-lid 24 removed from the body portion 12 . The sub-lid 24 is shown in a closed position, with the angled side edges 82 of the apron 80 of the insert 26 received in recesses in the front flange 36 of the sub-lid 24 .
[0043] FIG. 6 shows the sub-lid 24 and insert 26 snap-fit into the body portion 12 (via connectors 50 , 54 ( FIG. 1 )). In FIG. 6 , the sub-lid 24 is in the closed position. The lid 20 is pivoted rearward. Brackets 73 project downwardly from a lower surface of a top wall of the lid 20 . Pivot pins 74 project inwardly from the brackets 73 . The pivot pins 74 align with the tracks 48 .
[0044] FIG. 7 shows the connection of the lid 20 to the insert 26 . The pivot pins 74 snap-fit into an upper portion of the guide tracks 48 formed in the brackets 46 of the insert 26 . The upper portion of the guide track 48 retains the pivot pins 74 in the upper portion until sufficient force is applied to the lid 20 to force the pivot pins 74 past the upper portion of the guide track 48 into the remainder of the guide track 48 . In this manner, the lid 20 will remain in the open position during use until intentionally closed for transport when full.
[0045] FIG. 8 is a section view of the container 10 of FIG. 7 . As shown, the hinge pins 74 snap-fit into the upper portion of the guide tracks 48 above the narrow portion formed in the brackets 46 of the insert 26 . In FIG. 8 , the sub-lid 24 is pivoted to the open position and the lid 20 is in the open position. In this position, a user can place an object (e.g. a sharp) on the apron 80 of the insert 26 and it will slide or roll toward the rear of the container 10 , fall between the rearward edge of the apron 80 and the concave wall 28 of the sub-lid 24 onto the rear wall 29 of the sub-lid and then slide or roll forward into the container body portion 12 .
[0046] The space between the rearward edge of the apron 80 and the concave wall 28 of the sub-lid 24 is shown as distance A in FIG. 8 . This is the narrowest point in the path into the container 10 when the sub-lid 24 is open. In the example shown, the distance A is about 1.05″, but other distances could be used. The distance A may be chosen small enough to prevent a user's hand from reaching into the container 10 when the sub-lid 24 is open, but large enough to let most objects fall into the body portion 12 without requiring the user to touch the container 10 .
[0047] If a larger object is placed on the apron 80 , it may be larger than the distance A and therefore may stop at the rearward edge of the apron 80 . In that case, the sub-lid 24 can be rotated forward as shown in FIG. 9 . Because of the location of the pivot axis P (corresponding to pivot pins 32 , more precisely identified in FIG. 1 ) of the sub-lid 24 and the shape of the sub-lid 24 , the concave wall 28 and rear wall 29 move upward and rearward, thus enlarging the distance between the rearward edge of the apron 80 and the rear wall 29 to a distance B ( FIG. 10 , in this case about 1.58″). As the sub-lid 24 is pivoted forward, the larger object can drop into the body portion 12 of the container 10 , but only as the sub-lid 24 is being closed, which prevents hand access into the body portion 12 of the container 10 . When the sub-lid 24 is released, the weight of the rear wall 29 and concave wall 28 pivot the sub-lid 24 back to the open position.
[0048] As shown in FIG. 10 , when the container 10 is full, the sub-lid 24 can be pivoted forward firmly, forcing a locking protrusion 88 on a rear surface of the sub-lid 24 past a flange 90 on the insert 26 . This keeps the sub-lid 24 in the closed position. The lid 20 is then pivoted downward, forcing the pivot pins 74 into the tracks 48 , until the lid 20 is closed, as shown in FIG. 11 . When the lid 20 is closed, the tabs 62 on the lip 15 of the body portion 12 snap into the latch openings 60 on the lid 20 to keep the lid 20 in a closed position (tabs 62 and latch openings 60 shown in FIG. 4 ).
[0049] The closed container 10 can then be shipped to an appropriate facility for removing and disposing of the sharps, cleaning the container 10 and returning it to use.
[0050] A container 110 according to a second embodiment of the present invention is shown in FIGS. 12-19 . Referring to FIG. 12 , the container 110 includes a body portion 112 having a side wall 114 extending upwardly from a periphery of a base wall 116 . A lip extends outwardly and then downwardly from an upper most edge of the side wall 114 . A lid assembly 118 includes a lid portion 120 and a sub-lid 124 . The lid portion 120 includes a hood 138 generally over a rearward half (approximately) of the opening to the container body portion 112 . The hood 138 extends upwardly from rear and side portions of a lip portion 132 of the lid portion 120 . The upper wall of the hood 138 includes a pair of openings 137 . The sub-lid 124 includes a concave wall 148 having a pair of raised rail portions 158 along an exterior surface thereof, including an enlarged portion 160 . The rail portions 158 are aligned with and received in the openings 137 of the hood 138 .
[0051] FIGS. 13 and 14 are exploded views of the container 110 . The lid portion includes a pair of slots 134 formed in a front portion of the lip 132 . An upper wall 139 of the lid portion 120 extends rearwardly and downwardly from a front portion of the lip 132 . The lid portion 120 further includes a pair of arms 136 extending downwardly adjacent the upper wall 139 to form pivot pin receiving portions. Concave ribs 164 are formed on a rear wall and the upper wall of the hood 138 of the lid portion 120 .
[0052] The sub-lid 124 includes a concave wall 148 , which in the embodiment shown is semi-cylindrical, although greater than or less than 180° could also be used. The sub-lid 124 also includes opposed side walls 146 from which hinge pins 147 protrude for pivotably connecting to the lid portion 120 .
[0053] Hinge portions 128 are formed on a rear portion of the lip 115 .
[0054] The front portion of the lip 115 includes a protruding latch portion 130 , which snap-fit connects to a latch portion 162 formed integrally with the lid portion 120 . The raised rail portions 158 provide more stable support for stacking another container on them when the sub-lid 124 is closed. Complementary recesses 166 in the bottom wall 116 of the body portion 112 receive the rail portions 158 when stacked thereon.
[0055] FIGS. 15 and 16 show the sub-lid 124 pivoted to the open position. As shown in FIG. 16 , the flange 152 of the sub-lid 124 contacts the hood 138 of the lid portion 120 in the open position. The concave wall 148 of the sub-lid 124 together with the upper wall 139 of the lid portion 120 provide a tortuous path into the body portion 112 of the container 110 . Objects can be dropped through the opening between the hood 138 and the upper wall 139 of the lid portion 120 . If the object does not fall into the body portion 112 after rolling off the concave wall 148 , the object will drop into the body portion 112 when the sub-lid 124 is rotated back to the closed position.
[0056] When full, the container 110 is shipped to a disposal facility in the closed position as shown in FIG. 12 with the locking tabs 140 snap-fit into the slots 134 in the lid portion 120 ( FIGS. 13 and 14 ). At the disposal facility, the lid portion 120 is released from the body portion 112 by unlatching the latch portions 130 , 162 and pivoting the lid assembly 118 to the open position, as shown in FIG. 17 . The container is then emptied and washed before being returned for reuse.
[0057] As shown in FIG. 18 , the containers 110 can be stacked on one another in the closed position. As shown in FIG. 19 , the containers 110 can be nested within one another with the lid assemblies 118 in the open position.
[0058] A sharps container 210 according to a third embodiment of the present invention is shown in FIGS. 20-24 . Referring to FIG. 20 , the container 210 includes a body portion 212 having a side wall 214 extending upwardly from the perimeter of a base wall 216 . A lip 215 protrudes outwardly and then downwardly from an upper edge of the side wall 214 . The container 210 further includes a lid assembly 218 selectively enclosing the opening to the body portion 212 . The lid assembly 218 includes a lid portion 220 , a lock arm 222 and a sub-lid 224 . The lid portion 220 is connected to the lip 215 of the body portion 212 . The lock arm 222 and the sub-lid 224 are pivotably connected to the lid 20 .
[0059] An exploded view of the container 210 is shown in FIG. 21 . The body portion 212 includes hinge members 228 at a rear of the body portion 212 extending from the lip 215 . A lock 230 is secured to the lip portion 215 at the front of the body portion 212 .
[0060] The lid portion 220 includes a perimeter lip portion 232 having a pair of slots 234 formed through a front portion thereof. Pivot recesses 236 are formed in side portions of the lid portion 220 . The rear half (approximately) of the lid portion 220 includes a hood 38 extending upwardly from the perimeter lip 232 and forwardly to about a midpoint of the lid portion 220 . An upper wall 239 of the lid portion 220 extends from a front portion of the lip 232 and slopes downwardly to an approximate midpoint of the lid portion 220 . Thus, an opening is defined between the rearward edge of the upper wall 239 and the back wall of the hood 238 .
[0061] The lock arm 222 includes a pair of locking tabs 240 extending downwardly from a front wall 242 . The front wall 242 is defined between a pair of arms 244 , which pivotably connect to the lid portion 220 as shown in FIG. 20 .
[0062] The sub-lid 224 includes side walls 246 having pivot pins 247 extending therefrom. A concave upper wall 248 joins the two side walls 246 and is connected to a flat lower wall 250 . A flange 252 protrudes outwardly from an upper portion of the side walls 246 and the upper edge of the upper wall 248 .
[0063] FIG. 22 is a section view through the container 210 of FIG. 20 . In the open position, objects, such as hazardous, sharp medical objects can be deposited through the opening defined between the upper wall 248 of the sub-lid 224 and the upper wall 239 of the lid portion 220 . The lower wall 250 of the sub-lid 224 together with the upper wall 239 of the lid portion 220 define a tortuous path that permits small objects to drop into the body portion 212 , but prevents a hand from reaching into the body portion 212 . The sub-lid 224 remains in the open position due to weight balance and the hinge location. This also causes the sub-lid 224 to automatically rotate down into the closed position if the container 210 falls and rotates up-side-down.
[0064] As shown in FIG. 23 , the sub-lid 224 can be rotated downward to the closed position. The upper wall 248 of the sub-lid 224 covers the opening between the hood 238 and the upper wall 239 of the lid portion 220 ( FIG. 22 ). The sub-lid 224 can be repeatedly opened and closed in order to place more objects into the body portion 212 of the container 210 . When the container 210 is full, the lock arm 222 is rotated downward over the flange 252 of the sub-lid 224 , as shown in FIG. 24 . The locking tabs 240 snap into the slots 234 in the lip 232 of the lid portion 220 , thereby more permanently closing the container 210 . The locking arm 222 and sub-lid 224 cannot be opened again without special tools inserted into the small openings 256 formed at the front of the lip 232 of the lid portion 220 , in order to release the locking tabs 240 . The container 210 loaded with objects would be shipped as shown in FIG. 24 and would be opened at the disposal facility for disposing of the objects therein, possibly washing the container 210 and returning the container 210 for reuse.
[0065] FIGS. 25-28 illustrate a container 310 according to a third embodiment of the present invention. The container 310 includes a body portion 312 having a side wall 314 extending upwardly from the periphery of a base wall 316 . A lip 315 protrudes outwardly and then downwardly from an upper most edge of the side wall 314 . A lid assembly 318 is secured over an opening to the body portion 312 . The lid assembly 318 includes a lid portion 320 having a peripheral lip 332 , which is selectively latched to the lip 315 of the body portion 312 by a sliding latch member 330 , which can be released by sliding the latch member 330 to a release position 333 on the lid portion 320 .
[0066] FIG. 26 shows the container 310 in the open position, with the lid portion 320 pivoted upwardly about an axis at its rearward edge. The lid portion 320 includes side walls 336 projecting downwardly into the container 310 . A dump tray 324 is pivotably mounted in the mouth of the body portion 312 . A guard 370 is also mounted in the mouth of the body portion 312 .
[0067] FIG. 27 is an exploded view of the container 310 . The tray 324 includes a lower wall portion 348 and a pair of opposed pivot pins 347 about which the tray 324 can pivot.
[0068] The guard 370 includes a peripheral wall portion 372 having a lip about the periphery thereof. The guard 370 further includes a rear wall 374 extending downwardly and inwardly at an angle. In the embodiment shown, the rear wall 374 is concave.
[0069] Referring to FIG. 28 , when the lid portion 320 is opened, an opening is defined between the front edge of the lid portion 320 and the tray 324 . An object placed on the lower wall 348 of the tray 324 will cause the tray 324 to tip downwardly, thereby dumping the object into the body portion 312 of the container 310 . The wall 348 of the tray 324 together with the rear wall 374 of the guard 370 provide a tortuous path into the body portion 312 , thereby preventing a hand from entering the body portion 312 . An angled wall 378 extends downwardly from the lower wall 348 of the tray 324 to retain objects in the body portion 312 . The guard 370 includes a front wall angled inwardly to provide a stop for the tray 324 .
[0070] As shown in FIG. 29 , the entire lid assembly 318 can be pivoted to the open position as shown, to empty the contents of the container 310 and permit washing.
[0071] In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | A sharps container includes a sub-lid that normally defines an opening into the container that is too small for a hand. Upon closure of the sub-lid, the opening is enlarged so that larger objects can be placed in the container while the closure of the sub-lid continues to prevent a hand from reaching into the container interior. Other embodiments are also disclosed. | 0 |
BACKGROUND OF THE INVENTION
[0001] This application relates to a transverse flux machine, which may operate as a motor or a generator, and wherein a solid state current source power converter is incorporated into a compact package.
[0002] Transverse flux machines are known, and essentially are a multi-pole electrical machine. The stator consists of a single cylindrical coil for phase, with salient ferromagnetic poles. The rotor consists of permanent magnets. In a transverse flux machine, an electromagnetic force vector between the rotor and stator is perpendicular to the plane of magnetic flux lines. In standard flux machines, the electromagnetic force vector is parallel to the plane of the magnetic flux line. The transverse flux machine has a number of benefits over such standard machines, as are known.
[0003] Typically, a transverse flux machine has been provided with an inverter that is voltage sourced, and provided by a large capacitor. Packaging for a machine using a voltage source inverter would prove challenging.
SUMMARY OF THE INVENTION
[0004] A transverse flux machine has at least three phases each provided by a stator core and phase windings. Each of the at least three phases is captured within a common housing. Parallel lines extend from the at least three phases, and a current source converter is provided and received within the common housing.
[0005] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows a schematic of a first embodiment.
[0007] FIG. 2 shows an electrical schematic power module.
[0008] FIG. 3 shows the FIG. 1 schematic reconfigured in view of the FIG. 2 module.
[0009] FIG. 4 is a cross-sectional view through a FIG. 2 module.
[0010] FIG. 5 shows one phase of a machine.
[0011] FIG. 6 shows three phases of a machine.
[0012] FIG. 7A shows a construction of one of the phases.
[0013] FIG. 7B shows an outer view of the FIG. 7A embodiment.
[0014] FIG. 7C is a cross-sectional view through the FIG. 7A embodiment.
[0015] FIG. 8 shows a fully assembled machine.
[0016] FIG. 9 shows a second embodiment schematic.
[0017] FIG. 10 shows an electrical schematic of a module as incorporated into the FIG. 9 embodiment.
[0018] FIG. 11 shows the FIG. 9 schematic redrawn utilizing the module of FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] A schematic for a transverse flux motor drive 20 for a transverse flux machine 24 is illustrated in FIG. 1 . A DC power source 22 is connected to parallel lines 23 , each passing through an inductor 26 . The inductors 26 , a switching network having solid state switches 28 , diodes 29 , and commutating capacitors 32 , together form a current source converter. The switching network including solid state switches 28 , diodes 29 , and Wye-connected capacitors 32 provide a power module. The solid state switches 28 may be transistors.
[0020] FIG. 2 shows the combination made as a single power module 40 which can be utilized to create the circuit of the transverse flux motor drive 20 . Motor windings 34 are positioned downstream of the module 40 , and are operable to drive a rotor 46 , shown schematically in FIGS. 1 and 2 .
[0021] FIG. 3 shows the circuitry of transverse flux machine drive 20 reconfigured utilizing 6 of the modules 40 of FIG. 2 , with three modules (identified as 41 ) providing a lower leg and the modules 40 providing an upper leg.
[0022] The modules 40 , 41 allow for convenient packaging as will be explained below. As shown in FIG. 4 , each of the modules 40 (or 41 ) may include a plastic outer housing 42 , silicone gel or thermoplastic insulating resin 44 , a bonding wire 146 connecting each switch 28 to each diode 29 . Notably, the switch 28 may be a silicon carbide bipolar junction transistor (SiCBJT), SiCMOSFET, or SiCJFET. The diode 29 may be a silicon carbide Schottky diode. The module 40 may also incorporate aluminum silicon carbide baseplate 200 , Al N insulating substrate 202 , and AlSiC pads 204 . Notably, embodiments of modules 40 or 41 can extend to any number of other type components and materials. The above are given as examples only. Output lines 45 extend from each module and are connected as shown in FIG. 3 .
[0023] FIG. 5 shows the integration of a single phase of a transverse flux machine 24 to incorporate the power modules 40 and 41 , where the transverse flux machine 24 may be driven by transverse flux machine drive 20 of FIGS. 1 and 3 . As shown, the modules 40 and 41 are placed circumferentially between adjacent stator core pole pieces 50 . Stator coil 52 is positioned to extend as a cylindrical coil between all of the stator core pole pieces 50 .
[0024] An inductor 26 can be seen to be positioned into the plane of the page of this paper. The rotor 46 has a plurality of permanent magnets 48 .
[0025] As shown in FIG. 6 , three such combined phases can be placed to form three phases 60 , 61 , and 62 . The inductors 26 are positioned between the phases 60 , 61 , and 62 . The cylindrical spacer 64 secures the inductor 26 in the housing. In this manner, not only can the power modules 40 and 41 be packaged within the overall envelope of the housing, but so can the relatively large inductors 26 .
[0026] FIG. 7A shows a single one of the phases 60 having the core pole piece 50 surrounded by a nonferromagnetic disk 70 . The nonferromagnetic disks 70 are used to keep all stator cores 50 and coils 52 together. An outer housing outline 72 is also shown. As can be appreciated from FIG. 7B , the modules 40 and 41 will be positioned within this same housing. FIG. 7C shows the location of the stator coil 52 as provided by a ring-shaped coil.
[0027] FIG. 8 shows the overall assembly. As shown, an outer housing shell 80 which may be cylindrical in shape surrounds the three phases 60 , 61 , and 62 , the intermediate captured inductors 26 and spacers 64 . Bell housings 82 provide two end housing plates to secure all of the components together in a housing provided by shell 80 and end plates 82 . While the power modules 40 and 41 are not illustrated in this cross-section, it should be understood that they would be spaced into the plane of the paper, and as previously disclosed.
[0028] The machine as described to this point would be operable as a motor. However, similar machines can be provided which can operate as a generator. The arrangement of the switches 28 and diodes 29 in the power module 40 , 41 must be changed such that they now look like those shown in FIG. 9 . A driven rotor 115 is driven by a prime mover to rotate adjacent to the generator windings 114 . The generator windings 114 generate current which is passed back upstream to a load 102 . A housing 104 , inductors 106 , switches 110 , and diodes 108 , along with capacitors 112 are provided as an earlier embodiment.
[0029] As shown in FIG. 10 , the power module 116 is reconfigured such that the arrangement of the switch 110 and diode 108 is changed from the earlier embodiment depicted in FIG. 2 . Similarly, the circuit 100 in FIG. 11 which incorporates the modules 116 look somewhat different than that in the earlier embodiment of FIG. 3 . As in FIG. 3 , the circuit 100 of FIG. 11 includes three modules (identified as 118 ) providing a lower leg and the modules 116 providing an upper leg. However, for packaging purposes, the power modules 116 and 118 and the inductors 106 can be packaged as within the earlier embodiment.
[0030] A worker of ordinary skill in the art would recognize how to connect the various components as set forth in the housing diagram figures of FIGS. 5 , 6 and 8 , for example. The schematics of FIG. 1 , 3 , 9 or 11 will teach all that is needed to this worker to properly connect the various components in the arrangement as shown in FIGS. 5 , 6 and 8 .
[0031] Although embodiments of this invention have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. | A transverse flux machine has at least three phases, each provided by a stator core and phase windings. Each of the at least three phases is captured within a common housing. Parallel lines extend from the at least three phases, and a current source converter is created on each of the parallel lines by inductors, a switching network, and communicating capacitors, which are received within the common housing. | 7 |
GOVERNMENT LICENSING CLAUSE
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore.
FIELD OF THE INVENTION
The invention relates to novel apparatus and methods for evaluating energetic materials for ignitability, flamespread, pressure and thermal characteristics, energetic material interaction, and other properties. The invention also includes methods of using such an apparatus. The invention is particularly directed to an apparatus for analyzing the suitability of energetic materials for interactions with other energetic materials, explosive or non-explosive. For example, the apparatus of the invention may be used to analyze energetic materials for use in destroying rubble, which may itself contain explosive material.
BACKGROUND OF THE INVENTION
Whether energetic materials are to be employed as explosives, incendiaries, concussives, or other uses, they must be evaluated with regard to many properties to determine their suitable for such different uses. Such parameters may include ignitability, flamespread, pressure characteristics, thermal characteristics, energetic material interaction, and others. Traditional methods of examining energetic materials include large scale field tests and smaller scale analysis in test chambers.
For example, U.S. Pat. No. 3,545,252 describes a flammability test chamber which may be evacuated, filled with a desired gaseous environment for testing the test material, an ignition means, a probe for positioning of the test material, and a heating means. The chamber is essentially a crude explosion chamber, and it is incapable of the data collection achieved by the instant invention.
U.S. Pat. No. 3,578,756 describes an Autoignition Test Cell similar to that of U.S. Pat. No. 3,545,252. U.S. Pat. No. 4,990,312 describes a high-pressure promoted combustion chamber having a plurality of viewing ports. U.S. Pat. No. 6,354,137 describes a testing chamber for small amounts of explosive. U.S. Pat. No. 7,159,448 describes a pressure-determining combustion chamber, comprising a sensor having a piezoresistive thin metallic layer. U.S. Pat. No. 3,820,435 describes a system said to be useful for high-explosive studies, and “readily allows flash radiography of an event as it occurs. U.S. Pat. No. 7,128,057 describes a device for determining fuel quality.
While these test chambers may provide certain useful data, they are not readily adaptable to providing data regarding a plurality of properties (e.g., temperature, pressure, flammability, etc.) all in a single test. Moreover, they are not readily adaptable to the investigation of an energetic material's interaction with other energetic materials. In contrast, as indicated below, the inventive apparatus may be used to evaluate any single energetic material reaction or interactions between several energetic materials. Applications include evaluation of ignition behavior of an ignition energetic material against another material. The apparatus includes a method to control rupture pressure to evaluate the energetic material response to different rupture pressures.
The destruction of explosive mine rubble is a dangerous endeavor. Typically, energetic material is employed for such destruction, however, determining suitable compositions to be used for this purpose has essentially required full scale testing in the field in order to ascertain the particular characteristics of the composition, its effectiveness in destroying rubble, the attendant environment of the destruction process, and other parameters. Full scale field testing is prohibitively expensive, is capable of testing only a single composition per field test, and bears the risk of destroying the very instruments employed to collect data for the evaluation of the material.
The testing chambers in the art are unable to provide the necessary analysis because they do not provide results for multiple parameters and they are not suitable for interaction analysis.
The art is in need of improved tools for analyzing energetic materials.
SUMMARY OF THE INVENTION
Accordingly, it an object of the present invention to provide an apparatus capable of analyzing multiple parameters of an energetic material, including ignition, thermal, and pressure characteristics. The apparatus of the invention is also able to provide data regarding the interaction of energetic materials with other energetic materials, be they explosive or non-explosive. Additionally, the apparatus may be used with relatively small amounts of energetic material, and provide a more cost-effective means of evaluating energetic materials as well as permit tests to be repeated without the added cost of preparing full scale field tests in the early evaluation phase. Further, many such materials may be evaluated more quickly.
In an exemplary embodiment of the invention, the apparatus includes a combustion chamber, an ignition tube, and a firing mechanism. The apparatus is provided with instrument ports for the collection of a variety of data, including temperature, pressure, and heat flux measurements.
Other objects and advantages of the present invention are evident from the entirety of this specification and the drawings.
In one aspect, the invention is directed to an apparatus for evaluating energetic materials which includes a vented combustion chamber including a counterbore and a plurality of instrument ports for attachment of a plurality of instruments, an ignition tube inserted within the counterbore, the ignition tube including an ignition material, a first energetic material, and a burst disk, and a firing mechanism.
The instruments may be selected from among detectors for temperature, pressure, and heat flux, and other instruments. The combustion chamber may also have a burst port, and a burst seal affixed thereto. The burst seal, as well as the burst disk attached to the initiation tube, are adapted to burst at a desired pressure.
In another aspect, the combustion chamber may also have a cavity containing a second energetic material, thereby providing the ability to analyze the interaction of the two energetic materials. The invention is particular advantageous when the second energetic material is explosive mine rubble.
In another aspect of the invention, the firing mechanism includes a piston and a firing pin. In order to operate the apparatus and collect data results, an initiation means may be used, and may be selected from the group consisting of electrical, pressure, and impact means. Upon activation of the initiation means, a cascade of events occurs, the events including firing of the firing mechanism, ignition of the ignition material, ignition of the first energetic material, and injection of the ignited energetic material into an interior of the combustion chamber. Data is collected from the plurality of instruments.
In another aspect, the combustion chamber also includes a translucent window for optical observation, allowing visual observation and high speed video recording. Also, a combustion containment basin may be used to collect reactant products after an operation of the apparatus.
In another aspect, the invention provides a method of evaluating a first energetic material by analyzing data collected from the plurality of instruments connected to any apparatus of the invention, as well as visual data and examination of the containment basin contents.
These and other features of the invention are exemplified and further described in the Detailed Description of the Invention below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the combustion chamber according to an exemplary embodiment of the invention.
FIG. 2 is a schematic view of the primer firing mechanism and ignition cup according to an embodiment of the invention.
FIG. 3 is a detailed view of an ignition cup according to an embodiment of the invention.
FIG. 4 is a photograph according to an embodiment of the invention.
FIG. 5 is a photograph of an apparatus according to an embodiment of the invention.
FIG. 6 is a graph of data pertaining to average peak chamber temperature versus the type of material.
FIG. 7 is a graph of data pertaining to average peak chamber pressure versus the type of material.
FIG. 8 is a graph of data pertaining to average post-test TNT weight versus the type of material.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an apparatus capable of analyzing multiple properties of an energetic material, including ignition, thermal, and pressure characteristics, as well as information regarding interaction of the energetic material with other energetic materials. Energetic materials include explosives, incendiaries, concussive materials, and the like. Exemplary examples of energetic compositions are explosive compositions, such as, RDX and TNT explosives; flammable solids, such as, Thermite; oxidizers, such as, lithium perchlorate; and reactive materials, such as, nanoscale aluminum.
The advantages of the invention are achieved by providing multiple instrument access ports in the combustion chamber, into which a variety of instruments capable of providing different property measurements are affixed. The ability to investigate the interaction of energetic materials is provided by a cavity in the combustion chamber such that upon ignition of the first energetic material and its injection into the combustion chamber, the energetic materials interact and the instruments provide data to the investigator. A general description of the apparatus of the invention follows, after which exemplary embodiments of the invention will be more particularly described in the Examples.
In one embodiment of the invention, the apparatus of the invention includes a vented combustion chamber, an ignition tube, a firing mechanism, and a capture basin. The combustion chamber is constructed from steel or other materials capable of withstanding the pressure caused by combustion without significant deformation. The combustion chamber may be designed to accommodate different volumes, depending on the need of the investigator, the nature of the energetic material being analyzed, and the nature of the second energetic material whose interaction with the first energetic material is being analyzed. The vented combustion chamber is optionally provided with a burst port adapted for insertion of a burst seal designed to burst at a specified pressure. This burst port is independent of the ignition burst disk. The chamber burst port controls the chamber burst pressure to evaluate the effect of chamber pressure confinement on energetic material reaction rate. Materials generally react faster with higher pressure confinement. The chamber burst port may also serve as a pressure release port for safety purposes. The burst seal may be constructed from a variety of materials, such as metal shims, in order to achieve the desired burst pressure. Alternatively, where no burst seal is required, the burst port may be closed.
The combusion chamber is provided with instrumentation ports allowing for the collection of measurements of relevant properties, such as pressure, temperature, and heat flux. The combustion chamber is also provided on an outer surface with a counterbore passing completely therethrough, the counterbore having a narrower portion at the combustion chamber's interior surface, such that an ignition tube may be inserted in the counterbore, and prevented from entering the interior of the combustion chamber. The outer surface of the burst disk is thereby open to the interior of the combustion chamber.
The combustion chamber is provided with a cavity which may be left empty to evaluate an energetic material by itself, or which may be filled with a second energetic material to evaluate the reaction between the two materials.
The ignition tube contains the energetic material being analyzed. Generally, the maximum amount of material in the ignition tube depends on the size and strength of the combustion chamber and ignition tube. For a small ignition tube and chamber, the amount of material may be less than a gram. For a larger ignition tube and chamber, which is structurally stronger, perhaps several hundreds of grams may be tested. The ignition tube is hollowed at one end, thereby providing an ignition cup for holding the energetic material. The ignition cup end of the ignition tube is sealed with a burst disk. The burst disk is selected from suitable materials for retaining the ignited energetic material until the reaction pressure in the ignition tube builds up to a desired pressure, at which pressure the burst disk bursts and the ignited energetic material reactants are injected into the chamber cavity.
Generally, if the chamber does not involve the burst port and rupture window, then the chamber may survive and, depending upon the chamber size, hold greater than 100 PSI peak pressure. The burst disk that is on the ignition tube may be as low as about several hundred psi to about several thousand psi depending upon the material. Temperature does not affect the burst disk but it directly affects the reaction of the material itself. The opposite end of the ignition tube is also hollowed, and contains the ignition material to be ignited by a firing mechanism. The ignition material and the energetic material may be separated by a thin separating material, such as a mylar disk.
The firing machanism is secured to the top of the combustion chamber, such that its lower end abuts the ignition material end of the ignition tube. The firing mechanism may be used to initiate a variety of ignition sources, for example, electrical, pressure, or impact initiation.
In operation, the firing mechanism is activated, which initates the ignition material in the ignition tube, the energy of which is then transferred to the energetic material loaded in the ignition cup portion of the ignition tube. The energetic material is thereby ignited, building pressure until the pressure has reached the burst point for the ignition cup burst disk. The burst disk bursts, and the ignited reactants are injected into the chamber cavity.
The combustion chamber may be provided with an optical window to allow for visual observation and high speed video photography of the ignition event and flame spread. The optical window may be made from any translucent inert material sufficiently strong and of sufficient thickness to withstand the pressure in the combustion chamber.
In embodiments of the invention in which the interaction of the energetic material with a second energetic material is being analyzed, the second energetic material is situated in the chamber cavity, and a combustion containment basin is positioned below the chamber to capture the reaction products. The basin may further contain a liner to facilitate debris collection and may be used as a visible indicator of the completeness of the combustion.
EXAMPLES
The present invention will be further understood by reference to the following non-limiting examples.
(Actual) Example 1
An Apparatus of the Invention
With reference to the FIG. 1 , an apparatus of the invention was constructed with a steel combustion chamber ( 1 ) having a counterbore ( 2 ) on its upper surface. The combustion chamber ( 1 ) was 3 inches in diameter, and 2 inches in height. The upper surface also was provided with instrument ports: a thermocouple port ( 3 ), a heat flux port ( 4 ), and a pressure transducer port ( 5 ). The upper surface further comprises a vent connection ( 6 ), and a burst seal mounting ( 7 ). The counterbore, ports, vent, and burst seal mounting each abut the combustion chamber interior ( 8 ).
With reference to FIGS. 2 and 3 , a steel firing mechanism ( 9 ) comprises a steel piston ( 10 ) and steel pin ( 11 ), shown in the retracted pre-firing position supported by a coil spring ( 12 ). The lower portion of the firing mechanism ( 9 ) is threaded to securely fasten into the counterbore's ( 2 ) matching threads. The counterbore's ( 2 ) lower un-threaded portion ( 13 ) is sized to accommodate the steel ignition tube ( 14 ), which has an ignition cup ( 15 ) containing energetic material ( 16 ) and ignition material ( 17 ) separated by a mylar disc ( 18 ), and a steel burst disk ( 19 ) glued to the end of the ignition tube with cyanoacrylate.
In FIGS. 2 and 3 , the brass disk ( 19 ) was adhered to the bottom of the igniter cup (ignition tube) ( 15 ). In an exemplary embodiment, the disk ( 19 ) is a brass disk. The disk may be any material that matches the desired burst pressure.
As depicted in FIG. 4 , the combustion chamber ( 1 ) is loaded with the ignition tube ( 14 ) and the firing mechanism ( 9 ). Attached to the top of the firing mechanism is a system to provide pressure to initiate the firing. Additionally, a pressure switch ( 20 ) and a plastic window are provided ( 21 ).
As depicted in FIG. 5 , a combustion containment basin ( 22 ) is provided, having a heat resistant liner, to collect the debris from the reaction for further examination. The debris generally falls into the catch basin ( 22 ). The vent on a bottom of the chamber is a rupture disk that may break away at the pressure desired. Note, the rupture disk may be changed to a disk made of a thick steel, which does not rupture.
Example 2
Operation of an Apparatus of the Invention
In operation, the pressure system is activated, which in turn initiates the firing mechanism, which ignites the ignition material, which ignites the energetic material, which bursts the burst disk. The ignited reactants enter the interior of the chamber. The instruments attached through the instrument ports collect data during the operation. Where a second energetic material, such as explosive mine rubble, is present in a cavity of the combustion chamber (not shown), the incoming ignited reactants interact with the second energetic material, thereby providing additional information to the investigator.
The apparatus as described in Example 1 was operated more than 120 times to analyze a variety of energetic materials. Metal/oxidizer reactive materials and explosives, that is, TNT, were tested using an M42 primer as the ignition material. Thirty-two operations of the apparatus included TNT rubble as a second energetic material, placed in the cavity of the combustion chamber. The amount of rubble tested was 37 grams of explosive rubble. Generally, the amount is greater based on a size of the chamber. Data was collected for the properties of temperature, pressure, and heat flux. Visible combustion products were collected in the combustion containment basin, and examined to determine relative levels of combustion for the various energetic materials. The results provided a successful screening of energetic materials for those which had superior performance in combustion of TNT rubble, i.e., ignitability, high thermal output, low pressure, and improved mine rubble consumption.
Four operations of the apparatus, the energetic material GSI Baseline OXMIET (S/N A23) “M” rated produced only partial combustion of the second energetic material, TNT rubble, with 18.1 grams remaining. NJIT ZnNaNO3 (S/N ZN4) “H” rated fared better, leaving 5.9 grams of black residue, while GSI Hafnium OXIMET (S/N A37) “H” rated left 3.5 grams of residue. By contrast, DET TFE/HFP Terpolymer (S/N 3NM-5) “L” rated left 26.5 grams unconsumed, including TNT pellets.
Based on the apparatus and operation of the invention as indicated above, FIGS. 6 , 7 and 8 provide graphs of actual test data. FIG. 6 provides data pertaining to average peak chamber temperature versus the type of material. FIG. 7 provides data pertaining to average peak chamber pressure versus the type of material. FIG. 8 provides data pertaining to average post-test TNT weight versus the type of material.
Finally, any numerical parameters set forth in the specification and attached claims are approximations (for example, by using the term “about”) that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of significant digits and by applying ordinary rounding. | The invention relates to an apparatus for evaluating energetic materials for ignitability, flamespread, pressure and thermal characteristics, energetic material interaction, and other properties. The invention is directed to an apparatus for analyzing the suitability of energetic materials for interactions with other energetic materials, explosive or non-explosive. The invention includes a vented combustion chamber, an ignition tube and a firing mechanism. The invention also includes methods for using the apparatus. For example, the apparatus of the invention may be used to analyze energetic materials for their use in destroying rubble which may contain explosive material. | 6 |
This application claims the benefit of provisional application Ser. No. 60/462,317 filed Apr. 14, 2003, the contents of which are expressly incorporated herein.
This invention was made using funds from the United States government (grant no. 1R01 DK60106-01A1). The U.S. government therefore retains certain rights in the invention.
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The invention relates to the field of cancer therapeutics and drug development. In particular it relates to cancers that express proteins of the REG pathway.
BACKGROUND OF THE INVENTION
Antitumor drugs and radiation therapy work, to a significant degree, by activation of tumor cell apoptosis (Reed, J C. et al. J. Cell. Biochem 60:23-32, 1996). Therapeutic efficacy is therefore dependent on inherent mechanisms that regulate susceptibility to apoptosis. Apoptosis is regulated by at least two pathways; mitochondrial pathways and membrane death receptors (Green D R., Science 281:1309-12, 1998, Ashkenazi A., Curr Opin Cell Bio 11:225-260, 1999, Gross, A. et al . Genes Dev 13:1899-911, 1999). Mitochondrial release of cytochrome c into the cytosol activates procaspase-9 with resulting activation of downstream effector caspases and cellular apoptosis. Activated caspases are responsible for the proteolytic events important in mediation of apoptosis. Several antiapoptotic proteins, including Bcl-2, Bcl-XL, or Bcl-W, inhibit mitochondrial release of cytochrome c and prevent alteration of the megachannel (Green D R., Science 281:1309-12, 1998, Li, P., Cell 91:479-89, 1997, Yang, J., Science 275:1129-32, 1997, Tsujimoto, Y., FEBS Lett 466:6-10, 2000).
Thus anti-apoptotic proteins can stabilize mitochondrial membrane integrity, prevent cytochrome release, and block apoptosis. These molecular events contribute to the intrinsic tumor resistance to cytotoxic drugs and radiation (Sun Y., Cancer Res 62:6323-28, 2002, Violette, S., Int. J. Cancer 98:498-504, 2002, Amundson, SA., Cancer Res 60:6101-10, 2000). In vivo studies have confirmed these concepts, showing that high Bcl-2, and/or Bcl-XL are predictive of a poor prognosis in patients with colon cancer (Ogura, E., Oncol Rep 6:365-9, 1999, and Maurer Calif., Dig Dis Sci 43:2641-8, 1998). Bcl-2-mediated inhibition of in vivo apoptosis may also prevent immunogenicity of tumors, thus contributing to a progressive, metastatic and lethal phenotype of otherwise regressive clonal variants that arise during tumor growth (Bonnotte, B., J of Immuno. 161:1433-38, 1998). Thus one component of the persistence/resistance of tumor cells with increased Bcl-2 expression may reflect a reduced capacity to induce a host immune response.
Bcl-2 can be upregulated after treatment with prostaglandins (PGE2) in tumor cells (Sheng, H., Cancer Res 58:362-366, 1998). COX-2 mediated production of PGE2 may contribute to tumor resistance, in part, by regulating anti-apoptotic gene expression. Yet, Bcl-2 levels are maintained in cells treated with NSAIDs, suggesting that up-regulation of Bcl-2 can occur independently of PGE2 (Sun Y., Cancer Res 62:6323-28, 2002). Increased expression of Bcl-2, and Bcl-XL are noted in colorectal tumors compared with histologically normal mucosa (Sinicrope F A., Cancer Res 55:237-41, 1995). Thus factors that are responsible for the up-regulation of Bcl-2 family genes in tumors appear to represent a promising and yet unexplored therapeutic avenue.
One kinase responsible for protection against apoptosis in tumor cells may be Akt/protein kinase B. Akt, also referred to as Rac regulate the balance between survival and apoptosis by several mechanisms. Akt is activated by a variety of growth factors (Burgering B T., et al. Nature 376:599-602, 1995, Franke T F., et al. Cell 81:727-36, 1995) and acts in a LY294002 (inhibitor of PI3K) and Wortmannin-sensitive pathway. Akt is activated by phospholipid binding and phosphorylation localized to at least two sites (Thr308 and Ser473). Activated Akt inactivates by phosphorylation several targets, including caspase 9, Bad, GSK3, and members of the forkhead transcription factor family. Akt overexpression has been shown to be a critical and early event during sporadic colon carcinogenesis (Roy, H K., et al Carcinogenesis 23:201-5, 2002). Furthermore, phosphorylation of Akt is required for suppression of apoptosis and tumor progression of human colorectal carcinoma (Itoh N., et al Cancer 94:3127-34, 2002). Itoh showed that expression of phosphorylated Akt (Ser473) by immunohistochemistry was correlated with depth of invasion, lymph node metastasis, and advanced tumor stage in human colorectal. Correlation with Bcl-2 expression nearly reached statistical significance as well. In this study, increased phosphorylated Akt expression was also directly correlated with an increasing growth index and a decreased apoptotic index in human tumor tissue resection specimens. Direct inhibition of the Akt pathway, such as with LY294002, may have considerable toxicity given the potential physiologic role in normal cell senescence and differentiation in the colorectal mucosa (Alessi D R., et al. Curr Biol 7:261-69, 1997, Klippel A., et al Mol Cell Biol 17:338-44, 1997) as well as other tissues. This makes determination and selective targeting of relevant tumor upstream activators of the Akt pathway theoretically preferable.
The human Reg gene family of ligands consists of four secreted and structurally unique protein that share sequence similarity with the carbohydrate-binding domain of C-type lectins ( FIG. 1 ). The initial cDNA in this gene family was named Reg for its role in islet of Langerhans regeneration following partial pancreatectomy (now known as Reg Iα). Additional members of the human Reg gene family are regenerating gene homologue (Reg Iβ) and pancreatitis-associated protein (Reg III). All are constitutively expressed in the normal proximal gastrointestinal tract. While the function of this gene family is poorly understood, recent data has suggested that Reg family members may function as tissue mitogens. Reg Iα is mitogenic for gastric mucosal cells (Fukui H., et al. Gastro 115:1483-93, 1998), and pancreatic ductal and beta cells (Zenilman, Me., et al. Gastroenterology 110:1208-14, 1996, Zenilman, Me., et al. Pancreas 17:256-61, 1998, Watanabe, T., PNAS 91:3589-92, 1994). The serum concentration of Reg Iα is significantly increased in many gastrointestinal malignancies, including gastric and pancreatic adenocarcinoma (Satomura, Y., et al. J Gastroenterology 30:643-50, 1995). For patients with early stage colonic adenocarcinoma undergoing surgical resection, Reg Iα mRNA expression alone or co-expression of Reg Iα and Reg III mRNA by the carcinoma had an adverse affect on disease free survival that was independent of tumor stage or site (Macadam, RCA., et al British J Cancer 83:188-95, 2000).
We recently identified a novel member of this gene family, Reg IV, which has significant constitutive expression in the distal gastrointestinal tract (Hartupee J C., et al BBA 1518:287-93, 2001). We showed by molecular modeling, that the Reg IV protein showed maintenance of the conserved contact surface residues that cluster on a single face of the 3-dimensional molecule present in all other members of the Reg gene family ( FIGS. 1 and 2 ). This suggests that Reg proteins may share similar physiologic actions. Reg IV is of considerable interest because of its possible role, along with other members of the Reg gene family in the pathogenesis of colorectal adenocarcinoma. Reg IV is overexpressed by a majority of colorectal adenocarcimonas. By differential display, Reg IV was among several genes with increased mRNA expression in several colon cancer cell lines selected for increased in vitro resistance to a cancer chemotherapeutic agent, 5-FU (Violette S et al, Int J. Cancer 103:185-193).
Expression of many genes is increased or decreased in gastrointestinal malignancy as compared with the normal gastrointestinal mucosa. This correlation does not provide a causative association (e.g., apoptosis resistance or malignant phenotype). In fact most differentially regulated genes will not serve an integral role in the malignancy process or offer a currently recognizable therapeutic intervention. There is a need in the art to identify genes that do serve an integral role in the malignancy process and which will offer therapeutic interventions.
BRIEF SUMMARY OF THE INVENTION
In a first embodiment of the invention an antisense construct is delivered to a tumor cell. The construct comprises at least 15 nucleotides of the complement of a rat, mouse, or human Reg gene family cDNA selected from the group consisting of RegIα, RegIβ, RegIII, RegIV, and EXTL3. As a result of the delivery, the tumor cell expresses an mRNA molecule which is complementary to native mRNA of the Reg gene.
In a second embodiment of the invention an RNA interference construct is delivered to a tumor cell. The construct comprises at least 19 nucleotides of a rat, mouse, or human Reg gene family cDNA selected from the group consisting of RegIα, RegIβ, RegIII, RegIV, and EXTL3. As a result of the delivery, the tumor cell expresses a double stranded RNA molecule which is complementary to native mRNA of the Reg family gene.
According to a third embodiment of the invention a method is provided for causing cleavage of a Reg gene mRNA produced by a tumor cell. A siRNA is delivered to the tumor cell. The siRNA comprises 19 to 21 bp duplexes of a rat, mouse, or human Reg gene family RNA selected from the group consisting of RegIα, RegIβ, RegIII, RegIV, and EXTL3. The siRNA has 2 nt 3′ overhangs.
According to a fourth embodiment of the invention a method is provided for identifying a test substance that inhibits binding of a Reg protein to the EXTL3 protein. A rat, mouse, or human EXTL3 protein is contacted with a rat, mouse, or human Reg protein in the presence and in the absence of a test substance. The Reg protein is selected from the group consisting of RegIα, RegIβ, RegIII, and RegIV. Binding of the Reg protein to the EXTL3 protein is determined in the presence and in the absence of a test substance. A test substance which inhibits binding of the Reg protein to the EXTL3 protein is identified.
According to a fifth embodiment of the invention an inhibitor is delivered to a tumor cell. The inhibitor inhibits the binding of a rat, mouse, or human EXTL3 protein to a rat, mouse, or human Reg protein selected from the group consisting of RegIα, RegIβ, RegIII, and RegIV. Resistance to apoptosis by the tumor cell is thereby reduced.
According to a sixth embodiment of the invention an antibody is delivered to a tumor cell. The antibody specifically binds to a rat, mouse, or human Reg family protein selected from the group consisting of RegIα, RegIβ, RegIII, RegIV, and EXTL3. Binding of EXTL3 to a Reg gene in the tumor cell is thus inhibited.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 show the Reg gene family members in human and mouse.
FIG. 2 shows a comparison of the amino acid sequences of the Reg gene family members. (SEQ ID NO: 1-4).
FIG. 3 shows Reg gene mRNA expression in human colorectal cancer specimens.
FIG. 4 shows Reg 1a and Reg IV constitute the major Reg expression in colorectal cancer.
FIG. 5 shows Reg expression in individual tumors.
FIG. 6 shows Reg expression outside the normal murine gastrointestinal tract.
FIG. 7 shows Reg expression in the normal murine gastrointestinal tract.
FIG. 8 shows that 4 week min mice have significantly increased Reg expression.
FIG. 9 shows Reg expression in adenomas from 14 week min mice.
FIG. 10 shows Reg expression in 14 week min mice (normal appearing mucosa and tumor) versus wild-type mice.
FIG. 11 shows that human colorectal adenocarcinomas express abundant Reg IV protein.
FIG. 12 shows Bcl-2 and Bcl-XI expression in 14 week min mice and wild-type mice.
FIG. 13 shows that tumors expressing increased Reg IV also had increased Bcl-2.
FIG. 14 shows production of recombinant human Reg IV.
FIG. 15 shows dose-dependent induction of Bcl-2 mRNA by recombinant human Reg IV.
FIG. 16 shows the effect on other colorectal cell lines of recombinant human Reg IV.
FIG. 17 shows that Bcl-2 is increased in tumor (adenomas) from APC min mice.
FIG. 18 shows induction of Bcl-2 protein in HCT-116 cells by recombinant human Reg IV.
FIG. 19 shows activation of Akt in HCT-116 cells by recombinant human Reg IV.
FIG. 20 shows dose-dependent activation of the Akt kinase pathway by Reg Iα.
FIG. 21 shows that recombinant human Reg IV protects against peroxide-induced apoptosis.
FIG. 22 shows the development of Reg IV specific antibodies.
FIG. 23 shows expression of Reg IV in normal intestine.
FIG. 24 shows increased expression of Reg IV in human colorectal cancer.
FIG. 25 shows morphologic changes in the mouse intestinal epithelium following γ-irradiation.
FIG. 26 shows induction of Reg-R ligands in the radiation model of mucosal regeneration.
FIG. 27 shows that recombinant Reg Ia promotes stem cell survival following radiation.
FIG. 28 shows that recombinant human Reg IV promotes stem cell survival following radiation.
FIG. 29 shows that Bcl-xl/xs is upregulated in HT-29 cells following treatment with recombinant human Reg Ia.
FIG. 30 shows validation of Bcl-xl and Bcl-2 upregulation by recombinant Reg Ia.
FIG. 31 shows that Reg Ia promotes survival of HT-29 cells following gamma irradiation.
FIG. 32 shows that recombinant human Reg IV protects against radiation-induced tumor cell death.
FIG. 33 shows that treatment of colorectal adenocarcinoma cells with one Reg protein leads to increased expression of other family members.
DETAILED DESCRIPTION OF THE INVENTION
One of the problems with functional genomics is the sheer mass of data that are accumulated. For example, one can identify many genes whose expression varies under certain pathological conditions, but such variation does not imply a causative role for the genes identified. Functional studies must be devised to determine whether a gene whose expression varies is a relevant gene in the pathological condition. The present inventors have found that the Reg family of genes (broadly defined to include both the Reg ligands and their receptors) plays an important and deleterious role in the neoplastic process. In particular, the Reg family has been found to be involved in resistance to apoptosis inducing agents including anti-cancer therapeutic agents, such as chemotherapeutic agents and radiation.
Since the Reg family plays a deleterious role in the health of the cancer patient, is expressed rarely or at significantly lower levels in normal tissues, and is an extracellular protein family, it is an excellent target for therapeutic intervention. The Reg family functions by binding to a cell surface receptor, thought to be EXTL3. Thus, antagonism of the binding reaction of the ligand and receptor, or antagonism of expression of either the ligand or receptor can provide a therapeutic modality.
In order to antagonize the binding of either the ligand or receptor, an antibody can be used. The term “antibody” as used herein includes both monoclonal and polyclonal antibodies, as well as antibody portions or derivatives that contain the variable region of an antibody. Such portions or derivatives include, but are not limited to, single chain Fv (ScFv), Fab, F(ab′) 2 , and Fv. Also included are conjugates that present the variable region on a framework of another molecule. The antibody specifically binds to a Reg family ligand or receptor, preferably binding far less to other unrelated proteins. The binding to a desired Reg family target and to other proteins preferably differs by at least a factor of 10 2 , 10 3 , 10 4 , 10 5 , or 10 6 . Antibodies have long been administered to humans for a variety of purposes. Any method of administration known in the art can be used in the context of the present invention, including but not limited to intravenous, intraperitoneal, subcutaneous, intramuscular, intranasal, intrabronchial, intratumoral, and per os administration.
Additionally non-steroidal anti-inflammatory drugs (NSAIDs) and COX-2 inhibitors in particular can be administered to the tumor cell. Such drugs include indomethacin, naproxen, ibuprofen, naproxen, aspirin, celecoxib, diclofenac, etodolac, fenoprofen, ketoprofen, ketoprofen, ketoralac, oxaprozin, nabumetone, sulindac, tolmetin, valdicoxib (Bextra®) and rofecoxib. These can be administered simultaneously with the antibodies or before or after, preferably within 1 day, 1 week, or 1 month of the antibodies.
Therapeutic radiation can also be administered to the same tumor cell (or if in a patient, to the same cancer patient). Similarly anti-cancer chemotherapeutic agents can be administered to the same tumor cell or cancer patient. Such agents include: x-rays, cisplatin (Platinol®), daunorubicin (Cerubidine®), doxorubicin (Adriamycin®), etoposide (VePesid®)), methotrexate (Abitrexate®), mercaptopurine (Purinethol®), fluorouracil (Adrucil®), hydroxyurea (Hydrea®), Vinblastine (Velban®), Vincristine (Oncovin®), Irinotecan (Camptosar®, CPT-11), Levamisole, selective epidermal growth factor receptor tyrosine kinase inhibitors (e.g. ZD1839, Iressa®) and Pacitaxel (Taxol®). Preferably the agents co-administered with the antibodies are ones that induce apoptosis.
The types of tumors and tumor cells that are good targets for the treatments of the present invention include those of the non-squamous gastrointestinal tract (e.g. esophageal, gastric, small intestine, colon and rectal adenocarcinomas), the hepatobiliary tract and the pancreas. Suitable tumor targets also include ovarian, brain, prostate, breast, germ cell tumors, papillary serous carcinoma, lung carcinoma, acute myelogenous leukemia, B-cell chronic lymphocytic leukemia, insulinoma, prostate adenocarcinoma, fibrosarcoma, juvenile granulosa tumor cells. Other tumor cells, especially those which express members of the Reg gene ligand and receptor family can be targeted.
Similar to the antibody-type therapeutic agents, antisense constructs, small interfering RNAs (siRNAs), antisense oligonucleotides, and RNA interference constructs can be used to increase apoptosis in cancer cells. These agents function by preventing or interfering with expression of the Reg gene family of ligands and receptor. The use of such agents is well known in the art.
Antisense constructs, antisense oligonucleotides, RNA interference constructs or siRNA duplex RNA molecules can be used to interfere with expression of any of the members of the Reg gene ligand and receptor family. Typically at least 15, 17, 19, or 21 nucleotides of the complement of the selected mRNA sequence are sufficient for an antisense molecule. Typically at least 19, 21, 22, or 23 nucleotides of the selected RNA are sufficient for an RNA interference molecule. Preferably an RNA interference molecule will have a 2 nucleotide 3′ overhang. If the RNA interference molecule is expressed in a cell from a construct, for example from a hairpin molecule or from an inverted repeat of the desired Reg gene family sequence, then the endogenous cellular machinery will create the overhangs. siRNA molecules can be prepared by chemical synthesis, in vitro transcription, or digestion of long dsRNA by Rnase III or Dicer. These can be introduced into cells by transfection, electroporation, or other methods known in the art. See Hannon, G J, 2002, RNA Interference, Nature 418: 244-251; Bernstein E et al., 2002, The rest is silence. RNA 7: 1509-1521; Hutvagner G et al., RNAi: Nature abhors a double-strand. Curr. Opin. Genetics & Development 12: 225-232; Brummelkamp, 2002, A system for stable expression of short interfering RNAs in mammalian cells. Science 296: 550-553; Lee NS, Dohjima T, Bauer G, Li H, Li M-J, Ehsani A, Salvaterra P, and Rossi J. (2002). Expression of small interfering RNAs targeted against HIV-1 rev transcripts in human cells. Nature Biotechnol. 20:500-505; Miyagishi M, and Taira K. (2002). U6-promoter-driven siRNAs with four uridine 3′ overhangs efficiently suppress targeted gene expression in mammalian cells. Nature Biotechnol. 20:497-500; Paddison P J, Caudy A A, Bernstein E, Hannon G J, and Conklin D S. (2002). Short hairpin RNAs (shRNAs) induce sequence-specific silencing in mammalian cells. Genes & Dev. 16:948-958; Paul C P, Good P D, Winer I, and Engelke D R. (2002). Effective expression of small interfering RNA in human cells. Nature Biotechnol. 20:505-508; Sui G, Soohoo C, Affar E-B, Gay F, Shi Y, Forrester W C, and Shi Y. (2002). A DNA vector-based RNAi technology to suppress gene expression in mammalian cells. Proc. Natl. Acad. Sci. USA 99(6):5515-5520; Yu J-Y, DeRuiter S L, and Turner D L. (2002). RNA interference by expression of short-interfering RNAs and hairpin RNAs in mammalian cells. Proc. Natl. Acad. Sci. USA 99(9):6047-6052.
Antisense or RNA interference can be delivered in vitro to tumor cells or in vivo to tumors in a mammal. Typical delivery means known in the art can be used. For example, delivery to a tumor can be accomplished by intratumoral injections. Other modes of delivery can be used without limitation, including: intravenous, intramuscular, intraperitoneal, intraarterial, subcutaneous, and per os. Conversely in a mouse model, the antisense or RNA interference can be administered to a tumor cell in vitro, and the tumor cell can be subsequently administered to a mouse. Vectors can be selected for the desirable properties for any particular application. Vectors can be viral or plasmid. Non-viral carriers such as liposomes or nanospheres can also be used.
Additional therapeutic agents or candidate therapeutic agents can be identified using a binding assay. The assay can be performed in vitro using purified proteins, or using whole cells. A Reg gene family ligand protein is contacted with EXTL3 protein, in the presence and absence of a test substance. The order of the contacting can be varied. All components can be, but need not be simultaneously contacted. Pairs of reagents can be pre-bound, for example, and displacement by a third reagent can be assessed. The test substances can be natural products or synthetic products; they can be single compounds or combinations of compounds. They can be known or unknown for another use. They can be pre-selected based on structural similarities to other compounds, or they can be screened randomly. Any binding assay known in the art can be used. A two-hybrid type assay can be used in which expression of a reporter gene is dependent on the binding of two binding partner proteins. Alternatively, one of the binding partners may be bound to a solid support. One binding partner can be labeled. Bound or unbound complexes can be separated from the assay mixture, for example, using immunoprecipitation. Another assay utilizes cells which express one of the binding partners on their cell surface and the other binding partner is added exogenously. Any format for assessing binding between two proteins can be used. Once a binding inhibitor of the Reg gene family ligand and receptor has been identified, it can be used therapeutically to treat tumor cells and tumors. The inhibitor can be administered by any route, particularly intravenous, intramuscularly, subcutaneously, and per os.
All cited references are expressly incorporated herein in their entireties for all purposes. While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the spirit and scope of the invention as set forth in the appended claims.
EXAMPLES
Example 1
Expression of Reg Genes in Humans
Reg gene expression was examined in 10 human colorectal adenocarcinoma specimens ( FIGS. 3 and 4 ). Gene expression was measured using individual Reg-specific Taqman probe and primer sets in tumors and paired adjacent normal mucosa. FIG. 3 shows expression of the four individual human Reg mRNAs expressed as fold increase over expression in the normal colonic mucosa. Significant increases in the average Reg Iα, Reg Iβ, Reg III, and Reg IV were shown. FIG. 4 shows that Reg IV is the predominant Reg gene expressed in normal colonic mucosa. While tumorigenesis was accompanied by increases in all Reg genes, Reg Iα and Reg IV constitute the dominant Reg genes expressed in colorectal adenocarcinoma. FIG. 5 shows Reg expression (as a fold increase) in individual tumor specimens relative to the expression in the paired adjacent normal mucosa. Marked upregulation of Reg IV or de novo expression of another Reg member was universally present in each specimen. Each tumor demonstrated a unique mixture of Reg gene overexpression. 70%, 60%, 90%, and 40% of tumors show increases in Reg IV, Reg III, Reg Iα, and Reg Iβ greater than 1.5 fold over adjacent normal mucosa, respectively. No clear correlation with a particular histopathology or tumor stage was evident. In addition to expression in gastrointestinal malignancy, review of Unigene (Reg Iα, Hs.449407 (old number Hs.1032); Reg Iβ, Hs.4158; Reg III (PAP), Hs.423; Reg IV, Hs.105484) revealed expression in additional malignancies including germ cell tumors, papillary serous carcinoma, lung carcinoma, acute myelogenous leukemia, B-cell chronic lymphocytic leukemia, insulinoma, prostate adenocarcinoma, fibrosarcoma, juvenile granulose tumor.
Example 2
Expression of Reg Genes in Mouse
Reg gene expression was characterized in the normal mouse to allow further study in well-defined murine tumorigenesis models ( FIG. 6 and 7 ). Undetectable or low levels of the seven known murine Reg family members (listed in FIG. 1 ) were present in most non-gastrointestinal tissues. FIG. 6 , showing tissues outside the luminal GI tract (with ileum as a reference on both FIGS. 6 and 7 ) reveals significant expression in the spleen and pancreas. The columnar gastrointestinal tract, shown in FIG. 7 , in contrast, reveals distinct region-specific expression profiles for individual members of the murine gene family along the cranio-caudal axis (e.g. prominent Reg I expression in the proximal, Reg IIIγ and Reg IIIβ in the mid, and Reg IV in the distal gastrointestinal tract).
The APC (min) murine genetic model [APC(min/+)] of human gastrointestinal malignancy was studied to determine when Reg gene expression becomes dysregulated during tumorigenesis. Mutation of both copies of the APC gene is an early event in human colorectal cancer. Four week old min mice are heterozygous for the wild type APC gene despite a morphologically normal appearing epithelium. Tumors develop after a second spontaneous mutation occurs in the remaining normal copy of the APC gene. FIG. 8 shows that four week old mice have significantly increased Reg expression (1=normal mucosa). These results suggest that increased Reg may act as a tumor promoter or play a causative role in determining the malignant phenotype. At 14 weeks, visible adenomas [genotype (min/min)] were dissected along with a paired sample from nearby normal appearing mucosa [genotype (min/+) or (min/min)]. FIG. 9 shows gene expression in individual min tumors. COX-2 overexpression was used as a marker for successful adenoma isolation (increased seen in all but sample 19). Reg IV was most commonly increased in tumors, yet like human colon cancer specimens, individual tumors displayed unique patterns of Reg gene expression. FIG. 10 shows the alterations in Reg gene expression resulting from a APC (min) gene dose effect. This figure compares (A) normal litermate controls [APC (+/+)], (B) normal appearing 14 week mucosa [APC (min/+) or (min/min)], and (C) gross adenomas [APC (min/min)] in the proximal jejunum (PJ), ileum (IL), and colon. Increased expression for individual Reg genes occurred progressively in a region-specific fashion. FIG. 12 shows that this APC gene dosage effect was seen with the expression of anti-apoptotic genes Bcl-2, Bcl-xl, and COX-2. Patients with familial adenomatous polyposis (FAP), characterized by mutation in the APC gene also show significant upregulation of Reg IV (our data, not shown). These results collectively suggest that the APC min mouse is a valid model for the study of human colorectal malignancy.
Example 3
Correlation of Reg IV and Bcl-2 Expression
FIG. 11 shows that human colorectal adenocarcinomas express abundant Reg IV protein, paralleling increases described above for Reg IV mRNA. This expression was demonstrated by Western blot using monospecific anti-Reg IV antibody (also see FIG. 22 ). The possible relationship between increased Reg IV and increases in Bcl-2 mRNA. FIG. 13 shows that tumors specimens with increases in Reg IV mRNA (as a fold change compared with normal adjacent mucosa) also had increased levels of Bcl-2 mRNA. This data shows a close correlation between Reg IV overexpression and tumor expression of Bcl-2, an antiapoptotic protein.
Example 4
Functional Relationship Between Reg and Bcl Genes
To determine if the relationship between increased Reg IV and antiapoptotic gene expression was causative or simply correlative, we expressed recombinant Reg Iα, Reg III, and Reg IV by fermentation in Pichia pastoris . Details of the recombinant human Reg IV protein production and purification are outlined in Example 11 and FIG. 14 . Reg Iα and Reg III were expressed and purified in the same manner using methanol induction, centrifugation, sequential applications of tangential flow filtration/ultrafiltration followed by preparative HPLC. FIG. 14 (left) shows results of the fermentation of Pichia pastoris expressing recombinant human Reg IV using an optimized fed-batch protocol. Plotted parameters show the dissolved oxygen concentration (dO2, ♦) and wet cell weight (¤) during 144 hours of culture. The initial batch phase growth occurred in media containing 40 g/liter glycerol. Following a marked rise in dO2 occurring as a result of carbon source limitation at around 26 hrs, the glycerol fed-batch process was initiated. Glycerol was provided at 40 mls/hr for 14 hours to induce rapid expansion of the Pichia cell mass. Production phase was initiated by methanol feeding after a 3 hr carbon-source starvation. The rate of methanol feeding was slowly ramped up over 8 hours as described in methods and continued until 134 hours.
FIG. 14 (right) shows the analysis of recombinant human Reg IV by SDS-PAGE. Clarified culture supernatants were sampled at various times during the fermentation run and analyzed by Coomassie blue stained gels. Samples taken at approximately 24 and 48 hrs were during growth on glycerol, and at 72, 96, 120, and 144 hrs were after activation of the alcohol oxidase (AOXJ) promotor by methanol induction. Arrows indicate bands corresponding to the expected size of human Reg IV at 15.6 kDa. Western blot of a duplicate gel after immunostaining with 2H6, a monoclonal raised against recombinant human Reg IV. Bands were visualized by enhanced chemiluminescence (ECL, Amersham).
FIG. 15 shows that treatment with recombinant Reg IV results in a dose-dependent induction of Bcl-2 in HT29 colon cancer cells. Additional colorectal cell lines were also examined to determine if this was a generalized effect on gastrointestinal cells. Bcl-2 induction also followed treatment with Reg IV in SW480 and HCT116 cells. To determine if the increases in Bcl-2 mRNA also were associated with changes in Bcl-2 protein expression, Western blotting was performed on cell lysates taken at various times following Reg treatment. FIG. 18 shows that by 2 hours after Reg IV treatment, Bcl-2 is significantly upregulated at a protein level. FIG. 29 and 30 show that recombinant Reg Iα results in increased expression of Bcl-xl and Bcl-2. These results suggest that exogenous Reg proteins causally regulate the expression of anti-apoptotic genes. These results are particularly impressive given the endogenous production of Reg proteins occurring in gastrointestinal malignancy and further demonstrates the utility of therapeutic strategies designed to interrupt Reg signaling in gastrointestinal malignancy.
Increased expression of Bcl-2 in tumor adenomas provides additional support for the role of increased antiapoptotic proteins in tumor behavior. FIG. 17 shows immunohistochemistry using anti-Bcl-2 antibody on normal and adenoma tissues. Although not easily appreciated in this black and white picture, Bcl-2 expression in the normal intestine is restricted to the immune cell population in the lamina propria. In tumor sections, diffuse cytoplasmic staining is appreciated throughout the adenoma epithelium.
Example 5
Functional Relationship Between Akt and Reg IV
One kinase responsible for protection against apoptosis in tumor cells may be Akt/protein kinase B. Akt, also referred to as Rac, regulates the balance between survival and apoptosis by several mechanisms. Akt may regulate the expression of anti-apoptotic proteins. Because of the effect of Reg on the regulation of Bcl-2 (and Bcl-xl, discussed later), we examined the effects of recombinant Reg IV and Reg Iα on the activation of the Akt pathway. FIGS. 19 and 20 show that nanomolar concentrations of recombinant Reg results in rapid activation by phosphorylation of Akt in colon cancer cell lines (HCT116, HT29) and gastric cancer cells (N87). These data support the role of Reg proteins in the activation of the Akt pathway in gastrointestinal malignancies. Activated Akt has known pleiotropic effects (beyond effects on Bcl-2 family gene expression), reducing the amount of apoptosis occurring either at baseline or in response to a known proapoptotic stimulus. Thus our results suggest that interruption of the downstream effects of Reg proteins (e.g., upregulation of anti-apoptotic gene expression and activation of Akt) would increase tumor cell death at baseline or in response to therapies that result in enhanced apoptotic cellular death (e.g., radiation and chemotherapeutic agents).
Example 6
Immunohisotchemical Localization of Reg IV Expression
Expression of Reg IV in the normal intestine and upregulation of epithelial expression in colorectal malignancy are shown in FIGS. 23 and 24 . FIG. 23 shows the identification of Reg IV protein expression in the normal gastrointestinal mucosa. Paraffin embedded sections of normal human ileum were subjected to immunohistochemical analysis using the TSA-indirect tyramide immunostaining kit (NEN Life Science, Boston, Mass.). The 2H6 anti-human Reg IV monoclonal antibody (A, B, C) reacted with the 1-2 epithelial cells per crypt. Immunoreactive cells were typically located 2-10 cell positions from the base of the crypt (arrowhead). Rabbit polyclonal anti-P4261 (E, F). Anti-P4262 showed identical staining patterns (not shown). FIG. 24 shows epithelial staining from 3 sections of colorectal carcinoma.
Development of monospecific monoclonal and polyclonal antibodies to Reg IV are described in example 3 and shown in FIG. 22 . FIG. 22 details the immunologic studies showing (22A) identification of recombinant human Reg IV with affinity-purified Rabbit anti-peptide antibodies, and (22B) specificity of individual antibodies for Reg IV by Western blot. In panel A, rabbit antibodies at 2 μg/μl were preincubated for 1 hour in blocking buffer alone, or in blocking buffer containing either 0.1 μg/μl of peptide P4261 or P4262 before use in Western Blot. In panel B, specificity of the two individual rabbit anti-peptide antibodies and 2H6, a hamster anti-human Reg IV monoclonal antibody, were determined by Western blot using ˜0.5 μg of recombinant human Reg IV, Reg III, or Reg Iα.
Example 7
Function of Reg Proteins
FIG. 21 shows that nanomolar concentrations of recombinant Reg Iα result in reduced caspase activity in HT29 lysates following an oxidative stress (treatment with hydrogen peroxide).
Example 8
Reg Exression Response to Irradiation
Gamma irradiation is a well-defined pro-apoptotic stimulus and is a commonly applied experimental approach to study intestinal epithelial cell death. FIG. 25 shows the morphologic changes that occur at specific times in the intestine in response to gamma irradiation. At 6 hours marked apoptosis is seen in the crypt epithelium. By 24 hours, there is a loss of epithelial proliferation. Regenerating crypts, counted at 84 hours, are reflective of a single surviving stem cell. By 144 hours the intestinal epithelium shows restoration of the normal architecture. FIG. 26 shows that radiation results in up-regulation of endogenous Reg gene expression in the intestine.
Example 8
Functional Effect of Reg Proteins on Intestinal Stem Cells and Cancer Cells
Stem cells and their immediate progeny are the only cells in the normal epithelium that are capable of continued proliferation. In this context, epithelial malignancies may reflect a form of disordered stem cell biology. FIGS. 27 and 28 show the effect of exogenous Reg proteins on the survival of intestinal stem cells following 13 Gy radiation. Pretreatment with recombinant Reg Iα and Reg IV lead to significantly increased stem cell survival. The results suggest that the multiple anti-apoptotic effects of Reg proteins provide functional protection from a well-defined pro-apoptotic stimuli in normal epithelium. Reg expression is upregulated in gastrointestinal cancer, where current literature supports a functional resistance to apoptotic stimuli. We therefore conducted experiments to see if exogenous Reg would promote the survival of colorectal adenocarcinoma cells in response to gamma radiation. These results (shown in FIGS. 31 and 32 ) show that nanomolar concentrations of Reg Iα and Reg IV lead to improved cell survival from gamma radiation.
Example 9
Reg Gene Family Cöordinate Autoregulation
Our results above suggest that a number of the functional properties of Reg IV are also shared by Reg Iα, the most dissimilar member of the family (nucleotide/protein sequence similarity). One explanation for this finding could be that a single Reg protein can upregulate expression of other members of the Reg family. FIG. 33 shows that treatment of a number of colon cancer cell lines (e.g. HT29, SW480, T84) with recombinant Reg proteins (e.g. Reg Iα, Reg III, and Reg IV) leads to the upregulation of mRNA coding for other members of the Reg gene family. These results suggest that one should focus on the collective gene family in the design of a therapeutic to disrupt Reg signaling in malignancy.
Example 10
Isolation of a Reg receptor
A cell surface receptor has been identified for Reg I. We isolated a ˜110 kDa cell surface protein present on two rat cell lines which were mitogenically stimulated by recombinant Reg I. A cell surface receptor for rat pancreatic stone protein of ˜110 kDa was isolated using interaction cloning ( 125 I-labeled Reg I used to probe an islet xZAP II cDNA expression library) (Kobayashi S., et al. JBC 275:10723-26, 2000). The encoded rat protein sequence was >97% identical to a previously cloned human gene, EXT-like gene 3 (EXTL3), also known as EXT related gene 1 (EXTR1). EXTL3 is a member of a new gene family that is highly conserved from Caenorhabditis elegans to higher organisms. The idea that this molecule may be a Reg receptor is unexpected since this gene family was not thought to contain cell surface receptors or to have a role in cell surface signaling. Our data support that EXTL3 is the Reg receptor since we isolated it by Reg- specific affinity chromatography.
The first 332 amino acids of EXTL3 contain the Reg I recognition domain (the portion of the molecule represented in the original cDNA clone, Kobayashi et al.) By peptide phage display, we have also demonstrated that Reg is predicted to interact with a short peptide sequence represented in the amino terminal portion of the molecule. No data are available concerning receptor binding by other members of the Reg gene family (i.e., Reg Iβ, Reg III and Reg IV). A search using the standard BLAST algorithm has not revealed any additional genes with significant homology to this predicted Reg I binding domain. Furthermore, this domain seems to be uniquely present in EXTL3, but not in the other members of the exostoses family. Characterization of rat EXTL3 shows it to be a 919 amino acid protein, predictive of a type II transmembrane protein with a short intracellular domain (residues 1-28), a transmembrane domain (residues 29-51), and a long extracellular domain (residues 52-919). The intracellular domain of this molecule lacks known signaling motifs that would be expected for a functional receptor. This suggests that this molecule may not be the complete Reg signaling complex.
Example 11
Production, Purification, and Characterization of Recombinant Reg IV
We recently identified Reg IV, a novel regenerating gene product that is uniquely expressed by the normal distal gastrointestinal mucosa. The function remains poorly understood due to the lack of significant purified Reg IV for biochemical and functional studies. Recombinant human Reg IV was efficiently expressed under the control of the AOX1 gene promoter in Pichia pastoris using the Mut S strain KM71H. We describe the unique conditions that are required for efficient production of Reg IV protein in high density fermentation. Optimal protein expression was obtained by reduction of the fermentation temperature and addition of casamino acids as a supplemental nitrogen source and to minimize the activity of yeast produced proteases. Recombinant Reg IV protein was purified by tangential flow filtration and reverse phase chromatography. The purified protein was characterized by amino terminus sequence analysis and MALDI-TOFMS showing that the engineered protein had the expected sequence and molecular weight without secondary modification. Recombinant Reg IV was further characterized by specific monoclonal and polyclonal reagents that function for Western Blot analysis and for immunolocalization studies.
Materials and Methods
Vectors, Strains and Supplies: The pPICZα vector (Invitrogen) was used to direct secretion of human Reg IV. The pGEM-T Easy vector (Promega) was used to clone and sequence the PCR product. Escherichia coli DH5α was used for subdloning and Reg IV-pPICZα vector cloning. The Pichia pastoris strain KM71H (genotype, arg4 aox1::ARG4) was used for Reg IV protein expression. Preparative-scale (Pellicon 2) Biomax polyethersulfone cartridges with an 8 kDa and 50 kDa molecular weight cutoff and Durapore cartridges with a 0.45 μM pore size were purchased from Millipore. Antifoam 204 (Sigma) was autoclaved and used at a 1:50 dilution. Components of the trace mineral solution [Fe 2 (SO 4 )-7H 2 O, 65 gm/liter; ZnSO 4 , 42.2 gm/liter; CuSO 4 -5H 2 O, 6 gm/liter; MnSO 4 -H 2 O, 3 gm/liter; CoCl 2 -6H 2 O, 0.5 gm/liter; Na 2 MoO 4 -2H 2 O, 0.2 gm/liter; NaI, 0.08 gm/liter; H 3 BO 3 , 0.02 gm/liter] were purchased from Sigma.
Construction of the human regenerating gene IV expression vector: The cloning and cDNA sequence for human Reg IV has been previously reported. The cDNA encoding the mature secreted form of Reg IV, lacking the signal sequence, was amplified by PCR using the specific primers 5′-GGAATTCGATATCATCATGAGACCCAGCTG-3′ (SEQ ID NO: 7) and 5′-CTAACTCCTGCACAGCCCCGTCCTCTAGAGG-3′ (SEQ ID NO: 8). The forward primer contained an EcoR I site for cloning into pPICZα. The reverse primer incorporated the native stop codon and an engineered Xba I site. PCR products and vector were digested with EcoR I and Xba I, gel purified and ligated together. E. ccli DH5α was chemically transformed with the recombinant vector and cultured at 37° C. on low-salt LB with Zeocin (25 μg/ml) for selection of recombinants. The recombinant plasmid hReg IV-pPICZα was sequenced to ensure 100% identity with the expected nucleotide sequence and in-frame orientation.
Construction and Isolation of Reg IV expressing P. pastoris clones: The hReg IV-pPICZα plasmid was purified and linearized with Sal I prior to electroporation into P. pastoris KM71H. Yeast transformants were selected on YPD agar plates (2% Bacto peptone, 1% yeast extract, 2% dextrose) containing 1M sorbitol and 100 μg/ml Zeocin. Individual Zeocin resistant clones were screened for protein production in 50 ml culture tubes. Colonies were used to innoculate 5 mls of BMGY media and grown with shaking overnight. Subsequently the yeast were collected by centrifugation and resuspended in ¼ th of the original culture volume of BMMY media. Fresh methanol was added to 0.5% every 24 hours and cells were cultured for a total of 72 hours at 30° C. with shaking. Cleared supernatants were screened for protein expression by 12% SDS-PAGE and Coomassie brilliant blue R250 staining. Reg IV expressing Pichia clones were suspended in YPD media with 15% glycerol and stored at −80° C. Limited quantities of recombinant Reg IV were produced by direct scale up of these conditions in 2 liter shaker flasks.
Fermentation: Fermentation of the hReg IV (Mut s ) transformant of P. pastoris was carried out using a BioFlo 110 fermenter (New Brunswick Scientific Co.) equipped with software control (BioCommand Plus) of temperature (26 and 30° C.), agitation (1000 rpm), pH, anti-foam addition, supplemental oxygen addition (dO 2 ≧30% and ≧25%) and data logging. A frozen stock of KM71H containing the expression construct Reg IV-pPICZα was used to inoculate a 2 liter baffled flask containing 300 mls of YNB-glycerol media. After overnight incubation, the shaker flask contents were transferred to the 5.6 liter working volume fermenter containing 3.5 liters of fermentation basal salt-glycerol media [H 3 PO 4 , 27 ml/liter; CaSO 4 -2H 2 O, 0.9 gm/liter; K 2 SO 4 , 18 gm/liter; MgSO 4 -7H 2 O, 15 gm/liter; KOH, 4.1 gm/liter; glycerol 40 gm/liter; D-biotin, 0.87 mg/liter] supplemented with 4.4 ml/liter trace mineral solution. pH was maintained at 5.0 with 28% (w/v) NH 4 OH during batch and fed-batch growth on glycerol. Growth in batch mode was continued until the dissolved oxygen concentration increased as a result of carbon source limitation (26 hours). A 50% glycerol feeding solution was initiated (40 mL/hour) for 14 hours and supplemental oxygen automatically administered to maintain the dissolved oxygen concentration above 30%. After 3-4 hour carbon source starvation, methanol feeding was initiated (100% methanol containing 12 ml trace minerals/liter) at 4 ml/hour for 2 hours, and the feed rate then increased by 2.7 mls every 2 hours to a final rate of 12 muhour. At the initiation of the 96 hour production phase, and again after 24 hours, 10 grams of casamino acids (DIFCO laboratories) were added as a supplemental nitrogen source and to minimize the activity of yeast produced proteases. During the production phase, the temperature of the reaction chamber was reduced to 26° C. and supplemental oxygen was added as needed to maintain the dO 2 ≧25%. Similar protocols were applied to the production and purification of Reg Iα and Reg III.
Protein Purification and Analysis: Fermentation broth containing the secreted rHuReg IV protein was collected by centrifugation (3500 rpm). The supernatant was processed in a Millipore Pellicon-2 tangential flow filtration apparatus using a PVDF Durapore membrane with a pore size of 0.45 μM. The filtrate was retained and processed through a Biomax 50K polyethersulfone membrane. This filtrate was then processed through a Biomax 8K polyethersulfone membrane. The final purification step involved preparative reverse phase HPLC of the 8K retentate solution [Biomolecules Midwest (Waterloo, Ill.)]. Samples were eluted using a gradient of trifluoracetic acid, acetonitrile. Selected fractions were analyzed by Matrix Assisted Laser Desorption Ionization Time-of-Flight Mass Spectrometry (MALDI-TOFMS) on an Applied Biosystems Voyager-DE STR instrument (Foster City, Calif.). Additional samples were subjected to SDS-PAGE. Proteins were transferred to PVDF membrane and Coomassie stained. Individual bands were excised and subjected to Edman N-terminal sequence analysis on a PE-Biosystems Procise ABI494 (Foster City, Calif.).
Generation of polyclonal anti-Reg IV antibodies. Rabbit polyclonal anti-Reg IV specific antibodies were produced by immunization with KLH-coupled synthetic peptides. Synthetic peptides, RSWSGKSMGGNKHC (corresponding to residues 94-107), with a native C-terminal Cysteine and TIAEYISGYQRSQPC (residues 56-69), containing a non-native C-terminal Cysteine were synthesized by Biomolecules Midwest (Waterloo, Ill.) and coupled to maleimide-KLH (Pierce). Polyclonal antisera were produced by Harlan Bioproducts (Indianapolis, Ind.) using their standard rabbit protocol. Antibody titer was determined in a microtiter plate ELISA using Reg IV as the immobilized antigen. Immunoglobulins were affinity purified by peptide-sulfolink resin (Pierce). Final antibody concentrations were determined by BCA Assay (Pierce).
Monoclonal antibody production, ELISA, and Western Blot analysis: Armenian hamster monoclonal antibodies were produced to rHuReg IV at the hybridoma center at Washington University using standard protocols (e.g., URL address: http file type, domain name pathbox.wustl.edu, directory ˜hcenter). Briefly, a primary subcutaneous immunization was given using 100 micrograms of recombinant human Reg IV in Complete Freunds Adjuvant. Repeat SC booster immunizations were given at days 16 and 31 using incomplete Freunds Adjuvant, followed by a final IV boost given 4 weeks later. Splenocytes were fused to the P3X63Ag8.653 murine myeloma line 3 days after the IV boost using 50% w/v PEG 1500 and were plated under HAT selection. Supernatants were collected 14 days after fusion and hybridoma clones secreting antibodies specific for Reg IV were identified by ELISA using goat anti-Armenian hamster IgG coupled to horseradish peroxidase (Jackson ImmunoResearch, West Grove, Pa.) followed by colorimetric detection (TMB substrate, Pierce Corp., Rockford, Ill.). Positive clones were subcloned a second time to insure clonality. Positive and negative controls included a 1:100 dilution of serum collected from the immunized Armenian hamster and supematants from several unrelated hybridoma cultures. Specificity of individual clones was further examined by duplicating the ELISA experiments using plates coated with rHuReg Iα and Reg III. Immunoglobulin from Reg IV-specific hybridoma cultures was isolated using ImmunoPure IgG purification system (Pierce) and the final antibody concentration was determined using the BCA Assay (Pierce). Monoclonal and polyclonal specificity and suitability for use in Western blot analysis were further examined. Five hundred nanograms of recombinant human Reg IV, Reg III, and Reg Iα were subjected to SDS-PAGE electrophoresis in 10-20% gradient gels (BioRad, Hercules, Calif.) and transferred to PVDF membranes. Membranes were blocked and incubated with 0.1 micrograms/ml of IgG from individual hybridoma clones or polyclonal serum. Goat anti-Armenian hamster IgG or goat anti-rabbit IgG coupled to horseradish peroxidase (Jackson labs) was applied as a secondary antibody and immunoreactivity visualized by ECL (Amersham).
Tissue Immunohistochemistry: Formalin fixed paraffin embedded sections of normal human ileum were prepared using standard techniques and were subjected to immunohistochemical analysis. Slides are first treated with a solution of Antigen Decloaker for the monoclonal antibody or Nuclear Decloaker for the polyclonal antibodies (Biocare Medical, Walnut Creek, Calif.) in a pressure cooker @ 15 PSI for 3 minutes. Monoclonal and polyclonal antibodies were initially tested over a range of dilutions in a commercial blocking solution (Protein Block, Dako, Carpenteria, Calif.). Optimal staining with the polyclonal antibodies was between 1:2000 and 1:4000 (0.75-1.5 micrograms/ml), and at 1:100 (0.7 micrograms/ml) with the monoclonal antibody. Sections were stained using the TSA-Indirect immunohistochemistry kit (NEN Life Science, Boston, Mass.). Appropriate biotinylated anti-rabbit or anti-hamster IgG secondary antibodies (NEN Life Science, Boston Mass.) at a dilution of 1:2000, were prepared and applied according to the NEN protocol. Controls consisted of staining without the addition of primary antibody or the use of polyclonal antibodies in the presence of excess synthetic peptides. For blocking experiments, antibodies were preincubated with synthetic peptides at a concentration of 100 micrograms/ml for 1 hour at room temperature before incubation with the tissue section. Positive staining was visualized using the HRP chromogenic substrate 3,3′-diaminobenzidine (Vector Laboratories, Burlingame, Calif.) followed by a light hematoxylin counterstain.
Results
Expression of recombinant human Regenerating gene IV in P. pastoris . The cDNA corresponding to mature human Reg IV was fused in frame with the Saccharomyces cerevisiae α-mating factor secretion signal in the vector pPICZα (Invitrogen Corporation, Carlsbad, Calif.). This construct provides antibiotic selection in both E. coli and P. pastoris and directs the synthesis and extracellular secretion of Reg IV coupled with cleavage of the amino-terminal secretion sequence. This fusion protein is placed under the control of the Pichia AOX1 methanol-inducible promoter. As a result of our cloning strategy, two additional amino acids, Glu-Phe, follow the second Ste13 cleavage site, and precede the Asp-Ile-Ile-Met residues that initiate the amino terminus of mature Reg IV. Structural homology between Glu-Ala, a known Ste13 site, and Glu-Phe, raised the possibility that Ste13 might also recognize this as an alternative cleavage site. Approximately 300 Zeocin resistant transformants of KM71H resulted from electroporation, which were of the expected Mut S phenotype. Twenty-five were randomly selected and screened for functional expression of the Reg IV protein by SDS-PAGE and Coomassie staining. At selected intervals following methanol induction, aliquots of the cleared culture supernatant were examined to identify the clone with the highest level of Reg IV protein production.
Fermentation and characterization of recombinant hReg IV in P. pastoris . The P. pastoris expression clone selected above was used for production of human Reg IV in shaker flask culture ( Pichia Manual, Invitrogen Corporation, Carlsbad, Calif.). Yields of protein were approximately 1-2 mg per liter of starting culture, disappointingly low for planned animal studies. Accordingly, we attempted to scale up production in both yield and volume by fermentation. Fermentation of the clone expressing hReg IV was carried out using a BioFlo 110 fermenter (New Brunswick Scientific Co.) equipped with software control of the growth conditions and data logging. An overnight broth of KM71H containing the expression construct hReg IV-pPICZα was used to inoculate 3.5 liters of fermentation basal salt-glycerol media in a 5.6 liter working volume fermenter. The initial batch phase growth occurred in media containing 40 gm/liter glycerol ( FIG. 14 , left). Following a marked rise in dO2 occurring as a result of carbon source limitation at approximately 26 hrs, the glycerol fed-batch process was initiated. Glycerol was provided as a 50% glycerol solution containing 12 ml/liter of the trace minerals solution, administered at 40 mls/hr for 14 hours to induce rapid expansion of the Pichia cell mass ( FIG. 14 ). The production phase was initiated by methanol feeding after a 3 hr carbon-source starvation. The rate of methanol feeding was slowly ramped up over 8 hours and continued until 134 hours. The software control was set to maintain dO2≧30% during growth on glycerol and ≧25% during growth on methanol, requiring administration of supplemental oxygen between 28-42 hrs and between 58-103 hrs. Although not a part of a regular production batch, in some runs the methanol feeding was discontinued at 134 hours to assess the time until depletion of the carbon source, by dO2 monitoring. Typically, the dO2 would rise to ≧100% within 2-3 hrs ( FIG. 14 ). At the initiation of the 96 hour production phase, and again after 24 hours, 10 grams of casamino acids were added as a supplemental nitrogen source and to minimize the activity of yeast produced proteases. During the production phase, the temperature of the reaction chamber was reduced to 26° C. Fermentation runs performed without a reduction in the reaction chamber temperature or without the addition of casamino acids had appreciably less of the Reg IV product running at ˜15-16 kDa in association with the prominent appearance of lower molecular weight proteins of approximately 8 and 12 kDa molecular weight by SDS-PAGE. Amino terminus sequencing of these lower bands revealed the expected N-terminus of Reg IV, demonstrating that these lower molecular weight bands resulted from internal proteolysis near the carboxy terminus.
The production of recombinant human Reg IV was monitored by SDS-PAGE and Coomassie blue staining ( FIG. 14 , right). Samples taken at approximately 24 and 48 hrs, during growth on glycerol, lacked significant expression of any secreted protein. Whereas samples taken at 72, 96, 120, and 144 hrs, all times following activation of the alcohol oxidase (AOX1) promoter, had a prominent band at ˜15 kDa, corresponding to the expected size of human Reg IV. To determine the identity of this band, Western blotting was performed using the monoclonal and two polyclonal antibodies generated as described in methods. FIG. 14 , right “B” shows a duplicate gel after immunostaining with 2H6, a monoclonal raised against recombinant human Reg IV. Bands were visualized by enhanced chemiluminescence (ECL, Amersham). Identical staining was demonstrated using anti-P4262 and anti-P4261, polyclonal antibodies raised against 15-mer synthetic peptides representing two non-overlapping sequences derived from the human Reg IV cDNA sequence.
Purification steps. Recombinant human Reg IV was initially purified by tangential flow filtration. As is typical for the methylotrophic yeast Pichia pastoris , cleared supematants are pale green in color. The centrifuged fermentation supematant (˜3500 ml) was initially cleared using a 0.1 square meter Durapore 0.45 μM PVDF cartridge. Proteins or protein aggregates greater than 50 kDa were discarded in the Biomax 50 kDa polyethersulfone cartridge retentate. The substance resulting in the green color of the media was also removed in this step. A 50 kDa cutoff was selected because of the paucity of protein contaminants below this mass, and the well described propensity for other Reg family members to undergo dimerization. Seventy percent of the Reg IV was recovered in the 50 kDa permeate. Contaminants less than 8 kDa were then removed in the discarded 8 kDa permeate. Overall, thirty-five percent of the original Reg IV was recovered in the 8 kDa retentate (˜250 mls). Higher yields could be obtained by greater flushing of the 50 and 8 kDa filter cassettes, but this comes at the price of a significantly larger dilution of the final protein solution. The final purification step involved preparative C 18 RP-HPLC. Differences in the retention time as well as the broad elution profile for the fermentation sample suggested that there could be differences in the final protein products. Individual bands were subjected to Edman N-terminal sequence analysis on a PE-Biosystems Procise ABI494 (Foster City, Calif.). Unexpectedly, the processing and secretion of Reg IV differed between shaker flask production and fermentation. Furthermore, the leading shoulder for each preparation contained a prominent higher molecular weight band in addition to the expected Reg IV product. Edman N-terminal sequence of Reg IV produced by batch growth in a shaker flask was the DIIMRPSC (SEQ ID NO: 9), the expected amino terminus of mature Reg IV. The higher molecular weight band gave an identical sequence suggesting that this is a dimeric species of Reg IV that has survived both C 18 RP-HPLC and heat treatment at 95 degrees C. for 5 minutes in the presence of SDS and DTT prior to SDS-PAGE analysis. The N-terminal sequence of Reg IV produced under fermentation conditions was EFDIIMRPSC (SEQ ID NO: 5), reflecting inclusion of the two additional amino acids, Glu-Phe, that follow the second Ste13 cleavage site. A similar dimeric species containing the extended N-terminus was observed for the fermentation sample, yet tended to “bleed-across” the entire peak unlike the shaker flask counterpart. This data highlights the potential for differences in the processing and secretion of recombinant Reg IV unique to specific Pichia growth conditions. MALDI-TOFMS of the Reg IV produced by batch growth in a shaker flask showed a MW expt . of 15,917.3 in good agreement with an expected unmodified MW calc . of 15,913.9. MALDI-TOFMS for Reg IV produced by fermentation showed a MW expt . of 16,192.7, in agreement with a MW calc . of 16,190.2, corresponding to the amino terminus starting with EFDIIMR (SEQ ID NO: 6).
Immunologic characterization of the recombinant Reg IV protein. We elected to proceed with the development of Reg IV isoform specific antibodies by two independent methods; monoclonal antibodies and unique synthetic peptide-derived polyclonal antibodies. The identification of recombinant human Reg IV with affinity-purified Rabbit anti-peptide antibodies is shown in FIG. 22 . Both anti-P4261 and anti-P4262 specifically detected the recombinant protein and both could be blocked in the presence of the specific peptide used for immunization. The specificity of each individual antibody for Reg IV by Western blot is shown in FIG. 22 . All three antibodies specifically recognized Reg IV and failed to react with recombinant human Reg Iα or Reg III.
These specific antibodies provided the first opportunity to investigate the tissue and cellular localization of Reg IV. Paraffin embedded sections of normal human ileum were subjected to immunohistochemical analysis ( FIG. 23 ). The 2H6 anti-human Reg IV monoclonal antibody ( FIG. 23A , B) strongly reacted with the 1-2 individual epithelial cells per crypt. Immunoreactive cells were typically located 2-10 cell positions from the base of the crypt (arrowhead). High powered views showed that positive crypt cells appeared to be enterocytes by morphology and were not Paneth cells (by DIC microscopy) or enteroendocrine cells (by a Fontana-Masson argentaffin staining reaction, data not shown). Scattered cells also showed positive staining higher in the crypt or on the villus surface. These cells had a different morphology, resembling enteroendocrine cells. In serial sections these cells were found to be positive by Fontana-Masson argentaffin staining. Negative controls included sections stained, with omission of the primary antibody ( FIG. 23D ), or stained with an unrelated antibody (not shown). To provide independent validation, rabbit polyclonal anti-P4261 and anti-P4262 staining was perfomed. These experiments demonstrated an identical staining pattern. Controls for the rabbit polyclonal antibodies included staining in the presence of the competing synthetic peptide used for immunization.
Example 4
Tissues with significant (>30 tags/million) expression of Reg genes by SAGE analysis are listed below for each Reg gene.
Hs.9018: exostoses (multiple)-like 3 (A putative Reg receptor)
Ovarian Clear cell carcinoma cell line ES-2, poorly differentiated (31) Brain, Duke glioblastoma multiforme cell line, Duke_H392 (86) Brain, Duke glioblastoma multiforme primary tumor derived from a 51 year old male, GBM_H1110 (112) Brain, 5 pooled Duke glioblastoma multiforme primary tumors, pooled_GBM (47) Glioblastoma multiforme, Duke_H247_normal (32) Brain, normal, greater than 95% white matter. Post-mortem delay of 3:15, BB542 (41) Brain, normal human astrocyte cells harvested at passage 5, NHA(5th) (37) Brain, normal, pooled, normal_pool(6th) (47) Ovarian Clear cell carcinoma cell line ES-2, poorly differentiated, ES2-1 (31) Prostate cancer cell line, LNCaP (127) Primary ovarian tumor, serous adenocarcinoma, OVT-6 (46) Primary tumor, serous adenocarcinoma, OVT-7 (36)
Hs.49407 (Old Number Hs. 1032): Reg Ia, Regenerating islet-derived 1 alpha (pancreatic stone protein, pancreatic thread protein)
Prostate cancer cell line, LNCaP (31) Human breast adenocarcinoma from a malignant pleural effusion, SK-BR-3 (119) Colon, primary tumor, Tu102 (103) Colon, primary tumor, Tu98 (100)
Hs.423: Reg III, pancreatitis-associated protein, PAP
Colon, primary tumor, Tu102 (103)
Hs.4158: Reg Ib, Regenerating islet-derived 1 beta (pancreatic stone protein, pancreatic thread protein)
Colon, primary tumor, Tu102 (34)
Hs. 105484: Reg IV, Regenerating gene IV, gastrointestinal secretory protein GISP | Disruption of the Reg signalling pathway permits spontaneous and therapeutic induction of pro-apoptotic signals to be more effective. Disruption can be accomplished by means of antibodies, antisense, RNA interference, small molecule inhibitors, etc. These can be used in conjunction with conventional anti-neoplastic therapies. Inhibitors can be identified by assays that monitor the disruption of the binding of Reg ligands and the Reg ligand receptor. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/978,578, filed on Oct. 9, 2007. The entire disclosure of the above application is incorporated herein by reference.
FIELD
[0002] The present teachings generally relate to dual diaphragm assemblies. More particularly, the present teachings relate to a dual diaphragm assembly for a sanitation system. Additionally, the present teachings relate to a diaphragm assembly for a sanitation system having a waste chamber that drains toward an outlet.
BACKGROUND
[0003] A flush toilet basically operates to deliver a source of flush water to a bowl and transfer waste from the bowl to a remote location. Various types of systems are known, ranging from toilets that rely exclusively on flushing water for the transfer of waste to the remote location to vacuum system for assisting in the transfer of waste. While known systems have proven to be generally acceptable for their intended uses, a continuous need remains for improvement in the pertinent art.
SUMMARY
[0004] According to one particular aspect, the present teachings may provide a sanitary system includes a toilet, a source of flush water in fluid communication with the toilet, and a dual diaphragm pump assembly. The pump assembly includes a housing defining a working chamber, a water pump chamber and a waste pump chamber. A first diaphragm is disposed in the housing. The first diaphragm separates the water pump chamber and the working chamber. A second diaphragm is disposed in the housing. The second diaphragm separates the waste pump chamber and the working chamber. A common driver member interconnects the first diaphragm and the second diaphragm. A water inlet at least partially defines a water inlet path between a source of flush water and the water pump chamber. A water outlet at least partially defines a water outlet path between the water pump chamber and a bowl of the toilet. A waste inlet at least partially defines a waste inlet path between the bowl of the toilet and the waste pump chamber. A waste outlet is in fluid communication with the waste chamber. Movement of the driven member to a first position creates a positive pressure in the water pump chamber and a negative pressure in the waste pump chamber. Movement of the driven member to a second position creates a negative pressure in the water pump chamber and a positive pressure in the waste pump chamber.
[0005] According to another aspect, the present teachings may provide a waste pump for a sanitary system. The waste pump includes a housing defining a working chamber and a waste chamber. The waste chamber has a horizontally extending portion and a vertically extending portion. A waste diaphragm is disposed in the housing. The waste diaphragm separates the waste chamber and the working chamber. A driver member is disposed in the housing and is interconnected to the waste diaphragm. A waste inlet is in fluid communication with the vertically extending portion of the waste chamber. A waste outlet is in fluid communication with the vertically extending portion of the waste chamber. Movement of the driven member to a first position creates a negative pressure in the waste pump chamber and movement of the driven member to a second position creates a positive pressure in the waste pump chamber.
[0006] Further areas of applicability of the present teachings will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
DRAWINGS
[0007] The present teachings will become more fully understood from the detailed description and the accompanying drawings in which the disclosed subject matter is drawn to scale, wherein:
[0008] FIG. 1 is an environmental view of a sanitation system in accordance with the present teachings.
[0009] FIG. 2 is a perspective view of a pump assembly and associated shroud in accordance with the present teachings.
[0010] FIG. 3 is another perspective view of a pump assembly and associated shroud in accordance with the present teachings.
[0011] FIG. 4 is a side view of a pump assembly in accordance with the present teachings.
[0012] FIG. 5 is a cross-sectional view taken along the line 5 - 5 of FIG. 4 .
[0013] FIG. 6 is a front view of a pump assembly in accordance with the present teachings.
[0014] FIG. 7 is a cross-sectional view taken along the line 7 - 7 of FIG. 6 .
[0015] FIG. 7A is a cross-sectional view similar to FIG. 7 , illustrating the driven member in a first position.
[0016] FIG. 7B is a cross-sectional view similar to FIG. 7 , illustrating the driven member in a second position.
[0017] FIG. 8 is a top view of a pump assembly in accordance with the present teachings.
[0018] FIG. 9 is a schematic view of a sanitation in accordance with the present teachings.
DETAILED DESCRIPTION
[0019] The following description of various aspects of the present teachings is merely exemplary in nature and is in no way intended to limit the invention, its application or uses.
[0020] With initial reference to the environmental view of FIG. 1 , a sanitation system including a pump assembly 10 constructed according to the teachings of the present disclosure is illustrated. The sanitation system is generally illustrated to include a flush toilet 11 and generally identified at reference character 10 . The particular toilet 11 shown in the drawings will be understood to be merely exemplary. In this regard, it will be appreciated the teachings of the present disclosure are not limited to any particular toilet.
[0021] With continued reference to FIG. 1 and additional reference to FIGS. 2 through 9 , the pump assembly 10 will be further described. In one particular application the pump assembly may be a dual diaphragm pump assembly 10 that is operative for delivering a source of flush water 13 to the toilet 11 and further operative for pumping waste water from the toilet 11 . The pump assembly 10 may include a housing 12 . As perhaps best shown in the cross-sectional views of FIGS. 5 and 7 , the housing 12 may define a plurality of chambers. The plurality of chambers may include a first chamber 14 , a second chamber 16 and a third chamber 18 . The first chamber may be a working chamber 14 . The second chamber may be a water chamber 16 . The third chamber may be a waste chamber 18 .
[0022] The working chamber 14 is disposed between the water chamber 16 and the waste chamber 18 . In the embodiment illustrated, the chambers 14 - 18 are horizontally arranged with the water chamber 16 above the working chamber 14 and the waste chamber 18 below the working chamber 14 . In other embodiments, water chamber 16 may be disposed below the working chamber 14 and the waste chamber 18 above the working chamber 14 . In still other embodiments, the chambers 14 - 18 may be vertically arranged.
[0023] A first membrane or diaphragm 20 may be disposed within the housing 12 to separate the working chamber 14 from the first chamber 16 . A second membrane or diaphragm 22 may be disposed within the housing 12 to separate the working chamber 14 from the second chamber 16 . The diaphragms 20 and 22 may be constructed of EPDM, other rubber or other suitable material. As will be addressed below, the diaphragms 20 , 22 may be constructed to cooperate with the housing 12 to retain the diaphragms 20 , 22 relative to the housing 12 .
[0024] The housing 12 may include a plurality of sections. The sections may be generally cylindrical or of other suitable shape. As illustrated, the housing 12 may include a first or upper section 24 , a second or intermediate section 26 and a third or lower section 28 . The first diaphragm 20 may be peripherally captured between the first and second sections 24 and 26 of the housing 12 . The second diaphragm 22 may be peripherally captured between the second and third sections 26 and 28 of the housing 12 . The sections of the housing 24 , 26 and 28 may be constructed of polypropylene or other suitable material.
[0025] As shown, the adjacent sections of the housing 12 may be integrally formed to include cooperating peripheral flanges for capturing the respective diaphragms 20 , 22 . The diaphragms 20 , 22 may be formed to include upper and lower peripheral beads. As shown in FIG. 5 , for example, the radially outermost portion of the diaphragms 20 , 22 may have a generally t-shaped cross section. The peripheral beads of the diaphragms 20 , 22 may be received in corresponding peripheral grooves of the adjacent housing sections.
[0026] The upper section 24 of the housing 12 may define an upper cavity 25 . The upper cavity 25 may receive a switch 25 for controlling actuation of the pump assembly 10 . Operation of the switch 25 will be understood to be conventional insofar as the present teachings are concerned.
[0027] The third section 28 may be integrally or otherwise formed to include a base portion 33 suitable for mounting the pump assembly 10 to a floor or other rigid surface with fasteners or the like. As perhaps most particularly shown in FIG. 7 , the third section 28 may be further formed to include a chamber floor 29 . The chamber floor 29 may be oriented generally horizontally and upwardly spaced from the base portion 33 .
[0028] The configuration of the waste chamber 18 allows the pump assembly 10 to more effectively move water and sewage given a lack of air within the chamber 18 . This is because water is incompressible as opposed to air. With a lack of air in the waste chamber 18 and a negative pressure created by the diaphragm 22 , water/sewage will substantially fill the waste chamber 18 . Then, with a positive pressure created by the diaphragm 20 , the waste chamber 18 near completely empties the water/sewage to more effectively draw in the most amount of water/sewage possible in the next movement of the diaphragm 22 . The waste chamber 18 is also particularly designed to drain completely toward the outlet 46 when the pump is off assembly 10 , such drainage reducing the amount of sewage left in the pump assembly 10 , thereby reducing the odor permeating from the toilet 11 .
[0029] The first and second sections 24 and 26 may be coupled to one another with a clamp arrangement 30 that circumferentially surrounds the housing 12 . Similarly, the second and third sections 26 and 28 may be coupled to one another with a substantially identical clamp arrangement 30 that circumferentially surrounds the housing 12 . The clamp arrangements 30 may include first and second components 32 and 34 coupled to one other with fasteners or in any manner well known in the art. The clamp arrangements 30 may define a circumferential groove for receiving the cooperating flanges of the adjacent housing sections. The clamp arrangements 30 may be constructed of acetal, polyoxymethylene, other plastic, or other suitable material.
[0030] A driven member or shaft 36 may be disposed in the housing 12 for reciprocal movement and may interconnect the first and second diaphragms 20 and 22 between a first position and a second position. The driven member 36 may include disc-shaped upper and lower members 37 and 39 coupled by an intermediate member 41 . The driven member 36 may be coupled to the respective diaphragms 20 and 22 with fasteners 38 , for example. Washers may be positioned on the side of the diaphragms 20 and 22 opposite the respective disc-shaped members 37 and 39 . The fasteners 38 may pass through the washers and the respective diaphragm 20 or 22 and threadably engage the respective upper or lower member 37 or 39 .
[0031] The driven member 36 is illustrated throughout the drawings in a neutral position between the first position and the second position. With reference to the cross-sectional views of FIGS. 5 and 7 , for example, the first position is upwardly displaced from that illustrated within the limits defined by the diaphragms 20 and 22 . Conversely and again with reference to FIGS. 5 and 7 , the second position is downwardly displaced from that illustrated within the limits defined by the diaphragms 20 and 22 .
[0032] A water inlet 40 may at least partially define a water inlet path between the source of flush water 13 and the water chamber 16 . A water outlet 42 may at least partially define a water outlet path between the water chamber 16 and a bowl of the toilet (not shown). A waste inlet 44 may at least partially define a waste inlet path between the bowl of the toilet and the waste chamber 18 . A waste outlet 46 may be in fluid communication with the waste chamber 18 . The waste outlet 46 may be disposed proximate the bottom of the waste chamber 18 to facilitate drainage of the waste chamber 18 . Valves 50 may be disposed in each of the water inlet path, the water outlet path, the waste inlet path and the waste outlet path for controlling the flow of water and waste. The valves may be one-way valves 50 .
[0033] A rotatable motor arm 52 may be coupled to the shaft 36 for reciprocating the shaft 36 between the first and second position. When the motor arm 52 is rotated about its axis, a crank arm 54 may turn inside a slot 56 (see FIG. 5 , for example) in the shaft 36 . Due to an offset of the crank arm 54 , the shaft 36 is reciprocally driven in opposition vertical directions, thereby displacing both diaphragms 20 and 22 in vertical directions. The motor associated with the motor arm 52 may be an electrical motor. The switch 37 carried at the top of the pump assembly 10 may actuate the electrical motor.
[0034] In response to actuation by the switch 37 , the driven member 36 is reciprocated between the first and second positions. The diaphragms 20 and 22 simultaneously cooperate with the associated one-way valves 50 operate to create a negative pressure to draw fluid into each pump and then a positive pressure to push fluid out of each pump. More particularly, when the driven member 36 moves the first position (up in FIG. 5 , water is drawn from the flush water source 13 and pumped to the toilet 11 . When the driven member 36 moves to the second position (down in FIG. 5 ) waste is drawn from the toilet 11 and pumped to a remote area 43 . The remote area 43 may be a holding tank, a sewer or other receptacle.
[0035] The waste chamber 18 is particularly adapted to pump water/sewage out of the toilet 11 and into a holding tank assembly 10 , sewer, or overboard in addition to being mounted to the floor and support the pump in a vertical orientation. The work chamber 14 includes a horizontally extending portion 18 A in communication with a vertically extending portion 18 B. The horizontally extending portion 18 A is sized and positioned such that upon downward translation of the shaft 36 , contents within the horizontally extending portion 18 A are near completely displaced.
[0036] The sanitation system may further include shroud for substantially concealing the pump assembly 10 . The shroud may be secured to the pump assembly 10 in any manner well known in the art. The shroud provides a neat appearance and a surface that is easy cleaned.
[0037] It will now be appreciated that a pump assembly 10 is provided potentially having a lower cost, quieter operation and a more reliable mechanism. In this regard, the dual diaphragm arrangement of the present teachings compares favorably with conventionally pumping mechanism incorporating a hard plastic impeller for evacuating waste from a bowl and a flexible rubber impeller that supplies fresh water to the bowl. Such conventional structures are loud and experience significant wear when run dry. The dual diaphragm arrangement of the present teachings greatly reduces noise associated with the pump assembly 10 and has the ability to run dry for extended periods of time without undue wear.
[0038] As shown in the drawings, the present teachings may be used to provide a common unit for both waste and water pumping. The flexibility of the present teachings anticipates additional applications. In this regard, the present teachings may be used as a single waste pump by eliminating the water pump or a single water pump by eliminating the waste pump. Additionally, the present teachings may be adapted for use with a dual waste pump where the water pump is replaced with a second waste pump or a dual water pump where the waste pump is replaced with a second water pump.
[0039] The description of the present teachings is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. Furthermore, the present invention has been described with reference to two particular embodiments having many common and some distinct features. One skilled in the art will recognize that these features may be used singularly or in any combination based on the requirements and specifications of a given application or design. | A pump assembly includes a housing defining a working chamber, a water pump chamber and a waste pump chamber. A first diaphragm separates the water pump chamber and the working chamber. A second diaphragm separates the waste pump chamber and the working chamber. A common driver member interconnects the first diaphragm and the second diaphragm. Movement of the driven member to a first position creates a positive pressure in the water pump chamber and a negative pressure in the waste pump chamber. Movement of the driven member to a second position creates a negative pressure in the water pump chamber and a positive pressure in the waste pump chamber. | 5 |
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a by-pass arrangement for controlling the return flow of a pilot valve, which by being connected between the outlet connection from the pilot valve and the return connection to the pilot valve eliminates the return circuit and enables said arrangement to be connected downstream to an open circuit network used for the pulsating delivery of an irrigation liquid. The patents GB 1,286,538, GB 1,484,588, U.S. Pat. Nos. 3,698,195 and 4,009,832 describe localized open-circuit irrigation systems, widely used in agriculture, comprising a pipe directly connected to a feed source (hydraulic pump, pressurized water circuit etc.), from which hoses and secondary pipes of smaller dimensions extend at more or less regular intervals to disperse the liquid over the ground.
These secondary pipes or hoses are themselves variously structured to distribute the liquid as uniformly as possible, even at the points furthest from the source. All comprise pressure release means to cause the liquid to emerge in small quantities (droplets).
With these open circuit systems it is however difficult to achieve uniform irrigation at all points of the ground.
U.S. Pat. No. 4,176,791 describes an irrigation system comprising a pilot valve connected upstream to a pressurized liquid source and from which a succession of pipe sections extends, these being connected together in series by secondary valves provided with a spray nozzle.
The succession of pipe sections starts from the pilot valve and returns to it to form a closed ring.
Although this irrigation system improves the uniformity of liquid distribution over the ground compared with open systems, it is complicated by the use of a double pipe, i.e., an outward pipe and a return pipe to the pilot valve.
In addition, in a closed circuit it is difficult to expel the air which accumulates in the circuit with time and disturbs the correct operation of the valves.
Again, patent application IT 22449A/87 in the name of the present applicant describes a device for automatic pulsating delivery of an irrigation liquid connected downstream to a distribution network provided with valves sensitive to the pressure variations produced by a Venturi device which transmits them to a sliding member.
Said device is complicated by the presence of two counter-pressure membranes, one interposed between said sliding member and the source liquid feed orifice and the other interposed between said sliding member and the bleed orifice to atmosphere. It is the mechanical sliding of the piston and the extreme elasticity of the membranes which enable the valves included in the distribution network to open and close so that the liquid can escape and irrigate the ground.
Even though the system is theoretically usable, its lack of practical usability means that it has been almost completely abandoned.
SUMMARY OF THE INVENTION
To overcome the drawbacks of the known art, the applicant has now found that by connecting a suitable device, described hereinafter in detail, between the outlet pipe and the inlet pipe of the pilot valve, an irrigation system is obtained which because it is of open circuit type eliminates the drawbacks of the closed circuit such as the trapping of air, hence achieving uniform irrigation at all points of the ground.
In addition, the elimination of the return half-ring considerably simplifies the practical implementation of said system.
The present invention therefore provides a by-pass arrangement for controlling the return flow of a pilot valve, which by being connected between the outlet connection from the pilot valve and the return connection to the pilot valve eliminates the return circuit and enables said arrangement to be connected downstream to an open circuit network used for the pulsating delivery of an irrigation liquid.
The present invention further provides the irrigation system in which the device of which said by-pass arrangement forms a part is connected to a distribution network comprising a plurality of pressure-sensitive valves provided with a delivery nozzle.
BRIEF DESCRIPTION OF THE INVENTION
The invention is described hereinafter with reference to the accompanying drawings, in which:
FIG. 1 is a vertical section through an irrigation system in which the device of FIG. 2 is connected to a liquid distribution network provided with pressure-sensitive secondary valves;
FIG. 2 is a vertical section through one embodiment of the device for the automatic pulsating delivery of an irrigation liquid, of which the parts shown in section are the subject of the present invention;
FIGS. 3 and 4 are vertical sections through particular embodiments of the secondary valves usable in the distribution network of the irrigation system of FIG. 1;
FIG. 5 is a vertical section through a particular embodiment of the irrigation system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the irrigation liquid originating from the tank feeds the line by flowing from the pipe 1 through the valve 6 and pressing the plug 3 upwards with a certain force, aided by the action of the spring 2. Water hence enters the line section 9 and fills the entire hydraulic circuit.
When all the line sections are full, the water enters the chamber 5 via the by-pass arrangement according to the invention, to press against the diaphragm 7 and push it downwards with a certain force.
At a determined instant the hydraulic circuit is in equilibrium because the force exerted by the pressure on the diaphragm 7, being of greater surface area than the plug 3, equals the pressure exerted on the plug 3 plus the force exerted by the spring 2.
As the pressure in the pipe 1 increases, the force exerted on the diaphragm 7 prevails over that exerted on the plug 3 to open the port 4. The water present in the line section 9 then leaving from the line section 15 to create negative pressure in the line comprising the delivery units 13, 16, 17 etc.
As soon as the line section 10 reaches atmospheric pressure, the plug 3 returns to its shut-off position, water again fills the various line sections and the cycle recommences.
The rate of filling of the chamber 5 and hence the delivery frequency can be adjusted by adjusting the valve of the present invention.
The advantages deriving from this irrigation system have been previously described.
The second aspect of the present invention relates to irrigation systems incorporating the device of which said by-pass arrangement forms part, for the automatic pulsating delivery of the irrigation liquid.
In such systems said device is connected to a distribution network consisting of a series of line sections each provided at its downstream end with a pressure-sensitive secondary valve fitted with a delivery nozzle.
In a preferred embodiment the secondary valves connected to the network have the configuration shown in FIGS. 3 and 4. Specifically, in these figures it can be seen that the valve consists of a body 42 comprising the entry channel 43, the exit channel 44 and the delivery nozzle 45.
Inside the valve there is a piston 46 provided with a seal disc 51 to which the valving member 48 is connected. This latter consists of two flexible plastics columns 49 and 50, and when the piston 46 slides in its cylindrical guide 47 it closes the seat 52 on the delivery nozzle 45 or closes the entry channel 43, depending on the pressure in the channels 43 and 44.
During the filling stage the described pulsating device fills the distribution network until the network pressure reaches a value equal or close to the source pressure.
In this respect, with reference to FIGS. 1, 3 and 4, during the filling stage the liquid passes under the effect of the source pressure through the pulsating distributor D and the section 36 of the network R to reach the secondary valve 39. Within this valve the liquid presses against the piston 46, which itself urges the valving member 48 against the seat 52 to close it.
The liquid feed pressure also lowers the seal disc 51. This is facilitated by the flexibility of the plastic material with which the columns 49 and 50 of the valving member 48 are constructed. The lowering of the seal disc 51 opens a passage between the entry channel 43 and the exit channel 44 to hence fill the section 37 of the network R as far as the valve 40. This filling then continues until the entire network is filled.
When the network filling is complete, the liquid flow stops, and the feed pressure discharges through the by-pass and onto the diaphragm 7 to lower the plug 3. In this manner the line section 9 is connected to atmosphere 15 via the port 4, with a consequent drop in the pressure.
This drop in pressure is transmitted firstly to the section 36 of the network R, the effect of the difference in pressure between the section 37 (at a pressure equal or approximately equal to the source pressure) and the network section 36 (at atmospheric or approximately atmospheric pressure) causing the piston 46 of the valve 39 to move upwards into seat 47, dragging with it the valving member 48 which hence releases the seat 52 with consequent escape of irrigation liquid from the nozzle 45.
This escape of liquid from the section 37 continues until the pressure in said network section 37 reaches atmospheric or approximately atmospheric pressure.
The phenomenon is repeated for the various subsequent sections of the network R until the last network section.
The time for which the secondary valves open is measurable in terms of fractions of a second.
The refilling of the network R by the pulsating device D begins from the moment at which the pressure in the network section 36 has fallen to atmospheric or approximately atmospheric.
The time for refilling the network is greater than the emptying time and can vary from a few seconds to some tens of seconds depending on the size of the irrigation system, the flow rate of irrigation liquid from the circuit as controlled by the by-pass valve, and the feed pressure of the pulsating valve D.
The energy which enables the individual network sections to discharge the irrigation liquid by virtue of the available pressure is provided by the elasticity of the network, which is usually of plastics construction.
In the case of a poorly elastic network (for example of steel), each network section can be provided with a suitable elastic expansion chamber of dimensions chosen on the basis of the quantity of irrigation liquid to be delivered at each cycle.
FIG. 5 shows an example of a branched distribution network. In this case downstream of the pulsating device D there are two distribution network branches, namely the branch R1 formed of the sections 53, 54 and 55 with valves 56, 57 and 58 interposed between said sections, and the branch R2 formed of the sections 59, 60 and 61 with respective valves 62, 63 and 64.
In the figures A' indicates the flow control valve which is adjustable due to the threaded connection shown in the upper part thereof in FIG. 2, B' indicates the discharge from the pilot valve, C' indicates the pilot valve, D' indicates the feed pipe to the delivery units and E' indicates the entry for the irrigation liquid. | A valve arrangement of an irrigation system includes a by-pass; for controlling the return flow of a pilot valve, which by being connected between the outlet connection from the pilot valve and the return connection to the pilot valve eliminates the need for a return circuit and enables the arrangement to be connected downstream to an open circuit network used for the pulsating delivery of an irrigation liquid. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/552,569, filed Mar. 12, 2004, the complete disclosure of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention lies in the field of keystroke devices. In particular, the invention is in the field of computer or stenographic keyboards and methods and software for interpreting keystrokes of these keyboards.
Various keystroke devices exist in the art. The most prevalent keystroke device is a computer keyboard. The keys of a standard computer keyboard are merely switches electronically indicating only a depressed state. Therefore, no signal is output or indicated by the keyboard when a keyboard is at rest, and a signal corresponding to depressed key(s) is output or indicated only when at least one key is depressed sufficiently far to “set off” the switch of that key or the switches of that set of keys.
A typewriter also has a keyboard, which can be mechanical and/or electronic. Like the computer keyboard, actuation (e.g., depression) of a key is intended to print a character. In electronic typewriters, when a key is actuated sufficiently far, a signal is sent to a processor to have the corresponding key(s) printed on the typing medium (e.g., paper). Mechanical typewriters are similar to electronic typewriters, but with one significant difference. Mechanical typewriters connect the key of the keyboard directly to the hammer containing the corresponding character to be printed on the page. Such a connection typically places the key at the end of a lever connected to a fulcrum and, when the lever is depressed at a proximal end, the distal end of the lever forcibly contacts or causes a hammer to pivot its distal end towards the page. A printing ribbon is disposed between the page and the end of travel of the hammer and a character formed at the end of the hammer is printed on the paper because the raised character presses the printing ribbon against the page. Because such an assembly is a mechanical connection dependent upon the pressure imparted by the user, the hammer can hit the page with varying degrees of force. A relatively hard contact produces a clearly printed character on the page. In contrast, a relatively soft contact may produce a lightly printed character, which also can be referred to as a “shadow.” For mechanical typewriters, it is more desirable to have clearly printed characters than to have shadow characters. Therefore, improvements were made over the history of mechanical typewriters to guarantee relatively uniform contact between the hammer and the page, which improvements were, thereafter, incorporated into most electronic typewriters.
Another keystroke device can be found on stenographic devices. The most modern stenographic devices are entirely electronic and virtually immediately translate the stenographic key actuations into an accurate written representation of the spoken word. These modern devices are analogous to the electronic typewriters and computer keyboards in that a specific actuation of a key or set of keys will cause a clear printing or storage of the corresponding character or set of characters. Insufficient depression of a key(s) will not generate any output. Alternatively, depression of a set of keys (which is common for stenographic dictation) where one or more keys is sufficiently actuated but one or more other key(s) is insufficiently actuated will generate an output that does not correspond to the stenographers' intended output. Thus, the stenographer or computer associated with the stenographic device might not be able to accurately translate the inadequately actuated key(s) depending upon what was actually output to the paper or the electronically stored file.
The earlier stenographic devices provided an advantage over the modern stenographic devices. The older devices gave a stenographer some ability to determine a correct output from an incorrect input because these older mechanical devices printed the output on the paper in varying degrees of lightness. Stenographers refer to a lightly printed output as “shadow” output. So, if an intended output was lightly printed on the stenographic paper, that stenographer might have been able to determine what was intended during the original dictation and correctly translate the spoken word in the final transcript. Modern stenographic devices, however, are not able to electronically understand or store shadow output. If the stenographer does not actuate a key adequately, then no output is generated. And, if keys or a set of keys are actuated in varying degrees, then incorrect output is transcribed.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an electronic key depth sensing device and a method for interpreting keystroke levels of a key device that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that has a plurality of actuation levels in excess of merely on and off and that allows modern keystroke devices, in particular, stenographic devices, to register and interpret shadows, and methods and software for interpreting an actuation level of a multi-actuation level keystroke device.
Prior art keystroke sensing devices simply sense whether a key has been pressed or not. The device according to the invention, in contrast, senses how far a key has been pressed and displays, produces, and/or communicates intermediate values corresponding to the extent of key actuation. The output can be tertiary, in that the key is (1) not actuated, (2) partially actuated, or (3) fully actuated. Alternatively, the output can have any number of degrees, ten for example.
The keystroke device is used particularly with a stenograph machine (e.g., for court reporters) and emulates, in a modern digital stenograph machine, a sensitivity adjustment previously existing only in paper stenograph machines. In paper stenograph machines, when a court reporter lightly touched a key(s), then the paper would be printed, not with a clear print of the keystroke, but with a light or shadow keystroke. As used herein, the words “keystroke” or a “stenographic keystroke” include any possible actuation of a key device or set of key devices. In other words, the definition includes both recognized key actuations (whether for a single key or a set of more than one key) and any unrecognized, accidental, incorrect, and/or inadvertent actuation of a single key or a set of more than one key.
If the court reporter desired, the sensitivity of the paper machine could be adjusted for that court reporter's particular style of keystroke actuation using a sensitivity adjustment device. Such adjustment is considered advantageous for various reasons. First, court reporters use their fingers for hours at a time. Adjustment of keys towards the most comfortable return bias is, therefore, desirable. Second, different stenographers stroke the keys in unique ways. Allowing detection of shadows can correct one person's bad keystroke habits.
Now, digital machines are replacing paper machines. However, for digital machines, if a reporter actuates a key(s) lightly, then no stroke is registered at all. It is, therefore, desirable to emulate the paper machine functionality by registering lighter keystrokes on the computer, preferably, with a visibly shadowed or visibly lighter indication on the stenograph's digital display.
With the foregoing and other objects in view, there is provided, in accordance with the invention, a method for recording shadow keystrokes in an electronic stenographic recording machine having keys forming stenographic keystrokes when actuated, including the steps of sensing an extent of an actuation of at least one key and recording at least one intermediate value corresponding to the extent of the actuation of the at least one key.
With the objects of the invention in view, there is also provided a method for recording shadow keystrokes in an electronic stenographic recording machine having keys, including the steps of sensing at least one of a partially actuated and a fully actuated key and recording the sensed actuation of the key.
With the objects of the invention in view, there is also provided a method for recording shadow keystrokes in an electronic stenographic recording machine having keys, sensing an actuation of a key selected from one of a group consisting of a set of partial actuations and a full actuation and recording the sensed actuation of the key.
With the objects of the invention in view, there is also provided a method for recording shadow keystrokes in an electronic stenographic recording machine having keys forming stenographic keystrokes when actuated, including the steps of sensing an extent of an actuation of a subset of the keys as a stenographic keystroke, recording values selected from the group consisting of a full value and at least one intermediate value corresponding to the extent of the actuation of each of the subset of keys, and determining a first subset of possible translations of the stenographic keystroke based upon a second subset of possible combinations of the recorded values of the subset of the keys.
In accordance with another mode of the invention, there is provided the step of recording the sensed key in a memory as at least a part of a stenographic keystroke.
In accordance with a further mode of the invention, the sensing and recording steps are carried out for each of the keys actuated in each stenographic keystroke and determining a first subset of possible translations of each stenographic keystroke based upon a second subset of possible combinations of sensed intermediate values of at least one of the actuated keys.
In accordance with an added mode of the invention, the electronic recording machine is a digital stenograph machine and the actuation is at least a partial stroke of one of the keys.
In accordance with an additional mode of the invention, there is provided the step of placing an optical sensor at the key for sensing the extent of the actuation of the at least one key and carrying out the sensing step with the optical sensor.
In accordance with yet another mode of the invention, there is provided the step of translating the stenographic keystroke based upon the actuation of at least one of the keys and storing each translated stenographic keystroke in the memory.
In accordance with yet an added mode of the invention, there is provided the steps of associating a combination of each set of keys actuated as an untranslated stenographic data, transmitting the untranslated stenographic data to an external translating computer, and translating the untranslated stenographic data with the external translating computer.
In accordance with yet an additional mode of the invention, there is provided the step of receiving the translated stenographic data from the external translating computer.
In accordance with again another mode of the invention, there is provided the step of displaying the translated stenographic data to a user.
In accordance with again a further mode of the invention, the transmitting and receiving steps are carried out over the Internet.
In accordance with again an added mode of the invention, there is provided the steps of storing information including at least one of digital video images and audio data while the at least one key is being sensed and temporally associating the stored information with each key that is sensed.
In accordance with again an additional mode of the invention, there is provided the step of associating a portion of said stored information with at least one stenographic stroke.
In accordance with still another mode of the invention, the sensing step is carried out by sensing the extent of the actuation of each key of a subset of keys and recording at least one intermediate value corresponding to the extent of each actuation of the subset of keys.
In accordance with still a further mode of the invention, the translating step is carried out by associating translated stenographic strokes to known stenographic keystrokes with a set of closest-match comparisons.
In accordance with a concomitant mode of the invention, the set of partial actuations includes nine partial actuation levels.
The device according to the invention electronically senses an actuation depth of an individual key. A sensor is disposed to sense the actuation depth. In particular, an optical sensor is disposed near a cam and detects a light source emanating towards the optical sensor from another side of the cam. As the cam moves out of the light path or into the light path, such a sensor detects a strong or weak signal. The strong signal can mean that a standard character (not shadowed) is output and a weak signal can translate into a display of a shadowed character, or vice-versa depending upon the desired receiver configuration.
The device according to the invention can also include an integrated data processing system that translates, in almost real-time, the stenographic keystrokes into understandable English and stores both data in a memory (e.g., RAM, ROM, removable media) locally or wirelessly to an external location. The device can include a transceiver utilizing a bi-directional data channel to transmit untranslated stenographic data to a translating computer in real time. The translating computer can, then, translate the stenographic data and transmit a translated data stream back to the device, or to any combination of other devices that can be connected (directly or wirelessly) to the translating computer, for almost real time use and/or analysis by the stenographer. One example of such a system provides the stenographic device with a connection (direct or wireless) to the Internet and the translating computer with a connection (direct or wireless) to the Internet. Thus, commonly available Internet connection devices available at the location where the stenographer is taking data can be used to facilitate quick and inexpensive translation of stenographic data.
The device according to the invention can also include a multimedia recorder that can store, in a memory, digital video images and audio data. By recording the audio and/or video of the subject(s) of the stenographer on the device, it becomes possible to associate a portion of the multi-media file with a stenographic stroke. Such recording and coordination of stenographic and video and/or audio data allows the stenographer to playback images of and/or sounds from the subject to assist in the accurate translation of the stenographic keystrokes.
Such multi-media data can also be transmitted to other computers and/or locations through network connections, for example, over the Internet, by wireless connections, such as Bluetooth, by direct connections, such as RS-232, universal serial bus, IRDA, Firewire, or by any other available data communications method to assist the stenographer in accurate translation of the stenographic data.
Other features that are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in an electronic key depth sensing device and a method for interpreting actuation levels of a key device, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, 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 fragmentary, side elevational view of one embodiment of a keystroke device according to the invention;
FIG. 2 is a wire-frame perspective view of a machine having a key-retaining device for receiving a plurality of the keystroke device of FIG. 1 ;
FIG. 3 is a wire-frame side elevational view of the machine, the key-retaining device, and the keystroke device of FIG. 2 ;
FIG. 4 is a wire-frame perspective view of the machine and the keystroke device of FIG. 2 without the key-retaining device;
FIG. 5 is a perspective view of the machine and the keystroke device of FIG. 2 without the key-retaining device;
FIG. 6 is a fragmentary side elevational view of a first embodiment of a distal end of a distal portion of the keystroke device of FIG. 1 ;
FIG. 7 is a fragmentary side elevational view of a second embodiment of the distal end of the distal portion of the keystroke device of FIG. 1 ;
FIG. 8 is a fragmentary side elevational view of a third embodiment of the distal end of the distal portion of the keystroke device of FIG. 1 ;
FIG. 9 is a block circuit diagram of a stenographic system according to the invention;
FIG. 10 is a flow chart illustrating a first embodiment of the method for assigning shadows according to the invention; and
FIG. 11 is a flow chart illustrating a second embodiment of the method for assigning shadows according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a single keystroke device 10 to be used in a keyboard of some kind. The keystroke device 10 has a contact area 12 at which a user imparts the force for activating the keystroke device 1 . The contact area 12 is connected to a proximal portion 16 of a key lever 14 . The key lever 14 is connected movably to a key-retaining device 40 (see FIG. 2 ) at a pivot point 20 . The key lever 14 defines a pivot area 15 disposed between a distal portion 18 of the key lever 14 and the proximal portion 16 of the key lever 14 . The key lever 14 has a bias extension 19 (also referred to as a cam lever) for receiving a force that will be imparted upon the key lever 14 to keep the contact area 12 raised, i.e., in a non-actuated position.
In the embodiment shown in FIGS. 1 to 5 , the bias extension 19 has, at a distal end thereof, a hook 22 to be inserted through an end ring of a bias device 24 , e.g., a spring, illustrated only diagrammatically in FIG. 1 . To impart a raising force to the key lever 14 , the spring is oriented so that the force imparted on the bias extension 19 rotates the proximal portion 16 counter-clockwise with respect to FIGS. 1 to 5 about the pivot point 20 . The bias extension 19 and hook 22 shown in FIGS. 1 to 5 is only an exemplary embodiment for keeping the keystroke device 1 in a non-actuated position. The configuration of the bias extension 19 can take any form and the direction of force imparted by biasing spring can be in any direction so long as the contact area 12 is raised when not activated and biases the key to the raised position after being actuated. (The described configuration, of course, assumes that the keystroke device 10 is to be actuated by a lowering movement. Force in the opposite direction applies if the keystroke device 10 is to be lifted by a user.)
To communicate an actuation of the contact area 12 by a user to electronics of machine 1 in which the keystroke device 10 resides, the machine 1 has a switch or contact 50 . The contact 50 can take any form so long as a given actuation of the contact area 12 imparts a sufficient force to the contact 50 to indicate that a user wants the corresponding function of the keystroke device 10 to be activated (e.g., to print a character on a page and/or to store a character in an electronic file). The contact 50 can be merely a conducting contact surface that completes an electrical circuit when the keystroke device 1 is fully actuated or it can be a piston or lever that is depressed to actuate a switch physically when the keystroke device 1 is fully actuated. Therefore, it is not necessary to illustrate the contact 50 other than diagrammatically.
To sense a depression depth of the contact area 12 , a sensor 30 is disposed somewhere at the lever 14 such that the sensor 30 can detect how far the contact area 12 has been depressed. The sensor 30 can be disposed anywhere with regard to any portion ( 16 , 18 , 19 ) of the lever so long as it can detect movement of the lever 14 . In a preferred embodiment, however, the sensor 30 is disposed adjacent the distal portion 18 and on a side of the pivot point 20 opposite the proximal portion 16 . In this preferred embodiment, to keep movement of the segment of the distal portion 18 with respect to the sensor 30 linear, the measuring surface of the distal portion 18 (top surface in FIG. 1 ) has a longitudinal extent that passes directly through the center of the pivot point 20 . It is noted that if the sensor 30 can detect all of the desired number of movement “levels” from non-depression of the lever 14 to full depression of the lever 14 , then the contact 50 is rendered unnecessary.
For purposes of illustration, the sensor 30 in FIG. 1 has a circular cutout 32 . Therefore, in the view of FIG. 1 , the distal portion 18 can be seen through the cutout “window.” The position of the lever 14 in FIG. 1 is shown blocking approximately half of the window. Accordingly, if a light were placed on one side of the distal portion 18 and a light-detector was placed on the other side of the distal portion 18 , then the amount of light received by the detector would be approximately half of the amount received when the distal portion 18 was not blocking any part of the window.
The sensor 30 can detect movement of the distal portion 18 in any number of ways. In the preferred embodiment shown in FIG. 1 , the distal portion 18 blocks a non-illustrated light source of the sensor to vary an amount of light, the variance being proportional to a displacement of the contact area 12 by a user. Blocking of the light source is dependent upon the shape of distal portion 18 . FIGS. 6 , 7 , and 8 illustrate three exemplary embodiments for the distal end (furthest from the pivot point 20 ) of the distal portion 18 . When the distal portion 18 is curved as diagrammatically illustrated in FIG. 6 , the light source is blocked in a linear manner. In comparison, when the distal portion 18 is linear, as shown in FIG. 7 , the light source is blocked in an exponential manner. Finally, when the distal portion 18 is curved as shown in FIG. 8 , the light source is blocked in a non-linear manner.
The embodiment in FIG. 1 has a distal portion 18 with the shape corresponding to FIG. 6 . Thus, the light detected by the sensor 30 will be directly proportional to the travel of the proximal portion 16 . From the detected light, the sensor 30 (or the detector of the sensor 30 ) can output a signal (e.g., a voltage level) dependent upon the movement of the distal portion 18 . Such a signal can be processed to allow the machine 1 to not only register a keystroke, but also to register a partial-keystroke, i.e., a shadow. If an evenly and equally separate number of shadow levels are desired, then a linear output is preferred.
It is noted that the sensor 30 need not be placed at the distal portion 18 as illustrated in FIGS. 1 to 5 . Instead, the sensor 30 can be positioned at the proximal portion 16 . For example, if the sensor 30 is disposed above the proximal portion 16 as viewed in FIG. 1 , then a rest position of the lever 14 places the proximal portion 16 to completely cover the window 32 of the sensor 30 , and depression of the lever 14 moves the proximal portion 16 away from the window 32 to uncover the light source and allow light to be detected in an increasing manner the further the lever 14 is depressed.
In an embodiment of the sensor 30 where an analog voltage is output, a depth of the keystroke is registered by a change in the value of the analog voltage, which voltage is controlled by the distal portion 18 , attached to or integral with the key arm, selectively interrupting the optical receiver. When such an analog signal is provided, the sensor 30 can be connected to a downstream analog-to-digital converter for later digital interpretation of the level of the light received.
Other possible options for detecting a position of the lever 14 exist. For example, the depth of a keystroke can be registered with a digital decoder directly connected to the lever 14 . Such a decoder outputs a direct digital value dependent upon depth of the keystroke. Because the decoder is digital, the internal algorithm can, through appropriate software, make the output digital value change in any desired manner—linearly, exponentially, or otherwise—dependent upon the recorded depth of the keystroke.
Also, processing can include an algorithm that allows the user to selectively change/adjust the range and/or the number of levels of the output signal. An input device can be provided to give the stenographer a user-customized interpretation of a full key actuation, a partial key actuation, and/or any number of levels between no actuation and full actuation. The customizing input can be provided through appropriate manipulation of a physical item (a dial) or by executing a software program that controls the processing of the electrical input signal corresponding to the key actuation depth.
Alternatively, instead of generating more than two levels of a keystroke as set forth above, the sensor 30 can merely output two levels. In a first embodiment, the sensor 30 can output two levels corresponding to a partial key actuation (a shadow) and a full key actuation. In this configuration, a switch 50 is unnecessary. In a second embodiment, the sensor 30 can be, for example, a three-part system with two switches 50 : a first of the switches registering a partial key actuation; and a second of the switches registering a complete key actuation, or, the switch 50 can be a single two-level switch.
The sensor can also have the capability of using an optical encoding wheel to measure the key throw. For example, an encoder can be used to produce a pulse when the wheel (operatively connected to the lever 14 ) moves a given distance. Also, a focused light beam can be used to count rotations of the encoder wheel.
Varying degrees of movement of the lever 14 can also be detected using a resistive device, e.g., a resistor network or a potentiometer, with the depth of the keystroke being dependent upon a resistance presented by the device to a resistance measuring circuit. An accelerometer can also be used to detect the depth of the keystroke.
The above embodiments relate to the mechanics of the keystroke device 10 according to the invention. Once the sensor 30 generates the electrical output signal, this signal can be supplied to a processor μP for evaluation.
Emulation of the appearance of a printed stenograph output with a paperless electronic stenotype machine having an electronic display (e.g., LED, LCD, Flat Panel) can occur by electrically supplying depth information for each key pressed by the user in addition to the electronic data corresponding to the particular stenographic stroke, also sometimes referred to herein as a “word”. When a stroke is registered but is within a specified range less than a full depth of the stroke, the stroke can be stored electronically as a shadow. If, for example, ten values of shadow can be detected (or are programmed to be detectable), those values can be assigned to a specific level of brightness (e.g., in a look-up table or programmed in an EEPROM or stored in a flash RAM, hard drive, or static RAM) or, instead of a look up table, an equation can be used to shift the depth value byte four bits to get an intensity scale. Thus, the shadow will display on the output screen as characters lighter than a non-shadowed character. Instead of using merely brightness of the character(s) as the visible indicator, the shadow can also be varied using a difference in color, font, or other display attribute, or even by a combination of different display attributes.
FIG. 9 is a block circuit diagram of a stenographic device according to the invention. The stenographic machine 1 has a plurality of keystroke devices 10 , which are connected to an on-board microprocessor 2 . A memory 3 (e.g., RAM, ROM, hard drive, removable memory) is connected to the microprocessor 2 for storing data and supplying stored data to the microprocessor 2 . A display 4 is connected to the microprocessor 2 for displaying stenographic and/or translated data and for displaying the shadows determined/detected by the microprocessor 2 . The microprocessor 2 controls all electronic operations including receiving stenographic data and shadow data, storing all data, and displaying all desired processes, which processes can include the stenographic and/or level data itself, indications that data is being stored, indications that data is being translated, translated stenographic output, and many others.
Depending upon the configuration of the stenographic device, a translator 5 can be on-board the device and, therefore, it is directly connected to the microprocessor 2 for translating stored or incoming (real-time) stenographic data. Thus, input electronics for the keystroke device can be directly connected to the same processor 2 that controls the translation program, and the functions of input, shadow determination, translation, and correction/editing can be performed on a single unit 1 .
If the translator is not on board the stenographer's device 1 , then the device 1 can be connected to an external stenographic translator 6 , in which case the translator 6 is separate from the stenographic device 1 and information stored in the memory 3 is relayed 7 either by transfer through an intermediate media (e.g., floppy disk, micro-drive), in which case the device will have a floppy drive, USB port, Firewire port, etc., or wirelessly through some kind of communication data link (e.g., a Bluetooth, ISDN, Internet, or other wireless data link), in which case the device will have an on-board transceiver 8 .
In either case, the translator 5 , 6 translates the stenographic data to the respective language (e.g., English). When the device 1 is associated directly with a translation system, translation occurs quickly so that the stenographer can view his/her stenographic keystrokes in almost real-time and in relatively understandable English (dependent upon the quality of the word/translation processor). The memory 3 will store the translation locally 3 , 11 and/or externally 7 , 9 .
FIG. 9 further illustrates the stenographic device 1 and an embodiment 9 for connecting the device to an external stenographic translator 6 . In the example of FIG. 9 , the translator 6 is connected to the Internet and is housed at a location different from the stenographer's location. In such a networked configuration, the transceiver 8 can utilize a bi-directional data channel to transmit the un-translated stenographic data to the external translating computer 6 (represented by the dashed arrows), whether in real time or delayed. The translating computer 6 can, then, translate the stenographic data and transmit a translated data stream back to the device immediately or at a later time and to any other device that can be connected (directly or wirelessly) to the translating computer (also represented by the dashed arrows). Thus, the stenographer can have almost real-time analysis even without having an on-board translator.
One example of such a system 9 provides the stenographic device 1 with a connection (e.g., a direct or wireless transceiver 8 ) to the Internet and the external translating computer 6 with a connection (direct or wireless) also to the Internet. Thus, commonly available Internet connection devices available at the location where the stenographer is taking data can be used to facilitate quick and inexpensive translation of stenographic data without having to store the translation software on the stenographer's machine 1 .
When the device 1 has an integrated word processing system, then the functions of dictation, translation, and editing of the translation can be performed by the stenographer on a single machine.
The device 1 can also include a multi-media recorder 11 that can store, in a memory 3 , digital video images and/or audio data. By recording the audio and/or video of the subject(s) of the stenographer on the device, it becomes possible to associate a portion of the multi-media file with a stenographic stroke. Such recording and coordination of stenographic and video and/or audio data allows the stenographer to playback images of and/or sounds from the subject to assist in the accurate translation of the stenographic keystrokes. Such multi-media data can also be transmitted to other computers and/or locations through network connections, for example, over the Internet, by wireless connections, such as Bluetooth, by direct connections, such as RS-232, universal serial bus, IRDA, Firewire, or by any other available data communications measures to assist the stenographer in accurate translation of the stenographic data.
If a stroke registered by the device is not in the user's stenographic dictionary, an internal algorithm of the translator 5 , 6 can be activated to add and/or remove shadowed keys from the stroke until a stenographic match is found for the particular key(s) activation, somewhat like a closest-match routine known in the art of spell-checking devices. Thus, where a partial key actuation (shadow) occurs and the keystroke is not translatable, the shadowed keystroke can be combined with other similar stenographic keystrokes and, along with a spelling and grammar checking device, and can be corrected to fix a mis-stroke or can provide the stenographer with a list of various possible translations for that mis-stroke, which list would be examined by the stenographer at a later time, i.e., when the stenographic dictation breaks or at another location entirely.
A first exemplary method for interpreting a depth of the keystroke is illustrated with respect to the flowchart of FIG. 10 . In Step 100 , a query is performed to determine if a stroke has been detected. If a stroke has been detected, then, in Step 200 , the level of the stroke is determined, in other words, whether or not the stroke is a shadow stroke. If the level is determined to be full (complete actuation of the keystroke), then, the corresponding stenographic stroke with or without a full-level indicator is/are stored/transcribed in Step 300 . If the level of the stroke is determined to be partial, then two possibilities occur. If the system is only configured to register a full stroke or a partial-stroke, then, in Step 400 , the just-received stenographic stroke is indicated as being a partial-level (shadow), and the corresponding stenographic keystroke and a shadow indicator are stored/transcribed in Step 500 . If, however, the system is configured to detect more than just one partial-level, the corresponding actuation level is detected and the appropriate shadow is determined along with the detection of the just-received stenographic stroke in Step 400 . In such a case, the corresponding stenographic stroke and shadow level are stored/transcribed in Step 500 .
A query is made in step 600 to determine if stroke entry is finished (which, for example, may be indicated by a separate input from the stenographer). If the answer is no (e.g., the default situation), then, the device 1 waits in Step 700 for the receipt of a new stroke (meeting a predefined minimum keystroke depth requirement).
Registering of a keystroke is detected in Step 100 by a change transmitted by a keystroke device sensor, e.g., in an analog voltage or by a digital position indicator. In a digital system, the depth of the keystroke is translated into a digital numeric value. The value can have more than three variations or can be a tertiary value, including on, off, and shadow. Subsequently, the value is translated into a visual indicator for the corresponding shadow or full value, the indicator including color, shade, font style, position, and/or size of the symbol that represents the actuated key or set of keys (these examples being only representative of possible visual display characteristics). If the stenographer is finished entering keystrokes (i.e., end of the job), then the keystrokes are translated in Step 800 . It is noted that translation can be in real-time and, therefore, the circuit of Steps 100 to 700 can be repeated continuously and occur in parallel with translation. In such a configuration, Step 600 would be omitted and the dashed arrows in FIG. 10 would be performed instead.
A second exemplary method for interpreting depth of the keystroke is illustrated with respect to the flowchart of FIG. 11 . In Step 1000 , the stenographic dictation begins. In Step 1100 , audio and/or video of the proceedings to be stenographed are recorded electronically, which recording is an option to be selected by the stenographer. In Step 1200 , a query is performed to determine if any key has been pressed past its registration point. If not, the system waits until this event occurs. In Step 1300 , a query is performed to determine if all keys that are past the registration point create a recognizable stenographic stroke.
If the answer is yes, then, in Step 1400 a , the time of the recognizable stroke is recorded and stored with the stenographic data in a mass storage device and/or internal memory and the audio and/or video data file is also stored along with information regarding the location in the data file of the stored stenographic data. Accordingly, the user can go back to the stenographic stroke and correct any errors in transcription by examining the relevant video and/or audio. It is optional, in Step 1500 a , to pass the stored stenographic stroke to an internal translator and/or to produce a text display.
If the answer is no and a recognizable stenographic stroke is not created, then an attempt to produce a recognizable stroke is performed based upon all of the keys that passed the registration point in combination with any partial key presses that did not reach registration point but were pressed in some way. Specifically, in Step 1400 b , the time of the unrecognizable stroke is recorded and stored with the stenographic data in a mass storage device and/or internal memory and the audio and/or video data file is also stored along with information regarding the location in the data file of the stored stenographic data. Accordingly, the user can go back to the stenographic stroke and correct any errors in transcription by examining the relevant video and/or audio. In Step 1500 b , the unrecognizable stroke is passed to an internal translator to find a likely match or a set of possible matches. A text display can be made and/or a suitable signal (beep) can occur to notify the user that a potential error in transcription has occurred. The user can view the stroke, which will include any partial key presses identified by a different color, intensity of color, font, and/or size. If possible (because transcription is still occurring), the user can select the appropriate translation from the suggestions in real time.
In Step 1600 , the stenographic data is transmitted to an external translator through some communications link, e.g., RS-232, USB, Network, Bluetooth, Firewire, WIFI, or any other data transmission measures. Optionally, in Step 1700 , an external translator can check the translation data and relay that data through an available output device, such as an RS-232 port or network connection to an external display device such as a computer. This process is repeated until dictation is complete.
It is noted that the optional recording of audio and/or video data allows CIC and permits the user to track the stenographic data with the corresponding audio/video data and, thereby, correct any incorrect stenographic translation.
Other possible uses for the keystroke device 10 according to the invention include musical instruments. In one example, the volume of the note would increase or decrease based upon a level of the output signal. In another example, the volume of the note would increase dependent upon a rate of change of the signal (velocity). | A method for recording shadow keystrokes in an electronic stenographic recording machine having keys forming stenographic keystrokes when actuated includes the steps of sensing an extent of an actuation of a subset of the keys as a stenographic keystroke, recording values selected from the group consisting of a full value and at least one intermediate value corresponding to the extent of the actuation of each of the subset of keys, and determining a first subset of possible translations of the stenographic keystroke based upon a second subset of possible combinations of the recorded values of the subset of the keys. Also, an extent of an actuation of at least one key can be sensed and at least one intermediate value corresponding to the extent of the actuation of the at least one key can be recorded. | 1 |
TECHNICAL FIELD
This invention relates to blades for removing material (e.g., snow, dirt, ash) from surfaces.
BACKGROUND
Traditional shoveling of material or debris involves lifting and throwing material, pushing or some combination of pushing and throwing using a shovel or other apparatus. The following patent(s) disclose various shovels (U.S. Pat. Nos. 5,906,060; 1,206,235; 1,232,361; 2,460,560; 2,598,952, 2,772,490; 2,846,785; 2,852,872; 2,484,409 and 5,271,169). Material is removed from surfaces by sliding the blade across the surface, collecting the material on the blade and then moving the material to a desired location and tilting or lifting the blade to remove the material from the blade. Existing shovels or blades sometimes lose all forward momentum when encountering surface irregularities. This results in lost efficiency and requires increased effort and time by the operator.
SUMMARY
According to the first embodiment of the invention comprising a blade is provided. The blade may include a handle, an elongated member, and a blade body. The elongated member may have a first end and a second end spaced apart from the first end. The handle may be configured to receive the first end of the elongated member. The blade body may be configured to receive the second end of the elongated member. The blade body may include a first surface, a second surface, a first side, a second side, a first edge, a second edge, and a first runner. The second surface may be disposed opposite the first surface. The first side may have a first profile and the second side may have a second profile, with the second side disposed opposite and substantially parallel to the first side. The first edge may extend between the first side and the second side. The second edge may be spaced apart from the first edge and may extend between the first side and the second side. The first runner may be attached to the first side, the first runner having a first runner profile at least partially defined by the first profile and the first runner extending beyond the second edge.
The blade may have a second runner attached to the second side, the second runner having a second runner profile at least partially defined by the second profile and the second runner extending beyond the second edge, the second runner disposed substantially parallel to the first runner. The blade may have a blade body profile for a blade body runner attached to the blade body, the blade body runner having a blade body runner profile at least partially defined by the blade body profile and the blade body runner extending beyond the second edge, the blade body runner disposed substantially parallel to the first runner.
The first runner profile may have an arcuate profile that substantially matches the first profile, a portion of the first runner may not be in plane with the second surface, and a portion of the first runner may not be in plane with the second edge. The second runner profile may have an arcuate profile that substantially matches the second profile, a portion of the second runner may not be in plane with the second surface, and a portion of the second runner may not be in plane with the second edge. The blade body runner profile may have an arcuate profile that substantially matches the blade body profile, a portion of the blade body runner may not be in plane with the second surface, and a portion of the blade body runner may not be in plane with the second edge.
According to the second embodiment of the invention comprising a blade body is provided. The blade body may include a first surface, a second surface, a first side, a second side, an edge, and a first runner. The second surface may be disposed opposite the first surface. The first side may have a first profile and the second side may have a second profile, with the second side disposed opposite and substantially parallel to the first side. The first surface and second surface may define an edge extending between the first side and the second side. The first surface and second surface may define a blade body profile. The first runner may be attached to the first side, the first runner having a first runner profile at least partially defined by the first profile and the first runner extending beyond the edge.
The blade body may have a second runner attached to the second side, the second runner having a second runner profile at least partially defined by the second profile and the second runner extending beyond the second edge, the second runner disposed substantially parallel to the first runner. The blade body may have a blade body runner attached to the blade body, the blade body runner having a blade body runner profile at least partially defined by the blade body profile and the blade body runner extending beyond the edge, the blade body runner disposed substantially parallel to the first runner.
The first runner profile may have an arcuate profile that substantially matches the first profile, a portion of the first runner may not be in plane with the second surface, and a portion of the first runner may not be in plane with the edge. The second runner profile may have an arcuate profile that substantially matches the second profile, a portion of the second runner may not be in plane with the second surface, and a portion of the second runner may not be in plane with the edge. The blade body runner profile may have an arcuate profile that substantially matches the blade body profile, a portion of the blade body runner may not be in plane with the second surface, and a portion of the blade body runner may not be in plane with the edge.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of elements of the blade.
FIG. 2 is an exploded perspective view of elements of the blade with runners.
FIG. 3 is a perspective view of elements of the blade with runners.
FIG. 3A is a cross-section of elements of the blade with runners.
FIG. 3B is a side view of elements of the blade with runners.
FIG. 4 is a perspective view of an embodiment of the blade with integral runners.
FIG. 5 is a perspective view of elements of the blade with the embodiment of attached runners.
FIG. 5A is a perspective view of an existing blade with the embodiment of attached runners.
DETAILED DESCRIPTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may 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.
Referring to the drawings in detail wherein like elements are indicated by like numerals, there is shown a blade 102 that may include an elongated member 104 ; a blade body 106 ; a first side 108 ; a first profile 110 ; a second side 112 ; a second profile 114 ; a first edge 116 ; a second edge 118 ; a first runner 202 ; a first runner profile 204 ; a second runner 206 ; and a second runner profile 208 . FIG. 400 depicts an embodiment of the invention. See FIGS. 1, 2, 3, 3A, 3B, and 4 .
The elongated member 104 may have a first end 124 and a second end 126 spaced apart from the first end 124 and an elongated body extending therebetween. The second end 126 of the elongated member 104 receives the blade body 106 .
The blade body 106 has a first side 108 that follows the first profile 110 of the blade 102 . The first profile 110 may be defined by a substantially continuous section having a constant radius of curvature. In at least one embodiment, the first profile 110 may be defined by a linear section or a substantially non-continuous section having varying radii of curvature such that it is not piecewise continuous.
The blade body 106 has a second side 112 that follows the second profile 114 of the blade 102 . The second profile 114 may be defined by a substantially continuous section having a constant radius of curvature. In at least one embodiment, the second profile 114 may be defined by a linear section or a substantially non-continuous section having varying radii of curvature such that it is not piecewise continuous.
The first runner 202 may abut the first side 108 . The first runner 202 and the first side 108 may be substantially aligned with the first runner profile 204 substantially following the first profile 110 . Traditionally, the first surface 120 is the concave surface of the blade body 106 whereas the second surface 122 is the convex surface of the blade body 106 .
The first profile 110 and the first runner profile 204 may substantially follow the second surface 122 or in some embodiments, the first profile 110 is vertically offset from the first runner profile 204 . The offset between the first profile 110 and the first runner profile 204 also offsets the first runner 202 from the first surface 120 and/or the second surface 122 reducing the contact between the blade body 106 and the surface being shoveled.
The second runner 206 may abut the second side 112 . The second runner 206 and the second side 112 may substantially aligned with the second runner profile 208 substantially following the second profile 114 .
The second profile 114 and the second runner profile 208 may substantially follow the second surface 122 or in some embodiments, the second profile 114 is vertically offset from the second runner profile 208 . The offset between the second profile 114 and the second runner profile 208 also offsets the second runner 206 from the first surface 120 and/or the second surface 122 reducing the contact between the blade body 106 and the surface being shoveled.
The blade body profile 302 is substantially defined by the second surface 122 . The blade body runner profile 304 may substantially follow the blade body profile 302 . The blade body runner 306 may be substantially aligned with the blade body runner profile 304 .
The blade body profile 302 and the blade body runner profile 304 may substantially follow the second surface 122 or in some embodiments the blade body profile 302 is vertically offset from the blade body runner profile 304 . The offset between the blade body profile 302 and the blade body runner profile 304 also offsets the blade body runner 306 from the first surface 120 and/or the second surface 122 reducing the contact between the blade body 106 and the surface being shoveled.
The first surface 120 and the second surface 122 define the first edge 116 , wherein the first edge 116 extends between the first side 108 and the second side 112 . The first surface 120 and the second surface 122 define the second edge 118 , wherein the second edge 118 extends between the first side 108 and the second side 112 . The first edge 116 and the second edge 118 are spaced apart and disposed opposite one another. Traditionally, the first edge 116 is closest to the handle or the “trailing edge” and the second edge 118 is the “scraping” or “leading” edge of the blade body, which contacts the material first and the surface where the material resides.
The first runner 202 extends ahead of the direction of scraping of the second edge 118 . When a surface irregularity is encountered the first runner 202 traverses the surface irregularity reducing or avoiding impact with the second edge 118 .
The second runner 206 extends ahead of the direction of scraping of the second edge 118 . When a surface irregularity is encountered second runner 206 traverses the surface irregularity reducing or avoiding impact with the second edge 118 .
The blade body runner 306 extends ahead of the direction of scraping of the second edge 118 . When a surface irregularity is encountered blade body runner 306 traverses the surface irregularity reducing or avoiding impact with the second edge 118 .
The extension of the runners (first runner 202 , second runner 206 , and/or blade body runner 306 ) beyond the second edge 118 allows the blade body 106 to traverse surface irregularities when clearing material from irregular surfaces, while allowing the second edge 118 to maintain contact with the surface being cleared.
When a surface irregularity is encountered by at least one the runners (first runner 202 , second runner 206 , and/or blade body runner 306 ) the runners slide up the raised surface allowing the second edge 118 (the “scraping edge”) to easily transition to the new surface. The second edge 118 on a blade with runners contacts raised surfaces for a shorter duration of time than the second edge 118 on a blade without runners.
Without the runners (first runner 202 , second runner 206 , and/or blade body runner 306 ) extending beyond the second edge 118 , the second edge 118 would impact the irregularity, hampering the movement of the blade body 106 . The user would be required to lift and reposition the blade on the new surface and reinitiate momentum. The irregularity may also be a gap between resilient surfaces (metal, concrete, etc.) whereby the second edge 118 falls into the gap, hampering momentum when the second edge 118 contacts the other resilient surface. With the extension of the runners (first runner 202 , second runner 206 , and/or blade body runner 306 ) beyond the second edge 118 , the second edge 118 will not fall into the gap because the runners (first runner 202 , second runner 206 , and/or blade body runner 306 ) will “traverse” the gap between resilient surfaces without a hampering of the momentum of blade body 106 .
The vertical offset of the runners (first runner 202 , second runner 206 , and/or blade body runner 306 ) from the first surface 120 and/or the second surface 122 , and the extension of the runners (first runner 202 , second runner 206 , and/or blade body runner 306 ) beyond the second edge 118 may allow the blade body 106 to traverse surface irregularities when clearing material from irregular surfaces and keep the second edge 118 in contact with the surface when clearing material from flat surfaces.
Referring to FIG. 4 , the first embodiment 402 , the components may be integrally formed to the blade body. The integrally formed components for this embodiment may be: the blade body 106 ; the first side 108 ; the first profile 110 ; the second side 112 ; the second profile 114 ; the first edge 116 ; the second edge 118 ; first surface 120 ; the second surface 122 ; the first runner 202 ; the first runner profile 204 ; the second runner 206 ; the second runner profile 208 ; the blade body profile 302 ; the blade body runner profile 304 ; and the blade body runner 306 .
Referring to FIG. 5 and FIG. 5A , the second embodiment 502 the components may be added to an existing blade body. The components to be added on to an existing blade may be: the first runner 202 ; the first runner profile 204 ; the second runner 206 ; the second runner profile 208 ; the blade body runner profile 304 ; and the blade body runner 306 . In the second embodiment the edge 504 is the second edge 118 “scraping edge” of the first embodiment.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, 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 invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | A blade is provided having runners on the blade that extend forward of the blade's leading edge. These runners traverse surface irregularities allowing the blade to avoid colliding with surface irregularities. | 0 |
This application is a continuation of U.S. Ser. No. 584,436 filed Jan. 25, 1984, now abandoned.
FIELD OF THE INVENTION
The invention relates to a yarn-feeding apparatus, such as for a circular knitting machine, which can evaluate a combination of fault signals to effect shut down of the machine when predetermined fault conditions are determined.
BACKGROUND OF THE INVENTION
In a yarn-feeding apparatus of this type, which is known from European Patent Application No. EPA 80 10 6719 and its corresponding U.S. application Ser. No. 269,061 as filed May 18, 1981, now U.S. Pat. No. 4,386,508, the yarn-guiding elements are moved into nonfeeding areas by magnets, while their movement into feeding areas is effected by increased yarn tensions caused by the operation of the fingers in the circular mechanism. However, yarn-feeding apparati are also known in which the movement of the yarn-guiding elements is effected exclusively by tension changes in the yarn caused by the operation of the fingers of the circular mechanism. Each yarn-transporting element is a constantly driven belt which runs over a freely rotatable roller. As soon as the yarn-guiding element moves the yarn under the belt, same carries along the yarn and moves it to the associated finger. Vice versa during a movement of the yarn-guiding element into the nonfeeding area, the yarn is moved out from under the belt and stops. In the lastmentioned conventional yarn-feeding apparatus, it is necessary that the path of movement of the guiding elements is sufficiently long so that the yarn-guiding element compensates for unavoidable trailing movement of the yarn, which movement results due to the inertia of the yarn mass and the yarn elasticity, when the earlier effective acceleration is suddenly reduced by the yarn-transporting element. The position sensor which is connected with the yarn-guiding element emits a signal which indicates a yarn breakage in an end position of the yarn-guiding element in the nonfeeding area, which end position can be reached by the yarn-guiding element only when in addition to the normal trailing movement due to the yarn breakage the yarn-guiding element was able to move on. The knitting machine is turned off with this signal. In all other positions in the nonfeeding area and in the feeding area, the position sensor does not emit a signal. It is thereby disadvantageous that a signal cannot be produced with the position sensor when a yarn error occurs for which the knitting machine does not use the amount of yarn fed to it in an orderly manner, for example due to an interference in the path of the yarn to the circular mechanism and to the knitting needles or because of dirty yarn eyelets or an incorrect knitting machine adjustment. During such errors, the tension in the yarn which comes from the yarn-feeding apparatus is reduced, which causes the guiding element to move the yarn out of the feeding area, but without thereby reaching its end position. Shortly thereafter the yarn tension again increases, since the positive feed was ended, which causes the yarn-guiding element to move the yarn again into the feeding area. The position sensor does not react to this yarn error; rather, the guide element can reach its end position in which a shut-off signal is produced by the position sensor when the voltage in the in-feeding yarn decreases slowly, if such yarn was not processed for a longer period of time and due to vibrations or air streams starts to sag. Such an error is then difficult to find, in particular if the contact function of the position sensor is not particularly sensitive, and can cause a considerable standstill time for the knitting machine. A further yarn error exists when in the circular mechanism, after a color change, two yarns are processed simultaneously. This yarn error is also not indicated by the position sensor, since it does not reach its end position.
A basic purpose of the invention is to provide a yarn-feeding apparatus of the abovementioned type which, in response to actual and serious yarn errors, reliably and quickly turns off the knitting machine.
Each yarn-guiding element produces in the construction a signal when the yarn comes into engagement with the transporting element or out of engagement with the transporting element, and does not wait until the end position. The signals which are emitted by all position sensors and which are processed in the logic switching circuit form in the various operating conditions different signal combinations, from which the logic switching circuit can detect whether or not an error condition exists which requires the knitting machine to be turned off. The processing of the signals and the evaluation of the signal combination involves the recognition that, during orderly operation with no yarn breakage or yarn error, only one single yarn may be processed, which must then be fed positively, so that more than one positively fed yarn and also no positively fed yarn at all can only mean a yarn error. Incorrect errors are ignored, since it is of no importance for the signal emission of the positive sensor whether the yarn-guiding element is in the end position or not, because of suitable signal is already being formed as soon as the yarn moves out of or into the area of engagement of the transporting element. Due to the fact that, in this relatively narrow range between positive feed and no feed, the signal change of the position sensor is effected, it is possible to form with all provided position sensors practically delay-free combinations out of such signals, which in certain combinations are representative of a yarn error, and due to this the switching unit then quickly stops the knitting machine suddenly so that damage in the goods is kept as small as possible. When in a knitting machine which is equipped with such a yarn-feeding apparatus an orderly color change takes place with an overlap during which two yarns are processed simultaneously, then the knitting machine, does not not need to be turned off since no actual yarn error exists. No significant measures are needed for this. It is only important that the type and manner of forming signals by the position sensors makes it possible for the switching circuit to recognize actual errors immediately in connection with the help of the signal combinations and to turn off the knitting machine.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be discussed hereinafter in connection with the drawings, in which:
FIG. 1 is a schematic side view of a yarn-feeding apparatus;
FIG. 2 illustrates a first embodiment of an electric circuit of the yarn-feeding apparatus of FIG. 1;
FIG. 3 illustrates a second embodiment of the electric circuit; and
FIG. 4 illustrates a further embodiment of the electric circuit.
DETAILED DESCRIPTION
According to FIG. 1, a yarn-feeding apparatus has a housing 1 on which is mounted a clamp portion, with which the yarn-feeding apparatus can be secured on a circular support ring 2' above an associated knitting station in a horizontal circular knitting machine. In a multi-system circular knitting machine there are provided as many yarn-feeding devices as there are knitting stations in the knitting machine. The clamp portion 2 extends partly in and partly below the housing 1 and has a support plate 2a for a vertical axle 3, on which four yarn-feeding wheels 4A,4B,4C and 4D are supported freely rotatably, namely one above the other. A portion of the circumference of each yarn-feeding wheel has a yarn-transporting element formed as a belt 5A,5B,5C,5D engaging it. The belts are driven in a conventional manner in synchronism with the knitting machine in order to supply in this case four yarns FA,FB,FC,FD which come from not illustrated yarn spools. The yarns are then fed, preferably through guide eyelets, to the fingers in a circular mechanism (not illustrated), from where they then run to the knitting needles in the knitting machine.
Yarn-feeding guiding elements 6Ain,6Bin,6Cin,6Din and 6Aout,6Bout,6Cout,6Dout are pivotally supported in pairs on the housing 1, wherein an input-guiding element 6Ain, 6Bin,6Cin,6Din and a respective output-guiding element 6Aout,6Bout,6Cout,6Dout which is fixedly connected therewith is provided for each yarn FA,FB,FC,FD.
Each input-guiding element 6Ain,6Bin,6Cin,6Din can be pivoted back and forth, against the force of a spring (not illustrated) which urges it counterclockwise, between a feeding area and a nonfeeding area, as can the output-guiding elements 6Aout,6Bout,6Cout,6Dout. When the yarn-feeding element of a yarn is in a feeding-area position, the yarn lies under the belt and is positively fed by same, whereas when the yarn-feeding element for a yarn is in the nonfeeding-area position, the yarn lies outside of the region of engagement of the belt and feeding wheel and is no longer fed.
In FIG. 1 the input-guiding element 6Ain and the output-guiding element 6Aout are in the feeding-area position, so that the yarn FA is fed positively, while the other yarn-feeding elements are in their nonfeeding-area positions, so that the other yarns FB,FC,FD are not fed.
The yarn-guiding elements are supported in the housing 1 on shafts 8 which extend perpendicular with respect to the drawing plane (FIG. 1). A contact pin 7A',7B',7C',7D' is connected to each shaft, which pin together with a correspondingly arranged contact plate 7A",7B",7C",7D" forms an electric position sensor for sensing the position of the associated yarn-guiding element.
The contact plates 7A",7B",7C",7D" in this exemplary embodiment according to FIG. 1 are each conductive only in the left portion thereof and are nonconductive in the right portion thereof. In this manner, the position sensor emits a signal when the associated yarn-guiding element is in the feeding-area position, while in the nonfeeding-area position no signal is produced. Of course, this arrangement could also be reversed. The transition from the nonconductive portion to the conductive portion of each contact plate is arranged so that a signal is produced exactly when the associated yarn becomes disengaged from the belt 5A,5B,5C,5D or moves under the belt, namely the switching points of the position sensors lie exactly in the threshold regions in which a positive delivery of the yarn starts or stops. The respective signal is then maintained unchanged during further movement of the yarn-guiding element within the non-feeding area or the feeding area.
The contact plates 7A",7B",7C",7D" are connected by a connecting line to a control relay CR, which on the other hand is connected to a positive voltage source in the housing 1. The contact pins 7A',7B',7C',7D' are connected by a common line to a negative voltage source, also in the housing 1. The control relay CR has its relay contacts CR c connected in a circuit which includes the stop-motion relay of the knitting machine. The stop-motion relay, for example, turns off the knitting machine when it is energized. This circuit in the housing forms an electric logic switching circuit which operates in the aforementioned manner and switches off the knitting machine when all position sensors produce specific signal combinations which will be explained later.
FIG. 2 illustrates a circuit which can be used in the yarn-guiding apparatus of FIG. 1 wherein, if desired, a time element of a timer circuit TC with a time delay of t o is provided before the control relay CR. The positions of the contact pins 7A',7B',7C',7D' and the shafts 8A,8B,8C,8D of the yarn-guiding elements corresponds with the position shown in FIG. 1.
During a normal and orderly operation of the yarn-feeding apparatus of FIG. 1, namely in the positions shown in FIG. 1, the yarn FA is fed positively. The associated contact pin 7A' engages the contact on the contact plate 7A", whereby the d.c. circuit from (-) to (+) is closed through the control relay CR and, if provided, the time element TC. This means in this circuit that the control relay CR is energized and keeps it contacts CR c open, so that the circuit for the stop-motion relay of the knitting machine is open. The knitting machine thus operates. In the case of a breakage of the yarn FA or a drop in the yarn tension due to an outside influence, the yarn-guiding element 6Aout swings upwardly and the input-yarn-guiding element 6Ain swings downwardly. The contact pin 7A' is moved to the nonconducting region of the contact plate 7A", so that the d.c. circuit through the control relay is interrupted and the control relay CR is de-energized. The contacts CR c of the control relay CR then close the circuit for the stop-motion relay of the knitting machine, so that the knitting machine is promptly stopped.
The time element TC (FIG. 2) can be provided for the case that, during a yarn change in the knitting machine, no overlapping between the old and the new yarn takes place. This time element with its time t o then bridges the short time period during which no feeding-area signal is provided.
A further yarn error (overfeed) exists if for any reason the just processed old yarn or also a new yarn is not properly processed by the knitting needles or is not forwarded properly to the knitting needles by the respective finger in the circular mechanism. The position sensor for this yarn will produce, due to the reduction in yarn tension which occurs during this yarn error, a nonfeeding-area signal, or in other words none of the position sensors will produce a feeding-area signal. The logic switching circuit reacts to this signal combination and operates PG,12 the stop-motion relay, which causes the knitting machine to be turned off immediately.
A further yarn error exists if, after a yarn change, the old yarn, which should not be further processed, still remains tensioned, for example because in the circular mechanism or in front of the knitting needle cutting was not done correctly. Then, the old yarn is processed at the same time as the new yarn, namely, both yarns are fed positively. In this case, the knitting machine is supposed to be turned off. This occurs in the embodiments according to FIGS. 3 and 4 by the electronic switching circuit (indicated at A in FIG. 3 and by dashes in FIG. 4) recognizing a signal combination from the position sensors which indicates the yarn-error condition and subsequently turning off the knitting machine.
According to FIG. 3, the contact plates 7A",7B",7C",7D" are connected with a number of input connections of an electronic logic switching circuit A, which is created for example from common electronic logic components (as in FIG. 4) or is formed by a microprocessor. The output of the logic switching circuit A is connected with the coil of a control relay CR A , the relay contacts of which lie in a circuit controlling the stop-motion relay of the knitting machine.
The electronic logic switching circuit A is designed so that it produces an output signal for switching the control relay CR A in response to two error conditions which are represented by specific signal combinations, which causes the stop-motion relay of the knitting machine to be operated.
The first error condition consists of n nonfeeding-area signals from the position sensors 7A',7A",7B',7B", 7C',7C",7D',7D", where n is the number of position sensors. This combination of n-signals indicates that yarn is not being knitted or that the yarn intended for knitting is broken.
The second error condition is indicated by a signal combination which consists of (n minus a number greater than 1) signals, where n is the number of existing position sensors. In other words, a signal combination which indicates more than one feeding-area signal exists simultaneously with nonfeeding-area signals illustrates this error condition, during which for example two yarns are being knitted simultaneously.
It is possible to design the logic switching circuit for both error conditions so that it produces an output signal for the stop-motion relay of the knitting machine with a specific time delay, for example 20 milliseconds, thereby avoiding an erroneous turning off of the knitting machine during a yarn change. During a yarn change with an overlap two yarns are simultaneously fed positively for a short period of time, while during a yarn change without overlap no yarn at all is fed for a certain time span because the old yarn is no longer being fed and the new yarn is not yet being fed.
In the embodiment of FIG. 4, the position sensors are constructed by four phototransistors T1 to T4 and four photodiodes D1 to D4 as opto-electronic position sensors for the yarn-guiding elements. The emitters of the phototransistors T1 to T4 are connected through a resistor network NET r to an input of a first operational comparator or amplifier OP 1 and to an input of a second operational comparator or amplifier OP 2 . The other, negative input of the operational amplifier OP 1 is supplied with a reference voltage value. The other, positive input of the operational amplifier OP 2 is also supplied with a reference voltage. The output of the first operational amplifier OP 1 is connected to an input of a first NOR-gate NOR 1 . The output of the second operational amplifier OP 2 is connected by an intermediate resistor and a second timer circuit RC 1 to the second input of the first NOR-gate NOR 1 , wherein the time circuit RC 1 has for example a time constant of approximately 140 milliseconds. The output of the first NOR-gate NOR 1 is applied to both inputs of a second NOR-gate NOR 2 , the output of which is connected to a holding circuit through a second timer circuit RC 2 . The timer circuit RC 2 has for example a time constant of approximately 60 milliseconds. The holding circuit is an S-R flip-flop which consists of two NOR-gates NOR 3 and NOR 4 , the output of the NOR-gate NOR 2 being connected through an intermediate resistor to one input of the NOR-gate NOR 3 of the holding circuit. The other input of the NOR-gate NOR 3 is connected through a feedback loop to the output of the NOR-gate NOR 4 of the holding circuit. The output of the NOR-gate NOR 3 is connected to one input of the NOR-gate NOR 4 , while the other input of the NOR-gate NOR 4 is connected through a divider which includes a resistor and a capacitor to a contact of a reset switch SW 1 . The output of the holding circuit is connected to the base of a further transistor T 5 , which is connected through a connecting line to the stop-motion relay of the knitting machine, wherein a grounded indicating lamp L for providing a visual indication of an error condition is connected to the connecting line.
The holding circuit NOR 3 and NOR 4 holds the stop-motion relay of the knitting machine open after occurrence of an error condition and until such error condition is cancelled by operating the switch SW 1 .
The two operational amplifiers OP 1 , OP 2 and/or the NOR-gates NOR 1 -NOR 4 can advantageously be contained in an integrated switching circuit of conventional construction which simplifies the manufacture of the circuit and keeps the space required for the circuit small.
A switch SW 2 is connected by intermediate resistors to points between the position sensors and the two operational amplifiers OP 1 and OP 2 , with which switch under certain operating conditions the position sensors can be bridged. A diode is inserted in the connecting line between the switch SW 2 and the second operation amplifier OP 2 .
The electronic logic switching circuit according to FIG. 4 is mounted on the inside of the housing 1 of the yarn-feeding apparatus of FIG. 1. During the first aforementioned error condition, all four transistors T1 to T4 become conductive. Because of the resistors R 1 and R 2 which are placed in front of the first operation amplifier OP 1 , a voltage level will be provided by the resistor network NET R at one input of the first operation amplifier OP 1 , so that its output also emits a high voltage level or voltage potential which as a signal corresponds with a binary 1. If this high voltage potential is maintained for longer than 60 milliseconds, the signal finally goes through timer RC 2 to the base of the transistor T5, which causes said transistor to become conductive and to send a shut-off signal on the connecting line to the stop-motion relay of the knitting machine, which is maintained by the holding circuit NOR 3 and NOR 4 and also causes the lamp L to illuminate.
During the second error condition, only two of the four transistors T1 to T4 or less become conductive, through which due to the special design of the resistors R 3 and R 4 , which are placed in front of an input of the second operational amplifier OP 2 , a voltage level is fed to one input of the second operational amplifier OP 2 . The first operational amplifier OP 1 is designed so that it does not react to this voltage level. As a result the operational amplifier OP 2 emits a high potential at its output which is fed through the timer circuit RC 1 to the second input of the NOR-gate NOR 1 . When the high potential of the output of the second operation amplifier OP 2 exists longer than 140 milliseconds for timer RC, 60 milliseconds for timer RC 2 equalling 200 milliseconds, then the base of the transistor T5 receives a voltage potential, based on which the transistor T5 becomes conductive and produces a shut-off signal.
The invention is not limited to the earlier discussed exemplary embodiments. These exemplary embodiments are only to facilitate an understanding of the inventive thought to produce a signal from the yarn movement between the feeding area and the nonfeeding area exactly in the transition area from the positive feed to no feed, and to produce signal combinations from the signals which depend on the positions of the other yarns, which signal combinations represent exactly the existence of error conditions for which the knitting machine is to be turned off. It is thereby of subordinate importance how the turning off of the knitting machine is actually done. It can be chosen advantageously, depending on how the signals are evaluated by the position sensors, whether the respectively fed yarn or the just not fed yarns are monitored, namely each feeding-area signal will then be a positive signal (for example a binary 1), while the nonfeeding-area signals are negative signals (for example binary 0), or vice versa. It is preferred for various reasons to thereby give a check of the just not fed yarns. | A yarn-feeding apparatus for the positive feeding of several yarns to a circular mechanism of a circular knitting machine, comprising fingers which are arranged in the circular mechanism for receiving and guiding the yarn into a knitting position or taking the yarn out of a knitting position, including delivery apparatus with each including a yarn-transporting element and a yarn-guiding element which is movable back and forth between a feeding area in which the yarn is in engagement with the yarn-transporting element and a nonfeeding area, and wherein for each yarn-guiding element there is provided an electric position sensor which produces an electric signal in dependence on the position of the yarn-guiding element. Yarn errors, which would lead to damage in the finished goods if the knitting machine is not timely turned off, are detected by each position sensor always producing a feeding-area signal when the yarn-guiding element is in the feeding area or a nonfeeding-area signal when the yarn-guiding element is in the nonfeeding area. The position sensor is connected signal-transmittingly to an electric logic switching circuit for turning off the knitting machine, which circuit reacts to a combination from the signals of all position sensors, which combination represents a yarn breakage and/or a yarn overfeed and/or a yarn-changing error. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to cutting tools, particularly hole cutting tools, and with greater particularity, hole cutting tools for cutting round or irregular holes by starting the cut in the center of the hole.
2. Description of the Prior Art
Modern materials have led to the development of a variety of tools to cut such material. Such tools include: cutting torches or arcs; lasers; and water jet cutting apparatus. All of these tools are distinguished by the fact that they cut at one point and are moved during operation to cut a line or profile.
It is often desirable to cut large diameter holes or cutouts in sheets of material. If the hole is larger than the diameter of the cut made by the tool, the tool must be moved to produce the outline of the hole. Three basic methods are used presently to accomplish this movement. First, the tool may be manually moved to follow an outline on the workpiece. This method has the advantage of simplicity, but the disadvantage that high tolerance cannot be duplicated. A second method is to move the tool around a template or form. This method has the advantage of greater reproducibility at the expense of added complexity and preparation costs for the templates. The third method is to provide motor drives in the x and y directions and link the drives to a computer or robot. This method provides excellent reproducibility and flexibility at a greatly increased cost.
With the cutting tools described, it is desirable to begin cutting at the center of the hole. The initial start up of the tool can lead to an increased kerf size at the start point, in the case of lasers or torches. With water jets cutting laminated materials, the start up torch can cause a point of delamination. If the tool is started on the edge of the hole sought to be made, therefore, the hole will either be irregular or contain a deliminated portion. For the above reasons, it is desirable to begin the cut at the center or discarded portion of the hole.
Of the methods described above, only the first and last is capable of beginning at the center of the hole. Such a process could be programmed into a computer or robot at additional expense, or done by hand. It is, therefore, desirable to produce a simple method for producing holes of large size, or irregular shape by use of a cutting tool that starts the cut at the center.
SUMMARY OF THE INVENTION
The invention provides a simple mechanical means for generating movement of a tool in a circular or irregular closed pattern with a starting point in the center of the pattern. The tool may produce irregular or circular cut-outs of variable size. The invention will either accept pre-formed patterns, or can generate the curve by internal adjustment. Means may optionally be provided to return the tool to the center when cutting is completed. The invention is usable with torch, laser, water jet, or similar cutting tools. The above functions are accomplished with a minimal number of moving parts.
The invention incorporates a rotatible ring having a pivot point on its periphery. The ring may be housed in a housing that allows rotation of the ring relative to the housing. Means may be optionally provided to brake the rotation of the ring. A link is attached to the pivot point in such a manner that the link may pivot about such points. The cutting tool is attached to the link at a point removed from the pivot point. The tool may be attached to the link in a manner that allows rotation of the tool relative to the link. Finally, means are provided to apply a torque to the link in a manner as to cause the link to rotate on an axis that is between the points of attachment of the tool and the pivot.
To operate, the tool is started beginning a cut at the center of the desired hole. Torque is then applied to the link. The torque causes the link to pivot on the pivot point and pull the tool to the periphery of the hole. Since the pivotal movement of the link is limited, further application of torque results in rotation of the ring. The link and tool rotate with the ring and cut the outline of the hole. When the hole is complete, the torque may be reversed to return the tool to center, or, a spring may return the tool to center.
In one embodiment shown the stop of the links movement is adjustable to allow production of different sized circles. A second embodiment used readily interchangeable dies to limit the tools movement to produce irregular or various sized circular holes. The two methods may also be combined in one device to allow internal generation of holes or use of dies.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section perspective view of one embodiment of the invention.
FIG. 2 is a section plan view of the FIG. 1 embodiment through 2--2.
FIG. 3 is a section elevation view of the FIG. 1 embodiment through 3--3.
FIG. 4 is a diagram of the pattern produced by the invention.
FIG. 5 is a perspective view of a second embodiment of the invention.
FIG. 6 is a section elevation view of the FIG. 5 embodiment.
FIG. 7 is a section plan view of the FIG. 5 embodiment.
FIG. 8 is a section plan view of FIG. 5 embodiment with the ring gear removed in starting position.
FIG. 9 is a section plan view of the FIG. 5 embodiment with the ring gear removed in circumference cutting position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a sectional perspective view of one embodiment of the invention. The invention is shown as used on a water jet cutter, but it is realized that other cutters could be substituted; such as; lasers, cutting torches, or routers.
A cutting nozzle 1 is connected to an on-off valve 3 by supply tube 2. On-off valve 3 is connected to a source of high pressure fluid (not shown). Supply tube 2 is rotatably mounted to an upper link 4, and a lower link 5 by bearings 6. Bearings 6 could be either sleeve roller or equivalent bearings, dependent upon the duty cycle and temperatures of operation. The end of links 4 and 5, not connected to supply tube 2, is pivotly mounted by pivot pin 8 to ring 9. At a position intermediate to pivot pin 8 and supply tube 2, a means 7 for imputing a torque is attached to upper link 4. Means 7 could be a flexible shaft connected to a motor (not shown). Ring 9 is rotatably mounted to a housing 12. A journal bearing 11 is positioned between ring 9 and housing 12. An adjustment screw 13 is attached to housing 13 to bear on bearing 11, and ring 9, to vary the force necessary to turn ring 9 relative to housing 12. A stop 14 is attached to ring 9, also. A second adjustment screw 16 is attached to a projection on ring 9 on a level equal to that of the upper link 4. Finally, a bearing 17 is attached to the lower circumference of housing 12. Bearing 17 may be a ring of florocarbon polymer.
FIG. 2 is a plan view of the FIG. 1 embodiment. Housing 12 is seen to be circular, with bearings 11 mounted on its interior surface, thus, rotatably mounting ring 9. Also, mounted to a housing 12 is a stop 14 and friction adjustment 13. Friction adjustment 13 is adjusted so that the force required to rotate ring 9 relative to housing 12 is greater than that required to pivot link 7 on pivot 8 attached to ring 9. The position of the point of application of torque 7 to link 4 is shown as between pivot 8 and bearing 6, which mounts to tool 2. The position of adjustment screw 16 which determines the size of the hole cut is shown more clearly. Finally, bearing 17 is shown as the surface closest to tool 2. Bearing 17 is shown as circular in this view, but it is realized that it may be other shapes for cutting different shaped holes.
FIG. 3 is a section elevation view of the Figure embodiment. Link 4 is seen to be the uppermost of two links 4,5, which are mounted by a single pivot pin 8 to ring 9, which in turn is rotatably mounted to housing 12 by bearing 11. The torque attachment point 7 joins only to link 4, otherwise links 4,5, are identical.
FIG. 4 is a diagram showing motion of a tool caused by the invention. FIG. 4 will be explained in conjunction with FIG. 2 to clarify operation. To start, cutting tool 2 is in position 26 at the center of the apparatus. The tool is started, and a small hole cut at point 26. Torque is now applied to point 7 in a clockwise direction. As the direction of easiest movement is around pivot 8, tool 2 swings along an arc 27. This causes the cutting of an arc 27. Motion is stopped in this direction when the outer edge of link 4 contacts adjustment screw 16. The closer the end of screw 16 is to link 4, the smaller the hole cut will be. As there can be no further pivotal motion around 8, further application of torque around point 7 will cause rotation of ring 9 relative to housing 12. This motion caused tool 2 to move in a circular path 28 until torque is ceased. In the case shown after 11/2 turns, the torque is reversed and applied in a counter clockwise direction. This will cause link 4 to swing around pivot 8, forcing tool 2 to return to center along arc 29. Stop 14 will also force return to center. As an alternative, tool 2 can be spring loaded to return to center when torque 7 is stopped. Finally, bearing 17 can be contoured to form holes of other than circular outline, as tool 2 will follow bearing 17's profile, if adjustment screw 16 is removed.
FIG. 5 is a perspective view of a second embodiment of the invention. The invention is shown with a water jet cutting apparatus as a tool, but it is realized that a laser, or flame cutting apparatus, could be substituted.
As in the FIG. 1 embodiment, the FIG. 5 embodiment uses a cutting nozzle connected to a supply tube 32 controlled by a shut off valve 33. The apparatus is contained in a housing 36, closed by a top plate 38, and a shield 39 below. A motor 34 is mounted to top plate 38 to provide a source of torque. An extension 37 of housing 36 provides a covering for the pinion attached to motor 34. Motor 34 may be an electric, hydraulic, or pneumatic motor in different environments.
FIG. 6 is a sectional elevation view of the FIG. 5 embodiment. The tool shown is a water jet cutter, but the invention is equally adaptable to other cutters.
The cutter is controlled by an actuator 33 attached to supply tube 32, which ends in a nozzle 31. A mounting 41 and clamp ring 40 are attached to supply tube 32. Supply tube 32 is also rotatably attached to an upper link 46 and a lower link 42 by bearings 44, and, 43, respectively. Mounting 41 and clamp ring 40 are slidably attached to the housing top plate 38 and housing 36, respectively, to prevent the entry of cuttings, or other debris, into the mechanism. The top plate 38 is mounted to the housing 36 by a plurality of screws 45 to seal the interior. Mounted to top plate 38, also, is the drive motor 34. The shaft 53 of motor 34 has a pinion 52 attached by a set screw in this embodiment. It is recognized that other equivalent attachment means, such as, keys, etc., could be used. Pinion 52 is housed in an extension 37 of housing 36. Meshing with pinion 52 is a drive ring 51. Drive ring 51 is supported by a top bearing attached to top plate 38, and the main bearing 49 is attached to housing 36. Drive ring 51 is thus free to rotate in response to torque from pinion 52. A pin 54 connects drive ring 51 to a slot in top link 46. Top link 46 includes a bearing 44 allowing rotation relative to feed tube 37. A pivot pin connects top link 46 to a drive wheel 48 and a bottom link 42 in a manner similar to that of the FIG. 1 embodiment. Drive wheel 48 is rotatably supported by main bearing 49. Lower link 42 is similar to top link 46 in having a bearing 43 for allowing rotation relative to feed tube 37. A shield 39 prevents the operator from coming in contact with the cutting apparatus, and provides a mounting for a guide bearing 55. Guide bearing determines the size and shape of the hole cut.
FIG. 7 is a plan sectional view of the FIG. 6 embodiment with a portion of pinion and drive ring teeth shown for clarity. The main difference from the FIG. 1 embodiment is the method of applying torque to link 37. As motor shaft 53 turns, pinion 52 connected to shaft 53, is also turned. Pinion 52's motion, in turn, causes rotation of drive ring 51 in the opposite direction. Pin 54, connecting drive ring 51 and a slot 56 in link 46, will transfer the motion, placing a torque on link 46, which results in motion of feed tube 37 and the cutting nozzle. Housing 36 provides support and protection for the apparatus.
FIG. 8 is a plan section view of the FIG. 6 embodiment below the drive ring in starting position. Drive wheel 48 is seen to rest in main bearing 49 and top link 46 pivoted to drive wheel 48 by pivot pin 46. The amount of force needed to pivot links 46 and 42 relative to drive wheel 48, is less than that required to rotate drive wheel 48 relative to housing 36. In this position, the cutting tool is started, then torque is applied to pin 54 as described above. This torque is transferred through slot 56 to link 46, causing link 46 to pivot on pivot 47, into the position shown in FIG. 9. The pivoting motion is stopped when nozzle 31 impacts guide 55. Furthr application of torque causes rotation of drive wheel 48 relative to housing 48. This motion caused movement of a tool in the pattern shown in FIG. 4. To return to center, either the direction of torque may be reversed, or a spring employed. | A method and apparatus for cutting holes of circular or other shape by first cutting at the center of the proposed hole, then cutting to the circumference and following the shape desired. A tool that accomplishes these functions is described which includes a pivoted link attached to a ring at one end and the cutting tool at the other end, when torque is applied to the link the tool follows the desired cutting sequence. | 8 |
TECHNICAL FIELD
[0001] The present invention generally relates to telecom towers, and in particular, to a tubular antenna tower structure for use in a wireless communications system.
BACKGROUND
[0002] Prevailing technology for telecom towers/masts, whether self supported or guyed, are lattice steel constructions. These masts are often galvanized using hot dip galvanization, where the steel structure is coated with a layer of Zinc. Steel towers are usually manufactured for a design life between 30-50 years. Coated structures are sensible to mechanical wear, and lattice steel towers are no exception. Towers get surface damages during transportation and installation, and such damages need to be mended when the tower is installed. Since hot dip is not an option when the tower is installed, painting/spraying with cold galvanization is a method used. Damages to a protective Zink layer can not be avoided during transportation and installation and corrosion will start at damaged areas. Corrosion is what sets design life for all steel structures, and regardless of Zink cotes, certain maintenance is required to stop corrosion during a construction life time.
[0003] WO-2008136717-A1 discloses an antenna tower elongated structure which comprises base, intermediate, and terminating segments (S1-S4). The segments are reinforced concrete, and interconnected in a longitudinal direction by elongated fastening members that together form a longitudinal interconnection structure that interconnect the base segment to the terminating segment without gaps in the longitudinal direction. Each segment comprises fastening member guides formed in the wall of the segment and arranged to preserve the fastening members at predetermined configuration with respect to the segment. See FIG. 1 and FIG. 2 .
[0004] WO-2007108766-A1 and WO-2007108765-A1 disclose hollow conical antenna tower structures comprising vertical elongated tower body with an internal installation shaft. The tower is arranged to house a radio base station and the tower body comprises greater than or equal to 2 modular segments provided with mating interconnection mechanism comprising mating guide structures.
[0005] WO-2007108731-A1 discloses an antenna tower structure comprises Radio Base Stations; tubular tower sections having hollowed cross section; arrangement for moving a whole antenna radio base station along an elongation of the antenna tower structure, the antenna radio base station being disposed inside the tubular tower; and entrance into the antenna tower structure giving access for service of the antenna Radio Base station.
[0006] Other types of telecom towers/masts exist and are referred to as Monopoles, which basically are steel, aluminium or concrete poles on which a telecommunication system is attached on an external surface part.
[0007] In earlier versions of tower structures the second section between the ground section, conical section, and the third section, cylindrical section, is mostly made partially conical partially cylindrical. This was done in order to minimize and overcome some of the stress caused by horizontally forces combined with vertically forces. The second section was made according to FIG. 2 b in one part or in two parts as in FIG. 2 a . The stress on this section is very high due to its shape and due to the total shape of the tower. Also the strands inside the tower cause horizontal stress on the area between the conical shaped part and the cylindrical shape part since the post tension strands change direction from the lower parts to the upper parts of the earlier tower constructions. Large horizontal forces from the cables acting on the conical-circular cross area require large amounts of reinforcement in this specific part. This is even more important in location wherein earthquakes and other natural phenomenon might increase construction requirements. The shape and the forces on the section of prior art solutions imply that it has to be wet cast in a double sided mould. This resulted in a labour intensive and time consuming manufacturing process, and hence expensive. Manufacturing such a part in one form requires a quite complicated technique and resources not available in all part of the world. The special concrete ingredient used, in order to fulfil different requirements in different parts of the world, is not suitable for large scale production of a partially conical section as in FIG. 2 b . Also a totally conical tower would require a lot of work since every section need to be conical and the force on the connecting parts between the sections would be quite high.
SUMMARY
[0008] An embodiment of the present invention is therefore to introduce an antenna tower structure for use in a wireless communications network, wherein the tower is adapted for large scale production and less expensive to produce.
[0009] It is an object of the present invention to solve the problem of providing a more solid construction which also is easy to manufacture and which is possible to manufacture having regard to different manufacturing processes in different locations around the world.
[0010] This is achieved by the present invention which provides an antenna tower structure comprising a plurality of sections and wherein at least one connecting section, preferably second section, is made of a metal and/or an alloy such as steel, iron or any other similar material. The connecting section is located between a conical shaped base section and tubular shaped upper section, both with a hollowed cross section, of the tower. The antenna tower structure is arranged for use in a wireless communications network and for comprising one or more Radio Base Stations, RBSs.
[0011] An advantage achieved by introducing the connecting section is that most of the force between the conical and tubular parts of a heavy construction is captured by an easy to manufacture, solid and easy adjustable section.
[0012] In yet a further embodiment of the invention the connecting section is adapted to connect upper post tension strands and/or lower post tension strands.
[0013] An advantage achieved by this is that the whole tower has a connecting stabilising part that holds the construction together when the tower is exposed to tension forces, such as storms, hurricanes and earthquakes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates an antenna tower structure according to the prior art.
[0015] FIGS. 2 a and 2 b illustrates each a tower structure section sketch according to prior art.
[0016] FIGS. 3 a and 3 b illustrate a tower structure connecting section according to an embodiment of the present invention.
[0017] FIG. 4 illustrates a tower structure connecting section comprising a lower lid injection holes and sealing parts according to an embodiment of the present invention.
[0018] FIG. 5 illustrates a tower structure connecting section comprising adjusting means according to a further embodiment of the present invention.
DETAILED DESCRIPTION
[0019] Benefits of creating a tower, as described by the present invention, in concrete are uncountable. Problems with corrosion, cables and feeders out in the open, radio transmission interruption during service or reparation etc., are to be avoided by the present invention.
[0020] According to an embodiment of the present invention an antenna tower structure (ATS) is manufactured from reinforced concrete and wherein one connecting section is made of a metal or an alloy, such as steel. The metal or alloy connecting section makes it easier to mass produce such tower in a simpler and more cost effective manufacturing process. Preferably, the second section is made of a metal or an alloy such as steel. The second steel section is preferably conical shaped as the base section. This way the production procedure is simplified while still maintaining the benefits of the prior art towers mentioned above.
[0021] FIG. 1 illustrates a general form of an antenna tower structure according to prior art. This geometric form can still be used in combination with the present invention. This is considered to be a suitable form as a start of point since this tower has at least one tubular shaped upper section 2 with a hollow cross section and one conical shaped base section 1 with a hollow cross section. Preferably five such upper sections are used. The base section is made of segments (quarters, octets etc) that are connected together into forming the ground section. The tower structure, including all its sections, is a thin wall construction, leaving the entire tower structure to be hollow from its lowest part, base section, to its top. The segments and the sections are attached to each other by bolts or adhesive or a combination of both. Other techniques to attach the sections, such as but not limited to, welding, screwing, rivet together, locking mechanism, wedging are also to be used. The tower according to FIG. 1 illustrates a tower structure according to prior art wherein all parts, except the top section, are made of concrete.
[0022] FIGS. 2 a and 2 b illustrate as mentioned above two alternatives of a connecting tower section, usually a second section, which is a connecting section between a tubular upper section of the tower and a more conical base section. The tubular upper section is typically cylindrical but can also be slightly conical as well as any other similar form. In FIG. 2 a the connecting section is made of two parts, a conical part 4 and a tubular part 3 (less conical or cylindrical). As mentioned above the stress on this section, especially on the overlapping point S, requires that the connecting section includes heavily reinforcement. Also manufacturing process of such a part in one piece puts a challenging task on the manufacturing process. This is not a large scale friendly manufacturing process. Manufacturing the connecting section in two parts as in FIG. 2 a resulted in more problems because of the brittle/frail nature of concrete. Large stress force on the overlapping point S caused breaks and cracks in the concrete section.
[0023] FIG. 3 a illustrates a tower structure connecting section with a hollow cross section according to an embodiment of the present invention. The figure is an overview of a tubular section 10 looking at the section along the elongation of the tower (down-up overview). The section 10 comprises a number of holes 11 adapted for post tension strands attachment or for attachment to other sections. The section 10 further comprises stiffener beams 12 between an upper lid part and a lower lid part. Typically the section comprises one beam on each side of each strand hole. Preferably 16 beams are used. The beams are used to support the section and further on the whole tower structure. According to this embodiment the connecting section 10 , which is typically located between the conical shaped base section and the tubular shaped upper section, is made of a metal or an alloy, such as steel. The figure illustrates a conical shaped connecting section but the invention is not limited to this form.
[0024] An advantage of making the section in the tower in for example steel give the benefit that post tension strands may be directly attached to attachment parts 11 in the section 10 . Also the connecting part is made of a solid material which does not deform or crack as easy as concrete when exposed to both horizontal and vertical stress forces.
[0025] FIG. 3 b illustrates a further cross section view of the tower structure connecting section 10 according to an embodiment of the present invention. The section comprises a top lid part 13 , a lower lid part 14 , an outer surface 15 and inner surface 16 . The section 10 further comprises lower lid strands attachment arrangements 17 and top lid strands attachment arrangements 18 . The lower lid strands attachment arrangements 17 are used for attaching strands from a base section or from a foundation part of the tower structure. The connecting section 10 further comprises additional section attachment holes 19 for attaching the section 10 to the upper section and/or to the base section. In the figure, as an example a bolt is shown for attaching to the upper section, in dashed lines. The beams are not shown in this figure.
[0026] According to this embodiment of the present invention the strands are connected in a two-step-procedure which is totally new compared to prior art. According to a preferred embodiment of the present invention the post tension strands (wires) all connect in the mentioned section 10 . A number of cables connect from the foundation or the ground section to the lower part of the connecting section and a plurality of cables connect from the upper part of the “second” connecting section 10 to the tower part of a top section. In the figures holes for 8 cables shown even though possible to use any other number. Hence, the entire tower of the present invention is under compression from its lowest part to the top section by aid of a solid section.
[0027] The effect of such a construction is that the section forms and acts as a stabilization part in the tower. This is different from prior art versions which did not have this possibility. An additional benefit of the present invention is that the amount of reinforcement needed to achieve a solid construction is reduced.
[0028] In a further embodiment of the invention the outer and the inner surfaces 15 and 16 of FIG. 3 b are made of a protective surface with partially transparent areas, such as plastic. The surfaces thereby forms a 360 degree, circularly surrounding, window which will lead daylight into the inside hollow part of the tower. Alternatively the surfaces are made of a protecting metal layer. The surface may also include air flow ventilation holes.
[0029] FIG. 4 illustrates a tower structure connecting section 10 comprising lid injection holes or sealing parts 21 a , 21 b and according to an embodiment of the present invention. According to this embodiment one or more injection holes 21 a , 21 b , and 22 and one or more sealing parts 21 a , 21 b and 22 are adapted to be used for filling up and sealing gaps or cracks in the concrete or between the connecting section and the upper or base section. Any of 21 a , 21 b or 22 is a hole or a sealing part. The lower lid strands attachment arrangements 17 may further include strands sealing parts 23 adapted to seal the strands from injected concrete. In a further embodiment the injection parts are soft joints, easily removable sealing parts, leading to gaps between stress surfaces, shown with dashed arrows in the figure. The injection parts may also be used for filling up gaps between segments of the base section. Additionally one or more of the injection parts 21 a , 21 b or 22 are used as a sealing part. The connecting section 10 comprises several lid injection holes or sealing parts 21 a , 21 b and 22 in the lower lid part 14 .
[0030] In a further embodiment both the lower and the upper lid part 13 includes such injection holes and/or sealing parts. The invention is by now way restricted to holes and sealing parts in only in the lower lid part 14 .
[0031] In an additional embodiment the connecting section includes a lower lid part 14 with holes in it allowing injection of concrete in the vertical joints of elements of a base section. Such injection would not have been possible with concrete against concrete as in prior art solutions.
[0032] Again the solution according to FIG. 4 was not possible in prior art solutions which had problems with cracking surfaces in joint parts between the base section and the connecting section. The effect of this implementation is that stress in this heavy loaded area is reduced by an even load distribution resulting in fewer cracks in the concrete. The dimensions mentioned in the figures are not by any way limiting but other dimensions are possible.
[0033] FIG. 5 illustrates a tower structure connecting section comprising adjusting means 30 according to a further embodiment of the present invention. According to this embodiment the lower lid part 14 of the connecting section 10 further comprises one or more adjusting means 30 adapted to be used for stabilising the connecting section 10 . Typically, the one or more adjusting means 30 are a screw mechanism wherein the connecting section is stabilised by the one or more screws. In a further embodiment the screw mechanism 30 is combined with the injection procedure of FIG. 4 , in order to fill up the gaps after that the connecting section is stabilised and in place. Similar adjusting means may be included in the upper lid part 13 . Typically, but not in any way restricting, three screws are used to stabilise the section.
[0034] Different procedures for attaching the strands to the connecting section are possible, other than those showed in FIGS. 3 b and 4 . Alternatively, the strands are attached from the inner side along the inner wall of the tower e.g. not inside the sections. The effect of this implementation is to achieve a homogenous solid tower with less vertical holes in sections.
[0035] While the invention has been described with reference to specific exemplary embodiments, the description is in general only intended to illustrate the inventive concept and should not be taken as limiting the scope of the invention.
[0036] It will be understood by those skilled in the art that various modifications and changes may be made to the present invention without departure from the scope thereof, which is defined by the appended claims. | The present invention aims to provide a hollow antenna tower structure for use in a wireless communications net-work. The tower comprises tubular tower sections made of concrete, and having a generally hollowed cross section. The tower further comprises a connecting section 10 located between said conical shaped base section and tubular shaped upper section, the connecting section 10 is made of a metal or an alloy, such as steel. | 4 |
This is a continuation application of copending prior application Ser. No. 09/391,087 filed on Sep. 4, 1999, which is a continuation of application Ser. No. 09/025,160, filed on Feb. 18, 1998, that issued as U.S. Pat. No. 6,016,173 on Jan. 18, 2000, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to image generating systems including a reflective type, ferroelectric liquid crystal (FLC) spatial light modulator (SLM). More specifically, the invention relates to an optics arrangement including an FLC compensator cell for allowing the system to generate a substantially continuously viewable image while DC-balancing the FLC material of both the SLM and the compensator cell.
FLC materials may be used to provide a low voltage, low power reflective spatial light modulator due to their switching stability and their high birefringence. However, a problem with FLC materials, and nematic liquid crystal materials, is that the liquid crystal material may degrade over time if the material is subjected to an unbalanced DC electric field for an extended period of time. In order to prevent this degradation, liquid crystal spatial light modulators (SLMs) must be DC field-balanced.
Nematic liquid crystal materials respond to positive or negative voltages in a similar manner regardless of the sign of the voltage. Therefore, nematic liquid crystals are typically switched ON by applying either a positive or negative voltage through the liquid crystal material. Nematic liquid crystal materials are typically switched OFF by not applying any voltage through the material. Because nematic liquid crystal materials respond to voltages of either sign in a similar manner, DC balancing for nematic liquid crystal materials may be accomplished by simply applying an AC signal to create the voltage through the material. The use of an AC signal automatically DC balances the electric field created through the liquid crystal material by regularly reversing the direction of the electric field created through the liquid crystal material at the frequency of the AC signal.
In the case of FLC materials, the materials are switched to one state (i.e. ON) by applying a particular voltage through the material (i.e. +5 VDC) and switched to the other state (i.e. OFF) by applying a different voltage through the material (i.e. -5 VDC). Because FLC materials respond differently to positive and negative voltages, they cannot be DC-balanced in situations where it is desired to vary the ratio of ON time to OFF time arbitrarily. Therefore, DC field-balancing for FLC SLMs is most often accomplished by displaying a frame of image data for a certain period of time, and then displaying a frame of the inverse image data for an equal period of time in order to obtain an average DC field of zero for each pixel making up the SLMs.
In the case of an image generating system or display, the image produced by the SLM during the time in which the frame is inverted for purposes of DC field-balancing may not typically be viewed. If the system is viewed during the inverted time without correcting for the inversion of the image, the image would be distorted. In the case in which the image is inverted at a frequency faster than the critical flicker rate of the human eye, the overall image would be completely washed out and all of the pixels would appear to be half on. In the case in which the image is inverted at a frequency slower than the critical clicker rate of the human eye, the viewer would see the image switching between the positive image and the inverted image. Neither of these situations would provide a usable display.
In one approach to solving this problem, the light source used to illuminated the SLM is switched off or directed away from the SLM during the time when the frame is inverted. This type of system is described in copending U.S. patent application Ser. No. 08-361,775, filed Dec. 22, 1994, entitled DC FIELD-BALANCING TECHNIQUE FOR AN ACTIVE MATRIX LIQUID CRYSTAL IMAGE GENERATOR, which is incorporated herein by reference. However, this approach substantially limits the brightness and efficiency of the system. In the case where the magnitude of the electric field during the DC field-balancing and the time when the frame is inverted is equal to the magnitude of the electric field and the time when the frame is viewed, only a maximum of 50% of the light from a given light source may be utilized. This is illustrated in FIG. 1a which is a timing diagram showing the relationship between the switching on and off of the light source and the switching of the SLM image data.
As shown in FIG. 1a, the light source is switched on for a period of time indicated by T1. During this time T1, the SLM is switched to form a desired image. In order to DC balance the SLM, the SLM is switched to form the inverse of the desired image during a time period T2. In order to prevent this inverse image from distorting the desired image, the light source is switched off during the time T2 as shown in FIG. 1a.
In order to establish a convention to be used throughout this description, the operation of a given pixel 10 of a reflective type FLC SLM using the above mentioned approach of switching off the light source during the time the frame is inverted will be described with reference to FIGS. 1b-d. FIG. 1b shows pixel 10 when it is in its bright state and FIG. 1c shows pixel 10 when it is in its dark state. As illustrated in both FIG. 1b and 1c, a light source 12 directs light, indicated by arrow 14, into a polarizer 16. Polarizer 16 is arranged to allow, for example, horizontally linearly polarized light, indicated by the reference letter H and by arrow 18, to pass through polarizer 16. However, polarizer 16 blocks any vertically linearly polarized component of the light and thereby directs only horizontally linearly polarized light into pixel 10. This arrangement insures that only horizontally linearly polarized light is used to illuminate pixel 10. For purposes of clarity throughout this description, the various configurations will be described using horizontally linearly polarized light as the initial input light for each of the various configurations.
As also illustrated in FIGS. 1b and 1c, pixel 10 includes a reflective backplane 22 and a layer of FLC material 24 which is supported in front of reflective backplane 22 and which acts as the light modulating medium. The various components would typically be positioned adjacent one another, however, for illustrative purposes, the spacing between the various components is provided. In this example, the FLC material has a thickness and a birefringence which cause the material to act as a quarter wave plate for a given wavelength. In this example, the FLC material is typical of those readily available and has a birefringence of 0.142. Therefore a thickness of 900 nm causes the SLM to act as a quarter wave plate for a wavelength of approximately 510 nm.
FLC material 22 has accompanying alignment layers (not shown) at the surfaces which have a buff axis or alignment axis that controls the alignment of the molecules of the FLC material. For this example of a reflective mode SLM, the SLM is oriented such that the alignment axis is rotated 22.5 degrees relative to the polarization of the horizontally linearly polarized light being directed into the SLM. The FLC also has a tilt angle of 22.5 degrees associated with the average optic axis of the molecules making up the FLC material. Therefore, when FLC material 24 of the pixel is switched to its first state, in this case by applying a +5 VDC electric field across the pixel, the optic axis is rotated to a 45 degree angle relative to the horizontally linearly polarized light. This causes the pixel to act as a quarter wave plate for horizontally linearly polarized light at 510 nm. Alternatively, when the pixel is switched to its second state, in this case by applying a -5 VDC electric field across the pixel, the optic axis is rotated to a zero degree angle relative to the horizontally linearly polarized light. This causes the pixel to have no effect on the horizontally linearly polarized light directed into the pixel. In other words, the tilt angle is the angle that the FLC optic axis is rotated one side or the other of the buff axis when the FLC material is switched to its first and second states.
Now that the configuration of the pixel for this example has been described, its effect on the light as it passes through the various elements will be described. Initially, it will be assumed the light is monochrome at the wavelength at which the SLM acts as a quarter wave plate, in this case 510 nm. As illustrated in FIG. 1b, when the FLC material is switched to its first state, which will be referred to hereinafter as its A state, FLC material 24 converts the 510 nm wavelength horizontally linearly polarized light directed into the pixel and indicated by arrow 18 into circularly polarized light indicated by the reference letters C and arrow 26. Reflective backplane 22 reflects this circularly polarized light as indicated by arrow 28 and directing it back into FLC material 24. FLC material 24 again acts on the light converting it from circularly polarized light to vertically linearly polarized light as indicated by reference letter V and arrow 30. The vertically linearly polarized light 30 is directed into an analyzer 32 which is configured to pass vertically linearly polarized light and block horizontally polarized light. Since analyzer 32 is arranged to pass vertically linearly polarized light, this vertically linearly polarized light indicated by arrow 30 passes through analyzer 32 to a viewing area indicated by viewer 34 causing the pixel to appear bright to the viewer.
Alternatively, as illustrated in FIG. 1c, FLC material 24 has no effect on the horizontally linearly polarized light directed into the pixel when the pixel is in its second state, which will be referred to hereinafter as its B state. This is the case regardless of the wavelength of the light. Therefore, the horizontally linearly polarized light passes through FLC material 24 and is reflected by reflective backplane 22 back into FLC material 24. Again, FLC material 24 has no effect on the horizontally linearly polarized light. And finally, since analyzer 32 is arranged to block horizontally linearly polarized light, the horizontally linearly polarized light is prevented from passing through to viewing area 34 causing the pixel to appear dark.
Although the polarization state of the light is relatively straight forward when the light is assumed to be at a wavelength at which the SLM acts as a quarter wave plate, it becomes more complicated when polychromatic light is used. This is because even if the birefringence Δn of the FLC were constant, the retardance of the SLM in waves would vary with wavelength; furthermore, the birefringence of the FLC material also varies as the wavelength of the light varies. In display applications, this becomes very important due to the desire to provide color displays. FIG. 1d illustrates the effects the SLM has on visible light ranging in wavelength from 400 nm to 700 nm as a function of the wavelength of the light assuming typical FLC birefringence dispersions. Solid line 36 corresponds to the first case when the pixel is in its A state as illustrated in FIG. 1b and the dashed line 38 corresponds to the second case when the pixel is in its B state as illustrated in FIG. 1c. As is illustrated in FIG. 1d, the resulting output of this configuration varies substantially depending on the wavelength of the light as indicated by line 36. In fact, only a little more than 50% of the horizontally linearly polarized light at 400 nm that is directed into the SLM is converted to vertically linearly polarized light using this configuration.
The above described configuration makes use of crossed polarizers. That is, polarizer 16 blocks vertically linearly polarized light and analyzer 32 blocks horizontally linearly polarized light. This means that polarizer 16 and analyzer 32 must be different elements. If both polarizer 16 and analyzer 32 were configured to pass the same polarization of light, they would be referred to as parallel polarizers and could be provided by the same element.
In an alternative system configuration, a polarizing beam splitter may be used to replace both the polarizer and the analyzer. FIGS. 1e and 1f illustrate such a system when pixel 10 is in its A and B states respectively. In this alternative system, light from light source 12 is directed into a polarizing beam splitter (PBS) 40 as indicated by arrow 42. PBS 40 is configured to reflect horizontally linearly polarized light as indicated by arrow 44 and pass vertically linearly polarized light as indicated by arrow 46. The horizontally linearly polarized light indicated by arrow 44 is directed into SLM 24.
When pixel 10 is in its A state as illustrated in FIG. 1e, SLM 24 acts as a quarter wave plate as described above converting the horizontally linearly polarized light to circularly polarized light and reflective backplane 22 reflects this light back into SLM 24. Again, SLM 24 converts this circularly polarized light into vertically linearly polarized light as described above for FIG. 1b and as indicated by arrow 48. Since PBS 40 is configured to pass vertically linearly polarized light, this light passes through PBS 40 into viewing area 34 causing pixel 10 to appear bright.
When pixel 10 is in its B state as illustrated in FIG. 1f, SLM 24 has no effect on the horizontally linearly polarized light. Therefore, the horizontally linearly polarized light that is directed into SLM 24 as indicated by arrow 44 remains horizontally linearly polarized light as it passes through SLM 24, is reflected by backplane 22, and again passes through SLM 24. However, since PBS 40 is configured to reflect horizontally linearly polarized light, this light is reflected back toward light source 12 as indicated by arrow 50 causing pixel 10 to appear dark.
As mentioned above, in the configuration currently being described, the light source is turned off during the time in which the image is inverted for purposes of DC field-balancing the FLC material as illustrated in FIG. 1a. This substantially reduces the brightness or efficiency of the display. In order to overcome this problem of not being able to view the system during the DC field-balancing frame inversion time, compensator cells have been proposed for transmissive SLMs such as those described in U.S. Pat. No. 5,126,864. These compensator cells are intended to correct for the frame inversion during the time when the FLC pixel is being operated in its inverted state. FIG. 2a illustrates a transmissive mode system 200 which includes an SLM 202, a compensator cell 204, a polarizer 206, and an analyzer 208.
As described above for the FLC material of the SLM of the previous configuration, SLM 202 and compensator cell 204 each include an FLC layer which is switchable between an A and a B state. This results in four possible combinations of states for the SLM and compensator cell. For purposes of consistency in comparing various configurations described herein, these four cases will be defined as follows:
Case 1--compensator cell in B state, SLM pixel in A state
Case 2--compensator cell in B state, SLM pixel in B state
Case 3--compensator cell in A state, SLM pixel in B state
Case 4--compensator cell in A state, SLM pixel in A state
For this configuration, Cases 1 and 2 correspond to the normal operation of the system during which the compensator cell is in its B state and the SLM pixels are switched between their A and B states to respectively produce a bright or dark pixel. This is illustrated in the first half of FIG. 2b which is a timing diagram showing the states of the light source, the SLM, and the compensator cell. As shown in FIG. 2b, the light source remains ON throughout the operation of the system. During the first half of the time illustrated in FIG. 2b, the pixels of the SLM are switched between their A and B states to produce a desired image. Cases 3 and 4 correspond to the time during which the frame is inverted for purposes of DC field balancing (i.e. the SLM pixel states must be reversed) and the compensator cell is switched to its A state to compensate for the inversion. This is illustrated by the second half of the diagram of FIG. 2b. To properly DC field-balance the display as well as allow the display to be viewed continuously, Case 1 and Case 3 must give the same results and Case 2 and Case 4 must give the same results. That is, for this configuration, Cases 1 and 3 must both produce a bright pixel and Cases 2 and 4 must both produce a dark pixel.
In this example of a transmissive mode system, both the FLC layer of the SLM pixel and the compensator cell are 1800 nm thick which causes them to act as a half wave plate for a wavelength of 510 nm when in the ON state. In this configuration, the polarizer and analyzer perform the functions performed by polarizer 16 and analyzer 32, or alternatively PBS 40, of the reflective mode systems described above. Polarizer 206 is positioned optically in front of compensator cell 204 and the SLM pixel 202 such that it allows only horizontally linearly polarized light to pass through it into compensator cell 204. Also, analyzer 208 which only allows vertically linearly polarized light to pass through is positioned optically behind SLM 202.
FIGS. 2c and 2d illustrate the net result the above described transmissive system configuration has on light directed in to the system. FIG. 2c shows the results for Case 1 and 2 during which the compensator cell is in its B state and the SLM is switched between its A state for Case 1 and its B state for Case 2. Case 1 is indicated by solid line 210 and Case 2 is indicated by dashed line 212. FIG. 2d shows the results for Case 3 and 4 during which the compensator cell is in its A state and the SLM is switched between its B state for Case 3 and its A state for Case 4. Case 3 is represented by solid line 214 and Case 4 is represented by dashed line 216.
As clearly shown by FIGS. 2c and 2d, this transmissive configuration produces identical results, that is a bright pixel, for Case 1 and 3 as indicated by lines 210 and 214, respectively. It also produces identical results for Cases 2 and 4 as indicated by lines 212 and 216, respectively. It should also be noted that this configuration produces relatively good results over the entire wavelength range from 400 nm to 700 nm. The worst results are at 400 nm where approximately 80% of the horizontally linearly polarized light is converted to vertically polarized light.
Although the compensator cell approach works well for a transmissive SLM as described above, applicant has found that this same general approach does not work as well for a reflective type SLM. To illustrate this difference, and referring to FIG. 3a, a reflective type display system 300 including a reflective type SLM 302 having a reflective backplane 303, a compensator cell 304, a polarizer 306, and an analyzer 308 will be described. Compensator cell 304 is positioned adjacent to SLM 302. As described above for FIGS. 1b and 1c, polarizer 306 is positioned to direct only horizontally linearly polarized light into compensator cell 304. Because the light passes through the SLM and the compensator cell twice in a reflective mode system, the FLC material of SLM 302 and compensator cell 304 are configured to act as quarter wave plates for a wavelength of 510 nm rather than half wave plates as described above for the transmissive system of FIG. 2a.
In this example, the FLC materials of both SLM 302 and compensator cell 304 are 900 nm thick and both have a tilt angle of 22.5 degrees. The buff axis of the SLM is aligned with the horizontally linearly polarized light directed into the system by polarizer 306. Also, the buff axis of compensator cell 304 is positioned perpendicular to the buff axis of SLM 302. FIGS. 3b and 3c illustrate the net result that system 300 has on light directed in to the system. FIG. 3b shows the results for Case 1 and 2 during which the compensator cell is in its B state and the SLM is switched between its A state for Case 1 and its B state for Case 2. Case 1 is indicated by solid line 310 and Case 2 is indicated by dashed line 312. FIG. 3c shows the results for Case 3 and 4 during which the compensator cell is in its A state and the SLM is switched between its B state for Case 3 and its A state for Case 4. Case 3 is represented by solid line 314 and Case 4 is represented by dashed line 316.
As clearly shown by FIGS. 3b and 3c, system 300 produces identical results, that is, a bright pixel for Case 1 and 3 as indicated by lines 310 and 314, respectively. It also produces identical results for Cases 2 and 4 as indicated by lines 312 and 316, respectively. However, this configuration does not produces very good results over the entire wavelength range from 400 nm to 700 nm. The worst results are at 400 nm where only approximately 5% of the horizontally linearly polarized light is converted to vertically polarized light. At a wavelength of about 500 nm about 50% of the horizontally linearly polarized light is converted to vertically linearly polarized light. The best results are at 700 nm where about 80% of the horizontally linearly polarized light is converted to vertically linearly polarized light. Since the point to adding the compensator cell is to increase the efficiency or brightness of the system, this arrangement does not improve the efficiency or brightness for the lower wavelength range when compared to the system of FIG. 1b and 1c which simply turns OFF the light source during the DC field-balancing time.
As can be clearly seen when comparing FIGS. 3b-c to FIGS. 2c-d, the effects on the light caused by the various components of the reflective configuration of FIG. 3a are very much different from the effects on the light caused by the transmissive configuration of FIG. 2a. That is, the reflective configuration of FIG. 3a is not optically equivalent to the transmissive configuration of FIG. 2a even though it may initially seem as though they should be optically equivalent. These two configurations are optically different from one another because the light must pass through the SLM and compensator cell twice in the reflective configuration with the first pass through the compensator being before the two passes through the SLM and the second pass through the compensator cell being after the two passes through the SLM.
Due to this difference in the transmissive and reflective configurations, it has proved difficult to provide a reflective type system which is DC field-balanced and is substantially continuously viewable while providing improved efficiency or brightness compared to a system which simply turns off the light source during the DC field-balancing portion of the frame. The present invention provides arrangements and methods for overcome this problem.
SUMMARY OF THE INVENTION
As will be described in more detail hereinafter, a reflection mode, spatial light modulating system and methods of operating the system are herein disclosed. The reflection mode, ferroelectric liquid crystal spatial light modulating system, includes a light reflecting type spatial light modulator. The spatial light modulator has a light reflecting surface cooperating with a layer of ferroelectric liquid crystal light modulating medium switchable between first and second states so as to act on light in different first and second ways, respectively. A switching arrangement switches the liquid crystal light modulating medium between the first and second states and an illumination arrangement produces a source of light. An optics arrangement is optically coupled the spatial light modulator and the illumination arrangement such that light is directed from the source of light into the spatial light modulator for reflection back out of the modulator and such that reflected light is directed from the spatial light modulator into a predetermined viewing area. A compensator cell is also positioned in the optical path between the light source and the viewing area. The compensator cell has a layer of ferroelectric liquid crystal light modulating medium switchable between a primary and a secondary state so as to act on light in different primary and secondary ways, respectively.
In one embodiment, the optics arrangement includes a passive quarter wave plate positioned in the optical path between the light source and the spatial light modulator and in the optical path between the spatial light modulator and the viewing area. In this embodiment, the compensator cell is positioned in the optical path between the light source and the spatial light modulator and in the optical path between the spatial light modulator and the viewing area.
BRIEF DESCRIPTION OF THE DRAWINGS
The feature of the present invention may best be understood by reference to the following description of the presently preerred embodiments together with the accompanying drawings.
FIG. 1a is a timing diagram illustrating the timing at which a light source for a prior art DC-balanced display system is switched ON and OFF.
FIGS. 1b and 1c are diagrammatic cross sectional views of a pixel of a prior art reflective type SLM display system illustrating how the pixel acts on light when the pixel is in the ON and OFF states.
FIG. 1d is a graph illustrating the effects the system of FIG. 1b and 1c has on light after it passes through the system.
FIGS. 1e and 1f are diagrammatic cross sectional views of a pixel of a prior art reflective type SLM display system including a polarizing beam splitter.
FIG. 2a is a diagrammatic cross sectional view of a prior art transmissive SLM display system.
FIG. 2b is a timing diagram illustrating the timing at which a light source for a prior art DC-balanced display system is switched ON and OFF.
FIGS. 2c and 2d are graphs illustrating the effects the system of FIG. 2a has on light after it passes through the system.
FIG. 3a is a diagrammatic cross sectional view of a prior art reflective SLM display system.
FIGS. 3b and 3c are graphs illustrating the effects the system of FIG. 3a has on light after it passes through the system.
FIG. 4a is a diagrammatic cross sectional view of a first embodiment of a reflective SLM display system designed in accordance with the present invention.
FIGS. 4b-c are graphs illustrating the effects the system of FIG. 4a has on light after it passes through the system.
FIG. 5a is a diagrammatic cross sectional view of a second embodiment of a reflective SLM display system designed in accordance with the present invention.
FIGS. 5b-c are graphs illustrating the effects the system of FIG. 5a has on light after it passes through the system.
FIG. 6 is a diagrammatic cross sectional view of a third embodiment of a reflective SLM display system designed in accordance with the present invention.
FIGS. 7a-b are diagrammatic cross sectional views of a fourth embodiment of a reflective SLM display system designed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An invention is described for providing methods and apparatus for producing a substantially continuously viewable reflective type SLM display system which is DC field-balanced and which is more efficient or brighter than would be possible using a reflective type SLM display system which simply turns off the light source during the DC field balancing portion of each image frame. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. How ever, based on the following description, it will be obvious to on e skilled in t he art that the present invention may be embodied in a wide variety of specific configurations. Also, well known processes for producing various components and certain well known optical effects of various optical components will not be described in detail in order not to unnecessarily obscure the present invention.
Referring initially to FIG. 4a, the present invention will be described with reference to a first embodiment of the invention which takes the form of a reflective type SLM display system generally designated by reference numeral 400. As illustrated in FIG. 4a, system 400 includes an SLM 402 having a reflective backplane 403, a compensator cell 404, a polarizer 405, and an analyzer 406. Alternatively, in the same manner as described above, crossed polarizer 405 and analyzer 406 may be replaced with a polarizing beam splitter.
System 400 is configured in a manner similar to that described above for system 300 of FIG. 3a. That is, compensator cell 404 is positioned adjacent SLM 402. Also, polarizer 405 is positioned to direct only horizontally linearly polarized light into compensator cell 404. Similarly, analyzer 406 allows only vertically linearly polarized light to pass through it and into the viewing area after the light directed in to the system has passed through compensator cell 404 and SLM 402 and been reflected back through SLM 402 and compensator cell 404. However, in accordance with the invention, system 400 also includes a static quarter wave plate 408 positioned optically between compensator cell 404 and polarizer 405 and analyzer 406.
As would be understood by those skilled in the art, SLM 402 may be made up of an array of any number of individually controllable pixels which are individually switchable between two states. For purposes of consistency, it will be assumed that each pixel is switched to its A state by applying a +5 VDC electric field through the pixel and each pixel is switched to its B state by applying a -5 VDC electric field through the pixel. It should be understood that the present invention is not limited to these specific voltages and would equally apply regardless of the voltages used to switch the pixels.
System 400 further includes a light source 410 for directing light into the system in a manner similar to that described above for FIGS. 1b and 1c. With this configuration, light source 410 directs light into polarizer 405 as indicated by arrow 412. Polarizer 405 blocks any vertically linearly polarized portions of the light from passing through polarizer 405 an allows only horizontally linearly polarized portions of the light to pass through polarizer 405 into static quarter wave plate 408. This light passes through static quarter wave plate 408, compensator cell 404, and SLM 402 and is then reflected by reflective backplane 403 back through SLM 402, compensator cell 404, and static wave plate 408 to analyzer 406 as illustrated in FIG. 4a. Analyzer 406 then blocks any horizontally linearly polarized portions of the light and allows only vertically linearly polarized portions of the light to pass through it to a viewing area indicated by viewer 416. Since polarizer 405 blocks vertically linearly polarized light and analyzer 406 blocks horizontally linearly polarized light, this type of system is referred to as using crossed polarizers.
For this embodiment and as described above for system 300, because the light passes through the SLM and the compensator cell twice in a reflective mode system, the FLC material of SLM 402 and compensator cell 404 are configured to act as quarter wave plates for a wavelength of 510 nm. In this configuration, the FLC materials of both SLM 402 and compensator cell 404 are 900 nm thick and both have a tilt angle of 22.5 degrees. In this specific embodiment, the buff axis of the SLM is positioned at a 22.5 degree angle relative to the horizontally linearly polarized light directed into the system. Also, for this embodiment, the buff axis of compensator cell 404 is positioned perpendicular to the buff axis of SLM 402.
Although the buff axis of the SLM is described as being positioned at 22.5 degrees relative to the horizontally linearly polarized light directed into the system, this is not a requirement. In fact, this configuration works equally as well regardless of the orientation of the SLM buff axis relative to the horizontally linearly polarized light directed into the system so long as the buff axis of the compensator cell is oriented perpendicular to the buff axis of the SLM. This freedom in orienting the buff axis of the SLM relative to the horizontally linearly polarized light directed into the system makes this overall system easier to produce than other conventional systems because only the orientation of the SLM relative to the compensator cell must be precisely controlled.
The orientation of the static quarter wave plate relative to the horizontally linearly polarized light directed into the system is also important. Generally, static quarter wave plate 408 has a primary axis which is oriented at a 45 degree angle to the horizontally linearly polarized light directed into the quarter wave plate.
Although the tilt angles of SLM 402 and compensator cell 404 are described as being 22.5 degrees, this is not a requirement. The configuration described above for this embodiment works regardless of the tilt angle of the FLC material of the SLM and the compensator cell, but works best when the tilt angles of the two components are the same. Therefore, it should be understood that the present invention would equally apply to systems using SLMs and compensator cells having tilt angles other than 22.5 degrees. With this configuration, the bright states obtained by the system remain bright regardless of the tilt angle used provided the tilt angles match. However, the use of tilt angles in the range of 22.5 to 25.5 degrees provides optimum dark state extinction, with the choice of tilt angle at the low end of the range providing best extinction over a narrow range of wavelengths centered on the wavelength for which the SLM and compensator have quarter-wave retardance and with the choice of tilt angle towards the upper end of the range providing good extinction over a more extended range of wavelength. Increasing the tilt angle past 25.5 degrees eventually reduces dark state extinction.
Now that the physical configuration of system 400 has been described, its effect on light directed into system 400 will be described. FIGS. 4b and 4c illustrate the net result that system 400 has on light directed in to the system. FIG. 4b shows the results for Case 1 and 2 during which the compensator cell is in its B state and the SLM is switched between the A state for Case 1 and the B state for Case 2. Case 1 is indicated by solid line 420 and Case 2 is indicated by dashed line 422. FIG. 4c shows the results for Case 3 and 4 during which the compensator cell is in its A state and the SLM is switched between the B state for Case 3 and the A state for Case 4. Case 3 is represented by solid line 424 and Case 4 is represented by dashed line 426. Cases 1-4 correspond to Cases 1-4 for the systems described above in the background.
As illustrated in FIGS. 4b and 4c, because of quarter wave plate 408 is included in the configuration of system 400, Cases 1 and 3 result in a dark pixel rather than a bright pixel and Cases 2 and 4 result in a bright pixel rather than a dark pixel. This is the opposite of the results described in the background. However, this inversion of the bright and the dark states may be compensated for in a variety of ways such as reversing the A and the B states for the SLM (i.e. using a -5 VDC to switch the pixel to the A state and using a 5 VDC to switch the pixel to the B state). The important thing is that the results of Cases 1 and 3 are identical and the results of Cases 2 and 4 are identical.
For system 400, static quarter wave plate 408 is preferably a readily providable achromatic quarter wave plate. The use of an achromatic static quarter wave plate provides the best results over a broad color spectrum because it flattens out the curves 422 of FIG. 4b and 426 of FIG. 4c representing the bright states obtained by Case 1 and Case 2. This flattening out of the curve improves the optical throughput of system 400 by increasing the amount of light which passes through the system for a given pixel when the combination of that pixel and the other elements are switched to produce a bright state.
In one embodiment of the invention which reverses the bright and dark states described above for FIGS. 4a-c, parallel polarizers are used instead of crossed polarizers. FIG. 5a-c illustrate a system 500 which utilizes parallel polarizers. As described above for system 400, system 500 includes a SLM 502, a reflective backplane 503, a compensator cell 504, a polarizer 505, a static quarter wave plate 508, and a light source 510. Light source 510 directs light into polarizer 505 which blocks any vertically linearly polarized light and allows only horizontally linearly polarized light to pass through. This horizontally linearly polarized light then passes through and is acted upon by static quarter wave plate 508, compensator cell 504, SLM 502, and reflective backplane 503 in the same way as described above for FIG. 4a. However, in this embodiment, polarizer 505 also acts as the analyzer for the system. This use of polarizer 505 for both the polarizer and the analyzer is what makes this system a parallel polarizer system.
In the configuration of FIG. 5a, polarizer 505 acts as the analyzer by blocking any vertically linearly polarized light and allowing any horizontally linearly polarized light to pass into the viewing area. This is the opposite of the polarizations of light blocked and passed by analyzer 406 in system 400. This has the effect of reversing the bright and dark states of the system and results in the net effects illustrated in FIGS. 5b and 5c. FIG. 5b shows the results for Case 1 and 2 during which the compensator cell is in its B state and the SLM is switched between the A state for Case 1 and the B state for Case 2. Case 1 is indicated by solid line 520 and Case 2 is indicated by dashed line 522. FIG. 5c shows the results for Case 3 and 4 during which the compensator cell is in its A state and the SLM is switched between the B state for Case 3 and the A state for Case 4. Case 3 is represented by solid line 524 and Case 4 is represented by dashed line 526. Cases 1-4 correspond to Cases 1-4 for the systems described above in the background and Cases 1-4 described above for FIG. 4.
As clearly shown by FIGS. 5b and 5c, system 500 produces identical results, that is, a bright pixel for Case 1 and 3 as indicated by lines 520 and 524, respectively. It also produces identical results for Cases 2 and 4 as indicated by lines 522 and 526, respectively. This configuration also produces very good results over the entire wavelength range from 400 nm to 700 nm. In fact, as illustrated by lines 522 and 526, this configuration provides substantially uniform blockage of the entire range of wavelengths of the light that is directed into the spatial light modulator. Also, in both Cases 1 and 3, a large portion of the horizontally linearly polarized light passes through the system for the entire range of 400 nm to 700 nm. Since the point to adding the compensator cell is to increase the efficiency or brightness of the system, this arrangement dramatically improves the efficiency or brightness of system 500 over the complete wavelength range when compared to the system of FIG. 1b and 1c which simply turns OFF the light source during the DC field-balancing time. This also substantially improves the efficiency of the system compared to system 300 of FIG. 3 described above which does not include the static quarter wave plate. Furthermore, since essentially no light from the light source passes through the system to the viewing area when the elements are switched to produce a dark state as indicated by lines 522 and 526, this configuration also provides an excellent contrast ratio.
In another embodiment similar to system 400 of FIG. 4a, a birefringent element may be added to system 400 in order to provide results very similar to the results obtained by system 500 of FIG. 5a. Using like reference numerals to represent like components, FIG. 6 illustrates a system 600 including SLM 402, reflective backplane 403, compensator cell 404, polarizer 405, analyzer 406, static quarter wave plate 408, and light source 410. As described above for FIG. 4, polarizer 405 and analyzer 406 are crossed polarizers. However, in accordance with this embodiment of the invention, system 600 further includes an additional birefringent element 612 which can be positioned between SLM 402 and compensator cell 404, as shown here, or alternately, can be positioned between compensator cell 404 and static quarter wave plate 408.
In this embodiment, birefringent element 612 is a commercially available polycarbonate film having a retardance of approximately one half of the wavelength of the light for which the system is optimized, for example a wavelength of 510 nm. Alternatively, birefringent element 612 may be any birefringent material capable of providing the desired retardance such as poly vinyl alcohol or any other optically clear birefringent material.
In this embodiment, the buff axes of SLM 402 and compensator cell 404 are parallel to one another and birefringent element 612 has a primary axis which is oriented perpendicular to the buff axis of both SLM 402 and compensator cell 404. As describe above for system 400, polarizer 405 directs horizontally linearly polarized light into quarter wave plate 408 and quarter wave plate 408 is oriented at a 45 degree angle to the horizontally linearly polarized light. SLM 402, compensator cell 404, and birefringent element 612 may be oriented in any way relative to quarter wave plate 408 so long as the buff axes of SLM 402 and Compensator cell 404 are parallel to one another and the primary axis of birefringent element 612 is perpendicular to the buff axes of SLM 402 and compensator cell 404.
The addition of the birefringent element causes Case 1 and Case 3 for this embodiment to result in a bright state in which the throughput varies only slightly over the range of the wavelengths similar to curves 520 and 524 of FIGS. 5b and 5c. Also, the addition of the birefringent element causes Case 2 and Case 4 for this embodiment to result in a substantially more uniform dark state similar to lines 522 and 526 of FIGS. 5b and 5c. This results in a system that is able to provide a high contrast ratio while maintaining a relatively high throughput for the entire wavelength range even though crossed polarizers are utilized.
Although the above described embodiments have been described as having the static quarter wave plate positioned between the polarizer and the compensator cell, this is not a requirement. Instead, the static quarter wave plate may be located between the compensator cell and SLM and still remain within the scope of the invention.
In another embodiment, an off axis system may be utilized in order to provide a continuously viewable DC field-balanced reflective display system. FIGS. 7a and 7b illustrate one embodiment of an off axis display system 700. As illustrated in FIGS. 7a and 7b, system 700 includes a SLM 702, a reflective backplane 703, a compensator cell 704, a polarizer 705, an analyzer 706, and a light source 710. In this embodiment, the light is directed into the SLM at an angle and reflected back into a viewing area indicated by viewer 720 such that the light directed into the system only passes through the compensator cell once rather than passing through the compensator cell twice as described above for the previously described embodiments.
Since the light only passes through compensator cell 704 once, the thickness of compensator cell 704 is configured to be twice the thickness of the SLM. Generally, SLM 702 has a thickness which causes SLM 702 to act as a quarter wave plate when switched to its A state and compensator cell 704 has a thickness which causes it to act as a half wave plate when it is switched to its A state. Therefore, in the case in which an FLC material is used for both the SLM and compensator cell that has a birefringence of 0.142, the thickness FLC material for the SLM would be approximately 900 nm and the thickness of the FLC material for the compensator cell would be approximately 1800 nm. Both SLM 702 and compensator cell are configured to have substantially no effect on the polarization of the light passing through them when they are switched to their B states.
For the configuration being described, polarizer 705 is configured to allow only horizontally linearly polarized light to be directed into the system. Analyzer 706 is configured to allow only vertically linearly polarized light to pass into the viewing area. Also, for this embodiment, the buff axis of compensator cell 704 is oriented perpendicular to the buff axis of SLM 702 and the buff axis of SLM 702 is advantageously oriented parallel to horizontally linearly polarized light directed into the system. Other orientations of the buff axes are also effective provided that the SLM and compensator cell buff axes remain perpendicular to one another.
As described above for the previous embodiments, the off axis configuration shown in FIGS. 7a and 7b provide identical results for Cases 1 and 3 and Cases 2 and 4. This configuration also provides good results over a broad spectrum similar to the results illustrated in FIGS. 5b and 5c. Therefore, system 700 is also able to provide a continuously viewable system which more effectively utilizes light from the light source when compared to the conventional reflective systems illustrated in FIGS. 1b-c and FIG. 3a.
Although only certain specific embodiments of the present invention have been described in detail, it should be understood that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. For example, although the systems have been described above as using horizontally linearly polarized light as the initial input light polarization, this is not a requirement. Instead, it should be understood that the initial input light polarization may alternatively be vertically linearly polarized light. Therefore, the present examples are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims. | A reflection mode, ferroelectric liquid crystal spatial light modulating system, includes a light reflecting type spatial light modulator. The spatial light modulator has a light reflecting surface cooperating with a layer of ferroelectric liquid crystal light modulating medium switchable between first and second states so as to act on light in different first and second ways, respectively. A switching arrangement switches the liquid crystal light modulating medium between the first and second states and an illumination arrangement produces a source of light. An optics arrangement is optically coupled the spatial light modulator and the illumination arrangement such that light is directed from the source of light into the spatial light modulator for reflection back out of the modulator and such that reflected light is directed from the spatial light modulator into a predetermined viewing area. The optics arrangement includes a passive quarter wave plate positioned in the optical path between the light source and the spatial light modulator and in the optical path between the spatial light modulator and the viewing area. A compensator cell is also positioned in the optical path between the light source and the spatial light modulator and in the optical path between the spatial light modulator and the viewing area. The compensator cell has a layer of ferroelectric liquid crystal light modulating medium switchable between a primary and a secondary state so as to act on light in different primary and secondary ways, respectively. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for controlling an apparatus for texturizing multifilament yarn made of synthetic polymeric materials wherein the filaments of the yarn are pneumatically conveyed into a bulking chamber to form a compacted yarn mass and in particular, to a method and apparatus for controlling startup and shutdown of the apparatus as well as monitoring of faults in the bulking procedure during continuous operation.
Heretofore, many processes and apparatus have been developed for texturizing yarn made of thermoplastic polymeric materials by the employment of fluid jets or the like pneumatic means. Many of these prior developments have been relatively successful in providing bulky voluminous yarn having a degree of crimp uniformity and improved dyeing characteristics suitable for use in the production of textile fabrics, carpets and the like. The apparatus employed for carrying out these known processes is complex and often requires elaborate control systems to regulate the operation of the apparatus, especially during startup and shutdown.
Because of the advantages found in these pneumatic processes for producing texturized yarns, particularly the high yarn processing speeds, the need for such control systems for operating the apparatus have been accepted by the textile industry.
In the known processes for bulking yarn pneumatically, an initially straight and pre-drawn yarn which may be untwisted or slightly twisted is subjected to a turbulent heated fluid such as steam in such a manner that the individual filaments of the yarn are looped, coiled or crimped and the yarn is heat-set in this condition. The individual filaments are in this manner formed into a bulky wool-like product wherein each of the filaments in a relaxed condition exhibit a plurality of crimps or loops along a given length. Such crimps are usually offset and out of phase with each other in a random manner.
In order to ensure the provision of uniform crimps, bulking chambers are often employed to receive yarn from an aspirator jet to cause the formation of a compact mass of yarn or yarn plug which is continuously pushed or otherwise removed from the bulking chamber.
U.S. Pat. No. 3,373,470 describes a process for a stuffer-type crimping of thermoplastic filaments wherein the filaments are introduced into one end of an elongated confined space or bulking chamber by a stream of fluid such as steam under pressure and at a temperature sufficient to set the filaments. The filaments are tightly packed within the confined space by controllably releasing part of the fluid from the confined space laterally of the confined space at a position spaced from the other end and the packed filaments are then forced through the space to the other end under pressure by the remaining portion of fluid which exhausts with the yarn. The confined space required for this process is defined by a metal spring having gaps between the convolutions thereof. In this apparatus, the yarn is propelled by the action of the fluid from a nozzle through a tubular passage and then into the interior of the spring. The spring is curved to a desired extent to obtain optimum compacting of the yarn therein.
Additional apparatus and processes for texturizing synthetic yarns pneumatically are disclosed in U.S. Pat. Nos. 3,343,240 and 3,576,058. In the processes disclosed in each of these patents, steam is discloded as being a suitable fluid for conveying the filaments of the yarn into a zone wherein the yarn undergoes compression. An especially effective process and apparatus for texturizing yarns by aspirating the yarn into a bulking chamber is also described in the application of Brewster Eskridge, et al executed on even date herewith (Ser. No. 517,802, Oct. 24, 1974.).
During the start-up of such processes, the thermoplastic yarn may become overheated by the heated gas and consequently, the filaments of the yarn may become fused together or become sufficiently tacky to stick to each other and thereby cause plugging of the bulking chamber or other zone wherein the yarn is compacted. Also, during emergency stoppage of the apparatus due to a yarn breakage or the like breakdowns or during scheduled shutdown of the apparatus, the yarn again may become overheated by the steam and/or the heat retained in the apparatus and consequently there is a risk of the yarn again plugging the apparatus.
SUMMARY OF THE INVENTION
The present invention provides a method for controlling the operation of an apparatus and process for texturizing synthetic thermoplastic yarns wherein a gas at a lower temperature, preferably an unheated gas, is introduced into the pneumatic apparatus in place of the heated gas such as steam during start-up and shutdown in order to avoid overheating of the yarn and the resultant fusion of the filaments which causes plugging of the apparatus.
More particularly, in accordance with this invention, it has been found that the injection of compressed, unheated air into an aspirator or bulking jet to facilitate pneumatic conveying of the yarn into a bulking chamber or other zone wherein the yarn filaments are formed into a compact yarn mass, for a relative short period of time, for example, from about 2 to 15 seconds, sufficiently cools the yarn and the apparatus to avoid overheating of the yarn and the resultant fusion of the filaments which causes plugging of the apparatus. Also, during string-up, the compressed air prevents fusion of the filaments and advantageously also provides a means for rapidly inserting the yarn into the pneumatic apparatus to thereby avoid a cumbersome manual string-up procedure.
In particular, this invention contemplates a method for controlling a process for texturing multifilament synthetic polymeric yarn wherein the yarn is passed in a heated gas stream to a bulking chamber in which the yarn filaments are caused to impinge against each other and to thereby form a compact yarn mass and wherein during start-up and/or shutdown of the process, a stream of unheated air or similar inert gas is injected in place of the heated gas to pneumatically convey the yarn through the aspirator or bulking jet and into the bulking chamber; the stream of air being introduced in the aspirator jet and bulking chamber for a sufficient period during shutdown of the process to effect cooling of the yarn and cooling of the adjacent surfaces of the apparatus to thereby prevent fusion of the filaments of the yarn.
This invention is also directed to an apparatus for effecting start-up, shutdown and control of the pneumatic apparatus for the texturizing of synthetic polymeric yarns which includes a source of compressed air or like gas, conduit means connecting said source to the gas inlet of the pneumatic apparatus, valve means in said conduit means for initiating and for stopping the flow of air therein and control means operatively associated with said pneumatic apparatus for causing the air to be injected into the pneumatic apparatus in place of the heated gas during start-up and shutdown of said apparatus.
In general, the heated gas used to aspirate the yarn in pneumatic bulking processes is a dry gas such as superheated steam or compressed air. Superheated steam preferably is used. This steam has a pressure of from about 50 to 100 psig. and a temperature on the order of 200° to about 275° C. The preferred pressure for processing of nylon 6 carpet yarn is from about 70 to 80 psig. and the preferred temperature is from 220° to 240° C. Usually, the temperature of the steam is above the melting point of the yarn since heat losses in the system and the short residence time of the yarn with the steam prevent the yarn from being raised to this temperature.
Compressed air suitable for heating and conveying the yarn generally will be compressed to from 50 to 100 psig. and will be heated at the same temperature of the superheated steam, that is, from 200° to 275° C.
The lower temperature gas which is employed in place of the heated gas usually has a pressure on the order of from 50 to 100 psig. and a temperature ranging from ambient to 150° C.; preferably unheated, compressed air at ambient temperatures is employed. It will be appreciated, however, that other inert gases that may be used include carbon dioxide, argon, nitrogen, helium, etc.
After the yarn plug or mass has been pushed from the bulking chamber or compression zone, the yarn plug, while still intact, may be guided through a tubular conduit to a plug guide where the yarn is removed from the plug by a takeup device at a rate which is 15 to 25% slower than the feed rate into the aspirator jet. Sufficient tension is supplied to the yarn to cause it to stretch out to a length less than the original length and to pull the filaments back into a yarn bundle.
In one embodiment of this invention, formation of the plug within the bulking apparatus can be controlled by regulating the position of the end of the plug pushed out of the bulking chamber. The plug is moving at a rate on the order of 1/200 of the yarn input rate in the tubular conduit or like means for guiding the yarn. The plug is directed into a plug guide defining a yarn accumulation chamber wherein a yarn sensing means, e.g. feeler elements, contact the yarn. When the plug moves past a high yarn level in the accumulation chamber due to failure of the yarn take-up device to remove the yarn bundle at the required rate or due to break in the yarn entering the take-up device, the yarn feeler element closes a switch and thereby causes the apparatus to shutdown. If the yarn plug recedes towards a low yarn level near the inlet of the plug guide and accumulation chamber due to failure of the aspirator jet to deliver the yarn at a required rate or due to a break in the yarn entering the jet, another feeler element and associated switch are actuated to cause shutdown. A control system of this type is described in greater detail in the application of Roger H. Fink, executed on even date herewith (Ser. No. 517,786, filed Oct. 24, 1974.) In accordance with this invention, during this shutdown, the unheated air can also be introduced in place of the steam.
The method and apparatus of this invention will be further understood from the following detailed description and the accompanying drawing wherein:
FIG. 1 represents a schematic diagram of an apparatus for carrying out the pneumatic texturizing of a synthetic polymeric yarn wherein the method and apparatus of the present invention are employed;
FIG. 2 is a typical electrical control circuit used in the method and apparatus of the present invention.
FIG. 3 represents a schematic diagram of an additional embodiment of the apparatus shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, nylon feeder yarn 1 is drawn from a yarn package 2 by a pair of feed rollers 3 (driven by motor M-2) via guide 4, an air cylinder operated tension gate G (this gate remains open when the apparatus is running), over a plate heater H into an aspirator jet unit, generally designated by reference numeral 5. (The detailed construction of this unit, which includes a bulking chamber, is disclosed in the heretofore mentioned application of Brewster Eskridge, et al.) Superheated steam is supplied to the aspirator jet unit by steam inlet pipe 6 and valve V-1 and then discharges from a bulking chamber of this unit. The mass of compacted yarn or yarn plug formed within the bulking chamber is pushed into a plug guide 8. The yarn is withdrawn from the plug guide 8 in the form of a yarn bundle by a takeup roll 9 driven by moter M-1.
Limit switches LS-1 and LS-2 are provided on the tube guide 8 for determining the position of the end of the plug. This apparatus is described in greater detail in the heretofore noted application of Roger H. Fink.
The aspirator jet unit is also provided with an air inlet pipe 7 through which an auxiliary gas such as air may be introduced into the gas inlet of the jet in place of the superheated steam.
The yarn is initially delivered at a constant speed by the feed rollers to the aspirator jet. Delivery yarn speeds on the order of from 500 to 2,000 meters per minute may be used. Prior to entering the bulking jet, the yarn is preheated to a temperature on the order of from 150° to 200° C. by the plate heater or like heating device.
The yarn is aspirated into the bulking or aspirator jet by the venturi effect of the heated gas, that is superheated steam, and the yarn carried in the gas stream, then enters the bulking chamber. In normal, continuous operation, the temperature of the moving yarn is maintained below the sticking point to avoid the formation of separate coherent filament groups within the yarn as well as plugging of the apparatus.
In order to facilitate start-up of the apparatus, including stringing-up of the yarn, valve V-2 is used to control introduction of compressed air through pipe 7.
The following string-up procedure is employed:
1. Valve V-2 is opened and compressed air, 65 psig and 27° C. or ambient temperature is introduced into the aspirator jet via pipe 7.
2. The yarn, after being manually passed through guide 4, and gate G, and over plate H, is inserted into a gas inlet tube of the jet unit to be drawn in by the venturi effect created in the aspirator jet due to air flow through a nozzle provided therein.
3. After a length of yarn has passed through the aspirator jet, the bulking chamber and the plug guide, valve V-2 is closed and the yarn is secured to the take-up roller for forming a take-up package and inserted between feed rollers 3.
At this time, the apparatus shown in FIG. 1 may be started up by actuating the operation of the gate (the heater having been activated by a separate electrical circuit not shown), the feed rollers and the steam jet (by opening of valve V 1 ) and also the operation of the yarn take-up roll. Also, it is possible to start-up the apparatus, without the introduction of steam by introducing air for a short period of time for about 5 seconds. Moreover, a mixture of steam and air could be used to initiate start-up with the proportion of air in the mixture being in an amount that will reduce the temperature sufficiently to avoid overheating and fusion of the yarn filaments.
Although the yarn will become compacted and form a plug within the bulking chamber due to the impingement of the filaments of the yarn on each other and onto the walls of the bulking chamber, it is also possible to facilitate plug formation by holding a baffle device at the end of the bulking chamber to keep the yarn from blowing out until the yarn plug has formed therein.
Also, when the bulking apparatus is caused to stop, that is either by a scheduled shutdown or by an occurrence of a fault during the operation such as a break in the yarn or an end of the yarn plug being out of its proper position in the yarn guide, all elements of the apparatus are stopped and valve V-2 is opened to allow introduction of the unheated gas.
In this manner, during start-up and shutdown, fusion of the thermoplastic polymeric filaments of the yarn is prevented to thereby avoid plugging in the nozzle of the aspirator jet and in the associated bulking chamber.
As heretofore described, during shutdown of the bulking apparatus the unheated air or other gas serves to cool the heated yarn as well as the surfaces within the aspirator jet and bulking chamber so that the residual heat is dissipated.
With respect to the yarn guide plug 8, it will be appreciated that this guide includes a tubular member having an open end for delivery of the compacted yarn mass in the form of a plug and an outlet for allowing the yarn to be removed in the form of a yarn bundle.
Limit switches, LS-1 and LS-2 are operatively associated with feeler elements (not shown) which extend into contact with yarn in the plug guide 8. These feeler elements are depressed by contacting the yarn plug within the guide. In the embodiment of the sensing means illustrated in the drawings, when the feeler element associated with limit switch LS-1 is in the depressed position, that is pushed away from the interior of the tube guide, then the limit switch is maintained in an open position; whereas, the feeler element associated with the limiting switch LS-2 is biased in its raised position within the tubular guide element. Consequently, limit switch LS-2 is also in an open position. When the feeler elements associated with these limit switches are moved to cause actuation of the switches, then the apparatus is shut down in the same manner as when a scheduled stoppage is effected. It will be appreciated that depending on the control circuitry used to effect an on/off control of the texturizing apparatus, the limiting switches may be maintained in a closed position during normal operation.
In FIG. 2, an electrical circuit for controlling the apparatus of FIG. 1 is further illustrated with the same elements being identified by like reference letters or numerals.
In this figure, PB-1 designates a push-button switch connected across a power source via line 10, normally closed relay contact C 2 R-2 and the normally closed solenoid operated valve V-2. Actuation of the push-button switch causes valve V-2 to introduce air into the aspirator jet unit 5 during string-up. A main power switch SW M , which is shown in the normally open position, is connected across the power source via normally closed relay contact C R-4 , line 11 and relay R-1, and is used to initiate operation of the yarn texturizing apparatus. This switch, in its closed position actuates relay R-1. This relay is operatively associated with relay contact C 1 R-1 connected in parallel with push-button switch PB-1. Relay R-1 is also associated with normally open relay contact C 2 R-1 , which contact is connected in parallel with several elements of the texturizing apparatus, i.e. contact C 2 R-1 is connected via line 12 to motor M-1 of the yarn take-up roll 9 and a normally closed relay contact C 2 R-3 ; via lines 13 and 14 to motor M-2 of the feed rolls 3; via lines 13 and 15 to a solenoid valve causing operation of gate G; via lines 13, 16, and 17 to delay means D-1 operatively associated with relay R-2.
Upon actuation of relay R-1, normally open contact C 2 R-1 is closed to thereby energize motor M-1 of the yarn takeup roll 9, the motor M-2 of feed rolls 3, and the opening of gate G. At the same time, delay means D-1 act to delay current flow for a predetermined period, e.g. 5 to 15 seconds, to relay R-2. Delay means D-1 is a "pure" delay, i.e. a delay which acts to delay energy flow for a preset period before allowing the energy to flow continuously. Relay R-2 is operatively associated with relay contacts C 1 R-2 connected to valve V-1 and relay contact C 2 R-2 connected to the normally closed, solenoid operated valve V-2.
Actuation of switch SW M also causes normally open contact C 1 R-1 to be closed by operation of relay R-1. As a result, the valve V-2 is opened to allow the introduction of compressed air into the aspirator jet unit. The introduction of air during the startup procedure is continued until delay D-1 causes energization of relay R-2 which in turn causes normally closed contact C 2 R-2 to open. Relay R-2 also closes normally open contact C 1 R-2 to thereby energize valve V-1. This energization causes the valve V-1 to open and to allow steam to be injected into the aspirator jet unit via pipe 6.
In order to shutdown the texturizing apparatus during a scheduled stoppage, switch SW M is moved to the open position shown in FIG. 2 to thereby de-energize relay R-1 and to thereby stop motors M-1 and M-2 controlling the takeup roll 9 and the feed rollers 3, respectively. Also, gate G closes.
At the time switch SW M is opened, a monostable multivibrator MM-1 is energized via line 18. This multivibrator has a normally low output, that is, it has a "one" (mono) stable state. Upon triggering, this device gets a high output for only a preset period of time, for example 5 seconds; that is, output current passes for a period of about 5 seconds. Then the multivibrator returns to its stable or low output state where there is no output current. During the high or "on" state, the multivibrator actuates relay R-5 which in turn causes operation of normally open contact C 1 R-5 . This contact is connected to valve V-2, via line 19. Closing of this contact makes valve V-2 open to allow air to be introduced into the aspirator jet unit. Subsequently, upon the end of the preset period, that is about 5 seconds, the relay R-5 is de-energized and contact C 1 R-5 returns to its open position. In this manner, valve V-2 is again closed. At this time, the texturizing apparatus and the control apparatus are in the shutdown or "off" condition.
In order to provide shutdown during continuous operation of the texturizing apparatus due to a change in position of the end of the yarn plug within plug guide 8 or a break in the yarn in front of or behind the yarn guide 8, limit switches LS-1 and LS-2 are placed in parallel with relay R-3, via line 20 and lines 21 and 22, respectively. This relay may be energized by either one of the limit switches. R-3 is operatively associated with normally closed relay contacts C 1 R-3 and C 2 R-3 and normally open relay contact C 3 R-3 . Upon energization of one of the limit switches normally closed contacts C 1 R-3 and C 2 R-3 are opened thereby causing de-energizing of motor M-1 of yarn take-up roll 9 and closing of valve V-1 in steam inlet pipe 6. Also, normally open contact C 3 R-3 is closed to energize and open valve V-2 which allows air to again be introduced into the aspirator jet unit 5.
A delay means D-2 is also connected in parallel with switches LS-1 and LS-2 via lines 20 and 22 and lines 21 and 22, respectively. This delay means is connected to relay R-4, which is operatively associated with the normally closed relay contact C R-4 .
When relay R-3 is actuated, the delay means D-2 is also actuated. This relay has a preset delay time of for example 5 seconds. At the end of this time, relay R-4 is energized. This relay opens normally closed contact C R-4 which in turn shuts down the remaining elements of the texturizing apparatus by de-energizing relay R-1. Also, at this time, normally open relay contact C 1 R-1 is again allowed to open and thereby shut down valve V-2.
It will be understood that other switching circuits may be employed to effect the same type of control initiated by that shown in FIG. 2.
In FIG. 3 there is shown a schematic diagram of an apparatus of the type shown in FIG. 1 with the exception that an air steam mixture is introduced via valve V-2 and air inlet pipe 7 into the aspirator jet unit 5.
It will be also understood that the control method and apparatus of this invention may be used with many types of texturizing apparatus wherein an aspirator jet is employed to introduce yarn into a bulking chamber or zone and that the texturizing apparatus heretofore described and illustrated in the drawing is to be considered as representative of such apparatus.
It will be appreciated that at the higher operating pressures, e.g. at 70 psig or above, the aspirating effect that occurs at the yarn inlet of the jet means is no longer apparent, i.e. the pressure goes from negative to positive during the bulking operation. In this case, lower pressure air is needed to initiate the string-up procedure.
While novel embodiments of the invention have been described, it will be understood that various omissions, modifications and changes in these embodiments may be made by one skilled in the art without departing from the spirit and scope of the invention. | A method for texturizing synthetic thermoplastic yarn in a bulking apparatus wherein a heated, dry gas is employed to convey a yarn into a bulking chamber to form a compact mass of yarn. The process is characterized in that an auxiliary gas is introduced into the bulking apparatus at a lower temperature than that of the heating gas to convey the yarn during start-up and/or shutdown of the apparatus to avoid over-heating and fusion of the yarn, and to thereby prevent plugging of the apparatus. | 3 |
RELATED APPLICATION DATA
[0001] The present application is a continuation of U.S. Application Ser. No. 12/047,522, filed on Mar. 13, 2008, currently pending.
TECHNICAL FIELD
[0002] The present invention involves a shipping container capable of containing a variety of product sizes and shapes. The container is designed to ship products requiring thermal insulation in order to maintain product integrity throughout the shipping process. The shipping container is capable of being reduced in volume under certain vacuum conditions imposed within the container.
BACKGROUND OF THE INVENTION
[0003] There are a wide variety of containers used for shipping products over conventional channels. Whether shipping is done by air, cargo vessel, rail or truck, all shipping containers must exhibit certain basic characteristics depending upon the product being transported. The present invention deals specifically with containers which are useful in shipping products which are perishable or otherwise require maintaining a somewhat consistent temperature independent of ambient conditions. Most often, containers include cold packs or, in some instances, hot packs and insulative side walls which help to maintain stable temperatures throughout the shipping process. The use of a vacuum to minimize heat transfer is well known. For decades, vacuum bottles have been used having an internal volume and evacuated side walls to reduce thermal transfer.
[0004] More recently, it has been discussed in the literature that heat transfer can be reduced if the internal volume of a shipping container, as opposed to its side walls, is subjected to vacuum.
[0005] Specifically, U.S. Pat. No. 5,918,478 is directed to an insulated chest for storage of items at elevated or reduced temperature which has enhanced insulation, and a cover sealed tight by use of vacuum. The separate cover, four sidewalls, and bottom are formed with dual wall construction (relatively heavy plastic with insulation in-between). When the chest is manufactured, the sidewalls and bottom are internally evacuated and sealed to enhance their insulative qualities. After items are placed in the container with charged heating or cooling elements as needed, the hinged cover is closed and a vacuum pump is attached to a valve conduit that passes through the cover so as to draw a vacuum in the container. The vacuum seals the cover onto the chest and enhances the thermal security of the contents. A wrench is inserted into a channel in the cover to turn a valve to a closed positioned so the vacuum pump may be removed with the vacuum maintained in the chest for storage and transportation.
[0006] U.S. Publication No. 2007/0264485 is directed to several embodiments of enclosures using aerogel insulative blankets for holding a host of different materials. The volume and shape of the enclosure may be determined based on the aerogel material or the internal surface of non-aerogel material. The aerogel material may be an organic, inorganic, or a hybrid of organic/inorganic materials. In one embodiment, insulated strips and labels suitable for insulating beverage containers may be formed, with the insulative quality augmented through the use of vacuum during manufacture of the labels. According to the publication, a rough vacuum in a sealed label of approximately 100 TORR would result in a decrease in thermal conductivity by nearly a factor of 2.
[0007] U.S. Pat. No. 5,325,281 is directed to an insulated shipping container that uses vacuum insulated panels and expanded polystyrene panels. The container illustrated as a rectangular parallelepiped, is itself formed of four containers that fit snuggly within one another and are easily removed from the assembly to be replaced if damaged. The outer closeable container is formed of corrugated cardboard. Inside this outer container is the first insulating housing that is formed of expanded polystyrene. Within the polystyrene housing is the second insulating housing formed of vacuum insulated panels. Inside this vacuum insulated panel housing is an inner closed container of corrugated cardboard.
[0008] U.S. Publication No. 2007/0095712 is directed to a shipping container for transporting biologically hazardous materials safely, even at high altitudes. The outer box of the container is intended to be rigid and gas permeable (constructed for example from corrugated cardboard). The outer box includes an inner box constructed of expanded polystyrene foam insulation such as Styrofoam. The interior enclosure is a flexible bag preferably made of polyethylene plastic that is sized so as to be capable of engaging the interior of the exterior enclosure. When biologically hazardous materials are placed within the interior of the bag, the bag is then at least partially evacuated. The bag preferably includes lines providing visual indications to guide its evacuation and seal.
[0009] U.S. Publication No. 2007/0157564 is directed to a vacuum package system for transporting a plurality of medical containers. The packaging system 10 includes a tray 14 that holds a plurality of medical containers 16 , such as vials. When the containers are disposed in the tray and prepared for shipment, the tray is inserted into an air impervious vacuum bag. A vacuum is applied to the vacuum bag. When fully evacuated, the bag is sealed to embrace the vials and holds them from moving.
[0010] There are certain limitations inherent in the use of prior shipping containers which have been recognized and addressed in the present disclosure.
[0011] Recognizing that many products sold in this country are manufactured off shore, shipping volumes become of paramount economic interest. Manufacturers in, for example, Asia, attempt to house as many packages as possible within containers loaded on containerized vessels for transoceanic shipment. Sophisticated shipping containers such as those contemplated herein and in the prior art are provided with valves and insulated walls which occupy shipping volumes which, if reduced, could greatly improve the economies of containerized shipment. As such, it is one object of the present invention to provide a container which can be reduced in volume to the extent practical for maintaining the integrity of the product residing within its internal volume.
[0012] Yet another issue unaddressed by the prior art involves dealing with changes in internal pressure which inherently occur over time. For example, if dry ice was used as a coolant, the dry ice would sublimate and increase the pressure of the container. Under certain circumstances, a change in pressure could be dealt with by installing a valve through the side wall of the container but, in some instances, that is not a practical solution. Thus, it is yet another object of the present invention to provide a shipping container which can deal effectively with changes in container pressure whether or not a valve is employed.
SUMMARY OF THE INVENTION
[0013] A shipping container having side walls, a bottom and a top defining an internal volume. The top is selectively displaceable for gaining access to the internal volume and for sealing the internal volume of the container. A valve drawing a vacuum on the internal volume from outside of the container is provided. The side walls are capable of contracting and expanding as a result of the pressure within the internal volume.
BRIEF DESCRIPTION OF THE FIGURES
[0014] FIG. 1 is a perspective view of a shipping container of the present invention opened and within the imposition of a vacuum.
[0015] FIG. 2 is a perspective view of a shipping container of FIG. 1 once a vacuum has been imposed on its internal volume.
[0016] FIG. 3 is the shipping container of the present invention placed within an outer protective shipping box.
[0017] FIG. 4 is a perspective view of a shipping container of the present invention further including a support frame.
[0018] FIG. 5 is a perspective view of an alternative support frame to that shown in FIG. 4 .
[0019] FIGS. 6A and 6B are perspective views of an additional embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Turning first to FIG. 1 , shipping container 10 is shown comprising side walls having, as a preferred embodiment, inner side wall 15 and outer side wall 14 creating space 16 therebetween, the purpose of which will be discussed hereinafter. The shipping container also includes bottom 25 and top 11 , the latter being displaceable to gain access to internal volume 20 .
[0021] In operation, one would place the shipping contents within internal volume 20 together with, ideally, a cooling source such as ice, dry ice or a gel pack. Internal volume 20 would then be sealed by placing lid 11 on the side walls as shown. A vacuum would then be drawn through valve 12 . The extent of the vacuum in conjunction with the flexibility of side walls 14 and 15 will determine the extent to which shipping container 10 collapses in volume. Once collapsed, shipping container 10 could simply be shipped as any other shipping container or placed within outer container 30 ( FIG. 3 ) to enhance resistance to damage by external sources such as forklifts, hooks and sharp edges.
[0022] Once shipping container 10 reaches its ultimate destination and the recipient wishes to gain access to internal volume 20 , air or any other gas can be introduced to internal volume 20 through valve 13 . Once the vacuum is reduced or completely eliminated and internal volume 20 reaches ambient pressure, lid 11 can be easily removed. The present invention has further benefits from those described previously. For example, if the temperature rises in internal volume 20 because, for example, a cooling source becomes exhausted, pressure would build therein. Pressure could also increase if a sublimating solid such as dry ice was used as the cooling source. Not only could increased pressures be vented through optional valve 21 , but expanding side wall 17 having folds 28 could expand thus relieving pressure and maintaining a somewhat vacuum induced condition within internal volume 20 .
[0023] Further, in knowing the extent of gross shipping volume attributable to a shipment constituting the present invention, one could draw a vacuum through valve 12 to the extent necessary to reduce the external dimension of shipping container 10 until the appropriate dimension is reached. The only practical limitation would involve maintaining sufficient internal volume 20 to allow for receiving the product being shipped and an optional temperature maintaining source.
[0024] As a further embodiment, it also may be useful to include a heat source within internal volume 20 rather than a cold source if the product being shipped so necessitates. By providing side walls 17 that are collapsible, as the heat source dissipates, temperatures would drop within internal volume 20 and side walls 17 would accommodate reduced pressure by collapsing.
[0025] As noted previously, the exact extent of volume reduction in using shipping container 10 depends not only upon the relative pressure established within internal volume 20 vis-à-vis ambient pressure, but the resistance of side walls 17 to collapse. This latter variable can be significantly controlled by judicious choice of side wall materials, thicknesses, the extent of folds 28 and what, if anything, exists within space 16 between inner wall 15 and outer wall 14 . For the sake of product integrity, it is generally suggested that portion 18 of side walls 17 near top 11 be made without the present accordion feature as well as portion 19 located proximate bottom 25 . Thus the interface between lid 11 and side wall portion 18 will remain intact as will the footprint established by bottom 25 .
[0026] As is commonly done, a vacuum could be established between inner side wall 15 and outer side wall 14 within space 16 by providing valve 29 accessible to a vacuum source. Space 16 could also, as a preferred embodiment, be charged with a fire retardant solid, liquid or gas to provide an additional safety feature in using the present invention. Space 16 could also be charged with an insulator, such as Styrofoam.
[0027] As yet a further embodiment, reference is made to FIG. 4 . In this embodiment, support frame 55 is shown wrapped about the outside of side walls 51 to add additional structural support to shipping container 50 and to optionally urge side walls 55 into an orientation desired by the user. For example, frame 55 can be biased to resist contraction of side walls 51 by applying frame 55 to the side walls in a compressed orientation whereby the various coils 55 a, 55 b, etc., urge expansion and thus resist contraction along folds 53 . Conversely, structural member 55 can be applied to side walls 51 in an expanded orientation where loops 55 a, 55 b, etc., tend to move closer together when not urged apart by side walls 51 .
[0028] Although shown on the outside of side walls 51 , structural member 55 can be placed on or proximate to the inner side walls of shipping container 50 or between inner and outer side walls in a space akin to space 16 ( FIG. 1 ).
[0029] An alternative to structural member 55 is shown in FIG. 6 . In this instance, loops 55 , 55 b, etc., have been replaced with scissoring members 61 , 62 , etc., at pivot pin 63 enabling ends 64 and 65 to slide along lower rail 66 . The embodiment of FIG. 6 would enable one to lock element 61 , 62 , etc., in place at end points 64 and 65 to fix the appropriate shipping container at a preselected height. This would enable one to reduce the shipping container volume, fix the side wall height using structural member 60 and even if pressure increases within the internal volume of the shipping container urging the side walls to expand, structural member 60 would resist such expansion. This could be helpful in instances where the external dimension of the shipping container is the most important feature characteristic of use.
[0030] Reference is next made to FIGS. 6A and 6B illustrating another embodiment of the present invention. In this embodiment, shipping container 70 is illustrated comprised of outer wall 71 which is rigid and incapable of responding to pressure changes and inner side wall 72 having collapsing in a manner as disclosed with regard to previous embodiments. A vacuum can be drawn on belt 74 through lid 73 causing inner side walls 72 to be drawn towards lid 73 resulting in a reduction in internal volume 76 as depicted in FIG. 6B . Vacuum can be released through valve 75 to return the FIG. 6B configuration to that shown in FIG. 6A . Such an embodiment will not reduce the external volume of shipping container 70 but will enable one to draw a vacuum within space 76 for the purpose of reducing thermal transfer between space 76 and ambient. | A shipping container having side walls, a bottom and a top defining an internal volume. The top is selectively displaceable for gaining access to the internal volume and for sealing the internal volume of the container. A valve drawing a vacuum on the internal volume from outside of the container is provided. The side walls are capable of contracting and expanding as a result of the pressure within the internal volume. | 1 |
FIELD OF THE DISCLOSURE
[0001] The present disclosure is generally directed toward communications and more specifically toward communication systems and methods.
BACKGROUND
[0002] Most large companies these days have a heterogeneous mix of Private Branch eXchanges (PBXs)/enterprise communication systems. Many of these same companies have a “Hot Desk” environment where employees are allowed to sit at a different desk and a different telephone on occasion, or even each day. These companies would like for their employees to have one single enterprise communication address that can represent that employee for all calls received and made by the employee. These companies would also like for this to be the case regardless of the type and manufacturer of endpoint (e.g., Cisco endpoint, Avaya endpoint, Siemens endpoint, etc.) at which the employee is currently sitting.
[0003] Previous attempts to address the above-mentioned problem include: (1) Call Forwarding; (2) Session Initiation Protocol (SIP) “Call me/Call you”; and (3) Internet Protocol (IP) Softphone “Telecommuter” mode. The call forwarding solution simply sends incoming calls to a user's address to their hot-desk number. The SIP “Call me/Call you” can be used to have an application initiate a call from a hot-desk endpoint and make it look to the called party as if he/she was called from the user's address. The IP Softphone “Telecommuter” mode can be used to extend an incoming call to user's address out to the hot-desk number. It can also be used to initiate a call in the “Call me/Call you” paradigm described above.
[0004] The available solutions fall short in several ways. First of all, the available solutions do not allow for the user to initiate calls directly from the hot-desk endpoint. Rather, the user must use an application of some sort to initiate a “Call me/Call you” flow so that the far end sees the user's address.
[0005] A problem with the IP Softphone solution in particular is that an IP Softphone solution requires the IP Softphone to be running and be registered with a PBX. This softphone application consumes both desktop and PBX resources for the user's address, in addition to those being consumed by the hot-desk endpoint.
[0006] A problem with the call forward solution is that the call Forward solution for redirecting incoming calls requires a Computer-Telephone Integration (CTI) link to each of the heterogeneous PBXs. As can be appreciated, these links require time and resources to establish. Another big problem with the call forward solution is that it doesn't address outbound calls.
SUMMARY
[0007] It is with respect to the above issues and other problems that the embodiments presented herein were contemplated. In particular, embodiments of the present disclosure propose the ability to, among other things, utilize application sequencing to facilitate a better and more effective hot-desking solution. In some embodiments, every hot-desk user would be an provisioned SIP user of an enterprise communication system, even though they may not have any registered SIP endpoints. In some embodiments, a hot-desking application is provided and can be provisioned as a sequenced application for all user addresses of record. Furthermore, the hot-desking application could also be provisioned as a sequenced application for all of the possible SIP and non-SIP hot-desk endpoint addresses.
[0008] In one example operation, when the user sits down at a desk, she would note the address of the endpoint at that desk. In some embodiments, she would then associate that hot-desk address with her own public Address of Record (AOR). This could be done via a Web-based User Interface (UI), a Graphical User Interface (GUI), a Telephone User Interface (TUI), or the like. The system may, in some embodiments, write to a database accessible by the hot-desk sequenced application. Alternatively, the hot-desk association could be coupled with some other sign-in process (e.g., agent login) so that an extra user action is not required to complete the hot-desk association.
[0009] In some embodiments, for incoming calls to the user's AOR, all applications for the called user (e.g., termination or term-side sequenced applications provisioned for the called user) would be invoked. In this scenario, the hot-desk application would be the last such sequenced application. Upon receiving the incoming communication-initiating message (e.g., an INVITE message), the hot-desk application would check to see if the user's AOR is associated with a hot-desk address. In this case, it would find such an association, and would proxy the INVITE to the hot-desk address. Everything upstream of the hot-desk application (e.g., all previously sequenced applications) would see the communications as being with a device associated with the user's AOR, but in actuality they would be communicating with the hot-desk endpoint.
[0010] In some embodiments, for outgoing calls from the hot-desk endpoint, there are two separate origination sequence vectors. There is a sequence vector associated with the hot-desk address and a second sequence vector associated with the user address. The hot-desk application would typically be the only application in the origination sequence vector for the hot-desk address. When invoked, the application checks to see if there's an association between the hot-desk address and a user AOR. In this case, it would find such an association and would then change the asserted identity (calling number) of the call to correspond to the user's AOR. The user's sequenced applications (e.g., origination or orig. applications) would then be invoked before the call is delivered to the called party. All downstream applications and/or parties would see the call as coming from the user's AOR instead of from the hot-desk number.
[0011] In accordance with at least some embodiments, hot-desk users would be instructed to not call another hot-desk user directly (e.g., by dialing the hot-desk number rather than the user's AOR). If this practice is adhered to, all calls can be sequenced and have their identities manipulated. This is true even if the two parties (e.g., called and calling party) are using hot-desk endpoints on the same PBX.
[0012] In accordance with at least some embodiments of the present disclosure, a method is provided which generally comprises:
[0013] receiving a first message, the first message comprising an asserted identity that corresponds to a hot-desk number;
[0014] determining that the hot-desk number has been associated with a calling user's address of record; and
[0015] in response to determining that the hot-desk number has been associated with the calling user's address of record, changing the asserted identity of the first message to a non-hot-desk number associated with the calling user's address of record.
[0016] In accordance with at least some embodiments of the present disclosure, another method is provided which generally comprises:
[0017] receiving a first message, the first message comprising a Request Uniform Resource Identifier (R-URI) that comprises a non-hot-desk number which is associated with an address of record for a called user;
[0018] determining that the called user's address of record is also associated with a hot-desk number; and
[0019] in response to determining that the called user's address of record is associated with the hot-desk number, changing the R-URI to the hot-desk number.
[0020] The term “server” as used herein should be understood to include any server, collection of servers, processors within a server, blades within a server, one or more virtual machines being executed by a server, containers or processes being executed by a server, etc. In other words, “servers” are not necessarily limited to individual hardware components with dedicated processors and memory. “Servers” are also not limited to a particular type of container executed by a server, such as a J2EE server or any other version of a Java EE server. Non-limiting examples of containers that may be executed by or constitute a server include application containers (e.g., Java Virtual Machines), applet containers (e.g., web browsers or applet viewers), Enterprise JavaBeans (EJB) containers, web containers, Application Programming Interfaces (APIs), and the like.
[0021] The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
[0022] The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
[0023] The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material”.
[0024] The term “computer-readable medium” as used herein refers to any tangible storage that participates in providing instructions to a processor for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, magneto-optical medium, a CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, or any other medium from which a computer can read. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium and prior art-recognized equivalents and successor media, in which the software implementations of the present disclosure are stored.
[0025] The terms “determine”, “calculate”, and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.
[0026] The term “module” as used herein refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element. Also, while the disclosure is described in terms of exemplary embodiments, it should be appreciated that individual aspects of the disclosure can be separately claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The present disclosure is described in conjunction with the appended figures:
[0028] FIG. 1 is a block diagram of a communication system in accordance with embodiments of the present disclosure;
[0029] FIG. 2 is a first call flow diagram in accordance with embodiments of the present disclosure;
[0030] FIG. 3 is a second call flow diagram in accordance with embodiments of the present disclosure; and
[0031] FIG. 4 is a flow diagram depicting a hot-desking method in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
[0032] The ensuing description provides embodiments only, and is not intended to limit the scope, applicability, or configuration of the claims. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing the embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the appended claims.
[0033] FIG. 1 shows an illustrative embodiment of a communication system 100 in accordance with at least some embodiments of the present disclosure. The communication system 100 may be a distributed system and, in some embodiments, comprises one or more communication networks 104 that facilitate communications between communication devices 108 , 148 .
[0034] The communication network 104 may be packet-switched and/or circuit-switched. An illustrative communication network 104 includes, without limitation, a Wide Area Network (WAN), such as the Internet, a Local Area Network (LAN), a Personal Area Network (PAN), a Public Switched Telephone Network (PSTN), a Plain Old Telephone Service (POTS) network, a cellular communications network, an IP Multimedia Subsystem (IMS) network, a SIP network, a Voice over IP (VoIP) network, or combinations thereof. In one configuration, the communication network 104 is a public network supporting the TCP/IP suite of protocols. Communications supported by the communication network 104 include real-time, near-real-time, and non-real-time communications. For instance, the communication network 104 may support voice, video, text, web conferencing, or any combination of media.
[0035] In some embodiments, the communication network 104 may connect one or more external communication devices 108 with an enterprise communication network 110 . The external communication devices 108 may be considered “external” because they are not fully administered by the entity or group of entities that administers the enterprise network 110 . In some embodiments, however, the communication devices 108 may be operated by enterprise users and may be partially administered in accordance with communication rules within the enterprise network 110 .
[0036] In some embodiments, the enterprise network 110 corresponds to a communication network or set of communication networks that are owned and operated by a single entity. The enterprise network 110 , in some embodiments, may be distributed (e.g., a WAN) or it may be confined to a single location (e.g., a LAN). In other embodiments, multiple entities may share some or all of the components of the enterprise network 110 .
[0037] In the illustrated embodiment, the enterprise network 110 is shown to include an access element having a server table 116 , a communication server 120 , one or more application servers 132 capable of providing one or multiple communication features to users, one or more internal communication devices 148 , a data store 152 , and one or multiple other servers 144 . Some or all of the components of the enterprise network 110 may be interconnected by a (trusted or secure or private) Local Area Network (LAN) 156 .
[0038] It should be appreciated that some or all of the functions depicted in FIG. 1 may be co-hosted and/or co-resident on a single server. The depiction of components in FIG. 1 and the other figures provided herein are generally intended to be a logical depiction of the components of the system 100 . It should be appreciated that an enterprise network or multiple enterprise networks may comprise multiple LANs 156 connected via a WAN, such as the communication network 104 . A single enterprise communication network 110 is depicted in FIG. 1 and described herein for ease of understanding and simplicity and in no way is intended to limit embodiments of the present invention to a single enterprise network 110 .
[0039] Furthermore, it should be appreciated that while a single access element 112 is depicted, most larger enterprise networks 110 comprise multiple access elements 112 , which may or may not be of the same type. For example, a single enterprise network 110 may comprise a first access element 112 from a first vendor (e.g., an access element from Cisco) and a second access element 112 from a second vendor (e.g., an access element from Avaya). In accordance with at least some embodiments, the access element 112 corresponds to a PBX, multiple PBXs, or components within a PBX. More specifically, the access element 112 may provide network access capabilities similar to those provided by known PBX devices or PBX devices yet to be developed. Even more specifically, the access element 112 may be configured to make connections among the internal components of the enterprise network 110 and also connect them to the communication network 104 via trunk lines, for example.
[0040] The LAN 156 can be secured from intrusion by untrusted parties by a gateway and/or firewall located between the LAN 156 and communication network 104 . In some embodiments, the access element 112 may include the functionality of the gateway and/or firewall. In some embodiments, a separate gateway or firewall may be provided between the access element 112 and the communication network 104 .
[0041] Although only certain numbers of each server (e.g., a single access element 112 , a single communications server 120 , two application servers 132 , etc.) is depicted in FIG. 1 , one, two, three, four, or more instances of any server type may be provided in a single enterprise network 110 or across multiple separate LANs 156 owned and operated by a single enterprise, but separated by communication network 104 . In configurations where an enterprise or an enterprise network 110 includes two or more servers of a single type (e.g., multiple communication servers 120 ), each server may comprise similar functionality, but may be provisioned for providing its features to only a subset of all enterprise users. In particular, as a non-limiting example, a first communications server 120 may be authoritative for and service a first subset of enterprise users whereas a second communications server 120 may be authoritative for and service a second subset of enterprise users, where the first and second subsets of users generally do not share a common user. This is one reason why the access element 112 may be provided with a server table 116 —the server table 116 may comprise the information that maps a user to their authoritative communication server 120 .
[0042] Additionally, multiple servers can support a common user community. For example, in geo-redundant and other applications where users aren't necessarily bound to a single application server, there may be a cluster of equivalent servers where a user can be serviced by any server in the cluster.
[0043] The communications server 120 can be included in the access element 112 (e.g., be incorporated into PBX functionality). Alternatively, or in addition, the communication server 120 may comprise an enterprise server, components or applications executed within a server, a virtual machine provided by a server, combinations thereof, or other type of telecommunications system switch or server. The communication server 120 is, in some embodiments, configured to enable the execution of telecommunication functions such as the suite of applications and services made available via Avaya Aura™ platform of Avaya, Inc., including Communication Manager™, Avaya Aura Communication Manager™, Avaya IP Office™, Communication Manager Branch™, Session Manager™, MultiVantage Express™, and combinations thereof.
[0044] In some embodiments, the access element 112 is responsible for routing communications within the enterprise network 110 to the communications server 120 responsible for servicing a particular user involved in a communication session. For example, if a first enterprise user is being called by an external communication device 108 , then the access element 112 may initially receive the inbound call, determine that the call is directed toward the first enterprise user, reference the server table 116 to identify the authoritative communications server 120 for the first enterprise user, and route the inbound call to the authoritative communications server 120 . Likewise, communications between internal enterprise users (e.g., internal communication devices 148 ) may first be serviced by the originating user's authoritative communications server 120 during the origination phase of communications set-up. After the origination phase is complete, the authoritative communications server 120 of the terminating (or called) user may be invoked to complete the termination phase of communications set-up. In some embodiments, the communications server 120 for the originating and terminating user may be the same, but this is not necessarily required. In situations where more than two enterprise users are involved in a communication session, authoritative communications servers 120 for each of the involved users may be employed without departing from the scope of the present invention. Additionally, the authoritative communications servers 120 for each user may be in the same enterprise network 110 or in different enterprise networks 110 , which are owned by a common enterprise but are separated by the communication network 104 .
[0045] Each communications server 120 may include user preferences 124 and a feature sequencer 128 . The feature sequencer 128 provides the communication server 120 with the ability to route messages to the appropriate servers within the network 110 . Specifically, the feature sequencer 128 may be invoked in response to receiving a request to initiate a communication session (e.g., an INVITE message in a SIP environment, an HTTP GET request, an inbound or outbound phone call, an email message, a Short Message Service (SMS) message, etc.) or a request for some other type of information (e.g., a request for presence information such as via a SUBSCRIBE message, a database query, etc.). Once invoked, the feature sequencer 128 may be configured to refer to the user preferences 124 to determine which server is to be activated next (e.g., receive the message next). More specifically, the communication server 120 may be configured to establish a chain of Back-to-Back User Agents (B2BUAs) or proxies in at least one of a dialog and media path of a communication session by sequencing each B2BUA into an application sequence one-by-one until the entire application sequence has been constructed.
[0046] The user preferences 124 for a communication server 120 contains the feature/communication preferences for each user for which it is authoritative. As one non-limiting example, the user preferences 124 may define which applications 136 , 140 from the application server 132 should be invoked for a particular user's application sequence. In some embodiments, the user preferences 124 may be in a table format and may be provisioned by users and/or by administrative personnel. The user preferences 124 for a particular user are referenced by the feature sequencer 128 to determine which, if any, applications 136 , 140 should be invoked for the user.
[0047] The applications 140 that can be included in a particular application sequence (e.g., via the communication server 120 and application server 132 ) are generally included to accommodate the user's preferences 124 and to provide communication services in accordance therewith. Applications 140 may vary according to media-type, function, and the like. Illustrative types of applications 140 include, without limitation, a fixed mobile convergence application, a call setup application, a voicemail application, an email application, a voice application, a video application, a text application, a conferencing application, a call recording application, a communication log service, a security application, an encryption application, a collaboration application, a whiteboard application, mobility applications, presence applications, media applications, messaging applications, bridging applications, and any other type of application that can supplement or enhance communications. Additionally, one, two, three, or more applications of a given type can be included in a single application sequence without departing from the scope of the present invention.
[0048] The hot-desk application 136 corresponds to a specific type of application 140 that enables hot-desking for users within the enterprise 110 . More specifically, the hot-desk application 136 may be configured to analyze messages transmitted during a communication session or during setup of a communication session to determine: (1) if the message is received from a hot-desk number, (2) if the message is received from a user that has associated themselves and their AOR with a hot-desk number, (3) if the message is directed toward a hot-desk number, and/or (4) if the message is directed toward a user that has associated themselves and their AOR with a hot-desk number. As will be discussed in further detail herein, if the hot-desk application receives a message that meets one of the above criteria, the hot-desk application may be configured to alter one or more of the message's To value, Request Uniform Resource Identifier (R-URI), From header, Contact header, and P-Asserted-Identity (PAI) prior to forwarding the message to the next destination. The alteration of the message may occur within one or more message headers or in any other way allowed/defined by applicable standards and protocols.
[0049] The internal communication devices 148 can be similar or identical to the external communication devices 108 except the internal communication devices 148 are provisioned, and often owned, by the enterprise administering the network 110 . As can be seen in FIG. 1 , some internal communication devices 148 may be connected to the access element 112 via the LAN 156 while other internal communication devices 148 (e.g., analog and digital stations) may be connected directly to the access element 112 . Illustrative types of communication devices 148 include, without limitation, cellular phones, smartphones, laptops, Personal Computers (PCs), Personal Digital Assistants (PDAs), digital phones, analog phones, and/or any other type of capable phone, softphone or digital telephone. Examples of suitable telephones include the 1600™, 2400™, 4600™, 5400™, 5600™, 9600™, 9620™, 9630™, 9640™, 9640G™, 9650™, 9608™, 9611™, 9621™, 9641™, and Quick Edition™ telephones, IP wireless telephones (such as Avaya Inc.'s IP DECT™ phones), video phones (such as Avaya Inc.'s Videophone™), and softphones such as Avaya Flare™.
[0050] The other server(s) 144 may correspond to any other type of server or collection of servers within the network 110 . In some embodiments, the other servers 144 may include one or more of voicemail servers, email servers, calendar servers, presence servers, Instant Messaging (IM) servers, backup servers, virtual machines, or the like.
[0051] The data store 152 can be configured to include enterprise subscriber information, such as name, job title, electronic address information (e.g., telephone number, email address, instant messaging handle, direct dial extension, and the like), subscriber contact lists (e.g., contact name and electronic address information), other employee records, user preferences 124 , and the like. Information contained in the data store 152 can be updated by any of the components within the network 110 (assuming such devices have permissions to do so) and/or made available to one or more of the components within the network 110 via various types of databases, servers, Application Programming Interfaces (APIs), etc.
[0052] The various servers and components depicted in FIG. 1 may be implemented separately (i.e., on different servers) or together (i.e., on a single server). In particular, two or more depicted components (e.g., communication server 120 and application server 132 ) may be implemented on a single server without departing from the scope of the present invention. Thus, a single device may provide the functionality of several components depicted separately in FIG. 1 .
[0053] With reference now to FIG. 2 , a call flow and method of processing a call initiated by a user with a hot-desk endpoint 204 will be described in accordance with embodiments of the present disclosure. The hot-desk endpoint 204 may correspond to any communication device 148 that is shared by two or more enterprise users or is made available for temporary use by an enterprise user. In some embodiments, the hot-desk endpoint 204 comprises any type of communication device.
[0054] The method begins when a first message is transmitted from the hot-desk endpoint 204 to an access element 112 (step S 201 ). In some embodiments, the first message may correspond to a session-initiating message, such as a SIP INVITE message or variants thereof. In this particular example, the calling user (e.g., Alice) may be initiating a call to a called user (e.g., Bob). While the calling user, Alice, corresponds to an enterprise user, it is not a necessary condition that the called user, Bob, also be an enterprise user. Certain embodiments of the present disclosure, however, contemplate that Alice and Bob may both be enterprise users and both may or may not be utilizing a hot-desk endpoint. It should be noted that if the hot-desk endpoint 204 corresponds to a SIP endpoint, then the first message would not necessarily traverse the access element 112 but rather may be routed directly to the communication server 120 , thereby skipping step S 201 .
[0055] In the examples discussed herein, assume that Alice has a first AOR within the enterprise 110 and that first AOR is or has been associated with a first direct-dial number or extension (e.g., administratively associated). More specifically, certain communication systems and system providers enable a direct-dial number to actually be an AOR or vice versa. As an example, a user, such as Alice and Bob, may have an AOR as an alphanumeric AOR (e.g., Alice@enterprise.com), an E.164 AOR (e.g., +1303123456), and/or an enterprise canonical numeric AOR (e.g., 4567). For ease of understanding the example, assume that Alice's AOR is +13031234567. Thus, when other users want to call Alice directly, they dial Alice's AOR (e.g., +13031234567) or some variant thereof (e.g., extension 4567) depending upon the dial-plan assigned to Alice. In this example, assume that Alice has called Bob at +19089353456. This dialed number (e.g., Bob's number) may or may not correspond to a number internal to the enterprise network 110 .
[0056] Continuing the example of FIG. 2 , the access element receives the first message from the hot-desk endpoint 204 and routes the message to the appropriate communication server 120 (step S 202 ). Upon receiving the first message, the communication server 120 determines that the number from which the message was originated (e.g., the number of the hot-desk endpoint 204 , which for example may be 444-1234) corresponds to or falls within a number range that is configured to be sequenced to the hot-desk application 136 . At this point, the communication server 120 implicitly sequences the hot-desk application 136 by forwarding the message to the hot-desk application 136 (step S 203 ). It should be noted that the communication server 120 , in some embodiments, may sequence the hot-desk application 136 as the first application in the sequence of applications for Alice although this may not be necessary since the hot-desk application 136 will have already served its purpose by mapping the hot-desk number to the enterprise AOR.
[0057] Thus, when the hot-desk application 136 receives the message from the communication server 120 , the hot-desk application 136 determines that the number from which the message was originated (e.g., 444-1234) has been associated with Alice's AOR. In some embodiments, the hot-desk application 136 is made aware of the association between Alice's AOR and the hot-desk number because Alice registered herself (and her AOR) with the hot-desk endpoint 204 when she sat down and started using the hot-desk endpoint 204 . Details of this registration process are not described herein and it should be appreciated that any registration process or set of processes may be used. For instance, Alice may enter a TUI code or series of TUI codes at the hot-desk endpoint 204 to register herself and her AOR with the hot-desk endpoint 204 . As another example, Alice may use a web-based UI upon sitting down at the hot-desk endpoint 204 to communicate directly with the hot-desk application 136 and register herself and her AOR with the hot-desk endpoint 204 . Other registration examples will become readily apparent to those of ordinary skill in the art.
[0058] Furthermore, the hot-desk application 136 may be configured to analyze the From, Contact, and/or PAI header of the message to determine if the value contained in the analyzed header (e.g., 444-1234) is actually associated with a user's AOR. Once the hot-desk application 136 determines that the value in the From, Contact, and/or PAI header of the message has been associated with Alice's AOR, the hot-desk application changes the value in the header(s) to correspond to Alice's AOR (e.g., +13031234567). This causes the message to appear as though it was actually originated by Alice at her personal endpoint rather than Alice at the hot-desk endpoint 204 .
[0059] After the From, Contact, and/or PAI header value has been changed to Alice's direct-dial number or extension, the hot-desk application 136 returns the message back to the communication server 120 (step S 204 ). At this point, the communication server 120 now recognizes the message as being originated by Alice, rather than by hot-desk endpoint 204 , and invokes the feature sequencer 128 , which refers to Alice's communication preferences in the user preferences 124 . Upon looking up Alice's communication preferences, the communication server 120 is enabled to sequence other origination applications 208 for Alice in accordance with her user preferences 124 . In particular, the communication server 120 can forward the message along to other origination applications 208 (step S 205 ) and each of the other origination applications 208 can insert themselves into the communication session (e.g., dialog and/or media path) as a B2BUA or proxy, depending upon the nature of the other origination applications 208 . In some embodiments, the other origination applications 208 may correspond to various applications 140 . After each application has been appropriately sequenced for Alice, the method continues with the last origination application 208 providing the message back to Alice's communication server 120 (step S 206 ) so that the message can be forwarded along to Bob or Bob's communication server 120 , depending upon whether Bob is an enterprise user or not.
[0060] With reference now to FIG. 3 , a call flow and method of processing a call directed toward a user employing a hot-desk endpoint 304 will be described in accordance with embodiments of the present disclosure. The hot-desk endpoint 304 may by similar or identical to the hot-desk endpoint 204 in that it may correspond to any communication device 148 that is shared by two or more enterprise users or is made available for temporary use by an enterprise user.
[0061] Furthermore, with respect to the example of FIG. 3 , assume that Bob has a second AOR within the enterprise 110 and that second AOR is or has been associated with a second direct-dial number or extension (e.g., administratively associated). For ease of understanding the example, assume that Bob's AOR is +19707654321. Thus, when other users (e.g., Alice) want to call Bob directly, they dial Bob's AOR (+19707654321) or some variant thereof (e.g., extension 4321) depending upon the dial-plan assigned to Bob.
[0062] Although the call flow of FIG. 3 is depicted as being separate and distinct from the call flow of FIG. 2 , it should be appreciated that the flow of FIG. 3 may, in some embodiments, pick up where the flow of FIG. 2 left off. Specifically, step S 301 may be performed after step S 206 . It should also be appreciated that the flow of FIG. 3 can be performed independent of the flow depicted in FIG. 2 . For instance, the flow of FIG. 3 may be initiated in response to Bob receiving a call from an external communication device 108 .
[0063] In some embodiments, the call flow for the call to Bob begins with the communication server 120 (e.g., Bob's authoritative communication server) invoking the feature sequencer 128 to determine Bob's communication preferences from the user preferences 124 . Once this determination has been made, the communication server 120 invokes the application sequence for Bob via one or more other termination applications 308 (step S 301 ). In some embodiments, the termination applications may correspond to one or more applications 140 that are sequenced as B2BUAs or proxies by the communication server 120 so as to fulfill Bob's communication preferences. The communication server 120 knows that Bob's preferences should be fulfilled because the message is addressed to Bob's AOR or a direct-dial number associated with Bob's AOR. Every time an application is sequenced, the message may be transmitted back to communication server 120 to determine if another termination application is to be sequenced for Bob (step S 302 ). This back-and-forth between the communication server 120 and the other termination applications 308 continues until all of Bob's applications have been sequenced.
[0064] Thereafter, the communication server 120 sequences the hot-desk application 136 on behalf of Bob, in-case Bob is sitting at a hot-desk endpoint 304 (step S 303 ). Upon receiving the message, the hot-desk application 136 determines that Bob has associated himself with the hot-desk endpoint 304 having a hot-desk number (e.g., 555-6789). Bob may have associated himself and/or his AOR with the hot-desk endpoint 304 in a registration step that is similar or identical to the registration step discussed above.
[0065] When the hot-desk application 136 determines that the received message is associated with Bob and, therefore, also associated with a hot-desk endpoint 304 , the hot-desk application 136 is configured to change one or more of: the message's To value and a value of the message's R-URI header from Bob's AOR (e.g., +19707654321) to the hot-desk number (e.g., 555-6789). After the hot-desk application 136 has changed the To value and/or R-URI header of the message, the method continues with the hot-desk application 136 returning the message to the communication server 120 (step S 304 ).
[0066] As can be seen above, the hot-desk application 136 may correspond to the last sequenced application for Bob. In other words, the other termination applications 308 may be sequenced prior to sequencing the hot-desk application 136 . Therefore, when the communication server 120 receives the message from the hot-desk application 136 , it is most likely that no further applications need to be sequenced by the communication server 120 . Accordingly, the method continues with the communication server 120 forwarding the message to the access element 112 associated with the hot-desk endpoint 304 (step S 305 ), which subsequently provides the message to the hot-desk endpoint 304 at which Bob is sitting and has registered with (step S 306 ).
[0067] To further understand embodiments of the present disclosure, if the examples of FIGS. 2 and 3 were combined, then Alice would call Bob at (+19707654321) from hot-desk endpoint 204 (444-1234). After the message has been processed by hot-desk applications 136 for Alice and Bob, the message would ultimately reach Bob at the hot-desk endpoint 304 (555-6789) and it would appear to Bob and all other origination and termination applications 208 , 308 as though Alice is actually calling from her direct-dial line (+13031234567). Furthermore, all of Alice's origination applications 208 and Bob's termination applications 308 will be sequenced even if Alice and Bob happen to be using hot-desk endpoints 204 and 304 that are hosted on the same access element 112 .
[0068] With reference now to FIG. 4 , a method of hot-desking will be described in accordance with at least some embodiments of the present disclosure. The method is initiated when a user notes a hot-desk address of a communication device (e.g., a hot-desk endpoint) at a particular workstation or desk (step 404 ). The user then associates that hot-desk address with their AOR (step 408 ). In some embodiments, the user associates their hot-desk address with their AOR by performing a registration process. This registration process may occur via a web-based GUI or by implementing some sort of single sign on (SSO) process that is coupled with the user simply logging into the network 110 from the hot-desk endpoint. The registration process may also be accomplished via a TUI or the like.
[0069] The registration process causes the user's AOR to be stored with a logical association in the hot-desk application 136 or at some location that is accessible to the hot-desk application 136 (e.g., data store 152 ) (step 412 ). In some embodiments, the hot-desk application 136 maintains an internal record of the fact that the user associated their AOR with the hot-desk endpoint and specifically with the hot-desk number assigned to the hot-desk endpoint. By having this information available the hot-desking application 136 can easily invoke the hot-desking features discussed herein whenever the hot-desk application 136 is sequenced by the communication server 120 (step 416 ). As discussed above, the communication server 120 is configured to implicitly sequence the hot-desk application 136 for calls originating from the hot-desk endpoint and then sequence other applications for the user that is calling from the hot-desk endpoint. Likewise, the communication server 120 is configured to sequence the hot-desk application 136 for a called user that has been identified as sitting at or using a hot-desk endpoint.
[0070] In the foregoing description, for the purposes of illustration, methods were described in a particular order. It should be appreciated that in alternate embodiments, the methods may be performed in a different order than that described. It should also be appreciated that the methods described above may be performed by hardware components or may be embodied in sequences of machine-executable instructions, which may be used to cause a machine, such as a general-purpose or special-purpose processor (GPU or CPU) or logic circuits programmed with the instructions to perform the methods (FPGA). These machine-executable instructions may be stored on one or more machine readable mediums, such as CD-ROMs or other type of optical disks, floppy diskettes, ROMs, RAMs, EPROMs, EEPROMs, magnetic or optical cards, flash memory, or other types of machine-readable mediums suitable for storing electronic instructions. Alternatively, the methods may be performed by a combination of hardware and software.
[0071] Specific details were given in the description 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 details. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
[0072] Also, it is noted that the embodiments were described as a process which is depicted as a flowchart, a flow diagram, a data 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 re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. 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.
[0073] Furthermore, embodiments may be implemented by hardware, software, firmware, middleware, microcode, hardware description languages, or any 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 storage medium. A processor(s) 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 any 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 via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
[0074] While illustrative embodiments of the disclosure have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art. | A hot-desking application and methods of operating the same are described. The hot-desking application can be provisioned as an explicit sequenced application for all user addresses of record in addition to being provisioned as an implicit sequenced application for all of the possible hot-desk endpoint addresses. Through such provisioning, the hot-desking application can, among other things, allow for calls to be placed directly from a hot-desk endpoint but still show the user's address of record as the calling identity. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of timepieces and, more particularly, to the field of watches and, still more particularly, to the field of wristwatches and wristwatch cases.
2. Background Discussion
In order to better understand and appreciate the present invention relating to modern wristwatches and cases therefor, a brief horological perspective is considered desirable and is presented hereinbelow.
Devices for displaying the current time and measuring the passage of time have been known for hundreds if not thousands of years. Before mechanical clocks were invented, such time keeping devices as sun dials, hour glasses and water clocks had been in use for centuries. Early mechanical clocks were costly and village clock towers-often church steeples--which had clock faces that could bee seen from long distances and which tolled at least the hours were common and can still be seen in many towns and cities throughout the world. Perhaps the most famous clock tower in the world is the tower housing Big Ben in London, England.
As rural farming villages gave way to towns and cities, and as commerce became more important and widespread, and the income level increased, more and more families acquired their own timepieces. Thus, for example, wall and mantle clocks became a fixture in many well to do homes.
Major advances in exploration and particularly ocean navigation in the 1400's can be attributed to the invention of the chronograph which enabled sailing distances to be determined with accuracy. This enabled accurate mapping of the oceans, islands and continents.
A growing need soon arose for portable time pieces that could be carried by individuals. Perhaps the earliest type of portable timepiece was a pocket sundial, modern replicas of which are available as curiosities. Such portable sun dials had the distinct disadvantage that the sun must be available. Hence, pocket sundials could not provide time indoors or outdoors when the sun was not shining. Moreover, as clocks became common, more precise time determination was demanded of portable timepieces than could be provided by pocket sundials.
In any event, mechanical, wind-up pocket watches first came on the scene in about the 1700's, and are still in somewhat common usage, and fancy pocket watches on the ends of heavy gold chains became a symbol of status and importance. Pocket watches were, however, found to be relatively inconvenient to use-especially as the pace of life quickened and people increasingly began to live their lives by the clock rather than by sunrise and sunset.
Wristwatches came into popular use early in the 20th century and by the end of World War II most adults in industrialized counties had at least one wristwatch. By that time, wristwatches manufactured by such U.S. companies as Benrus, Bulova, Elgin, Hamilton, Longines and Whitanaur were well known. Wristwatches were then most commonly of the mechanical windup type, inexpensive versions of which later become popularized by the Timex watch company's jingle: "It takes a licking and keeps on ticking." More expensive, self-winding or "automatic" mechanical watches also became generally available after WW II.
As a commercial use of space-age technology and its microminiaturization technology, electric or electronic (i.e., battery-powered) analog watches became available to a limited extent in the United States in about the late 1960's. A notable example of an early electronic wristwatch is Bulova's high-end "ACCUTRON" battery-powered watch which used a transistorized circuit to drive a miniature tuning fork as a timing standard, and which used a miniature motor for operating the analog time display which consisted of hour, minute and second hands.
In the early 1970's, battery-powered wristwatches with digital time displays and quartz timing devices were introduced--initially principally as a "hi-tech" novelty and subsequently (and still currently) as an inexpensive alternative to mechanical watches. Digital watches employing power-hungry and often difficult to read red LED (light emitting diode) time displays, which had to be activated to read the time, were first on the market, but were soon displaced by constant-display LCD (liquid crystal displays) wristwatches. However, digital quartz wristwatches soon lost most of their popularity-except for low-end wristwatches--because LCD displays are difficult to read, especially in bright sunlight which overpowers the LCD display, and must be back lit to be read in low light or in the dark.
By the late 1980's, analog quartz wristwatches had become more or less the standard for most individuals; although, some multi-function watches have continued to use LCD displays, for example, for a second time zone display or for stop-watch purposes. Most analog electric watches are now manufactured by (or for) Japanese companies by such companies as Seiko, Casio and Citizen which essentially dominate the wristwatch market.
Nevertheless, there has remained through evolving wristwatch history what might be termed an important niche market for precision mechanical wristwatches, now primarily of the self-winding (i.e., automatic) type, as exemplified by such well-known Swiss-made watches as ROLEX and OMEGA. Many of such watches are very expensive for the average person and are often made with solid gold cases, with some models using gem stones, such as diamonds, in lieu of hour numbers on the watch face and/or as watch case decorations. To many, such wristwatches as ROLEX have become a symbol of status and are often worn more for display than for timekeeping purposes.
It is to this high-end, precision mechanical wristwatch market that the present modular wristwatch assembly invention is principally (but not necessarily) directed, since it enables the cost-efficient production of limited quantities of expensive wristwatches.
The present invention also enables, as described below, watchmakers to provide various models of different appearance without incurring the high tooling costs heretofore associated with introducing new watch models. It also enables the rapid introduction of new models and even permits customers to customize their own wristwatch.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a modular wristwatch assembly which comprises a case bezel having a transparent watch crystal mounted therein, and having first and second pairs of watch band lugs joined to opposite exterior side edge regions of the bezel. Included are a rigid watch back member and a rigid, annular watch movement retaining member disposed between the bezel and the back member.
Further included in the modular watch assembly is a watch movement, which may be either mechanical or electronic, having a watch face or dial and time indicating means. The watch movement is installed in the watch movement retaining member and has operating controls extending outwardly through the retaining member wall for manual operation by a wearer.
Further included are means for detachablably attaching the bezel and watch back member together with the watch movement retaining member, with the installed watch movement, retained or sandwiched therebetween. The watch movement may be mechanical or electronic (for example, quartz, and may provide time indicating means which are analog or digital, or a combination thereof.
There is included a wrist band having first and second ends which are detachably attached to respective first and second pairs of the watch band lugs on the bezel.
The means for detachably attaching the bezel and watch back member together, with the movement and the movement retaining member retained therebetween, preferably include a plurality of attachment ears sidewardly projecting from edges of the watch back member. Such ears are formed having apertures aligned with the watch band attachment lugs. Screws are installed through the apertures in the ears and extend into threaded recesses in lower regions of the lugs.
In accordance with a preferred embodiment of the invention, a decorative ring, which is preferably replaceable so as to provide different watch face appearances, is installed between an under surface of the bezel and an upper surface of the watch face. The ring is preferably detachably attached to the watch face, and is sized to fit around peripheral edge regions of the face so as not to interfere with the time indicating means and to be visible through the watch crystal in the bezel.
For some wristwatch assemblies, a transparent crystal is installed in the watch back member so that an underside of the watch movement installed in the watch movement receiving member is visible through the watch back member.
There is correspondingly provided a modular wristwatch case which comprises a case bezel having a transparent watch crystal mounted therein and having first and second pairs of watch band lugs joined to opposite exterior side edge regions of the bezel. Included is a rigid watch back member and a rigid, annular watch movement retaining member sized for being mounted between the bezel and t he back member.
Further included in the case are means for detachablably attaching the bezel and watch back member together with the watch movement retaining member held or sandwiched therebetween. Such means include a plurality of attachment ears sidewardly projecting from edges of the watch back member. Such ears are formed having apertures aligned with the watch band attachment lugs. Screws are provided for installation through the apertures in the ears and into threaded recesses in lower regions of the lugs.
A decorative ring, which is preferably replaceable with different configurations, is provided for installation between an under surface of the bezel and an upper surface of the watch face. The ring is configured for being detachably attached to said watch face, and is sized to fit around peripheral edge regions of a face of a watch movement installed in the movement retaining member so as not to interfere with time indicating means of the movement and so as to be visible through the watch crystal in the bezel.
For some wristwatch cases, a transparent crystal is installed in the watch back member so that an underside of a watch movement installed in the watch movement receiving member is visible through the watch back member.
By interchanging different bezels (for example, bezels of the same configuration but made from a variety of different materials and finishes such as gold, polished stainless steel or brushed stainless steel), watch movement retaining members (also of the same configuration but made from different material and/or finishes), watch back members and decorative rings (of the same or different configurations and materials and finishes), the appearance of the modular wristwatch case assembly can be easily and substantially changed. By interchanging watch movements and movement faces, the wristwatch assembly can be further changed and can be customized according to a customer's preference.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more readily understood by a consideration of the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is an enlarged perspective drawing of the modular watch of the present invention, showing its external features and showing its modular construction;
FIG. 2 is an enlarged exploded perspective f the modular watch of FIG. 1 showing all the component parts thereof;
FIG. 3 is an enlarged transverse cross sectional drawing taken along line 3--3 of FIG. 1 showing the manner in which a bezel; a decorative ring; a central, watch movement member and lower back member are interconnected;
FIG. 4 is an enlarged transverse cross sectional drawing taken along line 4--4 of FIG. 1 showing other internal features of the modular watch of FIG. 1; and
FIG. 5 is an enlarged perspective drawing of an alternative decorative ring.
In the various FIGS., the same elements and features are given the same reference numbers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIG. 1, an exemplary modular wristwatch assembly or system 10 in accordance with a preferred embodiment of the present invention. By way of illustration, with no limitation thereby intended or implied, modular wristwatch assembly 10 is depicted as being of an analog, chronometer type with day and date display and stopwatch function. It will be appreciated that the present invention applies as well to a single function analog wristwatch, a single or multi-functional digital wristwatch or a combination analog and digital wristwatch.
As more particularly described below, further comprising modular wristwatch assembly 10 is a bezel 12 having installed therein a watch crystal 14, and a centrally located, annular watch movement holding or receiving member 16. Included is a watch face or dial 18 of a watch movement (not shown in FIG. 1) which is retained in the movement receiving member 16. Watch movement control means 20 extend through a side wall of movement retaining member 16. Associated with watch face 18 are time display means 22. A removable and replaceable decorative ring 24 is shown mounted on top of watch face 18 beneath bezel 12 so as to be visible through watch crystal 14. Further included is a lower back plate or member 26.
Respective first and second pairs of wrist band lugs 30 and 32 are joined to opposite side edge regions of bezel 12 to enable the attachment of a conventional metal watch band or bracelet (not shown). By way of illustrative example, first and second wrist strap adapters 34 and 36, respective, are detachably connected to respective wrist band lug pairs 30 and 32 by pins 38 and 40, respectively, to enable the attachment of a narrower wristband 42, for example, a conventional leather wristband which is narrower than a metal watch band.
As further shown in FIG. 1, a first end 44 of watch strap 42 is detachably connected by a pin 46 to first adapter 34 and a second end 48 of watch strap 42 is detachably connected to second adapter 32 by a pin 50.
Although ends of pins 38, 40, 46 and 50 are shown in FIG. 1 for illustrative purposes, it is to be understood that ends of such pins would normally not extend entirely through pairs of lugs 30 and 32 and adapters 36 and 36, but would be hidden, spring types, such as are commonly used to attach wrist bands or straps to wristwatches.
Describing modular wristwatch assembly 10 more particularly, there is shown in FIG. 2, in exploded perspective, all the various component parts of the wristwatch assembly. Shown from top left to bottom left are circular watch crystal 14, which is preferably constructed from a scratch-resistant mineral glass or saphire; a watch crystal retainer ring 40 and bezel 12 having first and second, sidewardly extending pairs of watchband attachment lugs 30 and 32.
It is preferred for strength and appearance that first and second pairs of watch band attachment lugs 30 and 32 are machined in conjunction with the machining of bezel 12 to be integral with the bezel. Alternatively, but less preferably, lug pairs 30 and 32 can be separately formed and be welded to sides of bezel 12 after the bezel is formed.
First wrist strap adapter 34 is shown by way of example in FIG. 2, as is its connection pin 38. It will be appreciated, however, that if modular wristwatch 10 is provided with a metal band or bracelet with curved end attachments which match the curvature of bezel 14, first adapter 34 (as well as second adapter 36, which is not shown in FIG. 2) would ordinarily not be needed and would not be attached to lug pairs 30 and 32. Adapters 34 and 36 could, nonetheless, be supplied with wristwatch 10 as accessories in case a buyer later desires to attach a slender wrist strap, like strap 42, as depicted in FIG. 1. In such case, adapters 34 and 36 could be used to give the appearance that the watch strap "flows" or merges into bezel 14.
Bezel 12 and first and second pairs of lugs 30 and 32 can be constructed of such metals as gold and polished or brushed stainless steel.
Decorative ring 24 is depicted in FIG. 2, by way of illustration, with no limitation being thereby intended or implied, as being configured with first, second and third similar and interconnected ramps 60, 62 and 64, respectively, which widen as the height of the ramps increase. The purpose of ring 24 is to provide a distinctive appearance to modular wristwatch assembly 10 which cam be changes by the installation of rings 24 of different configurations.
Since ring 24 is not a structural part of modular wristwatch 10, it can be constructed, not only of a precious metal or stainless steel (polished or brushed), but of aluminum which can be anodized in different colors or of a plastic material which can be provided in different colors. As described above, ring 24 is installed under bezel and on top of watch face 18 and is sized to circle the periphery of the watch face without interfering with any time display and yet to be visible through watch crystal 14, as shown in FIG. 1.
Watch movement retaining member 16 is formed as an annular ring shaped to retain watch movement 66 and watch face 18. Retaining member 16 is formed having first and second pairs of shallow recesses or notches 68 and 70 for receiving, upon assembly of wristwatch 10, inner regions of respective pairs of wristband lugs 30 and 32 in a closely-fitting relationship so that the lugs appear to also be part of member 16.
Formed through a side of retaining member 16 are apertures 74, 76 and 78 for installation of control means 20. As shown in FIG. 2, control means 20 comprise a central knob 80 with a stem 82 which, for the day/date type of movement 66 depicted, is operatively connected for setting hour and minute hands 84 and 86 (associated with watch face 18) and the day and date functions visible through windows 90 and 92 in the watch face. First and second push buttons 94 and 96 are installed through respective apertures 76 and 78, the first button being operatively connected to movement 66 for starting and stopping stopwatch functions of the movement and second button 98 being operatively connected to the movement for resetting to zero the stopwatch function. It will, of course, be understood that other, more simple or more complex configurations of control means 20 can be provided depending on the functions provided by watch movement 66, with appropriate apertures being formed in movement retaining member 16.
Watch movement retaining member may be constructed, for example, gold and polished or brushed stainless steel. In any particular modular wristwatch assembly 10, movement retaining means 16 and bezel 12 (with) lug pairs 30 and 32) may be constructed of the same, different or contrasting materials, according to the appearance desired by the manufacturer or, in the instance of a customized wristwatch, the buyer.
For the type of movement 66 being described by way of illustration of the present invention, watch face 18 further includes first, second and third small, calibrated dials 100, 102 and 104. Hands 106, 108 and 110 shown associated with respective dials 100, 102 and 104 and connected (upon assembly) to movement 66 by respective drive pins 114, 116 and 118, may, for example, display tenths of seconds, seconds and minutes, according the type of movement 66 involved. As previously mentioned, the day and date provided by watch movement are visible through respective apertures 90 and 92 in face 19.
Watch face 19, regardless of configuration, may be made from any thin, suitable material, such as brass, and may be finished in any desired manner. As an example, there may be provided a black face with white dials 100, 102 and 104 and hour and minute hands 84 and 86 and black hands 106, 108 and 110, or the just mentioned color scheme may be reversed. Other color schemes may, of course, be used to provide a contrast or to coordinate with bezel 14 and/or movement retaining member 16, as may be desired by the watch manufacturer or customer.
Watch movement 66 may be any type, for example, an existing type that is commercially available or is already made by the manufacturer of modular wristwatch assembly 10. As previously mentioned, watch movement 66 may be of a mechanical type, either automatic (self winding) or a wind-up type, or may be a quartz electronic type, or any other type which may be or may become available.
A retainer ring 120 is provided for retaining movement 66 in a mating groove or recess 122 formed around the inside of movement retaining member 16 (see FIGS. 3 and 4).
Watch back member 26 comprises a flat peripheral edge region 124 which surrounds a concave, dished region 126. A central aperture 128 may be provided in back member 26 for mounting a case back crystal 130, which is retained in aperture 128 by a crystal retaining ring 132. Crystal 130 enables an under side 134 of watch movement 66 to be seen, as is desirable for some modular wristwatches 10 having mechanical movements. As an alternative, watch back crystal 130 may be replaced by a metal plate the size of the crystal if viewing of movement is not wanted. This enables watch back member to be used either with or without movement viewing. As still another alternative, back member 26 may be formed without central aperture 128 is watch movement viewing is not desired.
Case back member 26 is further formed having a plurality-four-of ears or tabs 134 which project sidewardly outward from peripheral region 124 and in the plane thereof. Ears 134 are located so that one of the ears is under a corresponding one of lugs 30 and 32. A small aperture 136 is formed through each ear 134 for receiving a screw 138 that upon assembly extends through the aperture and into a threaded recess 140 formed upwardly into one of lugs 30 or 32 from a bottom surface 142 thereof (FIG. 3).
Watch back member 26 is constructed of a non-corroding material, preferably, but not necessarily, of stainless steel or gold.
FIGS. 3 and 4 show cross sections of the assembled modular wristwatch 10. Such FIGS. show than an annular stepped region 150 of bezel fits downwardly over an annular shoulder region 152 of watch movement retaining member 16. Decorative ring 24 fits against an inner annular surface 154 of shoulder region 152 and rests against an upper surface 156 of watch face 18. Ring 24 may be detachably attached from an underside to watch face 18 by small screws 160 (FIG. 3).
As previously mentioned, watch movement 66 is retained in member 16 by retainer ring 120 which snaps into annular recess 122 formed around an inner surface 1164 of the member. As shown in both FIGS. 3 and 4, watch movement 66 fits downwardly into an inner corner region 166 of back member 26.
By way of example, an O-ring seal 166 is installed around stem 82 of control 80. If desired seals (not shown) may be installed at an interface 170 between bezel 12 and movement retaining member 16 and at an interface 172 between the movement retaining member and case back member 26.
There is shown in FIG. 5 by way of example, a variation decorative ring 24a having a jewel, such as a diamond or ruby, installed at the 3, 6, 6 and 12 o'clock positions. Other decorative rings of other construction and design can also be provided.
It is to be understood that a modular wristwatch case assembly can be provided which comprises all the above-described components of wristwatch 10 except watch movement 66 and perhaps watch strap 42 and adapters 34 and 36, and with or without apertures 74, 76 and 78 in movement retaining member 16. The modular wristwatch case can thus be supplied by case manufacturers to manufacturers of watch movements 66 for installation of the watch member and addition of a watch band or strap 44.
In this regard, a case manufacturer can supply bezels 12 and movement retaining members of different materials and/or finishes and decorative rings of various designs so that an assembler of modular wristwatch 10 can make various versions of the wristwatch using the standard parts.
Although for purposes of describing the present invention, modular wristwatch 10 has been illustrated and describes as being generally round in plan view, it is to be understood that it is within the scope of the invention that it be made in any shape, such as square, octagonal, oval, elliptical or any other shape in plan view that may be desired and for which a movement 26 can be provided or obtained. Bezel 12 may be faceted or be made with any decorative peripheral or surface shape or pattern; it may be set with jewels or may be engraved or textured in any desired manner without deviating from the scope of the present invention.
Although there has been described and illustrated a modular wristwatch assembly and a modular wristwatch case for case for the same in accordance with the present invention for purposes of illustrating the manner in which the invention may be used to advantage, it is to be appreciated that the invention is not limited thereto. Therefore, any and all variations and modifications that may occur to those skilled in the applicable art are to be considered as being within the scope and spirit of the claims as appended hereto. | A modular wristwatch assembly comprises a bezel having a transparent watch crystal mounted therein, first and second pairs of watch band lugs joined to opposite exterior side edge regions of the bezel, a rigid watch back member, and a rigid, annular watch movement retaining member disposed between the bezel and the back member. Included in the assembly are a watch movement, having a watch face and hands for indicating the time, installed in the watch movement retaining member and having operating controls extending outwardly therethrough. There is further included a decorative ring installed between an under surface of the bezel and an upper surface of the watch face, the ring being around peripheral edge regions of the face so as not to interfere with the time indicating means and being visible through said watch crystal. Screws are used for detachablably attach the bezel and the watch back member together with the watch movement retaining member and watch movement held therebetween. A corresponding modular wristwatch case is provided which does not have the watch movement installed. | 6 |
REFERENCE TO CO-PENDING APPLICATIONS
Priority is claimed as a divisional application of U.S. patent application Ser. No. 11/597,784 having a 371(c) filing date of Nov. 27, 2006 (currently allowed), which further claims priority from a 371 of international of PCT/IL2005/000612, filed on Jun. 9, 2005, which claims priority to Israeli patent application number 162449, filed on Jun. 10, 2004.
FIELD OF THE INVENTION
The present invention relates to improved fire-retardant formulations. More specifically, the present invention relates to improved fire-retardant formulations for styrene polymers and more particularly for High Impact Polystyrene (HIPS) and Acrylonitrile-Butadiene-Styrene terpolymer (ABS).
BACKGROUND
Styrenic resins are widely used in many applications including those where fireproof materials are necessary. Such applications include for example TV cabinets, in which there is a need for the incorporation of fire-retardants (FR) in styrene-polymeric materials.
Traditional FRs for these applications include, inter cilia, decabromodiphenyl oxide and more recently tris(2,4,6-tribromophenoxy)-s-triazine the latter known as FR-245. The advantages of FR-245 are good balance of properties, high level of mechanical properties, high processing heat stability, good light stability, high melt flow and no blooming. However, unlike formulations based on decabromodiphenyl oxide, the formulations based on FR-245 tend to induce long after glow time. This effect is enhanced when carbon black is added to the formulation.
JP 11323064 discloses the incorporation of fire-retardant formulation comprising tris(2,4,6-tribromophenoxy)-s-triazine known as FR-245, tris(3-bromo-2,2(bromomethyl)propyl)phosphate known as FR-370, antimony trioxide (Sb203) and PTFE (polytetrafluoroethylene) in rubber reinforced polystyrene also known as HIPS, wherein the bromine content, the main component responsible for fire retardation, is between 9.5 and 11 wt. % and wherein antimony trioxide, serving as a synergist, is between 3.5 and 3.7 wt. %.
This formulation is claimed to successfully meet the requirement of UL-94 class V-0 according to the flammability tests, where five specimens are ignited, twice each, and the fulfillment of 5 requirements is necessary to pass a UL-94 V-0 standard, namely:
1. Maximum after flame time≦10 seconds (for each ignition).
2. Total after flame time of 10 ignitions less or equal to 50 seconds.
3. Maximum after flame+after glow time less or equal to 30 seconds.
4. None of the test specimens burns or glows up to the holding clamp.
5. No cotton ignition by dripping.
UL-94V is UL (Underwriter Laboratories) Standard for Safety for Tests for Parts in Devices and Appliances.
A fire-retardant formulation containing FR-245 with 11.5 wt. % Br, 0.08 wt. % PTFE and 3.5 wt. % antimony trioxide is also rated UL-94 V-0, but reducing the bromine content to 10.5 wt. % Br results in derating to UL-94 V-1 because of long afterglow time. JP 11323064 overcomes this problem by introducing FR-370 to the formulation, which effectively reduces that time, while keeping relatively low levels of bromine-based fire-retardant.
Although JP 11323064 states that incorporation of FR-370 in the formulation allows maintaining low levels of bromine, which enhances technical properties of articles incorporating it and leads to cost-effective FR formulations, the inventors of the present invention note that FR-370 is a very expensive material and its use in fire-retardant formulations offers a high-cost non-economical solution for reducing or eliminating the afterglow phenomenon and for achieving V-0 flammability test rating.
SUMMARY OF THE INVENTION
The applicants have surprisingly found that by lowering the concentration levels of antimony trioxide to certain ranges while maintaining low levels of bromine, a fire-retardant formulation that essentially meets the requirement UL-94 class V-0 standards is achieved without evoking the need for high-cost or other materials. In particular, it has also been found that even when incorporating additives to the formulation as carbon black pigment those concentration ranges of the respective components still allow to successfully pass the standard flammability tests.
It is therefore an object of the present invention to provide a fire-retardant formulation that essentially meets the requirement standard according to the flammability tests.
It is yet another object of the present invention to provide a pigmented fire-retardant formulation that essentially meets the requirement standard according to the flammability tests.
Still another object of the present invention is to provide a fire-retardant formulation with improved technical and mechanical properties.
Still another object of the present invention is to provide a fire-retardant formulation that is cost-effective.
Still another object of the present invention is to provide a fire-retarded styrene-containing polymer for injection molding or extrusion essentially comprising said fire-retardant formulation.
Still another object of the present invention is to provide fire-retarded styrene-containing polymer that may be HIPS or ABS.
This and other objects of the invention will become apparent as the description proceeds.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a fire-retardant formulation that meets the requirement UL-94 V-0 standard according to the flammability tests and which is also cost-effective.
According to the present invention the formulation comprises FR-245, antimony trioxide, PTFE and optionally carbon black pigment, in which the acceptable concentrations of bromine range between about 9.0 and about 10.5 wt. % and those of antimony trioxide range between about 1.8 and about 3.2 wt. %.
Styrene rubber reinforced polymers containing fire-retardant formulations (FR-HIPS) are often required to possess a black or gray color. This is achieved by the incorporation of carbon black, a preferred pigment, to these formulations. However, a side-effect of carbon black when introduced in a fire-retardant formulation is long period of time afterglow effect, where the formulation comprises essentially the same components having the same concentrations as disclosed in JP 11323064, excluding the presence of FR-370.
In addition to the polystyrenic polymer, halogen based fire retardant, antimony oxide, PTFE and the carbon black, there can be present in the formulation conventional additives in their conventional amounts. Examples of such additives are: fillers, pigments, dyes, impact modifiers, UV stabilizers, antioxidants, processing aids, nucleating agents, lubricants and the like.
The flame retarded formulations may be shaped into the final object by processes that are well known to the person skilled in the art; non limiting examples of such processes are: injection molding, extrusion, press molding, vacuum forming, etc.
EXAMPLES
The present invention will now be described in more detail with Examples and Reference Examples.
Tables 1-3 below summarize the materials used for the preparation of the test samples as well as the methods and conditions for their preparation. Flammability was tested according to UL-94V.
TABLE 1 Materials TRADE NAME GENERAL INFO HIPS Styron 472 ex Dow Chemical ABS Magnum 3404 ex Dow Chemical Antimony trioxide ACC-BS ex Antraco FR-245 ex DSBG Tris(2,4,6-tribromophenoxy)-s- triazine F-3020 ex DSBG Endcapped brominated epoxy oligomer (MW 2,000) FR-1210 ex DSBG Decabromodiphenyl oxide Carbon Black PSB 183 ex Hubron manufacturing division limited PTFE Hostaflon 2071 ex Dynon-fine powder (500μ) Antimony trioxide is added as 80% concentrate in polystyrene carrier. Carbon black is added as 35% concentrate in polystyrene carrier.
Compounding
All formulations were prepared under the same conditions.
The components are weighed on Sartorius semi-analytical scales with consequent manual mixing in plastic bags, All the components are introduced into an extruder via K-SFS 24 gravimetric feeding system ex. K-Tron.
Compounding is performed in a co-rotating twin-screw extruder ZE25 ex Berstorff with L/D=32. The compounding conditions are presented in Table 2. The extruded strands are pelletized in pelletizer 750/3 ex Accrapak Systems Limited.
The obtained pellets are dried in a circulating air oven ex Heraeus Instruments at 75° C. for 4 hours.
TABLE 2 Compounding conditions PARAMETER UNITS Set values Feeding zone temperature (T 1 ) ° C. no heating T 2 ° C. 160 T 3 ° C. 230 T 4 ° C. 230 T 5 ° C. 230 T 6 ° C. 230 T 7 ° C. 200 T 8 ° C. 230 T 9 ° C. 230 Temperature of melt ° C. 230 Screw speed RPM 300
Injection Molding
Test specimens were prepared by injection molding in an Allrounder 500 150 ex. Arburg. All test specimens were prepared under the same conditions. The injection molding conditions are presented in Table 3.
TABLE 3 Injection molding conditions PARAMETER UNITS Set values T 1 (Feeding zone) ° C. 180 T 2 ° C. 200 T 3 ° C. 230 T 4 ° C. 230 T 5 (nozzle) ° C. 230 Mold temperature ° C. 40 Injection pressure bar 500 Holding pressure bar 250 Back pressure bar 20 Injection time sec 0.1 Holding time sec 10.0 Cooling time sec 5.0 Mold closing force kN 500 Filling volume (portion) ccm 21 Injection speed ccm/sec 10
Conditioning
Prior to UL-94 testing test specimens are conditioned at 70° C. for 168 hours and at 23° C. for 168 hours.
Compositions and flammability test results are presented in Table 4 for HIPS compositions and in Table 5 for ABS compositions.
TABLE 4
HIPS compositions and flammability test results
Reference
Reference
Reference
Reference
Reference
Reference
Reference
Reference
Reference
Components
Units
Example 1
example 2
example 3
example 4
example 5
example 6
example 7
example 8
example 9
HIPS Styron 472
%
82.5
81.5
84.4
84.5
83.4
79.2
78.2
81.5
81.6
FR-245
%
17.2
17.2
14.9
14.9
FR-1210
%
13.9
13.9
12.0
12.0
12.0
F-3020
%
Antimony trioxide
%
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
PTFE Hostaflon 2071
%
0.1
0.1
0.1
0.1
0.1
0.1
0.1
Carbon Black
%
1.0
1
1.0
Bromine calculated
%
11.5
11.5
10
10
10
11.5
11.5
10
10
Flammability UL-94V at 1.6 mm
Max flaming time
sec
2
1
2
4
1
2
1
2
3
Total flaming time
sec
10
9
10
17
10
11
7
12
11
Max after glow time
sec
12
0
0
0
11
20
36
31
0
Max after glow +
sec
13
1
1
1
12
22
36
31
1
after flame time
Specimens dripped
num
0
0
0
3
0
0
0
0
5
Cotton ignition
num
0
0
0
2
0
0
0
0
5
Sample burned up to
num
0
0
0
0
0
0
0
0
0
the holding clamps
Rating
V-0
V-0
V-0
V-2
V-0
V-0
V-1
V-1
V-2
HIPS compositions and test flammability results
Reference
Reference
Reference
Reference
Reference
Reference
example
example
example
example
example
example
Components
Units
10
11
12
13
14
15
Example 1
Example 2
Example 3
HIPS Styron 472
%
80.5
80.8
83.0
81.6
81.2
79.6
81.0
81.5
80.6
FR-245
%
14.9
14.9
14.9
14.9
14-9
10.4
14.9
14.9
10.4
FR-1210
%
F-3020
%
5.4
5.4
Antimony trioxide
%
3.5
3.2
1.0
2.5
2.5
3.5
3.0
2.5
2.5
PTFE Hostaflon 2071
%
0.1
0.1
0.1
0.02
0.4
0.1
0.1
0.1
0.1
Carbon Black
%
1
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
Bromine calculated
%
10
10
10
10
10
10
10
10
10
Flammability UL-94V at 1.6 mm
Max flaming time
sec
1
3
78
6
1
3
2
7
4
Total flaming time
sec
9
13
338
26
7
12
12
16
18
Max after glow time
sec
54
35
0
31
45
35
21
2
22
Max after glow +
sec
55
37
78
33
46
38
22
2
24
after flame time
Specimens dripped
num
0
0
3
0
0
0
0
0
Cotton ignition
num
0
0
3
0
0
0
0
0
Sample burned up to
num
0
0
4
0
0
0
0
0
0
the holding clamps
Rating
V-1
V-1
HB
V-2
V-1
V-1
V-0
V-0
V-0
Table 4 above summarizes several composition and flammability test results of prior art related fire-retardant formulations as well as of formulations relating to the present invention. From this table it is clearly seen that:
(a) Formulations (Reference Example-6) based on JP 11323064 pass successfully the V-0 flammability test, but introducing 1 wt. % carbon black pigment (Reference Example-7), results in derating to V-1 due to long afterglow time. (b) In fire-retardant FR-1210 (decabromodiphenyl oxide) based formulations—Reference Examples 1-5—the first two formulations substantially having the same bromine, antimony trioxide and PTFE concentrations as in Reference Examples 6 and 7 pass V-0 tests, even when containing carbon black pigment (Reference Example 2). Reducing bromine content to 10 wt. % and then further elimination of PTFE from this formulation result in V-0 and V-2 rating, respectively (Reference Example 3 and Reference Example 4), the latter is due to burning drops ignited cotton effect. Addition of carbon black to Reference Example 3 does not derate the formulation and it passes V-0 tests (Reference Example 5). It should be noted that the antimony trioxide remains essentially unchanged in all those formulation variations. (c) Reference Example 8, Reference Example 9, Reference Example 10 and Example 2 to Example 3 relate to FR-245 containing formulations having varying concentrations of the components Further reduction of FR-245 to 10 wt. % bromine while keeping the antimony trioxide concentration relatively high (Reference Example 8) results in derating to V-1. Omission of PTFE from this formulation (Reference Example 9) results in dripping with cotton ignition and V-2 rating. Further addition of carbon black to Reference Example 8 (Reference Example 10) results in long afterglow effect and a rating of V-1. However, reduction of antimony trioxide to 2.5 wt. % (Example 2) surprisingly improves flammability retardation and is rated V-0. Further reduction of antimony trioxide to 1 wt. % (Reference Example 12) results in total burning of the specimen up to the clamps and in a HB rating. The upper concentration limit of antimony trioxide is tested in Reference Example 11 vs. Example 1; at antimony trioxide concentration of 3.2 wt. % the formulation is rated V-1 because of long after glow time (Reference Example 11); at antimony trioxide concentration of 3.0 wt. % the formulation is rated V-0 (Example 1). The concentration limits of PTFE are tested in formulations Reference Example 13, 0.02 wt. %, and Reference Example 14, 0.4 wt. %. In the first an effect of burning drops ignited cotton leads to V-2 rating. The second is rated V-1 due to long afterglow time. (d) The employment of both FR-245 and F-3020 (MBEO endcapped brominated epoxy resin) as the bromine fire-retardants, the first contributing about 7 wt. % and the second about 3 wt. % of the bromine content, leads to long afterglow time (Reference Example 15) when incorporating 3.5 wt. % antimony trioxide, i.e. V-1 rating, and to successful results (Example 3) when lowering antimony trioxide concentration to 2.5 wt. %, i.e. V-0. These two results are similar to the ones achieved for formulations containing only FR-245, i.e. Reference Example 10 and Example 2, and further stress the optimal relation between bromine fire-retardant and antimony trioxide synergist contents.
TABLE 5
ABS compositions and results of flammability results
Reference
Components
Units
example 16
Example 4
ABS Magnum 3404
%
80.0
81.0
FR-245
%
14.9
14.9
Antimony trioxide
%
4.0
3.0
PTFE Hostaflon 2071
%
0.1
0.1
Carbon Black
%
1.0
1.0
Bromine calculated
%
10
10
Flammability UL-94V at 1.6 mm
Max flaming time
Sec
5
7
Total flaming time
Sec
16
29
Max after glow time
Sec
36
21
Max after glow + after
Sec
38
23
flame time
Specimens dripped
Num
0
0
Cotton ignition
Num
0
0
Sample burned up to the
Num
0
0
holding clamps
Rating
V-1
V-0
Table 5 demonstrates that the same effects, which are observed in HIPS formulations, are also applied in ABS based formulations.
HIPS and ABS containing fire-retardant formulations containing FR-245 or a combination of FR-245 and BEO's at low bromine content and with the incorporation of carbon black do not pass UL-94 V-0 because of long after glow time. It is surprisingly found that at low antimony trioxide concentrations it is possible to pass UL-94 V-0 and get economic cost-effective formulations with good mechanical, thermal and processing properties.
While examples of the invention have been described for purposes of illustration, it will be apparent that many modifications, variations and adaptations can be carried out by persons skilled in the art, without exceeding the scope of the claims. | A fire-retardant formulation for styrene-containing polymers comprising tris(2,4,6-tribromophenoxy)-s-triazine (FR-245), antimony trioxide and polytetrafluoroethylene (PTFE), wherein the bromine concentration in said fire-retardant formulation is from about 9.0 to about 10.5 wt. %, said antimony trioxide concentration being lower than about 3.2 wt. %. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. application Ser. No. 11/863,256 filed on Sep. 28, 2007, which is a continuation of U.S. application Ser. No. 11/071,117 filed on 4 Mar. 2005, now issued as U.S. Pat. No. 7,284,831, which is a continuation of U.S. application Ser. No. 10/893,373 filed Jul. 19, 2004, now issued as U.S. Pat. No. 6,871,938, which is a continuation of Ser. No. 10/291,706 filed Nov. 12, 2002 which is a continuation of Ser. No. 09/609,140 filed Jun. 30, 2000, now issued as U.S. Pat. No. 6,755,513, the entire contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the field of ink jet printing systems, and more specifically to a printhead support assembly and ink supply arrangement for a printhead assembly and such printhead assemblies for ink jet printing systems.
DESCRIPTION OF THE PRIOR ART
[0003] Micro-electromechanical systems (“MEMS”), fabricated using standard VLSI semi-conductor chip fabrication techniques, are becoming increasingly popular as new applications are developed. Such devices are becoming widely used for sensing (for example accelerometers for automotive airbags), inkjet printing, micro-fluidics, and other applications. The use of semi-conductor fabrication techniques allows MEMS to be interfaced very readily with microelectronics. A broad survey of the field and of prior art in relation thereto is provided in an article entitled “The Broad Sweep of Integrated Micro-Systems”, by S. Tom Picraux and Paul McWhorter, in IEEE Spectrum, December 1998, pp 24-33.
[0004] In PCT Application No. PCT/AU98/00550, the entire contents of which is incorporated herein by reference, an inkjet printing device has been described which utilizes MEMS processing techniques in the construction of a thermal-bend-actuator-type device for the ejection of a fluid, such as an ink, from a nozzle chamber. Such ink ejector devices will be referred to hereinafter as MEMJETs. The technology described in the reference is intended as an alternative to existing technologies for inkjet printing, such as Thermal Ink Jet (TIJ) or “Bubble Jet” technology developed mainly by the manufacturers Canon and Hewlett Packard, and Piezoelectric Ink Jet (PIJ) devices, as used for example by the manufacturers Epson and Tektronix.
[0005] While TIJ and PIJ technologies have been developed to very high levels of performance since their introduction, MEMJET technology is able to offer significant advantages over these technologies. Potential advantages include higher speeds of operation and the ability to provide higher resolution than obtainable with other technologies. Similarly, MEMJET Technology provides the ability to manufacture monolithic printhead devices incorporating a large number of nozzles and of such size as to span all or a large part of a page (or other print surface), so that pagewidth printing can be achieved without any need to mechanically traverse a small printhead across the width of a page, as in typical existing inkjet printers.
[0006] It has been found difficult to manufacture a long TIJ printhead for full-pagewidth printing. This is mainly because of the high power consumption of TIJ devices and the problem associated therewith of providing an adequate power supply for the printhead. Similarly, waste heat removal from the printhead to prevent boiling of the ink provides a challenge to the layout of such printhead. Also, differential thermal expansion over the length of a long TIJ-printhead may lead to severe nozzle alignment difficulties.
[0007] Different problems have been found to attend the manufacture of long PIJ printheads for large- or full-page-width printing. These include acoustic crosstalk between nozzles due to similar time scales of drop ejection and reflection of acoustic pulses within the printhead. Further, silicon is not a piezoelectric material, and is very difficult to integrate with CMOS chips, so that separate external connections are required for every nozzle.
[0008] Accordingly, manufacturing costs are very high compared to technologies such as MEMJET in which a monolithic device may be fabricated using established techniques, yet incorporate very large numbers of individual nozzles. Reference should be made to the aforementioned PCT application for detailed information on the manufacture of MEMJET inkjet printhead chips; individual MEMJET printhead chips will here be referred to simply as printhead segments. A printhead assembly will usually incorporate a number of such printhead segments.
[0009] While MEMJET technology has the advantage of allowing the cost effective manufacture of long monolithic printheads, it has nevertheless been found desirable to use a number of individual printhead segments (CMOS chips) placed substantially end-to-end where large widths of printing are to be provided. This is because chip production yields decrease substantially as chip lengths increase, so that costs increase. Of course, some printing applications, such as plan printing and other commercial printing, require printing widths that are beyond the maximum length that is practical for successful printhead chip manufacture.
SUMMARY OF THE INVENTION
[0010] According to an aspect of the present disclosure, an inkjet printhead assembly includes an elongate ink supply body defining a plurality of ink supply channels; an elongate cradle member defining a plurality of rows of apertures, the elongate cradle member being fastened to the elongate ink supply body to communicate ink within the ink supply channels through respective ones of said rows of apertures; and a plurality of printhead segments each having a carrier defining a plurality of rows of ink supply passages arranged in alignment with respective apertures of the cradle member, each printhead segment further having an elongate ink ejection printhead mounted to the carrier in fluid communication with the ink supply passages. Each carrier defines a complementary formation for mating serially with the cradle member.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a perspective view of one embodiment of an inkjet printhead assembly according to the invention;
[0012] FIG. 2 is a perspective view of the inkjet printhead assembly shown in FIG. 1 , with a cover component (shield plate) removed;
[0013] FIG. 3 is an exploded perspective view of a part only of the inkjet printhead assembly shown in FIG. 1 ;
[0014] FIG. 4 is a perspective partial view of a support extrusion forming part of the inkjet printhead assembly shown in FIG. 3 ;
[0015] FIG. 5 is a perspective view of a sealing shim forming part of the inkjet printhead assembly shown in FIG. 3 ;
[0016] FIG. 6 is a perspective view of a printhead segment carrier shown in FIG. 3 ;
[0017] FIG. 7 is a further perspective view of the printhead segment carrier shown in FIG. 6 ;
[0018] FIG. 8 is a bottom elevation of the printhead carrier shown in FIGS. 6 and 7 (as viewed in the direction of arrow “X” in FIG. 6 );
[0019] FIG. 9 is a top elevation of the printhead carrier shown in FIGS. 6 and 7 (as viewed in the direction of arrow “Y” in FIG. 6 );
[0020] FIG. 10 is a cross-sectional view of the printhead carrier of FIGS. 6 and 7 taken at station “B-B” in FIG. 8 ;
[0021] FIG. 11 is a cross-sectional view of the printhead carrier of FIGS. 6 and 7 taken at station “A-A” in FIG. 8 ;
[0022] FIG. 11A is an enlarged cross-sectional view of the seating arrangement of a printhead segment at the print carrier as per detail “E” in FIG. 11 ;
[0023] FIG. 12 is a cross-sectional view of the printhead carrier of FIGS. 6 and 7 taken at station “D-D” in FIG. 8 ;
[0024] FIG. 13 is an external perspective view of an end cap of the inkjet printhead assembly shown in FIG. 1 ;
[0025] FIG. 14 is an internal perspective view of the end cap shown in FIG. 13
[0026] FIG. 15 is an external perspective view of a further end cap of the inkjet printhead assembly shown in FIG. 1 ;
[0027] FIG. 16 is an internal perspective view of the end cap shown in FIG. 15 ;
[0028] FIG. 17 is a perspective view (from the bottom) of the printhead assembly shown in FIG. 1 ;
[0029] FIG. 18 is a perspective view of a part assembly of a support profile and modified sealing shim which are alternatives to those shown in FIGS. 4 and 5 ;
[0030] FIG. 19 is a perspective view showing a molding tool and illustrating the basic arrangement of die components for injection molding of the printhead carrier shown in FIGS. 6 and 7 ;
[0031] FIG. 20 is a schematic cross-section of the injection molding tool shown in FIG. 19 , in an open position; and
[0032] FIG. 21 is a schematic transverse cross-section of the injection-molding tool shown in FIG. 19 , in a closed position, taken at a station corresponding to the station “A-A” in FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] FIG. 1 shows in perspective view an inkjet printhead assembly 1 according to one aspect of the invention and, in phantom outline, a surface 2 on which printing is to be affected. In use, the surface 2 moves relative to the assembly 1 in a direction indicated by arrow 3 and transverse to the main extension of assembly 1 (this direction is hereinafter also referred to as the transverse direction of the assembly 1 ), so that elongate printhead segments 4 , in particular MEMJET printhead segments such as described in the above-mentioned PCT/AU98/00550, placed in stepped overlapping sequence along the lengthwise extension of assembly 1 can print simultaneously across substantially the entire width of the surface. The assembly 1 includes a shield plate 5 with which the surface 2 may come into sliding contact during such printing. Shield plate 5 has slots 6 , each corresponding to one of the printhead segments 4 , and through which ink ejected by that printhead segment 4 can reach surface 2 .
[0034] The particular assembly 1 shown in FIG. 1 has eleven printhead segments 4 , each capable of printing along a 2 cm printing length (or, in other words, within a printing range extending 2 cm) in a direction parallel to arrow 7 (hereinafter also called the lengthwise direction of the assembly 1 ) and is suitable for single-pass printing of a portrait A4-letter size page. However, this number of printhead segments 4 and their length are in no way limiting, the invention being applicable to printhead assemblies of varying lengths and incorporating other required numbers of printhead segments 4 .
[0035] The slots 6 and the printhead segments 4 are arranged along two parallel lines in the lengthwise direction, with the printing length of each segment 4 (other than the endmost segments 4 ) slightly overlapping that of its two neighboring segments 4 in the other line. The printing length of each of the two endmost segments 4 overlaps the printing length of its nearest neighbor in the other row at one end only. Thus printing across the surface 2 is possible without gaps in the lengthwise direction of the assembly. In the particular assembly shown, the overlap is approximately 1 mm at each end of the 2 cm printing length, but this figure is by no means limiting.
[0036] FIG. 2 shows assembly 1 with the shield plate 5 removed. Each printhead segment 4 is secured to an associated one printhead segment carrier 8 that will be described below in more detail. Also secured to each printhead segment 4 is a tape automated bonded (TAB) film 9 , which carries signal and power connections (not individually shown) to the associated printhead segment 4 . Each TAB film 9 is closely wrapped around an extruded support profile 10 (whose function will be explained below) that houses and supports carriers 8 , and they each terminate onto a printed circuit board (PCB) 11 secured to the profile 10 on a side thereof opposite to that where the printhead segments 4 are mounted, see also FIG. 3 .
[0037] FIG. 3 shows an exploded perspective view of a part only of assembly 1 . In this view, three only of the printhead segment carriers 8 are shown numbered 8 a , 8 b and 8 c , and only the printhead segment 4 associated with printhead segment carrier 8 a is shown and numbered 4 a . The TAB film 9 associated therewith is terminated at one end on an outer face of the printhead segment 4 and is otherwise shown (for clarity purposes) in the unwound, flat state it has before being wound around profile 10 and connected to PCB 11 . As can be seen in FIG. 3 , printhead segment carriers 8 are received (and secured), together with an interposed sealing shim 25 , in a slot 21 of half-circular cross-sectional shape in profile member 10 as will be explained in more detail below.
[0038] FIG. 4 illustrates a cross-section of the profile member 10 (which is preferably an aluminum alloy extrusion). This component serves as a frame and/or support structure for the printhead segment carriers 8 (with their associated printhead segments 4 and TAB films 9 ), the PCB 11 and shield plate 5 . It also serves as an integral ink supply arrangement for the printhead segments 4 , as will become clearer later.
[0039] Profile member 10 is of semi-open cross-section, with a peripheral, structured wall 12 of uniform thickness. Free, opposing, lengthwise running edges 16 ′, 17 ′ of side wall sections 16 and 17 respectively of wall 12 border or delineate a gap 13 in wall 12 extending along the entire length of profile member 10 . Profile member 10 has three internal webs 14 a , 14 b , 14 c that stand out from a base wall section 15 of peripheral wall 12 into the interior of member 10 , so as to define together with side wall sections 16 and 17 a total of four (4) ink supply channels 20 a , 20 b , 20 c and 20 d which are open towards the gap 13 . The shapes, proportions and relative arrangement of the webs and wall sections 14 a - c , 16 , 17 are such that their respective free edges 14 a ′, 14 b ′, 14 c ′ and 16 ′, 17 ′, as viewed in the lengthwise direction and cross-section of profile member 10 , define points on a semi-circle (indicated by a dotted line at “a” in FIG. 4 ). In other words, an open slot 21 of semicircular cross-sectional shape is defined along one side of profile member 10 that runs along its extension, with each of the ink supply channels 20 a - d opening into common slot 21 .
[0040] Base wall section 15 of profile member 10 also includes a serrated channel 22 opening towards the exterior of member 10 , which, as best seen in FIG. 3 , serves to receive fastening screws 23 to fixedly secure PCB 11 onto profile member 10 in a form-fitting manner between free edges 24 (see FIG. 4 ) of longitudinally extending curved webs 107 extending from the base wall section 15 of profile member 10 .
[0041] Referring again to FIG. 3 , sealing shim 25 is received (and secured) within the half-circular open slot 21 . As best seen in FIGS. 3 and 5 , shim 25 includes four lengthwise extending rows of rectangular openings 26 that are equidistantly spaced in peripheral (widthwise) direction of shim 25 , so that three lengthwise-extending web sections 27 between the aperture rows (of which two are visible in FIG. 5 ) are located so as to be brought into abutting engagement against the free edges 14 a ′, 14 b ′ and 14 c ′ of webs 14 a , 14 b , 14 c of profile member 10 when shim 25 is received in slot 21 . As can be gleaned from FIG. 4 , the free edges 16 ′ and 17 ′ of side wall sections 16 , 17 of profile member 10 are shaped such as to provide a form-lock for retaining the lengthwise extending edges 28 of shim member 25 as a snap fit. In other words, once shim 25 is mounted in profile member 10 , it provides a perforated bottom for slot 21 , which allows passage of inks from the ink supply channels 20 a - d through apertures 26 in shim 25 into slot 21 . A glue or sealant is provided where shim webs 27 and edges 28 mate with the free edges 14 a ′, 14 b ′, 14 c ′, 16 ′ and 17 ′ of profile member 10 , thereby preventing cross-leakage between ink supply channels 20 a - d along the abutting interfaces between shim 25 and profile member 10 . It will be noted from FIG. 5 that not all apertures 26 have the same opening size. Reference numerals 26 ′ indicate two such smaller apertures, the significance of which is described below, which are present in each aperture row at predetermined aperture intervals. A typical size for the full-sized apertures 26 is 2 mm×2 mm. The shim is preferably of stainless steel, but a plastics sheet material may also be used.
[0042] Turning next to FIGS. 6-12 , these illustrate in different views and sections a typical printhead segment carrier 8 . Carrier 8 is preferably a single microinjection molded part made of a suitable temperature and abrasion resistant and form-holding plastics material. (A further manufacturing operation is carried out subsequent to molding, as described below.) As best seen in FIGS. 6 and 7 , the overall external shape of carrier 8 can be described illustratively as a diametrically slit half cylinder, with a half-circular back face 91 , a partly planar front face 82 and stepped end faces 83 . FIG. 8 shows a plan view of back face 91 and FIG. 9 shows a plan view of front face 82 .
[0043] Carrier 8 has a plane of symmetry halfway along, and perpendicular to, its length, that is, as indicated by lines marked “b” in FIGS. 8 and 10 which lie in the plane. Line “b” as shown in FIG. 8 extends in a direction that will hereinafter be described as transverse to the carrier 8 . (When the carrier 8 is installed in the assembly 1 , this direction is the same as the transverse direction of the assembly 1 .) Lines marked “c” in FIGS. 8 , 9 , 11 and 12 together similarly indicate the position of an imaginary plane which lies between two sections of the carrier 8 of different length and whose overall cross-sectional shapes are quarter circles. Line “c” as shown in FIG. 9 extends in a direction that will hereinafter be described as lengthwise in the carrier 8 . (When the carrier 8 is installed in the assembly 1 this direction is the same as the lengthwise direction of the assembly 1 .) These sections will hereinafter be referred to as the shorter and longer “quarter cylinder” sections 8 ′ and 8 ″, respectively, to allow referenced description of features of the carrier 8 .
[0044] Each stepped end face 83 includes respective outer faces 84 ′ and 85 ′ of quarter-circular-sector shaped end walls 84 and 85 and an outer face 86 ′ of an intermediate step wall 86 between and perpendicular to end walls 84 , 85 . This configuration enables carriers 8 to be placed in the slot 21 of profile 10 in such a way that adjoining carriers 8 overlap in the lengthwise direction with the step walls 86 of pairs of neighbouring carriers 8 facing each and overlapping. Such an “interlocking” arrangement is shown in FIG. 2 , wherein it is apparent that every one of the eleven (11) carriers 8 has an orientation, relative to its neighbouring carrier or carriers 8 , such that faces 84 ′ and 85 ′ of each carrier lie adjacent to faces 85 ′ and 84 ′, respectively, of its neighbouring carrier(s) 8 . In other words, each carrier 8 is so oriented in relation to its neighbouring carrier(s) as to be rotated relatively by 180° about an axis perpendicular to the face 82 . In essence, neighbouring carriers 8 will align along a common lengthwise-oriented plane defined between the step walls 86 of adjoining carriers 8 , shorter and longer quarter cylinder sections 8 ′ and 8 ″ of adjoining carriers 8 alternating with one another along the extension of slot 21 .
[0045] Turning now in particular to FIGS. 7 , 9 , 11 and 11 A, front face 82 of carrier 8 includes on the shorter quarter cylinder section 8 ′ a planar surface 81 . Formed in surface 81 are two handling (i.e. pick-up) slots 87 whose purpose is described below. On the longer quarter cylinder section 8 ″, front face 82 incorporates a mounting or support surface 88 recessed with respect to edges 89 of sector-shaped end walls 84 that are co-planar with the surface 81 . As best seen in FIG. 11 , mounting surface 88 recedes in slanting fashion from a point on the back face 91 of the longer quarter cylinder section 8 ″ towards an elongate recess 90 extending lengthwise between walls 84 . Recess 90 is of constant transverse cross-section along its length and is shaped to receive in form-fitting manner one printhead segment 4 . FIG. 11A shows, schematically only, printhead segment 4 in position in recess 90 . Mounting surface 88 is provided to accommodate in flush manner with respect to the surface 81 the terminal end of TAB film 9 connected to printhead segment 4 , as is best seen in FIG. 3 . Due to the opposing orientations of neighbouring carriers 8 along the extension of assembly 1 , the TAB films 9 associated with any two neighbouring carriers 8 lead away from their respective segments 4 in opposite transverse directions, as can be seen in FIG. 2 .
[0046] Referring now to FIGS. 6 , 7 , 8 , 10 and 11 in particular, four rows of ink galleries or ink supply passages 92 a to 92 d of generally quadrilateral cross-section are formed within the printhead segment carrier 8 . The ink galleries 92 a to 92 d act as conduits for ink to pass from the ink supply passages 20 a to 20 d , respectively, via openings 26 in the shim 25 , to the printhead segment 4 mounted in recess 90 of the printhead segment carrier 8 . Galleries 92 a - 92 d extend in quasi-radial arrangement between the half-cylindrical back face 91 of carrier 8 and recess 90 located in the longer quarter cylinder section 8 ″ at front face 82 . The expression “quasi-radial” is used here because recess 90 is not located at a transversely central position across carrier 8 , but is offset into the longer quarter cylinder section 8 ″, so that the inner ends of galleries 92 a - 92 d are similarly off-set, as further described below. Each gallery 92 has a rectangular opening 93 at back face 91 . All rectangular openings 93 have the same dimension in a peripheral direction of face 91 and are equidistantly spaced around the periphery of back face 91 . Moreover, the openings 93 are symmetrically located on opposing sides of the boundary between shorter quarter cylinder section 8 ′ and longer quarter cylinder section 8 ″, as represented in FIG. 11 by the line marked “c”. All openings 93 in the shorter quarter cylinder section 8 ′ are of the same dimension, and equispaced, in the lengthwise direction. This also applies to the openings 93 in the longer quarter cylinder section 8 ″, except that openings 93 ′ in the longer quarter cylinder section 8 ″ which correspond to endmost galleries 92 a ′ and 92 b ′ are of smaller dimension in the lengthwise direction than the other galleries 92 a and 92 b , respectively.
[0047] By way of further description of how the galleries 92 a to 92 d are formed, printhead segment carrier 8 includes a set of five (5) quasi-radially converging walls 95 which converge from back face 91 towards recess 90 at front face 82 and two of which define the faces 81 and 88 . The walls 95 perpendicularly intersect seven (7) generally semi-circular and mutually parallel walls 97 that are equidistantly spaced apart in lengthwise extension of carrier 8 . Of walls 97 , the two endmost ones extending into the shorter quarter cylinder section 8 ′ provide the endwalls 85 of stepped end faces 83 , thereby defining twenty-four (24) quasi-radially extending ink galleries 92 a to 92 d , of quadrilateral cross-section, in four lengthwise-extending rows each of six galleries. The walls 97 are parallel to and lie between endwalls 84 .
[0048] FIG. 12 shows a cross-section through one of the lengthwise end portions of longer quarter cylinder section 8 ″ of carrier 8 . By comparison with FIG. 11 (which shows a cross-section through the main body of carrier 8 ), it will be seen that the quasi-radially extending walls 95 bordering end gallery 92 a ′ have the same shape as walls 95 which border galleries 92 a , whereas gallery 92 b ′ is bounded on one side by intermediate step wall 86 and by a wall 108 . FIG. 12 also shows a wall 111 and a wall formation 112 on the wall 86 , the purpose of which is explained below.
[0049] Converging walls 95 are so shaped at their radially inner ends as to define four ink delivery slots 96 a to 96 d which extend lengthwise in the carrier 8 and which open into the recess 90 , as best seen in FIGS. 11 and 11A . The slots 96 a to 96 d extend between the opposite end walls 84 of longer quarter cylinder section 8 ″ and pierce through the inner parallel walls 97 , including the endwise opposite walls 97 which form the end walls 85 of the shorter cylinder section 8 ′. FIG. 12 shows how slots 96 a to 96 d extend and are formed within the end portions of the longer quarter cylinder section 8 ″, where the slots 96 a to 96 d are defined by the terminal ends of two of walls 95 , walls 108 , 111 and wall formation 112 , wall formation 112 in effect being a perpendicular lip of intermediate step wall 86 .
[0050] The widths and transverse positioning of the ink delivery slots 96 a to 96 d are such that when a printhead segment 4 is received in recess 90 , a respective one of the slots 96 a - 96 d will be in fluid communication with one only of four lengthwise oriented rows of ink supply holes 41 on rear face 42 of printhead segment 4 , compare FIG. 11A . Each row of ink supply holes 41 corresponds to a row of printhead nozzles 43 running lengthwise along the front face 44 of printhead segment 4 . In the schematic representation of segment 4 in FIG. 11A , the positions of holes 41 and nozzles are indicated by dots, with no attempt made to show their actual construction. Reference to PCT Application No. PCT/AU98/00550 will provide further details of the make-up of segment 4 . Accordingly, each of the ink galleries of a specific gallery row 92 a to 92 d is in fluid communication with one only of the rows of ink supply holes 41 . Once a printhead segment 4 is form fittingly received in recess 90 and sealingly secured with its rear face 42 against the terminal inner ends of walls 95 , and wall formations 108 , 111 and 112 (using a suitable sealant or adhesive), cross-communication and ink bleeding between slots 96 a - 96 d via recess 90 is not possible.
[0051] When a carrier 8 is installed in its correct position lengthwise in the slot 21 of profile 10 , compare FIG. 3 , each opening 93 in its back face 91 aligns with one of the openings 26 in the shim 25 . Smaller openings 26 ′ in the shim 25 correspond to openings 93 ′ of the smaller galleries 92 a ′ and 92 b ′ of carrier 8 . Therefore, each one of the ink supply channels 20 a to 20 d is in fluid communication with one only of the rows of ink galleries 92 a to 92 d , respectively, and so with one only of the slots 96 a to 96 d respectively and only one of the rows of ink supply holes 41 . A suitable glue or sealant is provided at mating surfaces of the shim 25 and the carrier 8 to prevent leakage of ink from any of the channels 20 a to 20 d to an incorrect one of the galleries 92 , as described further below. The symmetrical location (mentioned above) of openings 93 on back face 91 of carrier 8 , which is matched by the openings 26 in shim 25 , enables the carrier 8 to be received in the slot 21 in either of the two orientations shown in FIG. 3 , with in both cases each row of ink galleries 92 a to 92 d aligning with one only of the ink supply channels 20 a to 20 d.
[0052] As mentioned above, the longer quarter cylinder section 8 ″ of carrier 8 has two galleries 92 a ′ and 92 b ′ at each lengthwise end that have no counterpart in the shorter section 8 ′. These galleries 92 a ′ and 92 b ′ provide direct ink supply paths to that part of their associated ink delivery slots 96 a and 96 b located in the longer quarter cylinder section 8 ″, and thus to the ink supply holes 41 of the printhead segment 4 that are located near the lengthwise terminal ends of segment 4 when secured within recess 90 . There are no corresponding quasi-radial galleries to supply ink to the end regions of the slots 96 c and 96 d . However, it is desirable to provide direct ink supply to the end portions of the other two slots 96 c and 96 d as well, without reliance on lengthwise flow within the slots 96 c and 96 d of ink that has passed through galleries 92 c and 92 d respectively. This is ensured by provision of ink supply chambers 99 c and 99 d which are shown in FIG. 12 and which supply ink to the slots 96 c and 96 d , respectively. Chambers 99 c and 99 d are bounded by the walls 84 , 86 , and wall formations 108 , 111 and 112 , are open towards slots 96 c and 96 d , respectively, and are in fluid communication through holes 113 and 114 in an endmost wall 97 with endmost ones of ink galleries 92 c and 92 d , respectively. The holes 113 and 114 have outlines shaped to match the transverse cross-sectional shapes of the chambers 99 c and 99 d , respectively, as shown in FIG. 12 , and the means whereby holes 113 and 114 are formed is described below.
[0053] FIGS. 13 and 14 show a first end cap 50 , which is sealingly secured to an open terminal longitudinal end of profile member 10 , as may be seen in FIGS. 1 and 2 . Cap 50 is molded from a plastics material and it incorporates a generally planar wall portion 51 that extends perpendicularly to a lengthwise axis of profile member 10 . Four tubular stubs 55 a - 55 d are integrally molded with planar wall portion 51 on side 52 of wall portion 51 which will face away from support profile 10 when end cap 50 is secured thereto. On the planar wall side 53 which will face the longitudinal terminal end of support profile 10 (see FIG. 14 ), four hollow-shaped stubs 57 a - 57 d are integrally molded with planar wall portion 51 . As best seen in FIG. 14 , ink supply conduits 56 a to 56 d are defined within tubular stubs 55 a to 55 d respectively, extend through planar wall portion 51 , and open within shaped stubs 57 a to 57 d , respectively, located on the other sides of cap 50 .
[0054] The shape of each one of the insert stubs 57 a to 57 d , as seen in transverse cross-section, corresponds respectively to one of the ink supply channels 20 a to 20 d of support profile so that, when cap 50 is secured to the terminal axial end of support profile 10 , the walls of stubs 57 a - 57 d are received form-fittingly in ink supply channels 20 a - 20 d to prevent cross-migration of ink therebetween. The face 53 abuts a terminal end face of the profile 10 . Preferably, glue or a sealant can be applied to the mating surfaces of profile 10 and cap 50 to enhance the sealing function.
[0055] The tubular stubs 55 a - 55 d serve as female connectors for pliable/flexible ink supply hoses (not illustrated) that can be connected thereto sealingly, thereby to supply ink to the integral ink supply channels 20 a - 20 d of support profile 10 .
[0056] A further stub 58 , D-shaped in transverse cross-section, is integrally molded to planar wall portion 51 at side 53 . In completed assembly 1 , the curved wall 71 , semi-circular in transverse cross-section, of retaining stub 58 seals against the inside surface of shim 25 , with the terminal edge of shim 25 abutting a peripheral ridge 72 around the stub 58 . Preferably, to avoid cross-migration of ink among channels 20 a to 20 d , an adhesive or sealant is provided between the shim 25 and wall 71 . The stub 58 assists in retaining the shim 25 in slot 21 .
[0057] A second end cap 60 , which is shown in FIGS. 15 and 16 , is mounted to the other end of the profile 10 opposite to cap 50 . Cap 60 has insert stubs 67 a to 67 d and a retaining stub 68 identical in arrangement and shape to stubs 57 a to 57 d and stub 58 , respectively, of end cap 50 . Insert stubs 67 a to 67 d and retention stub 68 are integrally molded with a planar wall portion 61 , and in the completed assembly 1 seal off the individual ink supply channels 20 a - 20 d from one another, to prevent cross-migration of ink among them. Wall 77 of the retention stub 68 abuts the shim 25 in the same way as described above. A sealant or adhesive is preferably used with end cap 60 in the same way (and for the same purpose) as described above in respect of end cap 50 .
[0058] Whereas end cap 50 enables connection of ink supply hoses to the printhead assembly 1 , end cap 60 has no tubular stubs on exterior face 62 of planar wall portion 61 . Instead, four tortuous grooves 65 a to 65 d are formed on exterior face 62 , and terminate at holes 66 a to 66 d , respectively, extending through wall portion 61 . Each one of holes 66 a to 66 d opens into a respective one of the channels 20 a to 20 d so that when the cap 60 is in place on the profile 10 , each one of the grooves 65 a to 65 d is in fluid communication with a respective one of the channels 20 a to 20 d . The grooves 65 a - 65 d permit bleeding-off of air during priming of the printhead assembly 1 with ink, as holes 66 a - 66 d permit air expulsion from the ink supply channels 20 a - 20 d of support profile 10 via grooves 65 a - 65 d . Grooves 65 a - 65 d are capped under a translucent plastic film 69 bonded to outer face 62 . Translucent plastic film 69 thus also serves the purpose of allowing visual confirmation that the ink supply channels 20 a - 20 d of profile 10 are properly primed. For charging the ink supply channels 20 a - 20 d with ink, film 69 is folded back (as shown in FIG. 15 ) to partially uncover grooves 65 a - 65 d , so that displaced air may bleed out as ink enters the grooves 65 a - 65 d through holes 66 a - 66 d . When ink is visible behind film 69 in each groove 65 a - 65 d , film 69 is folded towards face 62 and bonded against face 62 to sealingly cover face 62 and so cap-off grooves 65 a - 65 d and isolate them from one another.
[0059] Referring to FIG. 17 (and see also FIGS. 3 and 4 ), the printed circuit board (PCB) 11 locates between edges 24 formed on profile 10 , and is secured by screw fasteners 23 which engage with the serrations in elongate channel 22 of support profile 10 . The PCB 11 contains three surface mounted halftoning chips 73 , a data connector 74 , printhead power and ground busbars 75 and decoupling capacitors 76 . Side walls 16 , 17 of support profile 10 are rounded near the edges 24 to avoid damage to the TAB films 9 when these are wound about profile 10 . The electronic components 73 and 76 are specific to the use of MEMJET chips as the printhead segments 4 , and would of course, if other another printhead technology were to be used, be substituted with other components as necessitated by that technology.
[0060] The shield plate 5 illustrated in FIG. 1 , which is a thin sheet of stainless steel, is bonded with sealant such as a silicon sealant onto the printhead segment carriers 8 . The shield plate 5 shields the TAB films 9 and the printhead segments 4 from physical damage and also serves to provide an airtight seal around the printhead segments 4 when the assembly 1 is capped during idle periods.
[0061] The multi-part layout of the printhead assembly 1 that has been described in detail above has the advantage that the printhead segment carriers 8 , which interface directly with the printhead segments 4 and which must therefore be manufactured with very small tolerances, are separate from other parts, including particularly the main support frame (profile 10 ) which may therefore be less tightly toleranced. As noted above, the printhead segment carriers 8 are precision injection micro-moldings. Moldings of the required size and complexity are obtainable using existing micromolding technology and plastics materials such as ABS, for example. Tolerances of +/−10 microns on specified dimensions are achievable including the ink supply grooves 96 a - 96 d , and their relative location with respect to the recess 90 in which the printhead segments 4 are received. Such tolerances are suitable for this application. Other material selection criteria are thermal stability and compatibility with other materials to be used in the assembly 1 , such as inks and sealants. The profile 10 is preferably an aluminum alloy extrusion. Tolerances specified at +/−100 microns have been found suitable for such extrusions, and are achievable as well.
[0062] FIGS. 19 , 20 and 21 are schematic representations only, intended to provide an understanding of the construction of an injection-molding die used in the manufacture of a printhead segment carrier 8 . A multi-part die 100 is used, having a fixed base die part 104 , which in use defines the face 82 , recess 90 and slots 96 a to 96 d of the carrier 8 , and a multi-part upper die part 102 . The upper die part 102 is closed against the base part 104 for molding, and includes a part 101 with multiple fingers 101 a , which in use form the galleries 92 b (including galleries 92 b ′) and parts 106 which are fixed relative to part 101 . Also included in the upper part 102 are die parts 103 which are movable relative to the part 101 and which have fingers 103 a to form the remaining galleries 92 a , 92 c and 92 d . Parts 103 seat against parts 106 when molding is underway. Spaces between the fingers 101 a and 103 a correspond to the walls 97 . In use of the die 100 , terminal tips of the fingers 101 a and 103 a close against blades 105 which in use form the ink supply slots 96 a - 96 d of carrier 8 and which are mounted to male base 104 to be detachable and replaceable when necessary. Base die part 104 also has inserts 104 a , which in use form the pickup slots 87 . Because zero draft is preferred on the stepped end faces 83 in this application, the die 100 also has two movable end pieces (not shown, for clarity) which in use of the die 100 are movable generally axially to close against the upper die part 102 and which are shaped to define the end faces 84 ′, 85 ′ and 86 ′ of carrier 8 . FIG. 21 shows a schematic transverse cross-section of the mold 100 when closed, with areas in black corresponding to the carrier 8 being molded.
[0063] As was mentioned above, the two opposite end portions of the larger quarter cylinder section of carrier 8 incorporate two ink supply chambers 99 c and 99 d (see FIG. 12 ) to provide ink to the ink supply slots 96 c and 96 d in that region of the carrier 8 . These chambers 99 c and 99 d and associated communication holes 113 and 114 in parallel walls 97 that lead into the neighbouring galleries 92 c and 92 d , are formed in an operation subsequent to molding, by laser cutting openings of the required shape in the end walls 84 and the neighbouring inner parallel walls 97 from each end. The openings cut in end walls 84 are only necessary so as to access the inner walls 97 , and are therefore subsequently permanently plugged using appropriately shaped plugs 115 as shown in FIG. 6 .
[0064] Extrusions usable for profile 10 can be produced in continuous lengths and precision cut to the length required. The particular support profile 10 illustrated is 15.4 mm×25.4 mm in section and about 240 mm in length. These dimensions, together with the layout and arrangement of the walls 16 and 17 and internal webs 14 a to 14 c , have been found suitable to ensure adequate ink supply to eleven (11) MEMJET printhead segments 4 carried in the support profile to achieve four-color printing at 120 pages per minute (ppm). Support profiles with larger cross-sectional dimensions can be employed for very long printhead assemblies and/or for extremely high-speed printing where greater volumes of ink are required. Longer support profiles may of course be used, but are likely to require cross-bracing and location into a more rigid chassis to avoid alignment problems of individual printhead segments, for example in the case of a wide format printer of 54″ (1372 mm) or more.
[0065] An important step in manufacturing (and assembling) the assembly 1 is achieving the necessary, very high level of precision in relative positioning of the printhead segments 4 , and here too the construction of the assembly 1 as described above is advantageous. A suitable manufacturing sequence that ensures such high relative positioning of printheads on the support profile will now be described.
[0066] After manufacture and successful testing of an individual printhead segment 4 , its associated TAB film 9 is bumped and then bonded to bond pads along an edge of the printhead segment 4 . That is, the TAB film is physically secured to segment 4 and the necessary electrical connections are made. The terms “bumped” and “bonded” will be familiar to persons skilled in the arts where TAB films are used. The printhead carrier 8 is then primed with adhesive on all those surfaces facing into recess 90 that mate and must seal with the printhead segment 4 , see FIG. 11A , i.e. along the length of the radially-inner edges of walls 95 , 108 and 111 , the face of formation 112 and on inner faces of walls 84 . The printhead segment 4 is then secured in place in recess 90 with its TAB film 9 attached. Extremely accurate alignment of the printhead segment 4 within recess 90 of printhead segment carrier 8 is not necessarily required (but is preferred), because relative alignment of all segments 4 at the support profile 10 is carried out later, as is described below. The assembly of the printhead segment 4 , printhead segment carrier 8 and TAB film 9 is preferably tested at this point for correct operation using ink or water, before being positioned for placement in the slot 21 of support profile 10 .
[0067] The support profile 10 is accurately cut to length (where it has been manufactured in a length longer than that required, for example by extrusion), faced and cleaned to enable good mating with the end caps 50 and 60 .
[0068] A glue wheel is run the entire length of semi-circular slot 21 , priming the terminal edges 14 a ′, 14 b ′, 14 c ′ of webs 14 a - 14 c and edges 16 ′, 17 ′ of profile side walls 16 , 17 with adhesive that will bond the sealing shim 25 into place in slot 21 once sealing shim 25 is placed into it with preset distance from its terminal ends (+/−10 microns). The shim 25 is snap-fitted into place at edges 16 ′, 17 ′ and the glue is allowed to set. Next, end caps 50 and 60 are bonded into place whereby (ink channel sealing) insert stubs 57 a - 57 d and 67 a - 67 d are received in ink channels 20 a - 20 d of profile 10 , and faces 71 and 77 of retention stubs 58 and 68 , respectively, lie on shim 25 . This sub-assembly provides a chassis in which to successively place, align and secure further sub-assemblies (hereinafter called “carrier subassemblies”) each consisting of a printhead segment carrier 8 with its respective printhead segment 4 and TAB film 9 already secured in place thereon.
[0069] A first carrier sub-assembly is primed with glue on the back face 91 of its printhead segment carrier 8 . At least the edges of walls 95 and 86 are primed. A glue wheel, running lengthwise, is preferably used in this operation. After priming with glue, the carrier sub-assembly is picked up by a manipulator arm engaging into pick-up slots 87 on front face 82 of carrier 8 and placed next to the stub 58 of end cap 50 (or the stub 68 of cap 60 ) at one end of slot 21 in profile 10 . The glue employed is of slow-setting or heat-activatable type, thereby to allow a small level of positional manipulation of each carrier subassembly, lengthwise in the slot 21 , before final setting of the glue. With the first carrier subassembly finally secured to the shim 25 within the slot 21 , a second carrier sub-assembly is then picked up, primed with glue as above, and placed in a 180-degree-rotated position (as described above, and as may be seen in FIG. 3 ) next to the first carrier sub-assembly onto shim 25 and within the slot 21 . The second carrier sub-assembly is then positioned lengthwise so that there is correct lengthwise relative positioning of its printhead segment 4 and the segment 4 of the previously placed segment 4 , as determined using suitable fiducial marks (not shown) on the exposed front surface 44 of each of the printhead segments 4 . That is, lengthwise alignment is carried out between successive printhead segments 4 , even though it is the printhead segment carrier 8 that is actually manipulated. This relative alignment is carried out to such (sub-micron) accuracy as is required to match the printing resolution capability of the printhead segments 4 . Finally, the bonding of the second carrier sub-assembly to shim 25 is completed. The above process is then repeated with further carrier sub-assemblies being successively positioned, aligned, and bonded into place, until all carrier subassemblies are in position within the slot 21 and bonded in their correct positions.
[0070] The shield plate 5 has a thin film of silicon sealant applied to its underside and is mated to the printhead segment carriers 8 and TAB films 9 along the entire length of the printhead assembly 1 . By suitable choice of adhesive properties of the silicon sealant, the shield plate 5 can be made removable to enable access to the printhead segment carriers 8 , printhead segments 4 and TAB films 9 for servicing and/or exchange.
[0071] A sub-assembly of PCB 11 and printhead control and ancillary components 73 to 76 is secured to profile 10 using four screws 23 . The TAB films 9 are wrapped around the exterior walls 16 , 17 of profile 10 and are bumped and bonded (i.e. physically and electrically connected) to the PCB 11 . See FIG. 17 .
[0072] Finally, the completed assembly 1 is connected at the ink inlet stubs 55 a - d of end cap 50 to suitable ink supplies, primed as described above and sealed using sealing film 69 of end cap 60 . Power and signal connections are completed and the inkjet printhead assembly 1 is ready for final testing and subsequent use.
[0073] It will be apparent to persons skilled in the art that many variations of the above-described assembly and components are possible. For example, FIG. 18 shows a shim 125 that is substantially the same as shim 25 , including having openings 126 and 126 ′ corresponding to the openings 26 and 26 ′ in shim 25 , save for longitudinally extending rim webs 128 which, when the shim 125 is mounted to a support profile 110 , abut in surface-engaging manner against the outside of the terminal ends of side walls 116 , 117 of profile 110 instead of being snap-fittingly received between them as is the case with shim 25 . This arrangement permits wider tolerances to be used in the manufacture of the support profile 110 without compromising the mating capability of the shim 125 and the profile 110 .
[0074] In yet another possible arrangement, the shim 25 could be eliminated entirely, with the printhead segment carriers 8 then bearing and sealing directly on the edges 14 a ′- 14 c ′ and 16 ′, 17 ′ of the webs 14 a - 14 c and side walls 16 , 17 at slot 21 of support profile 10 .
[0075] It will be appreciated by persons skilled in the art that still further variations and modifications may be made without departing from the scope of the invention. The embodiments of the present invention as described above are in no sense intended to be restrictive. | An inkjet printhead assembly includes an elongate ink supply body defining a plurality of ink supply channels; an elongate cradle member defining a plurality of rows of apertures, the elongate cradle member being fastened to the elongate ink supply body to communicate ink within the ink supply channels through respective ones of said rows of apertures; and a plurality of printhead segments each having a carrier defining a plurality of rows of ink supply passages arranged in alignment with respective apertures of the cradle member, each printhead segment further having an elongate ink ejection printhead mounted to the carrier in fluid communication with the ink supply passages. Each carrier defines a complementary formation for mating serially with the cradle member. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 USC §119(e) to U.S. Provisional Application Nos. 60/417,462, filed Oct. 9, 2002, and 60/464,939, filed Apr. 23, 2003. The entire disclosure of each of these applications is hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to system design and development, and more particularly to a system and method for developing system requirements.
BACKGROUND OF THE INVENTION
[0003] System design and development is known in the art. A customer will typically contract with a designer/manufacturer to design and develop a system. The customer typically provides top-level system requirements within the contract. However, these requirements describe the performance of the entire system, and systems are designed and developed as individual elements (e.g., circuit cards, software packages, etc.). Hence, requirements development is the process of defining the requirements of each of the individual system elements such that they all work together to form an optimum system level solution.
[0004] Good requirements development is critical to the success of any development program. Complex systems require many different system elements to be developed at the same time and still be functional as large systems once integrated together. Hence, providing the detailed design requirements to each lower level element designer is crucial to the lower level designers' ability to create a good design the first time.
[0005] Traditionally, development programs have used a layered approach to generating lower level requirements for a system. As is illustrated in FIG. 1, such traditional approach starts with the top-level system requirements (typically provided by the customer contract) and a specification tree of the system to be developed. The top-level requirements are analyzed and flowed down to the next level in the specification tree, resulting in the development of the second level specifications. Next, the second level specifications are analyzed and flowed down to the next level in the specification tree, resulting in the development of the third level specifications. This process is then repeated until all the requirements have been flowed to the lowest level in the specification tree. The designers then use these specifications to develop the individual system elements.
[0006] As an example, FIG. 1 illustrates a typical specification tree, in this case relating to the development of weapons system. The top-level requirements typically come from the customer contract. Next, specifications are developed for each major sub-program (e.g., launch platform specification, missile specification, and launcher specification). Next, the major system element specifications for each sub-program are developed based on flowing down from the previous level specifications. In FIG. 1, only the major system elements for the missile specifications are shown (e.g., warhead specification, fuze specification, guidance section specification, etc.), although it will be appreciated that each sub-program will have its' own major system element specifications. In the fourth level, the major system element specifications from the third level are flowed down to define the specifications for the next level of system elements. In the case of the guidance section specification, the next level of system elements includes seeker specification, electronic unit specification, sensor assembly specification.
[0007] The above process is repeated until the last level of the program specification tree is populated. In the case of the electronics unit specification of the guidance section specification, the last level may include circuit card No. 1 specification and circuit card No. 2 specification, for example. Again, while each system element has not been fully expanded at each level in FIG. 1 for sake of clarity, it will be appreciated that each system element will likely have additional system elements dependent therefrom in lower levels.
[0008] Unfortunately, however, poor requirements development frequently negatively impacts the success of a complex development program. Bad or late requirements can cause the designer of a lower level system element to design to the wrong requirements at that level, thus creating a design that, when integrated with the other system elements, does not allow the system to meet the top level requirements. This can cause the particular system element, and possibly other system elements, to have to be redesigned, often resulting in massive cost and development schedule impacts.
[0009] With the above-described traditional layered approach, the emphasis is on each horizontal level of the program specification tree. This leads to one drawback wherein the approach is slow to get the requirements to the lowest levels of the specification tree. The layered approach requires the lowest level requirements to pass through many levels before the lowest level system element requirements can be developed.
[0010] Another drawback is that complex requirements are usually analyzed multiple times during flow-down from one level to the next. For example, a first set of analyses is done to determine the allocation of requirements at the second level of the specification tree, then again to determine the allocation between the elements at the next level, and so on. Each time the analysis is repeated in increasing level of detail, in order to refine the requirements as they flow down through the system. However, repeating the analysis many times can be inefficient. Also, there is a considerable likelihood of discontinuities between the analyses. In some cases the analyses are done completely up front, but then can be misunderstood later, forgotten, or even lost later in the requirements flow-down process.
[0011] Yet another drawback is that margins tend to be managed independently at each level of the flow-down. This can cause a lack of an integrated margin management approach across all levels of the specification tree. This lack of an integrated approach can cause more stringent requirements than necessary. Still another drawback is that if the requirements that were flowed down are found to be unachievable by the lower level system element designers, this is not discovered until late in the requirements development process. Thus, this often results in specification changes to the design element found to be unachievable. However, since this usually also results in a redistribution of requirements across other system elements, the specifications and designs of other system elements are also often impacted.
[0012] In view of the aforementioned shortcomings associated with traditional level-by-level requirements development, there is a strong need in the art for an approach which avoids delays in getting the proper requirements to the lowest level of the specification tree. Moreover, there is a strong need for an approach which avoids inefficiencies associated with multiple analyses of the same requirements. In addition, there is a strong need for an approach which avoids excessive margins that can result in unachievable requirements at the lower levels and/or overly stringent requirements.
SUMMARY OF THE INVENTION
[0013] The present invention relates to an automated system and method for developing system requirements which addresses the aforementioned shortcomings associated with the traditional layered approach. The present invention utilizes what is referred to herein as a “vertical approach” to requirements development. According to such vertical approach, the focus is on flowing all requirements directly to the lowest level in the specification tree. This is done by first flowing all the top level requirements to a series of system level requirements analyses, which then flow the requirements directly to each specification in the specification tree regardless of that particular specification's level within the specification tree.
[0014] Each top-level requirement is analyzed at the beginning of the approach. At that point, each requirement is also budgeted and allocated to each system element that contributes to the meeting of that requirement, regardless of the level of those elements in the specification tree. At the same time, the requirements margin for each requirement is determined and managed in the same analysis. Also, because the analyses are an indispensable part of the flow down process, an analysis database is changed in order to change any of the lower level specifications. By performing these analyses on every requirement, it shifts the focus away from the generation of specifications and instead focuses on the analysis of the requirements. Hence, the vertical approach creates analyses that determine each requirements allocation through the entire specification tree.
[0015] The present invention may be implemented using machine-readable code (e.g., computer software) executed on a computer or other automated processing device.
[0016] According to one aspect of the invention, a vertical requirements development method is provided for developing requirements for a system to be developed. The system to be developed includes top-level requirements and is representable by a program specification tree made up of multiple layers of individual system elements, with each lower layer of the multiple layers comprising individual system elements having lower level requirements associated therewith compared to an upper layer. The method includes the steps of identifying, based on the top-level requirements, a plurality of system level requirements analyses which, upon satisfaction, comply with the top-level requirements; and for each system level requirements analysis, allocating specification requirements to each of the individual system elements that contribute to the satisfaction of that system level requirements analysis, regardless of the level of the individual system elements that contribute in the program specification tree.
[0017] According to another aspect of the invention, a vertical requirements development system is provided for developing requirements for a system to be developed. The system includes a plurality of terminals; a requirements management database comprising a digital data storage medium and a server executing machine readable code for managing data stored in the digital data storage medium; and a network interconnecting the plurality of terminals and the requirement management database. Based on the top-level requirements, a plurality of system level requirements analyses are identified which, upon satisfaction, comply with the top-level requirements. For each system level requirements analysis, specification requirements are allocated to each of the individual system elements that contribute to the satisfaction of that system level requirements analysis, regardless of the level of the individual system elements that contribute in the program specification tree. The specification requirements allocated to each of the individual system elements are stored in the requirements management database.
[0018] According to yet another aspect of the invention, a data structure is provided useful in association with a vertical requirements development method for developing requirements for a system to be developed. The database structure includes data storage area for storing the specification requirements allocated to each of the individual system elements digitally in a requirements management database.
[0019] To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a conventional program specification tree representing system requirements development in accordance with a traditional layered approach;
[0021] [0021]FIG. 2 is an exemplary program specification tree representing system requirements development in accordance with a vertical requirements development approach of the present invention;
[0022] [0022]FIG. 3 is a diagram illustrating a vertical requirements development system in accordance with the present invention;
[0023] [0023]FIG. 4 is a flowchart representing operation of the vertical requirements development system in accordance with the present invention;
[0024] [0024]FIG. 5 is a more detailed view of the program specification tree of FIG. 2 in accordance with the present invention;
[0025] [0025]FIG. 6 is an exemplary user interface illustrating a system requirements entry in accordance with the present invention;
[0026] [0026]FIG. 7 is an exemplary user interface illustrating an exemplary requirements analysis entry in accordance with the present invention;
[0027] [0027]FIGS. 8A and 8B represent the content of the requirements management database in accordance with an exemplary embodiment of the present invention;
[0028] [0028]FIG. 9 is an exemplary user interface illustrating an exemplary element specification automatically generated in accordance with the present invention; and
[0029] [0029]FIG. 10 is a diagram illustrating a derived requirements development aspect of the vertical requirements development system in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention will now be described with reference to the drawings, wherein like reference labels are used to refer to like elements throughout.
[0031] Referring now to FIG. 2, shown is an exemplary program specification tree representing system requirements development in accordance with a vertical requirements development approach of the present invention. As in FIG. 1, the program specification tree in this example pertains to the development of a weapons system. However, the requirements for the system elements within the specification tree are not developed horizontally level-by-level as in the conventional approach described above with respect to FIG. 1. Rather, according to the present invention the requirements are flowed directly to the lowest level in the specification tree. This is done by first flowing all the top level requirements to a series of system level requirements analyses, referred to in FIG. 2 as “Program Requirements Analyses”. These system level requirements analyses serve to flow the requirements directly to each specification in the specification tree regardless of that particular specification's level within the specification tree. Thus, as represented by the arrows in FIG. 2, the present invention does not require development on a level-by-level analysis.
[0032] [0032]FIG. 3 illustrates a vertical requirements development system 20 in accordance with the exemplary embodiment of the present invention. The system 20 includes a requirements management database 22 linked via a network 24 to a plurality of user input/output terminals 26 . One or more of the terminals 26 may be associated with users representing system engineering which perform upper level operations in relation to the program specification tree of FIG. 2. Moreover, one or more of the terminals 26 may be associated with lower level operations in relation to the program specification tree. Such lower level operations may include circuit board design, etc., representing the development of the lower level system elements.
[0033] The requirements management database 22 includes a data storage medium 28 for storing requirements data as will be described in more detail below. The data storage medium may be any electronic data storage device such as a magnetic or optical disk hard drive, flash memory, digital tape, etc., as will be appreciated by those having ordinary skill in the art. In addition, the requirements management database 22 includes a requirements management server 30 for controlling operations of the development system 20 . More specifically, the server 30 comprises a computer such as a personal computer or mainframe which writes data to and accesses data from the database 28 in accordance with the invention. Even more specifically, the various functions of the present invention as described herein are compiled in computer or machine-readable code which is stored and executed on the server 30 using conventional programming and database techniques. A person having ordinary skill in the art of computer programming, based on the description provided herein, would be able to provide machine-readable code for carrying out all of the functions described herein without undue effort or experimentation. Accordingly, details of the particular programming have been omitted herein for sake of brevity. The server 30 executes such code in order to carry out the functions described herein in relation to the development of the requirements based on information and data input within the system via the terminals 26 as further described herein.
[0034] [0034]FIG. 4 is a flowchart representing an overview of the operation of the system 20 . Beginning in step 50 , the top level requirements for the system to be developed (e.g., the weapons system requirements in FIG. 2) are provided. As noted above, such top level requirements are typically provided by the customer such as in the customer contract. Based on the top level requirements, the system 20 identifies the system level requirements analyses to be performed. Such system level requirement analyses to be performed may be entered via one or more of the terminals 26 by a user(s) familiar with the particular type of system development.
[0035] For example, FIG. 5 illustrates within the box entitled “Typical Requirements Analyses” the particular system level requirements analyses which are to be performed when developing a weapons system. Such requirements analyses may include, but are not limited to, Probability of Kill (Pk), Thermal, Design to Cost (DTC), Power Distribution, . . . , Timelines, Reliability, etc. In step 50 , these system level requirements analyses are input to the system 20 via one or more of the terminals 26 , for example, and are stored by the server 30 in the database 28 . The user may be prompted by the server 30 to input the system level requirements analyses using an appropriately designed graphical user interface (GUI) presented at the terminal 26 as will be appreciated.
[0036] Alternatively, the server 30 may have prestored in the database 28 full or partial system level requirement analyses which relate to the particular type of system to be developed. For example, once the system level requirement analyses for developing a weapon system have been input, users subsequently developing another weapon system may access the system level requirement analyses already stored in the database 28 without the need to reenter such information. The server 30 may store previously entered system level requirement analyses for different types of systems on the database 28 and allow a user to access such information via a pull-down menu or the like from one of the terminals 26 as will be appreciated.
[0037] [0037]FIG. 6 illustrates an exemplary screen shown on a terminal 26 representing a user's ability to input the various system level requirement analyses. Such information may be input using a conventional database management software package such as the commercially available DOORS from Telelogic North America, Inc., or SLATE from EDS (Electronic Data Systems). FIG. 6 illustrates the entry of an exemplary top level requirement that the weapons system initiate a first missile motion within 150 ms of operator trigger pull, such requirement coming from the customer for example. The user at the terminal 26 may enter into the database 28 various headings or categories as line entries which facilitate evaluation and display of the requirements. Thus, for example, the user may enter the category “Characteristics” followed by the subcategories “Performance” and “Trigger Pull to First Missile Motion”, as shown in the first three line entries in FIG. 6.
[0038] The top level requirement that the weapons system initiate a first missile motion within 150 ms of operator trigger pull, as known by those having ordinary skill in the art, would be associated with the “Timelines” system level requirements analysis (see, e.g., FIG. 5). Thus, the user at the terminal 26 enters the top level requirement “The system shall initiate first missile motion within 150 ms of operator trigger pull.” under the appropriate heading “Trigger Pull to First Missile Motion” as shown in FIG. 6. In addition, the entry includes a field in which the user enters the identifier (ID) “Timeline” which is stored in the database 28 together with the top level requirement. The database 28 in combination with the database management software operating on the server 30 uses the identifier “Timeline” to link the top level requirement to the system level requirements analysis to which it applies.
[0039] A similar process is carried out for each of the top level requirements provided by the customer. The system 20 enables the user to enter each top level requirement into the database 28 together with a corresponding identifier which links the top level requirement to a corresponding system level requirements analysis. While FIG. 6 represents only the portion of the database 28 associated with the entry of the top level requirement that the system shall initiate first missile motion within 150 ms of operator trigger pull, it will be appreciated that the manner of entry of the remaining top level requirements will be the same.
[0040] In many cases, the applicable top-level requirements will extend beyond the top-level requirements provided by the customer. For example, design to cost or reliability requirements might appear in the contract statement of work rather than in the top-level requirements provided by the customer. The point is that all the requirements that should be flowed down to the designers to consider in their designs should be treated the same. All such requirements should be analyzed in the same manner described herein.
[0041] Following step 50 , the process continues to step 52 in which the top level requirements (e.g., those provided by the customer and entered into the database 28 as described above) are flowed down to the system level requirements analyses identified in step 50 .
[0042] [0042]FIG. 7 illustrates an example of a screen shown on the terminal 26 representing a user's ability to enter the Timeline system level requirements analysis. It will be appreciated that the process for the other system level requirements analyses will be the same, except with different data. As is shown in FIG. 7, the user may again enter various category or heading information such as “Scope”, “Applicable Documents”, “Requirements Analysis”, etc. Alternatively, the system 20 may be configured to generate the appropriate headings automatically based on those previously entered by the user in relation to FIG. 6.
[0043] In step 52 , the database management software running on the server 30 is programmed to automatically copy and paste under the heading “Requirements Analysis”, any and all entries entered in step 50 (e.g., FIG. 6) for the corresponding system level requirements analysis. Thus, for example, under the heading “Requirements Analysis” for the Timeline system level requirements analysis as shown in FIG. 7, the system 20 copies any and all top level requirements entries associated with “Timeline” in step 50 into corresponding database entries within the Timeline system level requirements analysis section. This may be done simply by the server 30 searching for, filtering on, or viewing all entries having the ID “Timeline” entered therewith as described above in relation to FIG. 6.
[0044] In the exemplary embodiment, the entry “The system shall initiate first missile motion within 150 ms of operator trigger pull.” is automatically copied into the Requirements Analysis section for the Timeline as shown in FIG. 7. In addition, the system 20 may also include a database entry identifier (e.g., “WS69”) indicating from which original database entry the entry was copied. Thus, when a user at a terminal 26 accesses the contents of the database 28 within the Timeline Requirements Analysis, the system 20 will have automatically provided for the user a complete list of entries corresponding to the top level requirements associated with the analysis.
[0045] Next, in steps 54 and 56 , system engineering users and element designers interact (via terminals 26 , personal meetings, telephone, etc.) to develop the appropriate criteria for each systems level requirements analysis. The systems engineers and designers both may draw from experience, previously developed analyses, etc. Depending on the particular system being developed, e.g., weapon, automobile, etc., the particular criteria can be different as will be appreciated. The element designers may provide input to the systems engineers which is significant at the lower levels of the product specification tree, independent of other system elements at various other levels. Interaction between the system engineers and the element designers in steps 54 and 56 at this point in the requirements development allows the development of a set of requirements which, if satisfied, satisfies a given systems level requirement analysis.
[0046] More particularly, interaction in steps 54 and 56 will yield system level requirement analyses which each will typically include design requirements, margin requirements, etc., that will be effected by system elements on different levels of the program specification tree. Based on such knowledge, a user (typically a systems engineer) at a terminal 26 will be aware of the particular issues in a given analysis. In step 58 , the user enters into the database 28 the relevant issues, concerns, requirements, etc. for each system level requirements analysis. Again, it is important to note that the analysis for a given system level requirement may encompass several levels of system elements in the specification tree.
[0047] The system level requirements analyses performed in the development of a system will vary from system to system, depending upon the top-level requirements.
[0048] The user in step 58 may then proceed to enter particulars associated with a given system level requirements analysis. Under the “Analysis” heading, the user enters various criteria explaining constaints, issues, parameters, etc., which define satisfaction of the system level requirements. Regarding trigger pull to first missile motion, a user at terminal 26 may enter the following into the database 28 as shown:
Per discussions with the aircraft design agent, the aircraft will require as much as 10 ms from trigger pull until a launch signal is provided to the launcher. Since the Launcher is CFE the time required by the lancher is fixed. Per the launcher spec and measurements taken on actual launchers, the launcher will require as much as 2 ms to receive the launch signal from the aircraft and provide a battery initiate pulse to the missile Per discussion with the battery manufacturer, the battery will require as much as 100 ms to come up to power after receipt of a battery initiate pulse Again, since the launcher is GFE the time required to sense battery power and initiate a launch command is fixed. Per the launcher spec and measurements taken on actual launchers, the launcher will require as much as 5 ms. Per discussions with the rocket motor manufacturer, the rocket motor will require as much as 5 ms to initiate missile motion after receipt of a launch command.
[0049] [0049] TABLE 1 Launch Timeline Summary Aircraft 10 ms Launcher (battery pulse) 2 ms Battery 100 ms Launcher (motor pulse) 5 ms Rocket Motor 5 ms Margin 28 ms Total 150 ms
[0050] Such entries address design criteria for several system elements, such as the launch platform (e.g., aircraft), launcher, battery, rocket motor, etc. These criteria flow down different levels of the program specification tree, and are not restricted to one level as will be appreciated.
[0051] Also in step 58 , the user enters into the analysis the specification requirements necessary for the satisfaction of the analysis based on the information compiled in steps 54 and 56 . For example, the database 28 includes an “Output Requirements” section in each of the system level requirements analyses as exemplified in FIG. 7. Under an appropriate category or heading, a user enters the specifications into the database 28 . From the exemplary Timeline system level requirements analysis which is summarized in the “Launch Timeline Summary” of Table 1, such specifications include that fact that the aircraft (launch platform) must provide a launch signal to the launcher within 10 ms of trigger pull; the battery must come up to power within 100 ms after receipt of a battery initiate pulse; and the rocket motor shall initiate missile motion within 5 ms after receipt of a launch command.
[0052] Accordingly, the user enters into the database 28 the specification requirement “The aircraft shall provide a launch signal to the launcher within 10 ms of trigger pull” under the heading “Launch Signal” as shown in FIG. 7. Moreover, the entry includes a field in which the user enters a specification identifier (SID) which identifies the particular system element or elements within the specification tree to which the entered specification applies. Thus, for example, the specification entry that the aircraft provide a launch signal to the launcher within 10 ms of trigger pull includes a user entered SID identifying the “Launch Platform” system element. Similarly, the user via the terminal 26 enters the specification “The battery shall come up to power within 100 ms after receipt of a battery initiate pulse” together with the SIDs “Missile” and “Battery” as the specification relates to the Missile and Battery system elements. Likewise, the user enters the specification “The rocket motor shall initiate missile motion within 5 ms after receipt of a launch command” together with the SIDs “Missile” and “Rocket Motor” as the specification relates to the Missile and Rocket Motor system elements.
[0053] Step 58 is repeated for every specification requirement generated through each of the system level requirements analyses so as to populate the database 28 . FIGS. 8A and 8B illustrate an exemplary structure of the information thus stored within the database 28 . The database 28 may be generalized as storing data representing the top level requirements with links to the applicable system level requirement analyses. In addition, the database 28 stores data representing the respective system level analyses together with links to the applicable system elements. Using the aforementioned links, the requirements management database 22 can automatically generate and/or view specifications for individual system elements as well as portions of the system or the entire system.
[0054] More particularly, step 60 in FIG. 4 represents a step in which the present invention allows element designers to generate their relevant specifications automatically. Moreover, step 60 provides the element designers with the ability to analyze the specifications for achievability. Specifically, the database 28 includes the SIDs for the respective specification requirements as noted above. The SIDs identify the particular system element(s) which relate to the specification. Thus, a user at a terminal 26 (in this case typically a designer) may query the database 28 via the server 30 for all specifications relating to a particular system element(s). The server 30 , in turn, collects all the entries in the database which include a SID corresponding to the queried element(s). This information may then be provided to the user via the terminal 26 as the specification particular to the queried system element(s). In the case where the queried element constitutes a root on the program specification tree, the database management system 22 can be configured to locate all SIDs corresponding to the root system element as well as any system elements branching therefrom, as will be appreciated.
[0055] Thus, in step 60 the database management system 22 is able to collect all the requirements for the specific lower level system element that are likely scattered throughout the various system level analyses and assemble them into one report for the element designers. As a result, the system 22 is able to generate automatically the system element specifications from the various analyses. FIG. 9 illustrates an exemplary specification generated automatically. In the case where a user at a terminal 26 enters the system element “Missile Specification” to obtain specifications corresponding to the missile, the database management system 22 searches for all SIDs equal to “Missile” corresponding to the system element “Missile Specification”. Thus, the automatically generated specification as shown in FIG. 9 will include the specification requirements “The battery shall come up to power within 100 ms after receipt of a battery initiate pulse” and “The rocket motor shall initiate missile motion within 5 ms after receipt of a launch command”.
[0056] It is noted that the specification “The aircraft shall provide a launch signal to the launcher within 10 ms of trigger pull” does not appear in the output of FIG. 9. This is because the specification corresponds to the system element “Launch Platform” and not the queried “Missile Specification”. In this manner, the requirements management database 22 only outputs the specification requirements pertaining to the system elements queried.
[0057] As noted in FIG. 9, the requirements management database 22 may be configured to automatically copy category or heading information into the generated specification and to generate appropriate sequencing and paragraph numbering to improve readability. In addition, the requirements management database 22 is configured to provide a link (e.g., “TL144”) adjacent a respective specification requirement to identify the source of such requirement within the database. Such information is useful in the even further detail is desired as to the analysis which resulted in the specification.
[0058] Referring again to FIG. 4, the present invention also provides the feature that allows optimization through the collaboration of designers and system engineers. In step 62 , element designers whom have obtained specification requirements generated in the manner above may review, understand and analyze their entire requirements set for achievability. If the element designers consider any specification requirements unachievable, they may “push back” on the specification requirements as appropriate. This may be done manually (e.g., personal conversations, emails, telephone calls, memorandums, etc.) or in the form of comments entered into the database 28 via the terminals 26 in relation with the respective specification requirements. In this way, the element designers can spawn a series of system wide negotiations and trade-offs. The tradeoffs and negotiations spawned will occur between the designers and the specification engineers who generated the requirements, as represented in step 64 .
[0059] In the cases when designers and specification engineers cannot correct an issue, the other designers who are contributing to meeting the top level requirement may need to be pulled into the tradeoffs to resolve the issue. If this is still not successful, the engineers generating other requirements may also need to be pulled into the tradeoffs in order to optimize the system between not only the design elements but also between requirements.
[0060] Upon resolution, all facilitated by the requirements management database system 22 , the specifications and analyses set up in the database may be revised and finalized as represented in step 66 .
[0061] The above discussion relates primarily to specification requirements distributed to system elements to assure compliance with system level requirements. It will be appreciated, however, that other types of requirements may be introduced, such as requirements generated to provide a complete set of requirements to all system elements. Such requirements may be referred to as “derived” requirements. Such requirements may be those which are not defined to assure compliance with system level requirements, but which are otherwise needed by other elements. In addition, or in the alternative, for example, the derived requirements may be those needed to define common element interfaces. FIG. 10 illustrates such an interface analysis for the system elements. To the extent specification requirements are generated based on such derived requirements, the requirements are entered into the database 28 in step 58 (FIG. 4) in the same manner described above in relation to the allocated requirements.
[0062] Accordingly, the system 20 in accordance with the present invention may be summarized as a combination of (i) system level analyses; (ii) automatic specification generation; and (iii) system level optimization through collaboration. Within the system level analyses, system engineering generates requirements analyses on all requirements and allocates the requirements to the lowest levels in the system to be designed. In the automatic specification generation, the element designers may automatically generate their lower level specifications in the program specification tree. In the system level optimization, the element designers may analyze these specifications for achievability. Then, designers and system engineers can participate on the requirements tradeoffs and negotiations to obtain a system level optimization of the system element requirements. These tradeoffs and negotiations should continue until all of the systems engineers and all the designers agree that all of the requirements are acceptably defined.
[0063] The invention provides the advantage of shifting the focus from development of specifications to analysis of requirements. The requirements are fully analyzed at the beginning of a program before design effort starts. Design margins are managed in one place and better control of analyses content is provided. Analyses are captured in one place for all to see. The analysis database can be changed/updated to be kept current and change specifications. The system can generate specifications with first cut analysis during the proposal phase. Moreover, the system promotes system level optimization and develops requirements that the designers need the most first. Requirements are flowed down to the lower levels more quickly than in traditional approaches. The system maximizes the likelihood of getting the design correct the first time. In addition, configuration control of the requirements can increase through the life of the program.
[0064] It will be appreciated that the present invention has been described herein in the context of the development of a weapon system. However, the present invention has application to the development of any type of system and the invention is not intended to be limited in the broadest sense to any specific type of system.
[0065] Although the invention has been shown and described with respect to certain preferred embodiments, it is obvious that equivalents and modifications will occur to others skilled in the art upon the reading and understanding of the specification. The present invention includes all such equivalents and modifications, and is limited only by the scope of the following claims. | A vertical requirements development method is provided for developing requirements for a system to be developed. The system to be developed includes top-level requirements and is representable by a program specification tree made up of multiple layers of individual system elements, with each lower layer of the multiple layers comprising individual system elements having lower level requirements associated therewith compared to an upper layer. The method includes the steps of identifying, based on the top-level requirements, a plurality of system level requirements analyses which, upon satisfaction, comply with the top-level requirements; and for each system level requirements analysis, allocating specification requirements to each of the individual system elements that contribute to the satisfaction of that system level requirements analysis, regardless of the level of the individual system elements that contribute in the program specification tree. | 6 |
This application is a continuation of U.S. application Ser. No. 545,660 filed Jan. 30, 1975, and now abandoned.
BACKGROUND
This invention relates to a process of producing magnesia from magnesium-containing carbonate ores, which comprises leaching with sulfuric acid, subsequently neutralizing the solution with magnesia, separating the undissolved impurities, crystallizing magnesium sulfate and thermally decomposing the latter to form magnesia and SO 2 , recovering sulfuric acid from the sulfur dioxide produced in the decomposing step and recycling the sulfuric acid to the leaching stage.
The magnesium chloride contained in sea water has mainly been used as a source of high-purity magnesia. An increase in concentration is succeeded by a thermal decomposing, which may be carried out, e.g., in accordance with German Patent 878,801 and results in a formation of magnesia and hydrogen chloride gas. This practice has the disadvantage that the resulting oxide has a purity of about 97% and is contaminated with boron compounds. A further disadvantage resides in the consumption of large quantities of energy required to increase the concentration of the originally highly dilute solution.
Another process of producing magnesia relies on the large deposits of carbonate ores. According to the U.S. Pat. No. 2,381,053, these ores are ground and in an aqueous medium are treated first with sulfur dioxide and then with air. This results in a formation of magnesium sulfite as an intermediate product and then of magnesium sulfate, which is filtered from solid residues and is concentrated by evaporation and finally thermally decomposed. The sulfur dioxide formed in the decomposing step is recycled to the first treating stage. This practice has the important disadvantage that the treatment with sulfur dioxide and the subsequent treatment with air result in solid-gas reactions which are relatively slow and require a high surplus of reactants, particularly in the second stage.
Another process has been proposed which also relies on magnesium-containing carbonate ores and in which the ores are leached in a surplus of hot sulfuric acid until the magnesium sulfate concentration exceeds 60% of the saturation concentration, free acid is neutralized with magnesia, the solid residues are separated, and magnesium sulfate is crystallized and is finally thermally decomposed (DOS 2,159,973). Sulfuric acid can be recovered from the gas produced by decomposing and may be re-used for leaching.
Whereas this process has considerable advantages compared to the one mentioned before, particularly because a much higher reaction rate is achieved during leaching, the further processing of the magnesium sulfate solution requires a multistep heat treatment, for instance by spray drying, final drying, and decomposing or by crystallization, drying, and decomposing. Besides, large quantities of dust which can be separated only with difficulty are formed by the thermal decomposing of magnesium sulfate from which all water has been removed. Moreover, only a rotary kiln has been described as a decomposing unit and has a low throughput rate per unit of the reactor volume and owing to the dissipation of radiant heat has a poor thermal efficiency.
SUMMARY
This invention provides a process which is free of the disadvantages of the known processes, has a high throughput rate and can be carried out in a particularly simple manner and with a high heat economy yielding a pure product of uniform quality.
Magnesia is produced according to the invention from magnesium containing ores by a process which includes the following steps:
(a) leaching said ore with sulfuric acid;
(b) neutralizing the solution from (a) with magnesia and separating undissolved impurities;
(c) crystallizing magnesium sulfate from the solution from (b) under superatmospheric pressure and at temperatures above 150° C
(d) forming magnesium sulfate crystals containing 1.5-4 mols of water of crystallization and having a fineness suitable for decomposition in a fluidized bed reactor;
(e) dehydrating and/or heating the crystals from (d) in a suspension-type heat-exchanger operated with exhaust gases from the fluidized-bed reactor;
(f) feeding the crystals from (e) after separation to the fluidized bed reactor where it is decomposed to form magnesia and sulfur dioxide, the heat required for the decomposition reaction being generated by approximately a stoichiometric combustion of fuel charged into the fluidized bed reactor;
(g) removing magnesia from the fluidized-bed reactor feeding same to a multi-stage fluidized-bed cooler operated with air as a fluidizing gas;
(h) feeding fluidized air from the fluidized bed cooler to the fluidized bed reactor of step (f);
(i) converting the sulfur dioxide produced in step (f) into sulfuric acid and recycling same to leaching step (a).
DESCRIPTION OF THE DRAWING
The accompanying drawing is a simplified flow diagram for carrying out the process of the invention.
DESCRIPTION
Crystallization under a superatmospheric pressure and at temperatures above 150° C is known to afford the advantage that a magnesium sulfate is formed which has a low content of water of crystallization.
The subsequent separation of the crystals from the mother liquor should be effected in such a manner that the subsequent cooling of the crystals results in a magnesium sulfate containing 1.5-4 moles of water of crystallization. As the crystals are cooled, the magnesium sulfate is known to take up any water which is present until an equilibrium has been reached between the saturated solution and the undissolved solids at the existing temperature. To inhibit during this cooling the formation of a sulfate having more than 4 moles water of crystallization, care must be taken during the separation of the crystals that the quantity of mechanically adhering mother liquor does not exceed the largest quantity which is permissible for the formation of a hydrate which contains 4 moles of water of crystallization. On the other hand, when the magnesium sulfate crystallizes as the monohydrate, the mother liquor must not be removed to such an extent that less water is available than is required to form a hydrate which contains at least 1.5 moles of water.
The separation of the crystals from the mother liquor may be effected under normal pressure. The methods of separation used for this purpose should suitably ensure a fast separation between the solids and the solution so that the formation of a salt having an excessively high content of water of crystallization or a redissolution of the previously crystallized magnesium sulfate is avoided. It will be particularly desirable to separate the crystals from the mother liquor under pressure and particurlarly to use for this purpose the pressure which prevails during the crystallization.
The crystals which have been separated from the mother liquor are desirably cooled in such a manner that a friable product is obtained. Cooling rolls or cooling belts are particularly suitable for this purpose.
The main reason for the performance of the crystallization, separation of crystals, and cooling of crystals under carefully controlled conditions resides in the surprising fact that a magnesium sulfate which has 1.5-4 moles of water of crystallization has excellent mechanical properties for the further processing, which comprises dewatering and/or heating in suspension-type-heat exchangers and decomposing in a fluidized bed. The solids remain granular and flowable and the particles exhibit virtually no tendency to disintegrate and form dust.
The cooled magnesium sulfate should generally disintegrated to the fineness required for the fluidized-bed decomposing. This disintegration is suitably accomplished in hammer mills, impact mills or pinned disc attrition mills. The magnesium sulfate is then charged into a suspension-type, heat-exchanger, which is fed with the exhaust gases from the fluidized bed reactor and in which the magnesium sulfate is dewatered and/or pre-heated in conjunction with a cooling of the gases and through a separator is fed to the fluidized-bed reactor, which is operated at a temperature of about 900°-1200° C.
The solids then enter a fluidized-bed cooler, which comprises a plurality of separate cooling stages flown through in succession. In that cooler, the solids deliver heat in steps to the fluidizing air, which is thus heated. The heated air is then fed to the fluidized-bed reactor, where the heat content of the air is utilized in the decomposition step.
The heat required for the decomposition step is generated by an approximately stoichiometric combustion of fuel charged into the fluidized-bed reactor. The term "approximately stoichiometric" means that there should be no or only a slight excess of air.
The fuel may consist of the conventional fuel oil and/or fuel gas as well as of high-sulfur fuel oils and sulfur-containing distillation residues, i.e., products or waste materials which can otherwise be processed only with difficulty. Contrary to expectations it has been found that the sulfur-containing impurities of these fuels do not contaminate the product but enter the gas phase as sulfur dioxide.
Particularly owing to the approximately stoichiometric combustion and the heat economy (recycling of heat to the decomposition step) the exhaust gas produced in the decomposing step has a high concentration of sulfur dioxide.
In a preferred embodiment of the invention, the magnesium sulfate is decomposed in an expanded fluidized bed having a mean fractional voidage of ε>0.7, the solids are separated in a recycling cyclone and a major portion of the solids are recycled into the fluidized-bed reactor. For this purpose the fluidizing air is introduced into the fluidized-bed reactor at such a high velocity that the gases produced in the decomposing step and the solids form a highly expanded fluidized bed, in which the solids are highly agitated and all or a major portion of the solids are discharged with the gases. A major portion of the discharged solids are then recycled to the fluidized-bed reactor. The proportion of recycled solids may be selected so that the residence time is kept within the required range.
According to another desirable feature of the invention, the fluidized-bed reactor for decomposing the magnesium sulfate is supplied with part of the turbulencing air as secondary air above the inlet for the fluidizing air. In this embodiment the ratio of fluidizing air to secondary air should be in the range of approximately 1:2 to 5:1 and the fuel should be charged between the inlets for the fluidizing air and secondary air.
As a result of the supply of air in two component streams, the reactor volume is divided into a reducing lower zone disposed below the secondary air conduit and a neutral upper zone disposed over the secondary air conduit. The temperature in these zones is virtually the same owing to the intense circulation of solids in the fluidized-bed reactor. This practice affords the advantage that the decomposing takes place under reducing conditions, which are more favorable, and nevertheless the fuel is fully utilized as a result of the after-burning above the secondary air inlet.
In connection with decomposing reactions it is known to use an expanded fluidized bed, which is preceded by a suspension type-heat exchanger stage and succeeded by a fluidized-bed cooler. This practice is disclosed in U.S. Pat. No. 3,579,616.
Because certain sulfur losses are inevitable in the process, these losses are desirably compensated by the production of sulfur dioxide in the decomposing step. To this end, the rate at which sulfur dioxide is produced in the decomposing step should be sufficient for the production of the sulfuric acid required for leaching. If the conventional fuel oils and/or fuel gases are used as fuel or the waste fuel does not contain enough sulfur for the production of the additional sulfur dioxide required, additional elementary sulfur and/or hydrogen sulfide may be supplied.
The exhaust gas formed in the decomposing step is purified in conventional manner, e.g., by hot gas filters, by an electrostatic purification of gas, by Venturi-tube scrubbers, and by wet-type electrostatic precipitators for fine purification, and is then catalytically processed to form sulfuric acid.
The invention will be explained more fully and by way of example with reference to the flow scheme and the example.
The leaching stage 1 is supplied with magnesium-containing carbonate ore through conduit 7, sulfuric acid through conduit 8, and water through conduit 9 and, if desired, conduit 27. After the treatment has been carried out for a sufficiently long time and surplus sulfuric acid has been neutralized with magnesia, an insoluble residue is removed through conduit 10. The magnesium sulfate solution flows through conduit 11 to the pressure crystallisation unit 2, from which water vapor-laden exhaust gases are withdrawn through conduit 12. The mother liquor is filtered and then recycled through conduit 13 to the leaching stage 1. The cooled magnesium sulfate crystals contain 1.5-4 moles of water of crystallization and are disintegrated to the fineness required in a fluidized bed and in conduit 14 are then fed to the decomposing unit 3, which is fed with fuel oil through conduit 15, air through conduit 16, and elementary sulfur through conduit 17. The hot magnesia leaves the decomposing unit 3 through conduit 18 and in the fluidized-bed cooler 19 is cooled by a heat exchange with air supplied through conduit 20, and is discharged at 21. The heated air flows through the above-mentioned conduit 16 into the decomposing unit 3.
The exhaust gas which has been formed in the decomposing step and which is used for pre-dewatering and/or preheating is fed through conduit 22 to a gas purifier 4, in which water and dust are removed. Dust is discharged through conduit 23. The condensed water may contain small amounts of sulfuric acid and flows through conduit 24 first to the washing unit 6, in which the filter residue is washed, which has been withdrawn through conduit 10 from the leaching stage 1. The water is then recycled through 9 into the leaching stage 1. The washed filter residue is discharged through 26 and discarded.
The gas which contains sulfur cioxide is fed through 25 to the sulfuric acid-producing plant 5 and is converted therein into sulfuric acid, which is recycled through conduit 8 to the leaching stage 1.
EXAMPLE
The leaching stage 1 is fed through conduit 7 at a rate of 2.3 metric tons per hour with raw magnesite having the following composition by weight:
80% MgCO 3
4% caCO 3
2% fe 2 O 3
14% acid-insoluble matter,
particularly silicates and is fed through conduit 8 with concentrated sulfuric acid at a rate of 2.05 metric tons per hour (calculated as 100% acid). The leaching stage 1 is also fed through conduits 9 and 13 with washing water from the washing unit 6, at a rate of 1.22 metric tons per hour, and with mother liquor from the pressure crystallization unit 2 at a rate of 3.45 metric tons per hour (0.65 metric ton magnesium sulfate and 2.8 metric tons water per hour). Additional water at a rate of 0.58 metric ton per hour is fed through conduit 27.
After a leaching treatment at 80° C for 2 hours, the slurry is neutralized with magnesia, and solids at a rate of 0.65 metric ton per hour are withdrawn through conduit 10, washed in the washing unit 6 with water at a rate of 1.22 metric tons per hour, and finally discharged through 26.
At a rate of 8 metric tons per hour (consisting of 3.04 metric tons magnesium sulfate and 4.96 metric tons water per hour) the solution is fed at 80° C through 12 into the pressure crystallization unit 2. At a temperature of 210° C, corresponding to a pressure of 18 kg/cm 2 above atmospheric pressure, water vapor-laden exhaust gases at a rate of 1.26 metric tons per hour are withdrawn through 12 and mother liquor at a rate of 3.45 metric tons per hour is withdrawn through 13. The filter residue obtained at a rate of 3.29 metric tons per hour is cooled to form hydrated magnesium sulfate at the same rate. The magnesium sulfate produced per hour consists of 2.39 metric tons of anhydrous magnesium sulfate and 0.9 metric ton of water of crystallization, corresponding to a content of 2.5 moles water of crystallization.
When the material has been ground to the fineness of 100% below 1 mm which is required in a fluidized bed, the material enters the decomposing unit 3, which consists of a suspension-type-heat-exchanger and a fluidized-bed reactor. Initially, in the suspension-type-heat-exchanger, the magnesium sulfate is dewatered and preheated by the exhaust gases from the fluidized-bed reactor, which are at 1130° C and by said treatment are cooled to 350° C. The pre-dewatered and heated magnesium sulfate then enters the fluidized-bed reactor, which is operated at 1130° C and is fed with air at a rate of 4000 standard cubic meters per hour, fuel oil at a rate of 0.45 metric ton per hour, and elementary sulfur at a rate of 23 kg/h. The air is used as fluidizing air and secondary air in equal parts. The magnesia which has been formed in the fluidized-bed reactor enters the fluidized-bed cooler 19, in which it is cooled to 130° C as it flows in a cross- and countercurrent to the fluidizing air and the air which is to be indirectly heated. The air streams leaving the fluidized-bed cooler have been heated therein to 400° C (fluidizing air) and 120° C (indirectly heated air) and are fed to the fluidized-bed reactor as secondary air and as fluidizing air.
Exhaust gases at 350° C leave the suspension-type-heat-exchanger stage of the decomposing unit 3 at a rate of 4500 standard cubic meters dry gas per hour and have the following composition by volume:
N 2 : 71.5%
co 2 : 15.9%
so 2 : 10.5%
o 2 : 2.1%
they flow through conduit 22 into a gas purifier 4, in which water is separated at a rate of 1.22 metric tons per hour. The water is recycled into the leaching stage 1 through conduit 24 and washing unit 6. The sulfur dioxide-containing, purified gas at 40° C is fed through 25 into the sulfuric acid plant 5, in which sulfuric acid is recovered at the rate of 2.05 metric tons per hour which is required in the leaching stage 1. | This invention relates to a process of producing magnesia from magnesium-containing carbonate ores, which comprises leaching with sulfuric acid, subsequently neutralizing the solution with magnesia, separating the undissolved impurities, crystallizing magnesium sulfate under pressure and above 150° C so the crystals have from 1.5 to 4 moles of water per magnesium sulfate molecule and thermally decomposing the latter to form magnesia and SO 2 , recovering sulfuric acid from the sulfur dioxide produced in the decomposing steps and recycling the sulfuric acid to the leaching stage. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a semiconductor device manufactured by molding an element such as a semiconductor integrated circuit mounted on a lead frame with resin, and to a manufacturing method for the lead frame.
[0003] 2. Description of the Related Art
[0004] A semiconductor device in which an element such as a semiconductor integrated circuit mounted on a lead frame is molded with resin is generally mounted onto a circuit board for use. In order to ensure sufficient mounting strength between the semiconductor device and the circuit board, leads of the semiconductor device are elongated to enlarge soldering area. Though solder wettability in a cut surface of leads of the semiconductor device, conventionally, has not been kept in good condition, large soldering area and Z-shaped forming of the leads make the solder wettability not only in both ends of the lead but also in heel portions of the leads good, permitting the solder to go up along the leads. Accordingly, a sufficient mounting strength can be ensured.
[0005] Large soldering area ensures mounting strength. However, along with the miniaturization of a semiconductor device, the mounting strength against a circuit board tends to be lower. Because increase in mounting density requires reduction both in lead area with which the semiconductor device is bonded to the circuit board, and in electrode area locating on a circuit board side. Solder is mainly used to mount a semiconductor device to a circuit board, and the mounting strength changes widely depending on whether or not the lead of the semiconductor device becomes wet easily with the solder. When the temperature of the solder reaches the melting point by reflow or the like, the solder melts together with plating covering the lead of the semiconductor device. At this time, formation of the plating on the entire lead surface of the semiconductor device is desirable, because a portion where plating is absent does not become wet by the solder and will have low strength. The smaller the semiconductor device is, the less the strength between the lead of the semiconductor device and the electrode of the circuit board becomes when bonded only with the solder. It is, thus, necessary to ensure an area which becomes wet with the solder as much as possible. In particular, the solder wettability is important in a lead-tip portion of the semiconductor device. This is because the lead-tip portion is apt to be affected by influence such as warpage of the circuit board when the semiconductor device is mounted onto the circuit board.
[0006] FIG. 6 is a schematic cross-sectional view showing a structure of a conventional semiconductor device. As shown in FIG. 6 , in the conventional semiconductor device, a formed lead 2 protrudes from a resin 21 . The lead 2 is covered by a plating layer 3 except a lead-tip end surface 12 in a lead-tip cut portion 10 made by cutting the lead 2 . The presence of the lead-tip end surface 12 deteriorates the wettability to a soldering material, which serves as a bonding agent at the time of mounting onto a circuit board or the like.
[0007] FIG. 7 is a simplified side view showing a structure of a conventional semiconductor device in a manufacturing process step. As shown in FIG. 7 , a lead 2 , which is also a portion of a lead frame connecting two resins 21 and 31 , has a uniform cross-section. When the lead frame having such a structure is cut and the semiconductor devices are separated from one another, the lead-tip end surface 12 as shown in FIG. 6 is formed.
SUMMARY OF THE INVENTION
[0008] In order to firmly bond a lead of a semiconductor device with an electrode of a circuit board, there is provided a semiconductor device having a lead in which plating covers entirely a lead-tip portion of the semiconductor device as means for improving solder wettalibity in the lead of the semiconductor device. Further, as another means, there is provided a semiconductor device having a lead in which an area of a lead-tip cut portion on which plating is not formed is less than half of a cross-sectional area of the lead of the semiconductor device.
[0009] According to the present invention, a molten soldering material melted by heat generated in reflow goes up the lead to the upper surface thereof, whereby mounting strength to a circuit board can be improved without enlarging the lead area of the semiconductor device. Further, it is possible to improve strength with respect to warpage or the like of the circuit board on which the semiconductor device is mounted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the accompanying drawings:
[0011] FIG. 1 is a schematic cross-sectional view showing a first embodiment of a semiconductor device according to the present invention;
[0012] FIG. 2 is a schematic cross-sectional view showing a second embodiment of the semiconductor device according to the present invention;
[0013] FIG. 3 is a schematic plan view showing the first embodiment of a lead frame according to the present invention;
[0014] FIG. 4 is a schematic plan view showing the second embodiment of the lead frame according to the present invention;
[0015] FIG. 5 is a schematic side view partially showing the lead frame according to the present invention;
[0016] FIG. 6 is a schematic cross-sectional view showing a structure of a conventional semiconductor device;
[0017] FIG. 7 is a schematic side view partially showing a conventional lead frame;
[0018] FIG. 8 is a schematic side view showing a third embodiment of the semiconductor device according to the present invention; and
[0019] FIG. 9 is a schematic cross-sectional view showing the third embodiment of the semiconductor device according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Hereinafter, embodiments of a semiconductor device according to the present invention will be described with reference to the drawings.
[0021] FIG. 1 is a schematic cross-sectional view showing a structure of a semiconductor device of a first embodiment of the present invention. The semiconductor device includes a resin 1 , a lead 2 , and a metal plating layer 3 covering the surface of the lead 2 . Since elements including a semiconductor integrated circuit (IC chip) are covered by the resin 1 , the elements can not be seen from outside thereof generally. One end of the lead 2 is electrically connected to the semiconductor integrated circuit inside the resin 1 , and another end thereof protrudes from the resin 1 . The protruding portion of the lead 2 is formed into a shape suitable for mounting onto a substrate by the use of a die or the like. The plating layer 3 is formed on the entire surface of a portion of the lead 2 which is exposed to the outside of the resin 1 . In the embodiment shown in FIG. 1 , the plating layer 3 covers a lead-tip portion 4 of the lead 2 at an end portion thereof so that no surface of the lead is exposed to the outside.
[0022] FIG. 2 is a schematic cross-sectional view showing a structure of a semiconductor device of a second embodiment of the present invention. In the embodiment shown in FIG. 2 , the lead-tip portion of the lead 2 has a portion covered by the plating layer 3 , and a lead-tip end surface 5 not covered by the plating layer 3 . A cross-sectional area of the lead-tip end surface 5 is made smaller than a half of the cross-sectional area of the lead 2 . Consequently, at the time of mounting the semiconductor device onto a circuit board or the like, it is easy for a soldering material to wet the plating layer, permitting the solder to go up the lead-tip portion to form a rigid mounting state.
[0023] FIG. 3 shows a first embodiment of a lead frame according to the present invention, that is, shows an aggregate in which a plurality of semiconductor devices are arranged on a single lead frame 20 . A lead 8 of each of the semiconductor devices is connected to another lead 8 by a plating bar 7 , and the plating bar 7 is joined to a side surface of the lead 8 and to a flame 6 . The plating bar 7 is a path for electric current at a time of performing electrolytic plating on a lead frame 20 . With the structure in which the plating bar 7 is joined to the side surface of the lead 8 , the semiconductor device whose lead-tip portion 4 is entirely covered by the plating layer 3 can be manufactured as shown in FIG. 1 .
[0024] FIG. 4 shows a second embodiment of the lead frame according to the present invention, that is, shows an aggregate in which a plurality of semiconductor devices are arranged on a single lead frame 20 . In this embodiment, a lead 8 of each of the semiconductor devices is extended to form a plating bar 9 and joined to a frame 6 . The plating bar 9 is a path for electrical current at a time of performing electrolytic plating on the lead frame 6 . A portion where the plating bar 9 is joined to the lead 8 becomes a cut surface after cutting the lead 8 later, and plating is not applied to the portion. Accordingly, it is desirable that the cross-sectional area of the plating bar 9 is smaller than a half of the cross-sectional area of lead 8 , and is even finer and thinner as much as possible.
[0025] FIG. 5 is a side view of a semiconductor device according to the second embodiment of the present invention and shows an intermediate state of a manufacturing process step in which two adjacent semiconductor devices 21 and 31 are connected to each other by a lead frame. As shown in FIG. 5 , in this embodiment, a lead frame thin portion 11 is formed in a lead frame 2 . Cutting the lead frame thin portion 11 between the semiconductor devices to separate from one another, the semiconductor device having the structure of the embodiment shown in FIG. 2 can be obtained.
[0026] FIG. 8 is a side view of the semiconductor device according to a third embodiment of the present invention and shows an intermediate state of a manufacturing process step in which two adjacent semiconductor devices are connected to each other by a lead frame. As shown in FIG. 8 , in this embodiment, a lead frame thin portion 11 is formed in a lead frame 2 . The lead frame thin portion 11 locates on a lower surface side where the semiconductor device is mounted onto a circuit board. Cutting the lead frame thin portion 11 between the semiconductor devices to separate from one another, a semiconductor device having the structure of the third embodiment shown in FIG. 9 can be obtained. With this structure, the upper surface of the lead is easy to become wet with the solder printed on the circuit board.
[0027] In a forming method of the lead frame thin portion 11 , at first a lead frame is cut into a desired shape by using a press die and then partial processing continues. As the partial processing, there are a method of forming a thin portion through etching by using chemicals, a method of performing a local crushing processing through press working, and other methods.
[0028] Finally, manufacturing process steps are schematically described. A semiconductor integrated circuit (IC chip) is bonded to a lead frame to make connection between the semiconductor integrated circuit and each lead by a wire. Next, the semiconductor integrated circuit is covered by a resin. Up to this process step, embodiments shown in FIGS. 3 and 4 are obtained. Then, plating is performed and a portion other than the resin is covered by film of plating. Further, the lead frame is cut by using a die or the like to separate the semiconductor devices from each other.
[0029] The semiconductor device according to the present invention can be widely used for products that are required to be small and light, such as mobile phones, laptop personal computers, and mobile electronic equipment. | Provided is a semiconductor device having an element covered with a resin mold and a metal lead protruding from the resin mold in which a lead-tip portion thereof is entirely covered by solder plating and in which a lead-tip end surface, which is not covered by solder plating, has an area less than half of a cross-sectional area of the metal lead, whereby solder wettability of the metal lead is improved and a bonding strength to a circuit board is also improved. | 8 |
FIELD OF THE INVENTION
The present invention relates to material compactors especially for waste or recyclable materials, and more particularly relates to compactors which may be transported by a truck, trailer or other vehicle for the purpose of compacting recyclable materials for subsequent transportation of the compacted recycled materials.
BACKGROUND OF THE INVENTION
Recycling programs may result in the collection, at collection stations, of sorted or unsorted recyclable materials, including, for example, plastic beverage bottles, aluminum beverage cans, and other recyclable materials (hereinafter collectively referred to as “recyclable materials” unless otherwise specifically indicated). In some cases, the recyclable materials are sorted at the collection stations and thereafter temporarily stored in large compressible containers such as fabric bags, in which, for example, between 1000 and 2000 beverage bottles or beverage cans can be temporarily stored, for subsequent transportation to a processing facility factory. In some cases, it may be necessary to transport collected recyclable materials a significant distance from the collection stations. However, as the recyclable materials may contain large volumes of air (for example, the volume of air in an empty plastic beverage bottles or empty aluminum beverage cans), when transporting and subsequently storing these recyclable materials, there may be significant inefficiencies and waste associated with the transporting and storing processes, as these large volumes of air are transported and stored.
It is desirable to have a portable compactor which may be transported to or installed at one or more of the collection stations, which may be utilized to receive the containers, e.g. the fabric storage bags filled with sorted recyclable materials, and thereafter compact the filled containers (and the contents thereof) and thereafter transport (and, where appropriate and/or desirable, store) the compacted recyclable materials and containers for subsequent processing of the recyclable materials. Preferably the compactor may be carried by a truck or trailer vehicle.
PRIOR ART
Compactors and balers for trash or waste material are well known. Typically these are loaded from the top, e.g. through a hopper, and have a hydraulic cylinder which moves horizontally in a compaction chamber to compress the trash. The trash may be compacted against a door which can be slid open when sufficient compaction has taken place, or may it may be compacted against a discharge channel which has converging walls, sometimes termed a “size reduction chamber”. In the latter case, it is usual for the compacting ram to have teeth at its forward end for the purpose of breaking up large pieces of material in the compaction chamber; such designs are shown for example in:
U.S. Pat. No. 3,541,949, issued Nov. 24, 1970 to Clar, and U.S. Pat. No. 4,134,335, issued Jan. 16, 1979 to O'Rourke, et al.
The need for teeth on the ram in these compactors has been noted as a drawback, since the teeth become worn and need replacement.
In some compactors or baling machines the compaction is done in two stages, by first and second hydraulic rams operating successively along directions perpendicular to each other. Such a design for example is shown in U.S. Pat. No. 5,203,261, issued Apr. 20, 1993 to Davis. This patent is concerned with compacting cans and similar articles for recycling; like many designs it is fed from the top, and the two mutually perpendicular rams act horizontally. Designs of this type, with two mutually perpendicular, horizontal rams, occupy considerable floor space, more than is desirable in a compactor intended to be carried by a vehicle. Also, the Davis design uses a slidable door against which to perform the second stage compaction; this slidable door requires its own hydraulic cylinder and this increases the expense and complexity of the apparatus.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a recyclable materials compactor which is of relatively simple form and which is compact enough to be carried in a vehicle.
The apparatus may make use of size reduction chamber for a second stage of compaction, but does not require the use of teeth on the compacting ram since the material being compacted can be separated into distinct batches by having been placed into bags or other compressible containers, which can be fed singly to the apparatus.
In accordance with this feature of the invention, the method of compacting waste material comprises:
placing said material in compressible containers such as bags, loading a single such filled container into a compaction chamber in compaction apparatus via a side inlet, compressing said container in a first direction by means of a first ram communicating with said chamber, further compressing said container in a second direction by means generally perpendicular to the first direction by means of a second ram while simultaneously ejecting said container via a size reduction chamber.
As indicated, in this method, unlike in the type of garbage compactor described by Clar or O'Rourke et al., the ram which moves the material into the size reduction chamber has no cutting teeth and needs none.
The containers are preferably loaded into the side of the compaction chamber, rather than into the top as is common with trash compactors. This of course means less lifting for the operators. It also allows the first ram to operate vertically, thus saving floor space, as compared for example to the Davis patent and other similar designs with mutually perpendicular, horizontal rams. A special feature of the invention is the means which allow the second ram, which acts horizontally, to have a good range of travel and yet to occupy little space in an inoperative condition when the vehicle is loaded and ready for travel.
In accordance with this latter feature of the invention, in apparatus suitable for use in a vehicle for compacting waste, including a base which carries the compaction chamber and which has a horizontally operating compaction ram movable in said chamber and a hydraulic cylinder for moving the horizontally movable ram, said cylinder has its outer end carried by a frame which has a first pivotal connection to the base allowing the cylinder to pivot 90° from a horizontal orientation up to a vertical orientation. The piston rod of the cylinder is connected to the horizontally operating ram by a second pivotal connection which is aligned with the first pivotal connection when the compaction ram is in a withdrawn position relative to the compaction chamber. In the preferred apparatus described, having also a vertically operating ram for giving a first stage compaction, this arrangement allows the second, horizontally operating ram to be folded vertically close to the vertically operating ram when the compaction apparatus is in inoperative condition for traveling. When folded out into the operative condition for loading the vehicle, the horizontally operating ram can project out of the rear door of the vehicle.
As indicated, the ram giving the first stage of compaction preferably operates vertically. To reduce the height of the hydraulic cylinder means needed for this first, vertically operating ram, such cylinder means may be inclined at an angle to the vertical. In the initial position, with the first ram raised, the cylinder means may be at an angle of more than 30° to the vertical; this angle reduces when the cylinder is extended. The fact that this cylinder means is providing much less than its maximum downwards force in the first stage of its action is unimportant since the compaction force needed at this stage is not as high as in the later stages. Preferably, these cylinder means comprises two cylinders symmetrically arranged so that the horizontal components of force which they apply to the first operating ram are balanced. The ram itself is in the form of a carriage having rollers which move along vertical guideways extending up from the corers of the compaction chamber.
The apparatus also includes means for tying the compacted containers; this however is not part of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention is described below with reference to the accompanying drawings, in which:
FIG. 1 is an isometric view of the apparatus of the present invention in the stored position;
FIG. 2 is a view of the same apparatus in the operative condition, with entry doors removed, with compaction rams retracted, and with the chamber holding an uncompressed container;
FIG. 3 is a similar view of the apparatus with the container having been vertically compacted;
FIG. 4 is a view of the apparatus with no container in place, and showing the rear part of the apparatus;
FIG. 5 is a view of the vertically operating carriage component which constitutes the first ram;
FIG. 6A is an enlarged rear isometric view of the means for supporting the second ram, and a portion of the second ram and its connection to the operating cylinder, with the latter cylinder in its inoperative position;
FIG. 6B is a cross-section view of one embodiment of a horizontally mounted grooved roller of one embodiment of the present invention, and
FIG. 7 is a view of a base component of the apparatus showing support means for the second, horizontally operating ram.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2 , a compactor apparatus, generally shown as 2 , has a base member assembly 4 which is separately illustrated in FIG. 7 , and which may be bolted or otherwise securely mounted to the floor of, for example, a truck or trailer (not shown). The apparatus has an the ejection ram assembly, generally shown as 10 , which in FIG. 1 is in the vertical storage position; as illustrated in FIGS. 2 , 3 and 4 this ejection ram assembly is in the horizontal operative position. Mounting means for this ram assembly will be described below with reference to FIGS. 4 , 6 and 7 .
As illustrated in FIGS. 2 to 4 the apparatus has a compaction chamber 12 , which as illustrated in FIG. 1 has doors 14 which open to provide a side inlet through which a fabric storage bag 20 filled with recyclable material may be inserted into the compaction chamber 12 , the doors 14 thereafter being securely fastened in the closed position (illustrated in FIG. 1 ) during the compaction phase described hereinafter. One end wall of the compaction chamber 12 is formed by the face 22 of the ejection ram 24 best seen in FIG. 4 , details of which will be described with reference to FIG. 6 . As seen in FIG. 4 , an opening 26 is provided in the lower portion of the end wall 28 of the compaction chamber opposite the ejection ram assembly 24 , the opening 26 providing a passageway to an exit chamber 30 as more fully described herein.
A vertically acting compaction ram 32 having a lower face plate 32 a initially positioned above the compaction chamber 12 , is provided. This ram 32 moves within a structure which includes vertical corner members 34 supporting opposed end walls 28 and 35 of an upper part of the compaction chamber 12 , a closed side face 36 , and the side doors 14 . At front and rear of the central part of the apparatus the upper ends of members 34 support triangulated brackets 37 the apices 37 a of which provide firm anchors for the outer ends of double acting hydraulic cylinders 38 , the lower ends of which cylinders are attached to the ram 32 , as described more fully below. The compaction ram 32 can be lowered by the two double-acting hydraulic cylinders 38 to come into contact with the fabric storage bag or container 20 filled with recyclable material positioned within the compaction chamber 12 . Further lowering of the ram 32 compacts the fabric storage bag 20 to a desired height, as shown in FIG. 3 . Once the lower face plate 32 a of the compaction ram is at or below the level of the top of opening 26 in the end wall 28 wall of the compaction chamber, the compaction ram 32 is maintained in that compacting position. Thereafter, the horizontal ejection ram 24 is activated and extended, pushing the compacted fabric storage bag filled with now compacted recyclable materials through the opening 26 in the wall 28 and into the exit chamber 30 .
In the preferred embodiment of the present invention, the walls of the exit chamber 30 are, over their length, each gently angled inwardly a short distance of approximately one half inch to reduce the width of the chamber by about one inch over its length to produce a gently tapered narrowing exit passageway through the exit chamber, (it being understood that a range of angles and width narrowing distances are possible in alternative embodiments of the present invention and that in an alternative embodiment of the present invention, the amount of angling and width narrowing distance may be adjustable). The inwardly angled/tapered walls constitute a size reduction chamber and thus provide some resistance to the movement of the compacted fabric storage bag 20 therethrough. After each compacted fabric storage bag has been pushed into the exit chamber 30 by the ejection ram 24 , it will remain in the exit chamber until expelled/pushed therefrom by the force applied thereto by the arrival of the next compacted fabric storage bag which is being forced through the opening 26 and into the exit chamber 30 . In this way, the force applied on this next compacted fabric storage bag by the ejection ram is partially opposed by the resistance of the previously processed fabric storage bag wedged in the exit chamber 30 , the ejection ram being able to overcome this resistance and forcing the most recently compacted fabric storage bag into the exit chamber 30 while at the same time moving the immediately previously processed fabric storage bag along the exit chamber 30 until it is expelled therefrom. In this way, the compacted shape and configuration of each processed fabric storage bag may be established.
As indicated above, the apparatus is designed to minimize both the height and length of the apparatus, as compared to what would be expected for conventional apparatus having both vertically and horizontally operating rams.
As seen in FIG. 5 , the vertically operating compaction ram 32 is formed as a horizontal rectangular face plate 32 a with stiffening side ribs 32 b , and stiffening cross ribs 32 c . At each corner the ribs support open vertical hollow structural tube members 40 with coped ends which are each provided with upper and lower rollers 42 , which rollers move in tracks provided on the inner facing surfaces of corner members 34 . The cross ribs 32 c support a central block 44 the opposed ends of which provide anchor points for the piston rods of cylinders 38 . Accordingly the cylinders 38 slope inwardly from the apices of the brackets 37 to the central block 44 of the ram 32 . When the ram 32 is in its uppermost position, as in FIG. 1 , the cylinders 38 slope at an angle of slightly more than 30° to the vertical (as seen from the side of the apparatus), thus reducing the height compared to what would be needed with conventional vertical cylinders. This slope reduces the downwards force which is applied to the ram, as compared to the force which would be given by vertical cylinders; however the reduction occurs mainly in the initial stages of compression, when comparatively little force is required; when fully extended the cylinders are within about 10° of the vertical.
FIGS. 4 , 6 A and 7 show how the ejection ram assembly 10 is pivotally mounted to the base member 4 so as to be pivotable (as illustrated by the arrow in FIG. 4 ) from the operative position of FIGS. 2 to 4 into the vertical storage position of FIG. 1 by means of double acting hydraulic pivoting cylinder 48 which is securely and pivotally attached 48 A, for example, to a cross-member 48 B and securely and pivotally attached 48 C for example, to the one side of the frame member 78 .
FIG. 6A shows details of the ejection ram 24 and its mounting means. The front face 22 of the ram 24 (seen in FIGS. 2 and 3 ) is provided by a rectangular plate 50 provided with vertical stiffening members 52 , which are in turn supported by upper and lower horizontal plates 54 and 56 and by outer vertical brackets 58 which connect the horizontal plates 54 and 56 and have their inner edges attached to members 52 . A further, intermediate, horizontal plate 60 connects vertical brackets 58 to a pair of inner vertical brackets 62 , having a connection to the ejection ram cylinder as will be described.
The lower horizontal plate 56 carries, at each of its four corners, a short vertical axle which rotatably supports a grooved roller 66 ; these grooved rollers movably engage inwardly projecting flanges of parallel rails 68 , which run along front and back sides of the bottom of the compaction chamber, being carried by base 4 . This roller and rail combination allows the ejection ram 24 to have relatively frictionless movement along the compaction chamber. In an alternative embodiment of the present invention, as illustrated in FIG. 6B , each of the grooved rollers 66 are rotatably supported by a short horizontal axle 98 , each of the grooved rollers 66 being movably engaged with parallel rails 68 in secure engagement with and supported by the base and the parallel rails 68 extending along the length of travel of the ejector ram, thereby supporting and positioning the ejector ram as it is extended and retracted (in this embodiment, as illustrated in FIG. 6B , inverted lengths of angle material welded or otherwise securely fastened to the base may be used to provide the parallel rails 68 ).
As also shown in FIG. 6A , the inner vertical brackets 62 have rear ends which carry a horizontal shaft 70 which provides a pivot connected to the piston rod of double-acting hydraulic cylinder 72 . FIGS. 6A and 7 also show fixed support brackets 74 extending upwards from the base assembly 4 ; as shown in FIG. 4 these brackets have a pivotal connection at 76 to frame members 78 constituting part of the ejector ram assembly 10 . The outer ends of members 78 hold the outer end of the ejector cylinder 72 by means of a pin (not shown) spanning the members 78 proximate the cross member closure plate 78 a about which pin a pivot sleeve (not shown) is positioned which is securely attached to the ejector cylinder 72 . The arrangement is such that when the ejector ram 24 is fully withdrawn, as in FIG. 6 , the pivot 70 is aligned with the pivotal connection 76 , so that in this situation the ejector ram assembly 10 , including frame 78 and the cylinder 72 , can be pivoted from the horizontal position to the vertical position by the pivoting cylinder 48 . As seem in FIG. 1 , this brings the ejector ram assembly 10 close to the main structure formed by the corner members 34 ; the height of the ejector ram assembly is then slightly less than the height of the main structure. In practice, this allows the ram assembly 10 to project out of the back of a vehicle in which it is mounted when the vehicle is being loaded, and to be folded clear of the rear doors of the vehicle for traveling.
In the preferred embodiment of the present invention, the compacted fabric storage bag may be securely bound in the compacted state by binding the compacted bag with wire, plastic or other banding material. For this purpose spools of banding material 80 and 82 are mounted respectively on the rear and front of the apparatus, outside the rear and front end walls 28 and 35 as illustrated in FIGS. 1 to 4 , which spools supply banding material which passes over pulleys 84 , 86 , and 51 shown in FIGS. 1 , 2 and 6 A respectively, subsequently being wrapped around the compacted fabric storage bag and thereafter securely fastened to maintain the compacted fabric storage bag in the compacted position. The means for feeding the banding material includes hollow steel tubes 55 (through which the banding material may freely pass) positioned beneath inverted lengths of angle material 53 welded or otherwise securely fastened to the base as shown in FIG. 7 and includes vertically movable carriages 88 movable by hydraulic cylinders 90 such as shown in FIG. 3 , which carriages carry probes for taking the banding material down to tying means (not shown) incorporated in the base 4 and positioned beneath holes 57 in the base through which holes 57 the binding material supplied by way of the probes and by way of the hollow steel tubes pass for tying. However, these tying means are not part of the present invention, and may be conventional, such as have been used for many years in the tying of hay bales.
The hydraulic cylinders referenced herein may be operated manually, or automatically to provide for the movement of the components described herein, it being understood that alternative mechanical, hydraulic or electrical components may be used as required or desired to achieve the above-described movement of the components described herein.
In one embodiment of the present invention, the compactor may be powered by the truck, trailer or other vehicle on which it is installed, it being understood that in an alternative embodiment of the present invention, it may be temporarily or permanently installed in a fixed location, such as at a depot or redemption centre where materials for recycling may be collected for subsequent transportation.
The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein. | A compactor comprising a base structure having a compaction chamber mounted thereto is provided. The compactor further comprises a ram which is horizontally movable through the compaction chamber between a withdrawn position and an extended position. An actuator is pivotally movable mounted to the ram at a first end portion. The actuator moves the ram from the withdrawn position to the extended position. An actuator frame is pivotally movable mounted to the base structure at a first end portion such that the pivot of the actuator frame is aligned with the pivot of the actuator when the ram is in the withdrawn position. A second opposite end portion of the actuator is mounted to a second opposite end portion of the actuator frame. The actuator frame is movable between a transport position where the actuator is oriented substantially vertical and an operating position where the actuator is oriented substantially horizontal. | 1 |
FIELD
[0001] The present disclosure relates to a mounting arrangement for an exhaust system of a vehicle. More particularly, the present disclosure relates to an exhaust isolator which is mounted directly to a vehicle's frame or underbody, thus eliminating the need for brackets, bolts, welded frame nuts, clipped in frame nuts or the like.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] Typically, automotive vehicles, including cars and trucks, have an internal combustion engine which is coupled to at least a transmission and a differential for providing power to the driven wheels of the vehicle. An engine exhaust system which typically includes an exhaust pipe, a catalytic converter, a muffler and a tail pipe is attached to the engine to quiet the combustion process, to clean the exhaust gases and to route the products of combustion away from the engine. The exhaust system is supported by exhaust mounts or isolators which are positioned between the exhaust system and the frame, the underbody or some other supporting structure of the vehicle's body. In order to prevent engine movement and/or vibrations from being transmitted to the vehicle's body, the exhaust mounts or isolators incorporate flexible mounting members or elastic suspension members to isolate the vehicle's body from the exhaust system.
[0004] Typical prior art exhaust mounts or isolators include an upper hanger which is attached to the vehicle's frame or other support structure of the vehicles' body. The upper hanger extends from the support structure such that it positions an elastomeric isolator at the proper location to accept a lower hanger which extends from the elastomeric isolator to one of the exhaust system's components. The elastomeric isolator is secured in a specific location between the upper hanger and the lower hanger. Typically, the upper hanger includes assembly hardware such as stamped brackets, bolts, welded frame nuts, clip-in frame nuts and/or formed rods which are utilized to secure the upper mount to the frame or other supporting structure and to secure the elastomeric isolator to the upper mount. This hardware increases the costs and the amount of labor necessary for the construction and assembly of the vehicle.
SUMMARY
[0005] The present disclosure describes an engine mount or isolator which is mounted directly to the vehicle's frame or other supporting structure of the vehicle's body. The direct attachment of the exhaust mount or isolator eliminates the need for the upper hanger and all of the associated hardware. The exhaust mount or isolator can be fit directly within an aperture formed in the support structure. The elastomeric portion of the exhaust mount or isolator includes a hole which accepts a support rod or lower hanger which is attached to a component of the exhaust system. The support rod or lower hanger can be formed to position the component of the exhaust system in the desired location. The exhaust mount or isolator includes a push and turn mounting system which simplifies assembly of the exhaust mount or isolator to the vehicle.
[0006] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0007] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
[0008] FIG. 1 is a perspective view of an exhaust system attached to a supporting structure of a vehicle with exhaust isolators in accordance with the present disclosure;
[0009] FIG. 2 is an enlarged perspective view of one of the exhaust isolators illustrated in FIG. 1 ;
[0010] FIG. 3 is a perspective view of the exhaust isolator illustrated in FIGS. 1 and 2 ;
[0011] FIGS. 4A-4C are perspective views illustrating the assembly of the exhaust isolator of the present disclosure;
[0012] FIGS. 5A-5B are perspective views partially in cross-section illustrating the inserts in the exhaust isolator of the present disclosure;
[0013] FIG. 6 is a perspective view in cross-section illustrating the exhaust isolator of the present disclosure;
[0014] FIG. 7 is a front perspective view of the inserts of the exhaust isolator of the present disclosure;
[0015] FIG. 8 is a rear perspective view of the inserts of the exhaust isolator of the present disclosure; and
[0016] FIG. 9 is an end view of the exhaust isolator in accordance with the present disclosure illustrating an orientation feature of the exhaust isolator.
[0017] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0018] Example embodiments will now be described more fully with reference to the accompanying drawings.
[0019] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. There is shown in FIG. 1 , an exhaust mounting system in accordance with the present disclosure which is identified generally by the reference numeral 10 . Exhaust mounting system 10 attaches an exhaust system 12 to a supporting structure 14 of a vehicle. The vehicle includes an internal combustion engine (not shown), an unsprung mass including wheels and a suspension system (not shown) and a sprung mass which includes a vehicle body (not shown) which is supported by supporting structure 14 . Exhaust system 12 is connected to the engine of the vehicle and exhaust system 12 routes the products of combustion of the engine to the rear of the vehicle. The internal combustion engine powers the wheels of the vehicle through a transmission (not shown) and a differential (not shown).
[0020] Exhaust system 12 comprises an intermediate pipe 22 , a muffler 24 , a tailpipe 26 and a plurality of exhaust isolator assemblies 30 . Intermediate pipe 22 is typically connected to a catalytic converter (not shown) which is connected to an exhaust pipe (not shown) which is in turn connected to an exhaust manifold (not shown) which is one of the components of the vehicle's internal combustion engine. The catalytic converter may be connected to a single exhaust pipe which leads to a single exhaust manifold or the catalytic converter can be attached to a branched exhaust pipe which leads to a plurality of exhaust manifolds. Also, intermediate pipe 22 can be connected to a plurality of catalytic converters which connect together prior to reaching muffler 24 using a branched intermediate pipe 22 or the vehicle can have a plurality of exhaust manifolds, connected to a plurality of exhaust pipes, connected to a plurality of catalytic converters, connected to a plurality of intermediate pipes, connected to a plurality of mufflers, connected to a plurality of exhaust pipes. The present disclosure is applicable to the above described exhaust systems as well as any other exhaust system known in the art.
[0021] Exhaust system 12 is utilized to route the exhaust gases from the vehicle's engine to the rear area of the vehicle. While the exhaust gases travel from the engine to the rear of the vehicle through exhaust system 12 , the catalytic cleaner cleans the exhaust gases and muffler 24 quiets the noises associated with the combustion process of the vehicle's engine. Exhaust isolator assemblies 30 provide for the support of exhaust system 12 underneath the vehicle and they operate to prevent engine movement and other vibrations from being transmitted to the vehicle's body. In addition, exhaust isolator assemblies 30 provide proper positioning and alignment for exhaust system 12 during assembly of exhaust system 12 and during the operation of the vehicle.
[0022] Referring now to FIGS. 2-8 , exhaust isolator assembly 30 comprises an elastomeric assembly 40 and an hanger pin 42 . Elastomeric assembly 40 comprises a first insert 44 , a second insert 46 each of which is molded into an elastomeric body 48 .
[0023] Elastomeric assembly 40 is a single-hole shear hub design where elastomeric body 48 defines a hole 50 which is designed to accept hanger pin 42 . Hanger pin 42 is secured to one of the components of exhaust system 12 and elastomeric assembly 40 is attached to the frame or supporting structure 14 of the vehicle. Thus, exhaust system 12 is secured to the vehicle through elastomeric assembly 40 . Elastomeric assembly 40 also defines a plurality of lobe flanges 52 on one end of elastomeric assembly 40 and a hexagonal structure 54 located on the end of elastomeric assembly 40 opposite to the plurality of lobe flanges 52 .
[0024] Elastomeric body 48 defines an outer circumferential void 56 and an inner circumferential void 58 . While voids 56 and 58 are illustrated as being asymmetrical with respect to hole 50 , it is within the scope of the present disclosure to have voids 56 and 58 symmetrical to hole 50 . The design of voids 56 and 58 , specifically their thickness, will determine the amount of travel until the rate of elastomeric assembly 40 spikes up due to the closing of voids 56 and 58 . Until the closing of voids 56 and 58 , the radial loads cause pure shear stress in elastomeric body 48 regardless of the loading direction.
[0025] The loading direction of elastomeric assembly 40 can be in any radial direction around hole 50 . Tuning for rate and deflection in selective directions can be accomplished independently from other directions by altering voids 56 and 58 in the appropriate circular sectors. As can be seen in FIG. 6 , void 56 overlaps with void 58 . The larger the overlap between voids 56 and 58 , the lower the stresses and stiffness for elastomeric assembly 40 . The peak loads bottom out voids 56 and 58 and start to impart compressive stress to elastomeric body 48 from hanger pin 42 and first and second inserts 44 and 46 . As illustrated in FIGS. 6-8 , first and second inserts 44 , 46 extend around the inner and outer regions of elastomeric body 48 . The bottoming of voids 56 and 58 and the subsequent compression of elastomeric body 48 makes the compressive stresses spread out rather than having the compressive stresses concentrated in a spoke or leg cross-section as in the prior art. This permits the stress magnitude to decrease as well as changing the stress loading to a more favorable type.
[0026] Hanger pin 42 is inserted through hole 50 during the installation of exhaust system 12 . Hanger pin 42 is a formed rod which can include compound bends such that a first end is positioned to axially engage hole 50 and a second, opposite end is designed to mate with and be secured to a component of exhaust system 12 . As illustrated, a different hanger pin 42 is used for each exhaust isolator assembly 30 but it is within the scope of the present disclosure to utilize as many common hanger pins 42 as the design for the specific application allows. An annular barb 60 is formed on the insertion end of each hanger pin 42 to resist the removal of the hanger pin 42 from hole 50 .
[0027] Elastomeric assembly 40 is designed to be assembled into a flanged aperture 66 defined by supporting structure 14 of the vehicle. As illustrated in FIG. 3 , aperture 66 defines a plurality of lobes 68 which are designed to correspond with and mate with the plurality of lobe flanges 52 defined by elastomeric assembly 40 . The assembly of elastomeric assembly 40 is illustrated in FIGS. 4A to 4C . First, as illustrated in FIG. 4A , the plurality of lobe flanges 52 defined by elastomeric assembly 40 are aligned with the plurality of lobes 68 defined by aperture 66 . A clearance around the entire circumference of elastomeric assembly 40 is provided between aperture 66 and elastomeric assembly 40 to allow the insertion of elastomeric assembly 40 into aperture 66 . Elastomeric assembly 40 is pushed axially into aperture 66 as shown by the arrow in FIG. 4A until a flange 68 , formed as part of hexagonal structure 54 , seats against the surface of supporting structure 14 that defines aperture 66 . Second, as illustrated in FIG. 4B-4C , elastomeric assembly 40 is rotated to misalign the plurality of lobe flanges 52 with the plurality of lobes 68 and thus lock elastomeric assembly 40 to supporting structure 14 . A stop 70 defined by elastomeric assembly 40 contacts the side of aperture 66 when elastomeric assembly 40 has been fully rotated. Hexagonal structure 54 is provided to assist in the rotation of elastomeric assembly 40 . A gap 72 defined between the plurality of lobe flanges 52 and flange 68 accommodate the flange portion of supporting structure 14 that defines aperture 66 .
[0028] While elastomeric assembly 40 is designed to have a clearance fit with aperture 66 when the plurality of lobe flanges 52 are aligned with the plurality of lobes 68 , the outside radial surface forming gap 72 between the plurality of lobe flanges 52 and flange 68 are designed to have an interference fit with the flanged portion of supporting structure 14 which forms the inside diameter of aperture 66 which mates with the outside radial surface forming gap 72 . In this way, the compression of elastomeric body 48 within gap 72 will act as means for retaining elastomeric assembly 40 in its rotated and locked position in aperture 66 .
[0029] While stop 70 is designed to indicate when elastomeric assembly 40 is in its fully assembled and locked position, it is within the scope of the present disclosure to form an indicator 80 on elastomeric assembly 40 as indicated in FIG. 7 . Indicator 80 is designed to align with a mark or indicator (not shown) on supporting structure 14 when elastomeric assembly 40 is properly installed. While indicator 80 is illustrated in FIG. 7 as being located on second insert 46 , indicator 80 will remain visible on elastomeric assembly 40 after the molding of elastomeric body 48 . In addition, it is within the scope of the present disclosure to have indicator 80 being formed only by elastomeric body 48 .
[0030] First and second inserts 44 and 46 are manufactured from plastic or metal and are illustrated in FIGS. 7 and 8 . First insert 44 defines a cylindrical portion 82 which surrounds hole 50 and a flanged portion 84 which extends radially outward from cylindrical portion 82 . Second insert 46 is disposed around first insert 44 and it defines indicator 80 , a plurality of lobe flanges 86 and a stop 88 . The plurality of lobe flanges 86 correspond to the plurality of lobe flanges 52 and stop 88 corresponds to stop 70 . While the plurality of lobe flanges 52 and stop 70 are illustrated as including the plurality of lobe flanges 86 and stop 88 , respectfully, it is within the scope of the present disclosure to have the plurality of lobe flanges 52 and stop 70 formed only from elastomeric body 48 .
[0031] As illustrated in FIG. 6 , second insert 46 includes a radially flange 90 extending radially outward from lobe flange 86 . Flange 90 is included in each of the plurality of lobe flanges 52 . Each flange 90 defines a radially outwardly extending flange 92 on elastomeric assembly 40 which entraps the flanged portion of supporting structure 14 that forms aperture 66 between flange 92 and flange 68 .
[0032] FIG. 9 illustrates an embodiment of the present disclosure where circumferential orientation of elastomeric assembly 40 with respect to aperture 66 can be achieved. Circumferential orientation may be required when the tuning rate and deflection in selective directions has been incorporated into elastomeric assembly 40 . As illustrated in FIG. 9 , one of the plurality of lobes 68 a and one of the plurality of lobe flanges 52 a extends a larger distance radially from hole 50 than the other two of the plurality of lobes 68 b , 68 c and the other two of the plurality of lobe flanges 52 a , 52 b . By having only one of the lobes 68 a and lobe flanges 52 a extend radially farther out than lobes 68 b , 68 c and lobe flanges 52 b and 52 c , elastomeric assembly 40 can only be inserted into aperture 66 in one single circumferential orientation.
[0033] 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 disclosure. 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 disclosure, and all such modifications are intended to be included within the scope of the disclosure. | An elastomeric assembly is disposed within an aperture defined by a supporting structure of a vehicle. The elastomeric assembly is movable between a first position where the elastomeric assembly can move axial within the aperture and a second position where the elastomeric assembly is prohibited from moving axially within the aperture. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 10/313,554, filed Dec. 6, 2002 now U.S. Pat. No. 7,052,097, which is hereby incorporated herein in its entirety by reference.
BACKGROUND
1. Field of the Invention
The invention relates generally to an apparatus and method for providing access to items to be dispensed, and relates more particularly to the automatic dispensing of medical supplies. The invention further relates to an apparatus and method for reducing the amount of power consumed by an automatic dispensing system.
2. Description of the Related Art
In typical medical facilities (for example, hospitals, clinics, rest homes, etc), medical supplies are maintained in centralized storage locations and delivered to remote locations (for example, an emergency room, patient ward, etc.) as needed. Once delivered, the medical supplies are then dispensed to a patient. “Medical supply” is intended to include, among others, any item that is administered to or dispensed for a patient or used by a medical caregiver to treat a patient (for example, pharmaceuticals, syringes, sterilized bandages, scalpels, etc.). The invention has been described herein with reference to the dispensing of medical supplies, but it should be recognized that the invention is applicable to fields other than the medical field.
A variety of systems are used for transferring (i.e., from the storage location to the remote locations) and for dispensing (i.e., from the remote locations to the patient) the medical supplies. A system may use, for example, mobile dispensing carts which are stocked at the centralized storage area and then wheeled to the remote location. The medical supplies may then be dispensed directly from the mobile dispensing cart for administering to the patient. Alternatively, a dispensing system may use a stationary dispensing cabinet located at the remote location. Medical supplies are dispensed from the dispensing cabinet for later administering to the patient. A restocking cart, loaded with replacement medical supplies from the centralized storage location, is used to replenish the stationary dispensing cabinet.
Of particular interest to the present invention are dispensing systems which dispense items which require close monitoring and control. A variety of schemes have been proposed for providing secured access to items that are held within such dispensing systems, including locking the items within the carts or allowing access to only one item at a time (commonly referred to as “single dose” or “unit dose” dispensing). In addition to providing secure access, the schemes direct the user to the location within the dispensing system of the item to be dispensed.
One such system is described in related U.S. Pat. No. 5,745,366 entitled “Pharmaceutical Dispensing Device and Methods” and U.S. Pat. No. 5,905,653 entitled “Methods and Devices for Dispensing Pharmaceutical and Medical Supply Items.” The system controls access to items to be dispensed and maintains an inventory of the items. The system includes a dispensing unit having a plurality of storage locations distributed within an enclosure. The storage locations may include a multiplicity of lockable receptacles disposed within at least some of the storage locations. The storage locations and the individual lockable receptacles may have sensors and indicator lights associated therewith.
A processor is operable to receive user input and, in response to the input, is operable to activate an indicator light corresponding to the storage location associated with the item to be dispensed. The processor activates locks to prevent access to non-selected storage locations. The processor unlocks the individual receptacle (within the selected storage location) containing the item to be dispensed and activates the indicator light corresponding to the unlocked receptacle. The processor is also connected to receive feedback signals from the receptacle-associated sensors, such that when the unlocked receptacle is opened by a user, a feedback signal is sent to the processor indicating that the item has been dispensed.
Another such system is described in related U.S. Pat. No. 6,109,774 entitled “Drawer Operating System” and U.S. Pat. No. 6,065,819 entitled “Jerk-Resistant Drawer Operation System.” The patents disclose a drawer operating system for controlling a plurality of elongated drawers having a plurality of bins consecutive with one another along a sliding direction for holding various dispensable items. The drawers are housed in an array in a cabinet, each drawer arranged to move independently between a closed position and graduated, progressively opened positions to allow access to one or more bins and the contents stored therein. The system controls access to the bins by only allowing the drawer to travel the distance necessary to expose the next bin containing the item. For example, if a drawer has five bins each containing the desired item, the system will only allow the drawer to move to a position in which the first bin is exposed. After the first bin is emptied, the system will only allow the drawer to move to a position in which the second bin is exposed. The process may be repeated until all five bins are emptied. The system includes a keyboard for inputting coded information concerning the particular item needed and information as to the party entering the information.
U.S. Pat. No. 6,011,999 entitled “Apparatus for Controlled Dispensing of Pharmaceutical and Medical Supplies” discloses a system for controlled dispensing of pharmaceutical and medical supplies. The system includes a cabinet having a plurality of drawers, each having a plurality of receptacles. Each receptacle is sized to hold one item and has an identifier associated therewith. Locks are provided for securing the lid. The locks include an electrically responsive actuator wire, which in response to an electrical current supplied to the electrically responsive actuator wire, causes the lock to engage and disengage the lid. A processor is in communication with the locks and is configured to send a signal to the electrically responsive actuator wire to actuate the lid. The lid is spring biased and includes a colored indicator on an inner portion of the lid, such that when unlocked, the lid pops open and the indicator is exposed.
U.S. Pat. No. 6,116,461 entitled “Method and Apparatus for the Dispensing of Drugs” discloses another dispensing system. The system includes modular receptacles which are filled and transported to remote automatic dispensing machines for later retrieval and distribution. The system includes the loading, refilling, and replacement of the modular receptacles at various stages in the process of the invention. The system includes a receptacle having a lockable lid. When required an electronic circuit causes a latch to be actuated, thus opening the lockable lid. The lid has a spring in the hinge assembly which pushes the lid open when the latch is freed, thus indicating to the user the correct receptacle.
U.S. Pat. No. 5,520,450 discloses a supply station with an internal computer. The supply station is comprised of a cabinet having a plurality of lockable doors. Information is provided to the computer which unlocks the doors and simultaneously and automatically updates a patient's record, billing information and hospital inventory. Relevant data may be displayed on a display or printed on a sheet of paper by a printer connected to the computer.
U.S. Pat. No. 5,346,297 discloses an auxiliary storage and dispensing unit for use with a computer-controlled supply and medication dispenser station. The dispensing unit includes a cabinet having a plurality of lockable doors, a device for interconnecting one or more of the doors to allow access to the cabinet and a door unlocking device interconnected to the computer-controlled station for selectively unlocking one or more of the doors as a function of information inputted to the station.
Computer controlled dispensing systems, such as those discussed above, have been developed in response to a number of problems existing in medical facilities. Computer controlled dispensing systems, for example, address problems such as the removal of medications by unauthorized personnel, dispensing the wrong medication for a patient, inaccurate record keeping, etc.
The AcuDose-Rx dispensing cabinet available from McKesson Automation Inc. of Pittsburgh, Pa. is an example of a computer controlled cabinet programmed to address the aforementioned problems. A user is required to logon to the computer (thereby identifying who is removing medications). After identifying a patient, the user is presented with a list of medications that have been approved for administering to the identified patient (thereby addressing the problem of incorrect dispensing). Records are kept for each dispensing event thereby creating an audit trail.
As discussed above, a variety of different storage options are available for dispensing cabinets to ensure the safe and accurate dispensing and administration of medications. These include, but are not limited to, drawers with individual locking pockets which provide access to only one medication in a drawer at any given time; unit-dose dispensing drawers, which provide access to one “unit-of-use” of a medication at any given time, and open matrix drawers, which consist of a plurality of open pockets and which provide access to multiple medications at any given time.
While such systems provide for access controlled dispensing, most require large amounts of power to keep the compartments locked. Furthermore, systems using lighted indicators require additional power, control circuitry, and wiring. In contrast, systems using non-lighted indicators rely on the drawer or lid to “spring” open. If an item is caught on the drawer or lid, an increased risk is encountered that the item will become airborne when the drawer or lid is opened. The airborne item may become lost or may strike a user.
Thus, a need exists for a secure unit dose dispensing cabinet that requires less power to operate and provides a mechanical indicator means for notifying the user of correct location of the item to be dispensed without “springing” open a drawer or lid. Additionally, there exists a need for a safer, less error-prone dispensing and replenishment system.
SUMMARY
One aspect of the present invention relates to an assembly comprising a plurality of bins, a plurality of lids each associated with one of the plurality of bins, wherein each of the bins has a notched tab and a touch latch. The notched tab and the touch latch are in one of an engaged state and a disengaged state when said lid is in a closed position. The assembly includes a lock assembly including a catch operable to prevent the notched tab and the touch latch from changing state and a mechanical indicator responsive to the catch.
Another aspect of the present invention relates to an automated dispensing cabinet, comprising a plurality of drawers, wherein at least one of the drawers includes a plurality of row assemblies, each of the row assemblies having a plurality of bins. Each of the plurality of bins includes a lid having a tab attached thereto, a touch latch operable to one of engage and disengage the tab when the lid is in a closed position, a lock assembly including a catch operable to prevent the notched tab and the touch latch from one of engaging and disengaging, and a mechanical indicator responsive to the lock assembly and viewable when the lid is in a closed position. The automated dispensing cabinet also includes a control computer operable to lock and unlock the plurality of drawers and to control the position of the catch of each of the bins.
Additionally, an aspect of the present invention relates to a method for dispensing an item contained in remote dispensing system. The method comprises granting a user access to the remote dispensing system having a plurality of lockable drawers with a plurality of lockable bins, accepting dispensing information from the user, unlocking at least one of the plurality of drawers, wherein the unlocked drawer contains an item to be dispensed, unlocking at least one of the plurality of bins located within the unlocked drawer while changing the state of a mechanical indicator associated with a bin that has been unlocked, verifying that the user has closed the unlocked bin, and locking the at least one of the plurality of bins and the at least one of the plurality of drawers.
Another aspect of the present invention relates to a method for restocking items contained in a remote dispensing system including a cabinet having with a plurality of drawers, at least one of the plurality of drawers having a plurality of bin row assemblies. The method comprises selecting a bin row assembly, opening the drawer containing the bin row assembly, identifying the selected bin row assembly, removing the selected bin row assembly from the drawer, inserting a restocked bin row assembly in place of the removed selected bin row assembly.
Yet another aspect of the present invention relates to an assembly comprising a plurality of bins, a plurality of lids, each lid being associated with one of the plurality of bins, each of the bins having a notched tab, a lock assembly including a catch operable to one of engage or disengage the notched tab when the lid is in a closed position, and a mechanical indicator responsive to the catch.
Those advantages and benefits, and others, will be apparent from the Detailed Description below.
BRIEF DESCRIPTION OF THE DRAWINGS
To enable the present invention to be easily understood and readily practiced, the present invention will now be described for purposes of illustration and not limitation, in connection with the following figures wherein:
FIG. 1 is a perspective view of a dispensing system located at a decentralized location according to one embodiment of the present invention.
FIG. 2 is a perspective view of a lockable drawer for the dispensing system shown in FIG. 1 according to one embodiment of the present invention.
FIG. 3A is a perspective view of a bin row assembly for the lockable drawer shown in FIG. 2 according to one embodiment of the present invention.
FIG. 3B is a front view of a the bin row assembly of FIG. 3A according to an embodiment of the present invention.
FIGS. 3C and 3D are left and right side views, respectively, of the bin row assembly of FIG. 3A according to an embodiment of the present invention.
FIG. 3E is a top view of the bin row assembly of FIG. 3A according to an embodiment of the present invention.
FIG. 3F is an exploded view of the bin row assembly of FIG. 3A according to an embodiment of the present invention.
FIGS. 3G and 3H illustrate a touch latch in the unhooked and hooked positions, respectively according to one embodiment of the present invention.
FIG. 4A illustrates a power control circuit board for the bin row assembly of FIG. 3A according to one embodiment of the present invention.
FIG. 4B is a detailed view of a portion of the power control board for the bin row assembly illustrated in FIG. 4A according to one embodiment of the present invention.
FIG. 4C is an exploded view of a portion of the power control board for the bin row assembly of FIG. 3A according to one embodiment of the present invention.
FIG. 4D is a sectional view taken along the lines A-A of the portion of the power control board for the bin row assembly illustrated in FIG. 4B .
FIG. 5 illustrates an operational process for dispensing items from the remote dispensing system shown in FIG. 1 according to an embodiment of the present invention.
FIG. 6 illustrates an operational process for restocking dispensed items from the remote dispensing system shown in FIG. 1 according to an embodiment of the present invention.
FIGS. 7A-7C are an electrical schematic of an input/output interface circuit and a manually activated override interface circuit for the remote dispensing system illustrated in FIG. 1 according to an embodiment of the present invention.
FIGS. 8A and 8B are an electrical schematic of a relay select circuit for the remote dispensing system illustrated in FIG. 1 according to an embodiment of the present invention.
FIGS. 9A and 9B are an electrical schematic of a manual override sequence control circuit for the remote dispensing system illustrated in FIG. 1 according to an embodiment of the present invention.
FIG. 10 is an electrical schemata of feedback circuits for the remote dispensing system illustrated in FIG. 1 according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of a remote dispensing system 10 located at a decentralized location according to one embodiment of the present invention. The system 10 illustrated in FIG. 1 may be comprised of, for example, an AcuDose-Rx™ cabinet 12 (available from McKesson Automation inc., 700 Waterfront Drive, Pittsburgh, Pa.) having a control computer 14 , and an AcuDose-Rx™ auxiliary cabinet 16 . A supply tower 18 is also illustrated. The control computer 14 controls the operation of the cabinet 12 , auxiliary cabinet 16 , and supply tower 18 .
The control computer 14 may include a memory device (not shown, such as a disk drive, tape drive, CD-ROM drive, etc.) having a local database. The local database may contain inventory, user, and patient information (among others). Alternatively, the control computer 14 may be in communication with another computer (for example, located at the centralized storage location) having a central database which contains the inventory, user, and patient information (among others).
The control computer 14 accepts entry of inventory, user, patient, and other information via a keyboard 20 , scanning device 22 , and datalink (not shown), among others. The control computer 14 , in programmed interaction with the entered information, provides output information to a display 24 , printer (not shown), etc. and provides output control signals to the cabinet 12 , auxiliary cabinet 16 , and supply tower 18 , etc.
The control computer 14 may be programmed to regulate access to the system's cabinets 12 , 16 and supply tower 18 and to generate records related to access, inventory, etc. The records may be stored in the local database, displayed on the display 24 , printed by a printer unit, or transmitted to a central database (among others). The control computer 14 may be preprogrammed with appropriate information regarding the medication types associated with, and their exact location within, each cabinet 12 , auxiliary cabinet 16 and supply tower 18 . The programming may, for example, be entered directly into the control computer 14 or downloaded from the central database.
As will be discussed in greater detail in conjunction with FIGS. 5 and 6 , a user logs onto the control computer 14 to perform a dispensing operation. After log-on, patient information and information regarding items to be dispensed are entered. Based on the entered information, the appropriate drawers 26 in the cabinet 12 and the auxiliary cabinet 16 , and various doors 28 on the supply tower 18 are unlocked. The user then accesses the unlocked drawers 26 and doors 28 and removes the appropriate item. After the item to be dispensed has been removed, its removal is recorded at the control computer 14 . The record may be entered manually by the user or automatically by a feedback signal. The user may continue to dispense items for the identified patient, enter patient information for another patient, or logoff.
Entry of information, including log-in, can be performed in a variety of ways with a variety of input devices, for example, using the keyboard 20 and barcode scanning 22 . Additional input devices or input means, for example, a touch screen, selecting items from a pick list, RF ID), flash memory, magnetic strips, OCR (none of which are shown), etc., may also be used. The reader will understand that the hardware illustrated in FIG. 1 is exemplary and is illustrated for purposes of demonstrating one type of hardware which may be located at the decentralized location.
The hardware illustrated in FIG. 1 limits access to the items to be dispensed to those individuals who have properly logged on. Thus, the hardware illustrated in FIG. 1 is referred to as a closed system for performing dispensing operations because a dispensing operation cannot be performed unless the user is identified to, and recognized by, the control computer 14 .
It should be noted that in the current embodiment, a limited access manual override system is also provided. Access is limited to individuals having keys to the rear of the AcuDose-Rx cabinet 12 , AcuDose-Rx auxiliary cabinet 16 , and AcuDose-Rx supply tower 18 .
FIG. 2 is a perspective view of one type of a lockable drawer 26 for use with the dispensing system 10 shown in FIG. 1 according to one embodiment of the present invention. For example, the lockable drawer 26 may be one of the drawers 26 from the AcuDose-Rx™ cabinet 12 or from the auxiliary cabinet 16 . Lockable drawer 26 is comprised of a housing 30 , a frame 31 , and a pair of slides 32 (one of which is seen in FIG. 2 ) which enable the frame 31 to move relative to the housing 30 . As illustrated in FIG. 2 , five (5) bin row assemblies 34 , each having five (5) bins 36 are secured to the frame 31 . The frame 31 and bin row assemblies 34 are slidably moveable between a closed position within the housing 30 and an open position outside of the housing 30 . It should be noted that the housing 30 may have a single frame 31 (with a plurality of bin row assemblies 34 secured thereto, for example, as shown in FIG. 2 ) or with a number of frames 31 (each having a single bin row assembly 34 secured thereto, for example) each mounted on corresponding slides 31 .
For simplicity, in the current embodiment the bins 36 are numbered from left-to-right and from back-to-front, relative to the lockable drawer 26 . Thus as illustrated, the first bin row assembly 34 is comprised of bins 1 - 5 , the second bin row assembly 34 is comprised of bins 6 - 10 , the third bin row assembly 34 is comprised of bins 11 - 15 , etc. It should be noted that the number of bin row assemblies 34 per drawer 26 , the number of bins 36 per bin row assembly 34 , and the scheme used to number the bin row assemblies 34 and bins 36 may be altered while remaining within the scope of the present invention.
The bin row assemblies 34 , to facilitate restocking procedures or changing of inventory, are separable from the open drawer 26 . For example if the bins 6 - 10 need to be restocked, the second bin row assembly may be removed from the open drawer 26 , taken to the central storage location, restocked, and then returned to the open drawer 26 , or swapped out with another bin row assembly, i.e., the second bin row assembly may be removed from the open drawer 26 and a previously stocked replacement bin row assembly 34 may be substituted in place of the second bin row assembly.
FIGS. 3A-3F are perspective, front, left side, right side, top, and exploded views, respectively, of a bin row assembly 34 for the dispensing system 10 shown in FIG. 1 according to one embodiment of the present invention. As best seen in FIG. 3E , the bin row assembly 34 is comprised of a base 38 , front wall 40 , back wall 42 , side wall 44 , and interior partitions 46 . As illustrated, the bin row assembly 34 in the current embodiment contains five (5) bins 36 . The front wall 40 includes a lip 48 and one or more spacers 50 configured to receive a power control circuit board 52 . The power control circuit board 52 is positioned under the lip 48 , abutting the spacers 50 , and attached to the front wall 40 (for example, with screws). The lip 48 includes a slotted indicator window 54 and a latching mechanism aperture 56 for each bin 36 .
A lid 58 is attached to the back wall 42 of each bin 36 via a hinge mechanism 60 . When the lid 58 is in the closed position, a notched tab 62 on the lid 58 enters the aperture 56 in the lip 48 and engages with a touch latch 63 that is mounted to the bin 36 (for example, on the lip 48 under the aperture 56 , among others). The touch latch 63 , as is known in the art, operates by pushing the notched tab 62 on the lid 58 into the touch latch 63 . The notched tab 62 “hooks” with the touch latch 63 . Referring briefly to FIG. 3H , a touch latch is illustrated in the hooked position. Thus, the lid 58 is closed it by pushing it down until the touch latch 63 latches and holds it closed. The lid 58 is opened by pushing down on the lid 58 again which causes the touch latch 63 to release (i.e., “unhook”) the lid 58 . Referring briefly to FIG. 3G , a touch latch is illustrated in the unhooked position.
When closed, the lid 58 may be locked in place by a lock assembly 66 (shown in FIGS. 4A-4C ) contained on the power control circuit board 52 . In the current embodiment, each bin 36 has a lid 58 associated therewith. Additionally, each lid 58 may be constructed of a transparent material so that both the contents of the bin 36 and the slotted indicator window 54 can be viewed when the lid 58 is in the closed position.
When a lid 58 is in the closed position (i.e., engaged by the touch latch 63 ) and locked by the lock assembly 66 , the slotted indicator window 54 displays a first color (for example, red) indicating to the user that the lid 58 cannot be opened. When the lid 58 is unlocked by the lock assembly 66 , the slotted indicator window 54 displays another color (for example, green) indicating to the user that the lid 58 can be opened. It should be noted that in the current embodiment, the indicator can be viewed even when the lid 58 remains closed. It should further be noted that other types of mechanical indicators may be used that permit the indicator to be viewed when the lid 58 is closed while remaining within the scope of the present invention.
It should be noted that an assembly having an alternative latching/locking means may be used while remaining within the scope of the present invention. For example, a lid 58 may have a notched tab 62 that is engaged by the lock assembly 66 without using a touch latch 63 . In one instance, the lock assembly's catch 74 may engage the notched tab 62 when the lid is in a closed position.
It should further be noted that, although the bin row assembly 34 of the current embodiment has five (5) bins, the number of bins 36 may be varied while remaining with the scope of the present invention. Additionally, certain bins 36 may not have a lid 58 associated therewith, for example, a bin 36 containing non-regulated supplies may not have a lid 58 .
FIG. 4A illustrates a power control circuit board 52 for the bin row assembly 34 of FIG. 3A according to one embodiment of the present invention. FIGS. 4B-4D are detailed, exploded, and sectional views of a portion of the power control circuit board 52 for the bin row assembly 34 illustrated in FIG. 4A according to one embodiment of the present invention.
Referring to FIG. 4A , power control circuit board 52 is comprised of a backing plate 64 with five (5) latch assemblies 66 (i.e., one associated with each bin 36 ) and a connector 68 attached thereto. The connector 68 is used to connect signal and power conductors for each lock assembly 66 to the system 10 . For example, the connector 68 couples with a complimentary connector (not shown) that is in electrical communication with the control computer 14 . The complimentary connector in the present embodiment is located on the drawer 26 .
As best seen in FIG. 4C , in the current embodiment each locking assembly 66 includes a solenoid 70 , pivot arm 72 , catch 74 . The catch 74 , in the current embodiment, includes the mechanical indicator for notifying the user whether the bin 36 is locked or unlocked. The lock assembly 66 may also include a relay 82 , Hall-effect sensor 84 , as well as associated hardware, for example, flat washers 76 , fastener standoff 78 , and screws 80 , among others.
In the current embodiment, latching solenoids 70 are used. A latching solenoid 70 refers to a solenoid 70 that does not have a default mechanical state and must receive an electrical pulse to change states. For, example in the current embodiment, the catch 74 slides from side to side to lock and unlock the lid 58 . When the catch 74 is engaged (i.e., the lid 58 is locked), the notched tab 62 of the lid 58 is prevented from being pushed down far enough to change the state of (i.e., engage or disengage) the touch latch. If power is removed from the latching solenoid 70 , the catch 74 remains engaged. The catch 74 remains engaged until a control pulse is applied to the latching solenoid 70 . Likewise, when a bin 36 is unlocked, the catch 74 is disengaged. If power is removed from the latching solenoid 70 , the catch 74 remains disengaged. The catch 74 remains disengaged until a control pulse is applied to the latching solenoid 70 . Thus, the use of latching solenoids 70 reduces the amount of power needed to operate the dispensing system 10 . It should be noted that other means for moving the catch 74 (for example, a non-latching solenoid, a motor, a pneumatic or hydraulic cylinder, an actuator, an electromagnet, etc.) may be used while remaining within the scope of the present invention.
Referring now to FIG. 4B , the lock assembly 66 is shown in the locked (i.e., engaged) position. For simplicity, the notched tab 62 and touch latch 63 are not shown in FIG. 4B . When an electrical pulse is applied via the relay 82 to the solenoid 70 , the solenoid plunger 71 extends (moves to the left as shown), causing the pivot arm 72 to rotate clockwise about its pivot point. The pivot arm 72 , in turn, causes the catch 74 to unlock (i.e., move to the right as shown) the lid 58 . When the lock assembly 66 is in the disengaged position and an electrical pulse with opposite polarity is applied to the solenoid 70 via the relay 82 , the solenoid plunger 71 retracts (moves to the right as shown), causing the pivot arm 72 to rotate counterclockwise about its pivot point. The pivot arm 72 , in turn, causes the catch 74 to unlock (i.e., move to the left as shown) the lid 58 . The Hall-effect sensor 84 produces a feedback signal (that is sent to the control computer 14 ) indicative of whether the lid 58 is closed or open.
As discussed above, when the lock assembly 66 is engaged, the notched tab 62 of the lid 58 is prevented from being pushed down far enough to change the state of (i.e., engage or disengage) the touch latch 63 . Thus, it should be apparent to one skilled in the art that the direction of travel of the catch 74 to lock and unlock the lid may be changed while remaining within the scope of the present invention.
In the current embodiment, the locking/unlocking and the mechanical indication of the bin's status (i.e., locked or unlocked) are combined in a unitary function, i.e., as the bin is locked or unlocked, the mechanical indicator changes state. The catch 74 , for example, may have an indicia (such as colors, words, symbols, marks, etc.) representative of whether the catch is engaged (i.e., the bin 36 is locked) or disengaged (i.e., the bin 36 is unlocked). For example as discussed in conjunction with FIGS. 3A-3F , catch 74 may have red colored portions and green colored portions which show through the indicator window 54 when the bin in locked and unlocked, respectively. It should be noted, however, that other mechanical indicia, such as raising a flag or pin, rotating a cylinder having “locked” on one portion and “unlocked” on another portion, turning a dial, etc. may be used while remaining within the scope of the present invention. Also, the function need not be unitary, that is, the bin may be locked or unlocked followed by the mechanical indicator changing state. It should be apparent to one skilled in the art that any mechanical indicator that is responsive to the lock assembly 66 may be used while remaining within the scope of the present invention.
FIG. 5 illustrates an operational process 500 for dispensing items at a remote dispensing system 10 according to an embodiment of the present invention. Operation 500 is initialized by a user logging onto the remote dispensing system's control computer 14 at operation 501 . In the current embodiment, the remote dispensing system 10 includes a control computer 14 , AcuDose-Rx cabinet 12 , AcuDose-Rx auxiliary cabinet 16 , and a supply tower 16 as discussed in conjunction with FIG. 1 .
After logging onto the control computer 14 , the user is granted access to the remote dispensing system 10 in operation 502 . In the current embodiment, the access may be either restricted or unrestricted. Restricted access allows the user to access fewer than all of the drawers 26 and bins 36 located at the remote dispensing station 10 and prevents the user from removing some or all of the bin row assemblies 34 from a drawer 26 . On the contrary, unrestricted access allows the user access to all of the drawers 26 and bins 34 located at the remote dispensing station 10 and allows the user to removing all of the bin row assemblies 34 from a drawer 26 .
The control computer 14 then accepts dispensing information from said user in operation 503 . In the current embodiment, dispensing information may include inventory, user, patient, and prescription information, among others. The dispensing information may be entered via a keyboard 20 , scanning device 22 , and datalink (not shown), among others.
After accepting the dispensing information, the drawers 26 containing the items to be dispensed are unlocked in operation 504 . In the current embodiment, the control computer 14 , in programmed interaction with the entered information, provides the output control signals for unlocking the drawers 26 of the cabinet 12 , auxiliary cabinet 16 , and supply tower 18 .
The bins 36 within the unlocked drawers 26 , which contain the items to be dispensed, are unlocked in operation 505 . In the current embodiment, the bins 36 contain a mechanism that not only locks/unlocks the bin 36 , but also simultaneously indicates to the user whether the bin 36 is locked or unlocked. In the current embodiment, a mechanical indicator is used which can be viewed when the bin's lid 58 is closed. It should be noted that even when unlocked, the bin's lid 58 remains closed until lifted by the user, or the lid can be spring loaded so the pushing down on an unlocked lid causes the lid to spring up.
Once the bin(s) 36 have been unlocked, the user can remove the desired item and close the bin lid 58 . Typically, the user then enters information into computer 14 to create a dispensing record. In the current embodiment, feedback signals are sent from the bins 36 to the control computer. The feedback signals may be used, among others, to verify whether a drawer 26 , bin 36 , etc. is locked or unlocked, and whether a bin's lid 58 is opened or closed.
After the remote dispensing station 10 verifies that the user has closed the unlocked bin(s) 36 and closed the drawer 26 in operation 506 , the closed bins 36 and closed drawer 26 are locked in operation 507 . As discussed above, the mechanism used not only locks/unlocks the bin 36 , but also simultaneously indicates to the user whether the bin 36 is locked or unlocked. A mechanical indicator is used which can be viewed when the bin's lid 58 is closed.
After the opened bins 36 and drawers 26 are locked in operation 507 , the user indicates whether another dispense is desired in operation 508 . If another dispense is desired, operational process 600 returns to operation 603 and the user enters new dispensing information. If another dispensing operation is not desired, the user is logged off of the control computer 14 in operation 509 .
FIG. 6 illustrates an operational process 600 for restocking dispensed items with the remote dispensing system 10 according to an embodiment of the present invention. Operation 600 is initiated by operation 601 when the remote dispensing system 10 detects that a bin row assembly 34 within the remote system 10 is depleted or below par (i.e., below an acceptable inventory level). In the current embodiment, the control computer 14 may be manually notified by a user, notified by a centralized computer, or the control computer 14 may automatically detect, that a bin row assembly 34 has been selected (i.e., it is depleted or below par).
The remote dispensing system 10 then unlocks the drawer 26 containing the selected bin row assembly 34 in operation 602 . In the current embodiment, the user is notified of which drawer 26 has been unlocked on the control computer display 14 . Alternatively, an indicator located on the cabinet or auxiliary cabinet may also be used to notify the user.
The selected bin row assembly 34 , within the unlocked drawer 26 , is then identified in operation 603 . In the current embodiment, the selected bin row assembly 34 is identified on the control computer display 24 . Alternatively, an indicator located on the drawer, cabinet, or auxiliary cabinet may also be used to identify the selected bin row assembly 34 .
After the selected bin row assembly 34 has been identified, the user removes the selected bin row assembly 34 from the drawer 26 in operation 604 . In one embodiment, the bin row assembly 34 can be secured within the drawer 26 such that a user having restricted access (as discussed in conjunction with FIG. 5 ) can only remove the selected bin row assembly 34 from the drawer 26 that has been unsecured by the control computer 14 . The user having restricted access is unable to remove the bin row assemblies that remain secured.
A restocked bin row assembly 34 is then inserted into the drawer 26 in operation 605 . In the current embodiment, the restocked bin row assembly 34 is filled at a centralized storage location. Each bin in the restocked bin row assembly 34 is locked at the centralized storage location, prior to transporting the restocked bin row assembly 34 to the remote dispensing system 10 . After the restocked bin row assembly 34 is inserted into the unlocked drawer 26 and the drawer 26 is closed, the control computer 14 locks the drawer 26 in operation 606 . Operational process 600 is then terminated in operation 607 .
FIGS. 7A-7C are an electrical schematic of an input/output interface circuit 86 and a manual override interface circuit 94 for the remote dispensing system 10 illustrated in FIG. 1 according to an embodiment of the present invention. The input/output interface circuit includes filters 87 , flip-flops 88 , inverters 89 , and buffers 90 , among others. Column select and row select input bits on pins 91 , sent from control computer 14 , are received by the input output interface circuit 86 , inverted, buffered and output to a relay select circuit 92 (discussed in conjunction with FIG. 8 ) via row select and column select pins 93 . FIG. 7 also illustrates a manual override interface circuit 94 , which in conjunction with a flip-flop 88 A, may be used to disable the row and column select inputs 91 should a manual override be instituted. FIG. 7 also illustrates a start transaction bit carried on line 102 which is input to a power drive 104 through a one-shot 106 . Finally, a flip-flop 88 is used to generate signals for determining the direction needed to drive the solenoids 70 . It should be noted that alternative input/output interface and manual override interface circuits may be used while remaining within the scope of the present invention.
FIG. 8 is an electrical schematic of a relay select circuit 92 for the remote dispensing system 10 illustrated in FIG. 1 according to an embodiment of the present invention. In the current embodiment, the relay select circuit 92 has a row select circuit 108 and a column select circuit 110 that receive signals from the row select and column select pins 93 of the input/output interface circuit 86 . The row select circuit 108 and column select circuit 110 each fire one of a plurality of output lines that feed a grid or matrix of relay circuits 95 . In the current embodiment, each bin 36 in the remote dispensing station 10 has a corresponding relay circuit 95 . If a given relay circuit 95 receives both a row select signal (e.g., “X”) and a column select signal (e.g., “Y”), the relay for that “X-Y” coordinate is selected. The output of the relay circuit 95 is used to pulse the latching mechanism's 66 latching solenoid 70 for the desired bin 36 , thus locking or unlocking the bin 36 . It should be noted that an alternative relay select circuits or other circuits may be used to actuate the latching mechanism 66 for locking and unlocking the bins 36 while remaining within the scope of the present invention.
FIG. 9 is an electrical schematic of a manual override sequence control circuit 96 for the remote dispensing system 10 illustrated in FIG. 1 according to an embodiment of the present invention. The circuit of FIG. 9 is comprised of a pair of counters that enable each bin 36 of a selected drawer 26 to be separately and sequentially addressed and unlocked, before proceeding to the next drawer and separately and sequentially addressing and unlocking all of the bins 36 in that drawer 26 . In this manner, the power requirements are maintained at an acceptable level. A similar scheme could be implemented with the control computer 14 if it is still functioning and an override is needed for some reasons other than a control computer 14 malfunction. It should be noted that the actual sequence employed, as well as the auto-sequence circuit used for the manual override (among others) may be varied while remaining within the scope of the present invention.
FIG. 10 is an electrical schematic of a portion of a feedback circuit for the remote dispensing system 10 illustrated in FIG. 1 according to an embodiment of the present invention. As discussed, the latching mechanism 66 for each bin 36 produces one or more feedback signals. For example, a feedback signal may indicate that the lid 58 is opened or closed (e.g., designated as 0 /C in FIG. 10 ). In the current embodiment, the feedback signal for the bins 36 in each column (i.e., within a drawer 26 ) are sent to a feedback selector 114 . It should be noted that only one feedback selector 114 is shown in FIG. 10 for simplicity. Although not shown in FIG. 10 , the feedback circuit includes a number of feedback selectors 114 to receive feedback from each bin 36 . The output of the feedback selectors 114 are then sent to the control computer 14 (e.g., via pin PORT 3 BIT 0 ). It should be noted that other feedback circuits may be used while remaining within the scope of the present invention.
It should be recognized that the above-described embodiments of the invention are intended to be illustrative only. Numerous alternative embodiments may be devised by those skilled in the art without departing from the scope of the following claims. | One aspect of the invention relates to an assembly comprising a plurality of bins with a plurality of lids associated therewith. Each of the bins has a lock assembly that includes a catch operable to lock the lid in its closed position and a mechanical indicator responsive to the catch. Another aspect of the invention relates to an automated dispensing cabinet that includes a control computer and a plurality of drawers having a plurality of row assemblies therein. Each row assembly has bins that include a tabbed lid, a lock assembly with a catch operable to engage and disengage the tab, and an indicator responsive to the lock assembly. Methods for dispensing from and restocking the remote dispensing systems are also given, as well as a method for indicating which item is to be dispensed from one of a plurality of bins. | 4 |
BACKGROUND OF THE INVENTION
The invention relates generally to hydraulic systems and more particularly to an improved hydraulic system embodying a demand compensated principle in which a minimum feedback fluid pressure is maintained.
In the past, systems such as that shown in the U.S. Pat. No. 2,892,312 granted to J. R. Allen et al. maintained a constant pressure increment or standby pressure between a pump and a motor. This pressure increment was determined by internal biasing in the output control mechanism of the pump which opposed the pilot line fluid feedback. With this arrangement, a first portion of the pressure increment was required to compensate for pressure drops between the pump and the motor at the maximum flow rates and a second portion was required to satisfy any constant pressure requirements in the hydraulic circuit. When high, constant-operating-pressure motors were included in the hydraulic circuit, the second portion became substantial and was always imposed over and above the total pressure required to compensate for pressure drops and to supply the fluid motors. Any pressure increment above the maximum required pressure for the motors becomes a serious power drain and requires that the mechanical components be designed to withstand higher pressures than would be required by all the fluid motors at their maximum pressure demand.
Attempts at solving this problem have included such systems as those disclosed in U.S. Pat. No. 3,754,400 granted to D. J. Parquet and the U.S. Pat. No. 3,826,090 granted to J. M. Bahl. These systems provided pressure boosting means for satisfying the high, constant-operating-pressure equipment and a means for providing a fixed pressure ratio between the pressure required at the pump and at the motor which would compensate for the pressure drop therebetween. However, this fixed pressure ratio while being satisfactory for narrow operating pressure ranges was unsatisfactory for wide operating pressure ranges because a satisfactory compensation for pressure drop at a low pressure was magnified to an excessive compensation at a high pressure.
SUMMARY OF THE INVENTION
The present invention provides an improved demand compensated hydraulic system which includes a pressure regulator valve operatively associated with the pilot line to maintain a minimum fluid feedback pressure and not add any pressure to the feedback at pressures above the minimum. The inclusion of the pressure regulator valve allows the system to have a high standby pressure which does not affect the operating pressures of the system. Further, it provides for the pump output control mechanism of the pump to be set so as to compensate only for the pressure drops in the hydraulic circuit and to maintain only this compensation throughout the operating pressures.
The present invention further provides the advantage of reducing the system response time since a higher standby pressure is possible and thus the pressure increment increase from the standby pressure to the operating pressure will be smaller.
The present invention still further provides increased pump efficiency since all the feedback flow will not have to pass to the reservoir.
The above and additional advantages of the present invention will become apparent to those skilled in the art from a consideration of the following detailed description of the preferred embodiment when taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
The drawing shows schematically and partially in section, the demand compensated system employed with a plurality of motors and incorporating the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, therein is a shown a variable displacement pump 10 having an output control mechanism 12 by which the output of the pump 10 may be varied. The specific type of pump is not material, as long as it is any of the well-known variable displacement types in which the output control mechanism 12 is arranged so that its output is increased by a mechanical force, such as a compression spring 14 acting against a piston 16 and the piston 16 is carried in a cylinder 18 so that its face is subjectable to fluid pressure admitted to a fluid receivable chamber 19 opposite the spring 14 to decrease the pump output.
The pump 10 is connected to a reservoir 20 by an intake line 22. The discharge side of the pump 10 is connected via an output line 24 and a supply line 26 to a constant-operating-pressure fluid motor 28. The output line 24 is further connected by a supply line 30 to a motor control valve 32. The control valve 32 may be manually and/or servo operated by any suitable means, represented here schematically at 34. The control valve 32 is illustrated schematically, as are many of the well-known hydraulic components employed in the system, and is of the closed-center type, which permits no flow when in neutral as shown. A pair of motor lines 36 and 38, respectively, connect the control valve 32 to opposite ends of the cylinder of a two-way, fluid pressure motor 40. When the control valve 32 is shifted downwardly from its neutral position, the supply line 30 is connected to the motor line 36 so as to retract the motor 40 and the return of fluid is via the motor line 38 to an exhaust or reservoir line 42. Movement of the control valve 32 to an upward position, opposite the position just described, will interchange the connections so that the motor lines 38 and 36 are connected respectively to the supply and reservoir lines 30 and 42 to extend the motor 40.
To control the output control mechanism 12 there is provided a demand control valve 56. The demand control valve 56 is disclosed in its entirety in the U.S. Pat. No. 2,892,312 granted to J. R. Allen et al. and does not form a part of the present invention, but for purposes of this disclosure it may be described as being a dual-pilot operated, normally-closed valve. The pressure side of the demand control valve 56 is connected to the output line 24 by a line 58 and the non-pressure side is connected to an output control line 60 and through an orifice 62 to the reservoir 20. A first pilot line 63 of the demand control valve 56 is connected to the line 58 and a second pilot line 65 is connected to a main pilot line 64. The demand control valve 56 is biased to its normally-closed position by the action of a spring 66 on the same side as the second pilot line 65. To the extent thus far described, it will be seen the the demand control valve 56 is subjected to at least two forces; namely, pressure via the output line 24 and the spring load via the spring 66. It will be further seen that when the demand control valve 56 is open, pressure from the output line 24 is transmitted via the line 58, the output control line 60, and a control line 68 to the fluid receivable chamber 19 of the output control mechanism 12 so as to oppose the effect of the spring 14 and decrease the pump 10 output. It should be noted that a conventional relief valve 70 is placed in parallel with the demand control valve 56 to limit the maximum pressure output from the pump 10.
In addition to the forces acting on the demand control valve 56 as previously described, the demand control system adds the main pilot line 64 pressure through the second pilot line 65 in conjunction with the force imposed by the spring 66. This main pilot line 64 pressure is obtained through a first and second pilot line branches 72 and 74 which contain check valves 76 and 78, respectively, and which are connected to motor lines 36 and 38, respectively.
The main pilot line 64 is further connected by a reservoir line 82 through a restrictor 84 to the pressure side of a normally-closed, pressure regulator valve 86. The non-pressure side of the pressure regulator valve is connected by a reservoir line 88 to the reservoir 20. The pressure regulator valve 86 is pilot-operated by means of a pilot line 90 connected between the restrictor 84 and the pressure side of the pressure regulator valve 86. The pressure regulator valve 86 is held in its closed position by an adjustable spring 92.
The main pilot line 64 is further connected by a pressurizing line 94 to the output line 24. Disposed in the pressurizing line 94 is an orifice 96 and a check valve 98.
During initial start-up, there will be no pressure in the main pilot line 64 and in the output control line 60, thus the pump 10 will go to maximum stroke to pressurize the output line 24. As the pressure in the output line 24 builds up, the major portion of the fluid will supply the constant pressure fluid motor 28 while a small portion will be diverted through the orifice 96 and check valve 98 to pressurize the main pilot line 64. As the pressure builds up in the main pilot line 64, the demand control valve 56 will remain in its closed position since the pressure in the line 58 initially will not exceed the pressure in the second pilot line 65 plus the force of the spring 66. Thus, the pump 10 will continue to operate at its maximum displacement.
As the pressure in the main pilot line 64 reaches a predetermined stand-by pressure level as determined by the adjustable spring 92, the pressure regulator valve 86 will maintain the pressure by opening to allow fluid flow from the main pilot line 64 through the the reservoir lines 82 and 88 to the reservoir 20. As the pressure in the line 58 exceeds the pressure in the second pilot line 65 plus the force imposed by the spring 66, the demand control valve 56 will open to begin pressurization of the output control line 60. As the fluid receivable chamber 19 pressure increases above the force of the spring 14, the pump 10 displacement will begin to decrease. When the output pressure of the pump 10 substantially balances the pressure in the main pilot line 64 due to the setting of the pressure regulator valve 86 plus the force of the spring 66 and the pressure in the output control mechanism 12 equals the force of the spring 14, the output pressure of the pump 10 will stop changing and a constant standby pressure will be established.
When the control valve 32 is moved from its neutral position so as to cause activation of the fluid motor 40 and increased demand, the pressure in the first or second pilot line branch 72 or 74 will increase causing an increase in the main pilot line 64 pressure.
As the pressure in the main pilot line 64 increases, the pressure regulator valve 86 will be opened and the demand control valve 56 will be closed due to pressure in the second pilot line 65. With the demand control valve 56 closed, the output control line 60 will drain through the orifice 62 causing a decrease of pressure at the output control mechanism 12. As the pressure decreases, the piston 16 will move to increase the displacement of the pump 10 to compensate for the demand. The displacement of the pump 10 will increase until the pressure in the first pilot line 63 opens the demand control valve 56 to supply the pressure required at the output control mechanism 12 to maintain the operating pressure in the output line 24. Thus, the output pressure of the pump 10 will only be greater than that required by the fluid motors 28 and 40 by the pressure required by the output control mechanism 12 and the pressure component due to the setting of the pressure regulator valve 86 is eliminated.
When the control valve 32 is returned to neutral position, the pressure in the main pilot line 64 will be again reduced to the standby pressure as determined by the pressure regulator valve 86 and the output control mechanism 12.
It should be noted that the orifice 96 in the pressurizing line 94 serves a dual function. First, it allows flow from the pump 10 to enter the main pilot line 64 so as to provide predictable pressurization of the main pilot line 64 as compared to a system wherein fluid leakage through the demand control valve 56 is used to pressurize the main pilot line 64. Second, the orifice 96 establishes a controlled flow of warm fluid through the main pilot line 64 to keep it warm so that increases in fluid viscosity in cold environments will not adversely affect the response time of the demand compensated system.
While the invention has been described in conjunction with a specific embodiment, it is to be understood that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the aforegoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations which fall within the spirit and scope of the appended claims. | A hydraulic system having pilot line fluid feedback from a fluid motor to valving which operates to change pump output to compensate for motor demand includes a pressure regulator valve for maintaining a predetermined minimum pressure in the pilot line. The pressure regulator valve eliminates the power wasting pressure differential which normally exists between the pump output and the fluid motor demand in demand compensated hydraulic systems. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from U.S. provisional application No. 60/681,971 filed May 18, 2005, which is titled “Traffic information signal and method and apparatus for providing the signal,” and Korean application No. 10-2005-0099532, filed Oct. 26, 2005, the entire contents of which are incorporated herein by reference.
BACKGROUND
1. Field
The present document relates to providing traffic information including sub-links of link and using the provided traffic information.
2. Description of the Related Art
With the advancement in digital signal processing and communication technologies, radio and TV broadcasts are being digitalized. Digital broadcasting enables provision of various information (e.g., news, stock prices, weather, traffic information, etc.) as well as audio and video content.
SUMMARY
In one general aspect, a method for identifying traffic information for at least one sub-link is provided. The method includes receiving traffic information including a sub-link identifier enabling a determination of whether the received traffic information includes sub-link information, traffic status information enabling a determination of traffic information for a sub-link, information identifying a link within which the sub-link is located, and sub-link location information enabling a determination of a portion of the link that corresponds to the sub-link. The method also includes determining, based on the sub-link identifier whether the received traffic information includes sub-link information and dependent on whether the sub-link identifier enables a determination that the received traffic information includes sub-link information.
Implementations may include one or more additional features. For instance, the method may include receiving a data length associated with the traffic information, a text name or description of the sub-link, and a start and end location of the sub-link. Receiving sub-link location information may include receiving vertex, coordinate, or longitude and latitude information that corresponds to a location associated with the sub-link. Receiving sub-link location information may include receiving vertex, coordinate, or longitude and latitude information that corresponds to the link.
Also, in the method, after the sub-link is determined to be within the link, additional sub-link information to enable deletion of the sub-link may be received. The sub-link may, only if the received additional sub-link information includes an identifier that enables a determination that the sub-link is to be deleted, be deleted. The received additional sub-link information may specify the sub-link identifier and the identifier of the link.
The method may further include receiving additional sub-link information after the sub-link is determined to be within the link, and using the received additional sub-link information to alter the position of the determined sub-link within the link. The received additional sub-link information may include at least one of a start location and an end location of the determined sub-link. The received additional sub-link information may be used to extend or shorten a length of the sub-link. Additional sub-link information may be received after the sub-link is determined to be within the link, and the received additional sub-link information may be used to alter the position of the determined sub-link beyond location constraints associated with the link.
Also, the method may further include receiving information corresponding to a message management structure including information corresponding to a generation time of the information included in the message management structure. The generation time included within the received message management structure may relate to the status information for the sub-link. The generation time included within the received message management structure may relate to a plurality of message component structures that correspond to more than one of a predicted or current traffic tendency, a predicted or current amount of traffic, a predicted or current speed, and a predicted or current time to traverse a particular link. Receiving information reflecting a message component structure may include receiving information associated with identification and configuration of the sub-link.
Further, in the method, the traffic status information for the sub-link may include information associated with at least one of a predicted or current travel speed on the sub-link, a predicted or current congestion level or amount on the sub-link, a predicted or current travel time to traverse the sub-link, or a predicted or current speed of travel on the sub-link, may be received. The traffic status information for the sub-link may differ from traffic status information for the link. The traffic status information for the sub-link may be received after receiving traffic status information that is configured to reveal status for the link, the sub-link status information being configured to enable updated status information for a portion of the link corresponding to the sub-link. Receiving sub-link information may include receiving a text descriptor associated with the sub-link.
In another general aspect, a traffic information communication device is provided. The device includes a data receiving interface configured to receive traffic information including a sub-link identifier enabling a determination of whether the received traffic information includes sub-link information and traffic status information enabling a determination of traffic information for a sub-link. The device is also configured to receive information identifying a link within which the sub-link is located, and sub-link location information enabling a determination of a portion of the link that corresponds to the sub-link. The device also includes a processing device configured to process the traffic information received from the data receiving interface and to determine sub-link status information based at least in part on the traffic information received.
Implementations may include one or more additional features. For instance, the data receiving interface may receive additional sub-link information after the sub-link is determined to be within the link, and the processing device may be configured to use the received additional sub-link information to alter the position of the determined sub-link within the link. The received additional sub-link information may include at least one of a start location and an end location of the determined sub-link. The processing device may be configured to use the received additional sub-link information to extend or shorten a length of the sub-link. The data receiving interface may receive additional sub-link information after the sub-link is determined to be within the link, and the processing device may be configured to use the received additional sub-link information to alter the position of the determined sub-link beyond location constraints associated with the link.
In a further general aspect, an apparatus for identifying traffic information for at least one sub-link is provided. The apparatus includes means for receiving traffic information including a sub-link identifier enabling a determination of whether the received traffic information includes sub-link information, traffic status information enabling a determination of traffic information for a sub-link, information identifying a link within which the sub-link is located, and sub-link location information enabling a determination of a portion of the link that corresponds to the sub-link. The method also includes means for determining, based on the sub-link identifier whether the received traffic information includes sub-link information and means for, dependent on whether the sub-link identifier enables a determination that the received traffic information includes sub-link information.
Implementations may include one or more additional features. For instance, the means for receiving may include means for receiving additional sub-link information after the sub-link is determined to be within the link, the apparatus further comprising means for using the received additional sub-link information to alter the position of the determined sub-link within the link.
The method may also include means for using the received additional sub-link information to extend or shorten a length of the sub-link. The means for receiving may include means for receiving additional sub-link information after the sub-link is determined to be within the link, the apparatus may further include means for using the received additional sub-link information to alter the position of the determined sub-link beyond location constraints associated with the link.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate various implementations. In the drawings:
FIG. 1 illustrates a schematic diagram of a network through which traffic information is provided;
FIG. 2 a illustrates a partial syntax of a component frame including traffic information;
FIG. 2 b illustrates a format of a TPEG-CTT message with an emphasis on status components delivering traffic information;
FIG. 2 c illustrates a format of a TPEG-CTT message with an emphasis on coordinate components delivering link information;
FIG. 3 a illustrates a syntax of a link information component
FIG. 3 b illustrates a format of the TPEG-CTT message with an emphasis on link information components;
FIG. 3 c illustrates a format to transmit information on a sub-link through coordinate components;
FIG. 4 illustrates a block diagram of a navigation terminal that receives traffic information transmitted from a server; and
FIGS. 5 a through 5 c illustrate examples of displaying traffic information such as average speed in a link, and a sub-link.
DETAILED DESCRIPTION
One such use for digital broadcasts is to satisfy an existing demand for traffic information. Proposals that involve the use of digital broadcasts for this purpose contemplate the use of standardized formatting of traffic information to be broadcast. This approach may be used to enable the use of traffic information receiving terminals made by different manufacturers, which each could be configured to detect and interpret traffic information broadcast in the same way.
FIG. 1 is a schematic diagram of a network through which traffic information is provided. A traffic information providing server 100 in a broadcast station may transmit traffic information, e.g., traffic congestion information collected from various sources (e.g., operator input, or information received from another server or probe cars through a network 101 ) wirelessly so that a traffic information receiving terminal (e.g., navigation system installed in a car 200 ) may receive the traffic information. In the below explanation about implementations, the traffic information means traffic congestion information.
The traffic information wirelessly transmitted from the traffic information providing server 100 may be of the form of a component frame. As shown in FIG. 2 a , a component frame may include a field 201 indicative of the number of messages included therein and a sequence of transport protocol expert group messages 202 , where the number of the messages being equal to the value stored in the field 201 . The transport protocol expert group message will be referred to as the TPEG-CTT message hereinafter.
As shown in FIGS. 2 b and 2 c , one message segment of the sequence 202 , i.e., one TPEG-CTT message, may include a message management container including information on date and time, the message occurrence time, etc., a congestion and travel-time information (CTT) container, and a TPEG-CTT location container. The CTT container may include a field 211 indicative of the number of CTT components included in the CTT container and the TPEG-CTT location container. The field 211 may be followed by CTT components, the number of which is equal to the value stored in the field 211 .
In various implementations, if a CTT component includes traffic congestion information, the CTT component is given an ID of 0x80, as shown in FIG. 2 b , and includes one or more status components therein. Each status component may include an ID indicative of the information included therein. For example, a status component including an ID of 0x00 delivers the average speed in a link. A status component including an ID of 0x01 delivers link travel time. A status component including and ID of 0x03 delivers information on the degree or type of congestion. In the description, specific IDs are described as assignments to structures associated with specific information. The actual value of an assigned ID (e.g., 0x80) is exemplary, and different implementations may assign different values for specific associations or circumstances. Thus, the CTT component may be used to provide various different types of data that may be signaled based on an identifier. For example, FIG. 2B illustrates components with identifiers of 0x00 and 0x01 signaling, respectfully, speed and travel-time information.
Further, according to the various implementations if a CTT component includes link location information, the CTT component is given an ID of 0x90, as shown in FIG. 2 c , and includes one or more TPEG-CTT location sub-containers. Each TPEG-CTT location sub-container ‘Tpeg_loc 13 container’ includes one or more TPEG-CTT location components, each of which includes one or more coordinate components having an ID of 0x00. Each coordinate component delivers information on a link or links for which the status component includes traffic information. A link may refer to a road segment which starts and ends at junctions and has no junction in between. A coordinate component including an ID of 0x00 includes information on the link type (e.g., express way, national road, etc). A coordinate component including an ID of 0x01 includes coordinate information which may be expressed in the WGS84 format. A coordinate component including an ID of 0x03 includes link description information and a coordinate component including an ID of 0x10 includes link identification information.
The server 100 may construct the TPEG-CTT information as shown in FIGS. 2 a through 2 c from traffic information collected from various sources and may transmit the constructed TPEG-CTT information to traffic information receiving terminals wirelessly.
Information may be provided on a specific link in more detail. For example, if a driver wants to go to a location within a link which ends at an intersection and there is traffic congestion around the intersection, the average speed in the road segment is very low. If the driver estimates the approximate arrival time based on the average speed in the road, the actual arrival time may significantly deviate from the estimated arrival time, such as, for example, when the destination is near the congested intersection. As a result, the driver may benefit from detailed traffic information around the specific location.
In various implementation, the server 100 collects traffic information in a centralized manner, and creates and provides traffic information for a sub-link within a link. In one implementation, a sub-link is created if the difference between the average speed in the sub-link and the average speed in the other segment within the link exceeds a predetermined threshold level (e.g., 5 m/s or 10 m/s).
A process, according to various implementations, for providing traffic information on a virtual sub-link that does not correspond to a full actual link will now be described in detail.
To provide traffic information on a sub-link 10 within a link, the server 100 may construct a link information component, as shown in FIG. 3 a , and may deliver the link information component via a TPEG-CTT location sub-container. The link information component is allocated an ID of 0x01 distinct from the ID of a coordinate component.
As shown in FIG. 3 b , each link information component may include a link allocating sub-component 301 for allocating a sub-link as a virtual link within a link and a link canceling sub-component 302 for canceling an existing sub-link. A sub-link need not be an actual link but may be treated as a link in that congestion and traveling time information may be provided for each sub-link.
The link allocating sub-component 301 has an ID of 0x00 and may include a sub-link ID to allocate to a sub-link to be established, the ID of a parent link within which the sub-link is established, coordinate information indicative of the start and end positions of the sub-link, and/or a descriptor. In various implementations, the coordinate information may be a pair of 4-byte longitude and 4-byte latitude or indices of the vertices corresponding to the start and end positions of the sub-link formed within the parent link. The link canceling sub-component 302 has an ID of 0x01 and may include a sub-link ID, which is the ID of the sub-link to be canceled, and a parent link ID.
The server 100 may construct the TPEG-CTT information as shown in FIGS. 2 a through 2 c from traffic information collected from various sources and may transmit the constructed TPEG-CTT information to traffic information receiving terminals wirelessly. Under various circumstances, such as, for example, during the transmission, if the difference between the average speed in a local segment within a link and the average speed in the other segment of the link exceeds a threshold value, the server 100 may create a link allocating sub-component 301 for establishing the local segment as a sub-link and may deliver the link allocating sub-component 301 via the link information component 300 .
In another implementation, information on sub-link allocation and cancellation may be carried by a coordinate component including an ID of 0x00, as shown in FIG. 3 c . In this case, IDs of, for example, 0x11 and 0x12 are allocated to a coordinate component carrying sub-link information to distinguish from other coordinate components carrying road-type list, WGS84, link description, and link identification.
In this implementation, location information that may be needed for allocating a sub-link, for example, WGS84 information on start and end points and sub-link description information, may be included dispersedly in both a WGS84 component and a description component shown in FIG. 2 c.
The server 100 may transmit traffic information (e.g., average speed, link travel time, the degree of congestion, etc) for the sub-link in a similar manner to links.
According to various implementations, if the length of the sub-link which shows an average speed deviation larger than a threshold level changes, i.e., the change in the length of the sub-link exceeds a predetermined length (e.g., 20 m in the case of downtown roads), the server 100 may create and may transmit a link allocating sub-component (or sub-link allocating coordinate component) for reallocating a sub-link including the changed start and end positions. In this case, the server 100 may allocate the sub-component an ID, e.g., 0x02 (or 0x13) instead of 0x00 (or 0x11 indicative of a sub-link allocating coordinate component) to inform traffic information receiving terminals that a sub-link is established again within a parent link which already has a sub-link therein. A similar process may be used to shorten or move a sub-link, with the creating of a link shortening sub-component or a link moving sub-component.
After a sub-link is allocated in a link, the average speed in the link and the average speed in the sub-link may be provided separately.
In one implementation, if the difference between the average speed in a sub-link within a link and the average speed in the other segment of the link goes below the same or a different threshold value while the server 100 transmits traffic information for the sub-link, the server 100 may create a link canceling sub-component 302 for canceling the allocated sub-link as shown in FIG. 3 b and may deliver the link canceling sub-component 302 via the link information component 300 .
FIGS. 4-6 are example implementations of systems for receiving and utilizing traffic information. Other systems may be organized differently or include different components. Specifically, FIG. 4 is an example of a block diagram of a navigation terminal that receives traffic information transmitted from the server 100 .
The navigation terminal includes a tuner 1 for receiving modulated traffic information signals by resonating at the required frequency band, a demodulator 2 for outputting traffic information signals by demodulating the modulated signals from the tuner 1 , a TPEG-CTT decoder 3 for extracting traffic information by decoding the demodulated traffic information signals, a GPS module 8 for calculating the current position (i.e., latitude, longitude, and altitude) by receiving signals from a plurality of satellites, storage structure 4 for storing various graphic data and an electronic map including information on links and nodes, an input unit 9 for receiving user input, a navigation engine 5 for controlling screen display based on the user input, the current position, and extracted traffic information, a memory 5 a for storing data temporarily, an LCD panel 7 for displaying data, and an LCD drive 6 for driving the LCD panel 7 according to data to be presented. The input unit 9 may be a touch screen incorporated into the LCD panel 7 .
The tuner 1 tunes to the frequency of the signals transmitted by the server 100 and the demodulator 2 demodulates the tuned signals in a predetermined manner. The TPEG-CTT decoder 3 extracts TPEG-CTT messages, as shown in FIGS. 2 a through 2 c and FIG. 3 a and 3 b (or 3 c ), and stores the TPEG-CTT messages temporarily. Interpreting the temporarily stored TPEG-CTT messages, the TPEG-CTT decoder 3 sends the extracted information and/or control data to the navigation engine 5 . Though various kinds of information is provided for the navigation engine 5 by the TPEG-CTT decoder 3 , for purposes of brevity, the following description will focuses on the method for allocating sub-links and the method for processing traffic information for sub-links.
The TPEG-CTT decoder 3 extracts data/time and message occurrence time included in the message management container of each TPEG-CTT message and determines if the following container is a CTT event container based on ‘message element’ information (i.e. an identifier). If it is determined that the following container is a CTT event container, the TPEG-CTT decoder 3 provides the navigation engine 5 with the information obtained from the CTT component included in the CTT event container so that the navigation engine 5 can display congestion and travel-time information and link information, which will be described below. Providing the navigation engine 5 with the information may include determining, based on identifiers, that the traffic information includes a message management container including status or sub-link information within various message components within the message management container. The components may each include different status or sub-link information associated with different links, composite links, or locations and identifiers associated with the different status or sub-link information. The containers and components may each include information associated with a generation time, version number, data length, and identifiers of included information.
The TPEG-CTT decoder 3 then extracts information on the link location about which the previously extracted information may be created from the following TPEG-CTT location container. The position information may be, for example, the coordinates (i.e., latitudes and longitudes) of the start and end positions or a link ID, depending on the type of the TPEG-CTT location container. If the navigation terminal is equipped with the storage structure 4 , the navigation engine 5 finds the link location about which the received information is created with reference to information on each link and node stored in the storage structure 4 . The navigation engine 5 may convert the coordinates of the link into the link ID or vice versa.
In the implementation of FIG. 3 b , the TPEG-CTT decoder 3 may determine if a link information component including an ID of 0x01 is delivered via a TPEG-CTT location sub-container and if so, may extract each sub-component from the link information component. If the extracted sub-component is a link allocating sub-component (e.g., includes an appropriate identifier), such as including an ID of 0x00 for allocating a sub-link, the TPEG-CTT decoder 3 may extract the ID of the sub-link to allocate, the ID of the parent link, information on the start and end positions, and descriptor and provides the extracted information for the navigation engine 5 so that the extracted information may be stored as a temporary link entry in the memory 5 a . If the extracted sub-component is a link canceling sub-component (e.g., includes an appropriate identifier), such as including an ID of 0x01 for canceling an existing sub-link, the TPEG-CTT decoder 3 may make a request for removing a temporary link entry including an ID that is the same as the sub-link ID of the sub-component so that the navigation engine 5 can remove the sub-link entry from the memory 5 a.
In the implementation of FIG. 3 c , a sub-link allocating coordinate component or a sub-link cancellation coordinate component may be extracted from a TPEG-CTT location component including ID of 0x00 included in a TPEG-CTT location sub container, and the above-explained operations may be conducted according to information included in the extracted component.
The navigation engine 5 reads a part of the electronic map centered around the position coordinates received from the GPS module 8 from the storage structure 4 and displays the map on the LCD panel 7 via the LCD drive 6 . A particular graphic symbol is displayed at the location corresponding to the current position on the LCD panel 7 .
The navigation engine 5 may display the average speed or average travel time in a link received from the TPEG-CTT decoder 3 at a location corresponding to the coordinates or link ID delivered via the TPEG-CTT location container following the container delivering the average speed or average travel time information. In this case, the navigation engine 5 may search the storage structure 4 for the link corresponding to the coordinates or link ID received from the TPEG-CTT location container. If the link is not found, then the navigation engine 5 may determine if there is a matched temporary link entry in the memory 5 a . In this search operation, temporarily allocated sub-links as well as actual links may be searched. The traffic information for the link and/or sub-link specified by the search operation may be extracted from the corresponding status component included in a CTT component including an ID of 0x80.
There are various alternative methods for the navigation engine 5 to display traffic information. For example, the navigation engine 5 may show links in different colors according to the average speed in the links, as shown in FIGS. 5 a and 5 b , or may show the average speed with number in each link as shown in FIG. 5 c . In FIGS. 5 a and 5 b , the red, orange, green, blue colors indicate average speeds of 0-10 km, 1020 km, 2040 km, over 40 km, respectively.
If the navigation terminal is not equipped with the storage structure 4 for storing an electronic map, the terminal may show the average speed or the travel time in links located in front of the current position with different colors as shown in FIG. 5 b , or with figures as shown in FIG. 5 c . If the route of the car with the navigation terminal installed is determined, the navigation terminal may show the average speed in the links included in the determined route instead of the links located in front of the current position.
If the traffic information for a temporary link entry stored in the memory 5 a , i.e., a sub-link, is received, the navigation engine 5 may display the traffic information for the sub-link with colors or figures, as marked ‘A’ in FIGS. 5 a through 5 c to be distinguished from the traffic information for the parent link.
If the terminal in FIG. 4 is equipped with a voice output device, the terminal may output received traffic information for a specified link or sub-links included in a specified route in voice. If the specified link or one of the links included in the specified route is a sub-link, a voice message describing the average speed in the sub-link is generated. If the descriptor in the link allocating sub-component (or link description component) shown in FIG. 3 b is “xxx”, the voice message may be “the average speed in xxx segment is nn”.
The present disclosure enables estimation of an approximate arrival time even when the roads around the destination are congested locally by providing additional traffic information for a road segment showing a big deviation in the average speed from the other segment of the road.
In the previous discussion, wherever average speed has been referenced, it may be interpreted as either of actual or predicted average speed, or it may be replaced or supplemented with other status or component based information, such as, for example, actual or predicted travel time (e.g., to traverse the link), congestion tendency, and/or congestion amount.
The foregoing description has been presented for purposes of illustration. Thus, various implementations with improvements, modifications, substitutions, or additions within the spirit and scope as defined by the following appended claims. | A method for identifying traffic information for at least one sub-link includes receiving traffic information including a sub-link identifier enabling a determination of whether the received traffic information includes sub-link information, traffic status information enabling a determination of traffic information for a sub-link, information identifying a link within which the sub-link is located, and sub-link location information enabling a determination of a portion of the link that corresponds to the sub-link. The method also includes determining, based on the sub-link identifier whether the received traffic information includes sub-link information and dependent on whether the sub-link identifier enables a determination that the received traffic information includes sub-link information. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an apparatus using a microprocessor, and more particularly, to an apparatus and a method for upgrading a program that controls a microprocessor. The present application is based on Korean Application No. 2001-63950, filed Oct. 17, 2001, which is incorporated herein by reference.
[0003] 2. Description of the Related Art
[0004] An existing digital television or a set-top box has a microprocessor and a built-in program that operates a system to meet the needs of a user. The program is stored in a non-volatile memory when the system is manufactured in a factory, and can be modified and upgraded by a service engineer after the system is released.
[0005] While analog broadcasting is replaced by digital broadcasting, the broadcasting specification may be changed. Additionally, there may be a problem with the program. Therefore, the program needs to be changed frequently.
[0006] As a result, easy upgrading of the program is more important than ever before.
[0007] [0007]FIG. 1 shows an existing method for upgrading a program.
[0008] With reference to FIG. 1, a system 100 is controlled by a microprocessor 102 . A program that controls the microprocessor 102 is stored in a program memory 104 . The program memory 104 is implemented as a non-volatile memory for upgrading the program, such as a flash Read Only Memory (ROM), an Electrically Erasable and Programmable Read-Only Memory (EEPROM) and a nonvolatile random access memory (NVRAM).
[0009] The NVRAM is a non-volatile RAM that can protect recorded data even though external power to a computer is turned off or lost. Some modems use the NVRAM as a memory that saves a telephone number designated by a user or a setup value of the modem.
[0010] In some cases, the program stored in the program memory 104 of the system 100 shown in FIG. 1 needs to be upgraded for improvement, to provide enhanced performance, or to eliminate a bug.
[0011] For upgrading, the system 100 shown in FIG. 1 includes an RS-232C 106 and an RS-232C connector 108 that can interface with an external computer 150 . The RS-232C is a specification that describes a physical connection and a protocol that enable the computer and relevant devices to perform a serial data communication at a relatively low speed.
[0012] As the external computer 150 , a portable notebook PC is used.
[0013] To upgrade the program, the service engineer connects the external computer 150 and the system 100 , using the RS-232C cable, and downloads an upgrading program from the external computer 150 . The downloaded program upgrades the program stored in the program memory 104 .
[0014] In a boot area of the program memory 104 , there is a boot loader that is a program which controls the program upgrading. The boot loader stores the downloaded program in an empty area of the RAM or the program memory 104 , and upgrades the existing program using the downloaded program.
[0015] After the program upgrading is completed, the system is rebooted. The boot loader loads the upgraded program and the system is controlled by the upgraded program.
[0016] When upgrading the program of the system shown in FIG. 1, the service engineer should carry the notebook PC which saves the upgrading program and connect the external computer with the system 100 , using the RS232C cable in order to upgrade the program.
[0017] Therefore, the existing program upgrading is disadvantageous in that it necessitates a complicated process and the external computer.
SUMMARY OF THE INVENTION
[0018] To solve the above-described problems, it is an object of the present invention to provide a method for upgrading a program of a system easily.
[0019] It is another object of the present invention to provide an apparatus which is suitable for the program upgrading.
[0020] To achieve the above object, a method for upgrading a program stored in a memory in a system which includes a microprocessor and the memory that has a program designed to control the microprocessor, the program upgrading method including:
[0021] installing a Personal Computer Memory Card International Association (PCMCIA) interface device in the system;
[0022] recording the upgrading program in a PCMCIA card;
[0023] downloading the upgrading program from the PCMCIA card through the PCMCIA interface device installed in the system under the control of the program stored in the memory; and
[0024] upgrading the program stored in the memory with the downloaded program under the control of the program stored in the memory.
[0025] To achieve another object, the system using the microprocessor according to the present invention includes:
[0026] a microprocessor;
[0027] a memory having application programs designed to implement a specific operation by controlling the microprocessor and a boot program deigned to control the loading of the application programs during booting; and
[0028] a Personal Computer Memory Card International Association (PCMCIA) interface unit.
[0029] The method for upgrading a program stored in a memory in a system which includes a microprocessor, application programs designed to implement a specific operation by controlling the microprocessor, the memory that stores a boot program designed to control the load of the application programs during booting, and a Personal Computer Memory Card International Association (PCMCIA) interface unit, the program upgrading method including:
[0030] downloading an upgrading program from the PCMCIA card through the PCMCIA interface device under the control of the application programs stored in the memory;
[0031] saving the program downloaded under the control of the application programs stored in the memory in a buffer memory area;
[0032] setting a flag indicating the program upgrading in the memory area which is referred to by a boot loader and rebooting the system; and
[0033] upgrading the application programs stored in the memory with the program stored in the buffer memory area and resetting the flag if the flag is set.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The above object and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
[0035] [0035]FIG. 1 shows an existing method for upgrading a program;
[0036] [0036]FIG. 2 is a flowchart showing a method for upgrading a program according to the present invention;
[0037] [0037]FIG. 3 is a block diagram showing the configuration of a program upgrading apparatus according to the present invention; and
[0038] [0038]FIG. 4 shows a detailed process where the program upgrading apparatus shown in FIG. 3 upgrades a downloaded program.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The present invention will now be described in detail by describing preferred embodiments thereof with reference to the accompanying drawings.
[0040] A program upgrading method according to the present invention uses a Personal Computer Memory Card International Association (PCMCIA) card. The PCMCIA is an international standard association which was established in 1989 in order to develop a specification on an IC card and improve interworking between mobile computers.
[0041] Until 1991, the PCMCIA defined an I/O interface of a 68-pin connector used in a memory card and prepared specifications on a socket service and a card service.
[0042] As demand for high-speed applications such as a multimedia and a high-speed network have recently been increasing, the PCMCIA established specifications on a card bus and a zoomed video for MPEG video and 100 Mbps applications. The PCMCIA continued to add specifications in order to enhance compatibility and added 3.3 V operation or a power management function for mobility. The PC card of the PCMCIA is applied not only to a mobile computer, but also a digital camera, a cable TV, a set-top box and an automobile.
[0043] The physical specifications include Type I, Type II and Type III. The three physical specifications use a 69-pin connector with the same width (54 mm) and length (85.6 mm) and with different thickness (3.3, 5.0, 10.5 mm). Due to the different thicknesses, the three physical specifications are used for different applications. Type I is used for a memory such as RAM, flash, OTP (one-time programmable) and SRAM (static random access memory). Type II is used for a fax, a modem, a Local Area Network (LAN) and a memory device. Type III is used for a hard disc.
[0044] [0044]FIG. 2 is a flowchart showing a method for upgrading a program according to the present invention.
[0045] With reference to FIG. 2, a PCMCIA interface device is installed on the system in step S 202 . The PCMCIA interface device includes the connector to which the PCMCIA card is connected.
[0046] The PCMCIA card that saves the upgrading program is connected to the PCMCIA connector of the system in step S 204 .
[0047] The upgrading program is downloaded from the PCMCIA card in step S 206 .
[0048] The existing installed program is upgraded by the downloaded program in step S 208 .
[0049] Since the program upgrading method according to the present invention does not use the RS232C, the external computer is not needed, and connecting and downloading from the external computer are not required. Therefore, the program upgrading can be performed easily and quickly.
[0050] [0050]FIG. 3 is a block diagram showing the configuration of a program upgrading apparatus according to the present invention.
[0051] With reference to FIG. 3, a system 300 is controlled by a microprocessor 302 . A program that controls the microprocessor 302 is stored in a program memory 304 . The program memory 304 is implemented as a non-volatile memory that can be recorded for upgrading the program, such as a flash ROM, EEPROM and a nonvolatile random access memory (NVRAM).
[0052] In some cases, the program stored in the program memory 304 of the system 300 shown in FIG. 3 needs to be upgraded for improved performance or for elimination of a bug.
[0053] For program upgrading, the system 300 shown in FIG. 3 includes a PCMCIA interface unit 306 and a PCMCIA connector 308 .
[0054] To upgrade the program, the service engineer inserts the PCMCIA card 350 that stores the upgrading program into the PCMCIA connector 308 , and downloads the upgrading program. The downloaded program is stored in a buffer memory 310 temporarily and upgrades the program stored in the program memory 304 .
[0055] The downloaded program may be a compressed program. Thus, before program upgrading is performed, the compressed program needs to be decompressed.
[0056] In a boot area of the program memory 304 , there is a boot loader that is a program which controls the program upgrading. The boot loader stores the downloaded program in an empty area of the buffer memory 310 or the program memory 304 , and upgrades the existing program using the downloaded program.
[0057] After the program upgrading is completed, the system is rebooted. The boot loader loads the upgraded program and the system is controlled by the upgraded program.
[0058] [0058]FIG. 4 shows a detailed process where the program upgrading apparatus shown in FIG. 3 upgrades a downloaded program.
[0059] With reference to FIG. 4, the program memory 304 includes a boot loader area 304 a that stores the boot loader, and a main program area 304 b that stores a main program. The buffer memory 310 may be a non-volatile memory where additional recording can be performed, or a reserved space of the program memory 304 .
[0060] A menu program is used to select downloading/upgrading. The menu program is included in the main program.
[0061] That is, a user selects the upgrading of the program in a menu program. If the user enters a request for program upgrading, the upgrading program is downloaded from the PCMCIA card 350 . The downloaded program is stored in the buffer memory 310 .
[0062] When the downloading is completed, a flag for upgrading of the program stored in the EEPROM 312 is set and the system is rebooted. The EEPROM 312 may be an additional memory module which is separated physically from the program memory 304 . In addition, the address of the EEPROM 312 may constitute a part of an extensive address system including the program memory 304 .
[0063] If the system is rebooted, the boot loader controls the installation of the main program, and refers to the flag for upgrading of the program stored in the EEPROM 312 . If the flag is set, the downloaded program stored in the buffer memory 310 is recorded in the main program area 302 b. Then, the program upgrading is performed.
[0064] After the program is upgraded, the boot loader resets the flag for upgrading of the program stored in the EEPROM 310 and reboots the system.
[0065] When the system is rebooted, the boot loader refers to the flag for upgrading of the program stored in the EEPROM 312 . If the flag is reset, the main program recorded in the main program area 302 b is loaded.
[0066] After the above process, the main program controls the system.
[0067] As described above, the program upgrading method according to the present invention can upgrade the program easily, using the PCMCIA interface.
[0068] Although preferred embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | An apparatus and a method for upgrading a program that controls a microprocessor. The program upgrading method includes: installing a Personal Computer Memory Card International Association (PCMCIA) interface device in the system; recording the upgrading program in a PCMCIA card; downloading the upgrading program from the PCMCIA card through the PCMCIA interface device installed in the system under the control of the program stored in the memory; and upgrading the program stored in the memory with the downloaded program under the control of the program stored in the memory. The program upgrading method can perform program upgrading through a PCMCIA interface easily. | 6 |
This Application is based on and claims benefit of German Application No. 197 42 100.8 filed Sep. 24, 1997, to which a claim of priority is hereby made.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a process for transmitting a time signal from a satellite as well as process for receiving a time signal at a ground based receiver.
2. Description of the Related Art
A terrestrial time signal transmitter for example the DCF-77 transmitter of the Federal Institute of Physical Engineering at Frankfurt um Main, transmits its time signal in the long wave frequency band in order to facilitate long range transmission. However, despite the high transmitting power, a range of only 1,200 to 2,000 kilometres results. In addition this time signal is designed only for one national time and furthermore uses a special transmitter frequency) and intrinsic encoding, so that in an area in foreign countries the receiver has to be suitable for several different time signals or else it is no longer capable of reading the signal. In an area at sea far removed from the coast, reception is in general no longer possible. Setting the time with the aid of satellite positioning systems (GPS) is certainly possible, however in this country they lack the supplementary information such as daylight saving time, leap second and so on, so that an involved semi-manual adjustment is necessary in order to maintain the actual local time.
So-called multiple radio clocks are also known, which make it possible to receive or exploit time signals in different countries. However, it is necessary in this connection for the clock to be adjusted by the user so that the time of the place in which it is located is known. These multiple radio clocks are, however, not able to function in all countries.
A process for determining a position of a receiver is known from U.S. Pat. No. 5,408,444. In order to be able to set the correct time in this receiver, its position has to be determined using at least three satellites of the GPS satellite system. If the position is established, the time adjustment is carried out using a correction value for this position, the said correction value being filed in a data bank of the receiver.
Likewise from U.S. Pat. No. 5,574,670, it is known how to fix the position, by means of the GPS system, of a receiver situated on the ground. In addition, provision is made in the receiver situated on the ground to redirect the antenna to the respective orbit.
From DF 43 13 945 A1, several satellites are combined together to form a satellite system. For the position determination of the receiver, which is to receive the time signal, merely the doppler curve over time is used. However, position determinations of this type are very imprecise.
The purpose of the invention is to specify a process for transmitting and receiving a time signal, in which process simply a transmitter for determining the position of the receiver has to be provided in order to be able to set the actual local time.
SUMMARY OF THE INVENTION
The process of the invention provides that, to achieve global reception of the time signal, the transmission occurs from an aerospace vehicle moving relative to a point on the earth's surface. The time signal is transmitted according to the invention with a particular frequency or several frequencies by the aerospace vehicle, which moves around an orbit with a high inclination. Further, provision is made that the signal rotates in the form of a beam at the transmitter in a predeterminable orbit and the rotating transmission beam contains angular information which is used to determine the direction of the transmitter. If the time signal transmits with one frequency, the distance between transmitter and receiver can be determined using the doppler curve. If several frequencies are used, the distance between transmitter and receiver can be determined by the propagation time scatter. In addition, because the angular information is acquired by the receiver from the rotating beam, the position of the receiver is determined in order to be capable of ascertaining whether the receiver is the left or right of a ground track of the aerospace vehicle. Consequently, an accurate position fixing of the receiver is possible, so that the actual local time can be set in the receiver. For determining the position of the receiver the radiated signal is therefore not radiated downwards uniformly, but rotates by means of a rotating beam. This rotation can be produced either by mechanically-driven antennas or by suitable electronic means. The rotating beam is altered in a suitable fashion as a function of the radiated angular position so that the instantaneous radiation angle can be determined from the received signal. This can be carried out for example by an auxiliary frequency, so that each angular position, or that is to say each range of angular positions between 0° and 360°, has a defined auxiliary frequency. An angle of 90° or 270° at the time of the greatest convergence then defines the side of the flyby.
A receiver independently determines its own geographic position on the earth from the received signals of the time signal transmitter and fixes the actual local time from that, without user intervention being necessary. A normal satellite cannot be considered for such a time signal because either the altitude is too high because of the required life and consequently the required incoming-signal levels are not obtained or the inclination of the orbit is too low, so that the entire surface of the earth cannot be radiated. With a low-flying satellite or space station (at an altitude of for example 200 km to 400 km) with a high orbit inclination, it is possible however to cover the earth's surface within the region of ±70 to 80 degrees of latitude. With a high orbit inclination, the entire earth's surface is overflown in the course of time by the satellite or space station.
By means of a special antenna geometry of the device according to the invention, the scanned area of the earth's surface can be expanded in width so that only the polar regions cannot be provided for
Terrestrial radio clocks are normally synchronised only once a day, in order to save the battery. This normally takes place at night because the changeover between daylight saving time and winter time also occurs at that time. With a space-supported radio clock, this is not so readily feasible since the transmitter must stay in the reception area for the given time. That is why the time signal transmitter transmits other supplementary data on the time of the next overflight for a particular area in addition to the basic time information, so that the receiver already knows in advance the contact time of reception. On first switching-on the clock or on losing the contact times the receiver switches on again only briefly in order to ascertain whether the time signal can be received. A quiet period is then inserted which is shorter than one reception time window, so that a possible contact cannot be missed. As soon as the first reception contact has been established, the clock goes over to the normal switching-on cycle.
The reception area for a particular point on the ground of the transmitter can extend over several time zones. That is why the receiver must determine, how far the instantaneous point on the ground, for which the transmitted data was calculated, is removed from its own geographic position. Two alternatives are provided for this:
1. During an overflight by the satellite on space station relatively close to the receiver, the doppler shift in the received frequency caused by the high velocity of the transmitter is so large that the time of the overflight, and therefore the distance, can be determined from the sudden change in frequency and from the form of the frequency jump.
2. During a relatively far distant flyby of the transmitter, the propagation time scatter of different frequencies (and therefore the dependency of the wave motion velocity of propagation on the wavelength or frequency) while passing through the earth's ionosphere is exploited. The electrically-conducting upper atmospheric layers (ionosphere) impede the propagation radio waves depending on the frequency of the transmitted signal of varying strength. This causes the simultaneously radiated signals of various frequencies to arrive at the receiver at different times. If the electrical conductivity of the ionosphere is known, the distance of the transmitter from the receiver can be determined from this time shift. The current characteristics for the ionosphere can be determined by ground station, or the time signal transmitter itself continually measures the ionosphere, by analysing the echo of a test signal.
In a further advantageous design of the invention, the earth's surface is subdivided into numbered zones for saving in memory and computer requirements inside the receiver. The transmitter then transmits a number of the current zone and the previously mentioned supplementary information in addition to the time signal. These data are stored in the receiver. The transmitter therefore can also predict orbit corrections and time change-overs and communicate these to the receiver. By the division of the earth into suitable zones, which do not have to be identical to the international time/zones, the receiver is therefore capable of calculating the actual time in which the receiver is situated, by simple offset- addition or subtraction of the transmitted time information.
The transmitter transmits the actual times and the supplementary information continuously and in an iterative manner. So that the receiver does not have to wait the full period for an already started data packet before the transmission of a complete packet can be started, easily recognised synchronisation signals are embedded in the data stream, so that the analysis can be started in the middle of a packet as well. This minimises the time for which the receiver has to be activated and therefore decreases the electrical current consumption of the clock.
In accordance with international regulations, transmitters on satellites or space stations are not permitted to exceed a certain transmitter power (power flux density), so that other systems are not interfered with. In order to meet this boundary condition, the so-called spread spectrum technique is used in the process according to the invention, actually so that separate encoding and modulation can be carried out. The transmitter signal is then shifted periodically by a given frequency shift in the transmitter frequency (sweeping). This sweeping and all other changes in the transmitter signal occur synchronously and phase-locked to the time standards on board the time signal transmitter, so that the received time can be determined from the instantaneous sweep frequency and the sweep phase position with a resolution into the microseconds range.
For adjustment of the time on board the time signal transmitter, on the one hand control signals from a ground or control station are used, on the other hand the time signal transmitter itself can decode the time signals of national time transmitters during overflight in order to synchronise itself with them.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now described in more detail using a design example, with reference to the drawings which show:.
in FIG. 1 a diagrammatic illustration of a space-supported global time signal system, and
in FIG. 2 a diagrammatic representation of the world, and
in FIG. 3 a typical reception area on each, and
in FIG. 4 a graph of a doppler shift.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a space supported global time signal system 1 , which is used for distributing an almost globally-received time signal 14 in order to produce an automatic adjustment of clocks to the prevailing local time in which the clock is situated. The time signal system 1 has an aerospace vehicle 2 in the form of a satellite 3 , a receiver unit 4 , a time signal generator 5 and a ground station 10 . 2 together with an antenna 10 . 1 .
The satellite has a time signal transmitter 6 which serves to distribute or send out the time signal 14 as well as other supplementary information. The time signal 14 is indicated symbolically in the representation in FIG. 1 by a semicircular wave train and therefore no conclusion can be drawn on the actual propagation direction of the time signal 14 and the supplementary information. The device required for operation of the satellite 3 , for example power supply, or flight control, are not provided with reference markings for reason of clarity.
The receiver unit 4 , which is situated on the ground 7 , has a time signal receiver 8 and a clock 9 . The clock 9 , which preferably also can be designated as a wristwatch, and the time signal receiver 8 are connected to each other by a connecting line so that synchronisation information can be transmitted from the time signal receiver 8 to the clock 9 .
The time signal generator 5 is used to produce a time base by means of an atomic clerk for example, The time signal generator 5 is connected to the ground station 10 . 2 , also described as a control station. The ground station together with its antenna 10 . 1 is used to transmit a signal, which is indicated by an arrow 15 in FIG. 1 and is used for synchronizing the on board time of the satellite 3 .
The orbit of the satellite 3 is indicated in FIG. 1 by an arrow 13 . An additional arrow 16 marks a signal flow direction of the time signal 14 from the time signal transmitter 6 to the time signal receiver 8 .
FIG. 2 shows in diagrammatic representation the earth 7 which is divided into several segments of zones 17 . Two adjacent zones 17 are separated from one another by a zone border 18 , which runs parallel to the meridans of longitude or to the parallels of latitude, so that the zones 17 are quasi quadratic or rectangular in shape. The zones 17 can be selected as far as possible so that they correspond roughly with the existing time zones on each 7 ; however this is only approximately possible, since there are few straight time zone boundaries in the world. In FIG. 2 the zones 17 are only drawn diagrammatically and therefore no conclusion can be drawn on its actual size in practice the size of the zone 17 can be dimensioned so that it is smaller than the reception area. The satellite 3 together with its orbit 19 is drawn only diagramatically to complete the picture. The correct flight path, or that is to say the correct orbit, 19 can be inferred from FIG. 3, which is described in more detail below.
In a developed view of the earth, FIG. 3 shows the reception area 20 of the satellite 3 on the earth 7 . A high inclination, or that is to say a large inclination of the orbit of the satellite 3 produces an orbit 19 which has a sinusoidal form. Several passes of the satellite 3 around the earth therefore results in extensive coverage of an almost global reception area 20 . In FIG. 3 the reception area 20 of the satellite 3 is drawn so that a reception code 21 projected onto the earth 7 is instantaneously situated over Europe. In FIG. 3 it can be easily recognised that the reception cone 21 projected onto the earth 7 , the said cone being formed by the development of the earth 7 elliptically in the illustration, includes the whole of Europe and thus sweeps over several real existing time zones.
FIG. 4 shows a graph 22 with an exemplary frequency curve 25 of a doppler shift, as received from the viewpoint of the time signal receiver 8 . Time is laid off on the abscissa 23 and frequency on the ordinate 24 on the graph 22 of FIG. 4. A dashed vertical line 26 marks an overfly time t 0 at which the time signal receiver 8 is at the minimum distance from the time signal transmitter 6 . The area to the left of the dashed line 26 indicates the approach of the time signal transmitter 6 to the time signal receiver 8 and corresponds to the area to the right of the line 26 , the area in which the time signal transmitter 6 is going away from the time signal receiver 8 . The larger the velocity component of the time signal transmitter 6 towards the time signal receiver 8 , the closer the satellite 3 is flying by the time signal receiver 8 , and the more marked (i.e. the larger) the frequency shift within the bounds of the overfly time t 0 . Consequently, the time signal receiver 8 can determine from the frequency response curve 25 the distance to the time signal transmitter 6 frequency.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims. | A satellite provides a time signal that is adjusted for position of a receiver on the surface of the Earth. A receiver determines appropriate local time from the time signal, and can adjust a local clock accordingly, the satellite time signal in the form of a rotating beam containing angular information to determine the position of the satellite transmitter for proper synchronization. A fixed receiver can also measure the radiation angle of the transmitted beam. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a structure for engaging blades with an inner frame of a plug.
2. Description of the Related Art
A typical plug includes two or three blades. In manufacture, an end of a wire is placed into a wire-receiving groove in an end of a respective blade. The end of the respective blade is then pressed to securely clamp the end of the wire. Referring to FIG. 1 of the drawings, after the clamping procedure, the blades 1 are disposed in an inner frame 12 which is then placed into a mold for forming a housing of the plug by means of injection molding. However, it was found that the blades 1 could not be reliably positioned in the inner frame 12 during the injection molding procedure such that disqualified products were produced frequently. Further, undesired contact between the blades 1 extending through holes (not labeled) of the inner frame 12 occurred easily. As a result, a short circuit was apt to occur when the blades 1 were in a conductive state.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a structure for engaging blades with an inner frame of a plug, thereby securely positioning the blades during an injection molding procedure for forming a housing of the plug.
In accordance with an aspect of the invention, a combination of an inner frame and at least two blades for a plug is provided. The combination includes an inner frame and at least two blades. The inner frame includes at least two positioning holes and at least two hook members respectively located adjacent to the positioning holes. Each blade extends through an associated one of the positioning holes of the inner frame. Each blade includes a portion engaged with an associated one of the hook members, thereby retaining the blades in the inner frame during formation of a housing of a plug by injection molding.
In an embodiment of the invention, the blades include a positive blade and a negative blade. Each blade includes an insulating layer formed on a rear section thereof. The insulating layer includes a flange that is engaged with the associated one of the hook members.
In another embodiment, the blades further include a grounding blade having an engaging hole for engaging with an associated one of the hook members.
In a further embodiment, the insulating layer of each blade includes a protruded portion, thereby forming a recessed portion on an outer side of the inner frame. The inner frame includes a plurality of through-holes extending through a bottom wall of the recessed portion and thus communicating with the recessed portion. Molten plastic material for forming the housing of the plug fills the recessed portion via the through-holes, thereby improving the bonding strength of the housing and the inner frame. Preferably, the through-holes include two rectangular through-holes.
A separation wall is formed between two positioning holes to eliminate the risk of short circuit resulting from a contact between the blades when in a conductive state.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of two blades and an inner frame of a conventional plug.
FIG. 2 is an exploded perspective view of a first embodiment of a structure for engaging blades with an inner frame of a plug in accordance with the present invention.
FIG. 3 is a sectional view of the blades and the inner frame in FIG. 2 .
FIG. 4 is a plug made from the blades and the inner frame in FIG. 3 .
FIG. 5 is an exploded perspective view of a modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention.
FIG. 6 is a perspective view of the blades and the inner frame in FIG. 5 .
FIG. 7 is a plug made from the blades and the inner frame in FIG. 6 .
FIG. 8 is an exploded perspective view of another modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention.
FIG. 9 is a sectional view of the blades and the inner frame in FIG. 8 .
FIG. 10 is a plug made from the blades and the inner frame in FIG. 9 .
FIG. 11 is an exploded perspective view of a further modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention.
FIG. 12 is a perspective view of the blades and the inner frame in FIG. 11 .
FIG. 13 is a plug made from the blades and the inner frame in FIG. 12 .
FIG. 14 is an exploded perspective view of still another modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention.
FIG. 15 is a sectional view of the blades and the inner frame in FIG. 14 .
FIG. 16 is a plug made from the blades and the inner frame in FIG. 15 .
FIG. 17 is an exploded perspective view of yet another modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention.
FIG. 18 is a perspective view of the blades and the inner fame in FIG. 17 .
FIG. 19 is a plug made from the blades and the inner frame in FIG. 18 .
FIG. 20 is a sectional view similar to FIG. 3 , illustrating still another modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 is an exploded perspective view of a first embodiment of a structure for engaging blades with an inner frame of a plug in accordance with the present invention. FIG. 3 is a sectional view of the blades and the inner frame in FIG. 2 . FIG. 4 is a plug made from the blades and the inner frame in FIG. 3 .
The inner fame 2 includes two positioning holes 21 through which two blades 31 (a positive blade and a negative blade) extend, respectively. Two resilient hook members 23 are provided on the inner frame 2 and respectively located adjacent to the positioning holes 21 of the inner frame 2 . Further, a separation wall 25 is formed between the positioning holes 21 .
Each blade 31 includes an insulating layer 33 formed on a rear section thereof. The insulating layer 33 is made of plastics and formed on the rear section of the blade 31 by injection molding. The insulating layer 33 further includes a flange 331 on a rear end thereof.
Referring to FIG. 3 , when the respective blade 31 is disposed in the inner frame 2 and extends through the respective positioning hole 21 of the inner frame 2 , the respective resilient hook member 23 bends away from the respective blade 31 and then returns to its original position after the flange 331 of the insulating layer 33 of the respective blade 31 has passed through a hook end 230 of the respective resilient hook member 23 . The respective blade 31 is thus retained in place, as the insulating layer 33 of the respective blade 31 is reliably positioned by the respective resilient hook member 23 , best shown in FIG. 3 . Next, the inner frame 2 together with the blades 31 are placed into a mold for forming a housing 4 by means of injection molding, thereby providing a plug with two blades, as shown in FIG. 4 . It is noted that formation of the housing 4 is performed after clamping of an end of a respective wire in a wire-receiving groove 332 ( FIG. 2 ) of the respective blade 31 . Further, provision of the separation wall 25 between the positioning holes 21 of the inner frame 2 eliminates the risk of short circuit resulting from a contact between the blades 31 when in a conductive state.
FIG. 5 is an exploded perspective view of a modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention. FIG. 6 is a perspective view of the blades and the inner frame in FIG. 5 . FIG. 7 is a plug made from the blades and the inner frame in FIG. 6 .
In this embodiment, in addition to the two positioning holes 21 , the inner frame 2 includes a positioning hole 22 through which an additional blade 32 (a grounding prong or blade) extends. Further, an additional resilient hook member 24 is provided on the inner frame 2 and located adjacent to the positioning hole 22 of the inner frame 2 .
The grounding blade 32 includes an engaging hole 321 for engaging with the resilient hook member 24 of the inner frame 2 when the grounding blade 32 is disposed in the inner frame 2 .
Similar to the above embodiment, each blade 31 includes an insulating layer 33 formed on a rear section thereof. The insulating layer 33 is made of plastics and formed on the rear section of the blade 31 by injection molding. The insulating layer 33 further includes a flange 331 on a rear end thereof.
Formation of a housing 5 of the plug is substantially the same as that of the first embodiment.
FIG. 8 is an exploded perspective view of another modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention FIG. 9 is a sectional view of the blades and the inner frame in FIG. 8 . FIG. 10 is a plug made from the blades and the inner frame in FIG. 9 .
The only difference between this embodiment and the embodiment of FIGS. 2 through 4 is that the insulating layer 33 of the respective blade 31 includes two opposite sides 33 A that are flush with two lateral sides of the respective blade 31 .
FIG. 11 is an exploded perspective view of a further modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention. FIG. 12 is a perspective view of the blades and the inner frame in FIG. 11 . FIG. 13 is a plug made from the blades and the inner frame in FIG. 12 .
The only difference between this embodiment and the embodiment of FIGS. 5 through 7 is that the insulating layer 33 of the respective blade 31 includes two opposite sides 33 A that are flush with two lateral sides of the respective blade 31 .
FIG. 14 is an exploded perspective view of still another modified embodiment of the structure for engaging blades with an inner flame of a plug in accordance with the present invention. FIG. 15 is a sectional view of the blades and the inner frame in FIG. 14 . FIG. 16 is a plug made from the blades and the inner frame in FIG. 15 .
The only difference between this embodiment and the embodiment of FIGS. 2 through 4 is that the insulating layer 33 of the respective blade 31 includes four sides 33 B that are respectively flush with four sides of the respective blade 31 .
FIG. 17 is an exploded perspective view of yet another modified embodiment of the structure for engaging blades with an inner fire of a plug in accordance with the present invention. FIG. 18 is a perspective view of the blades and the inner frame in FIG. 17 . FIG. 19 is a plug made from the blades and the inner frame in FIG. 18 .
The only difference between this embodiment and the embodiment of FIGS. 5 through 7 is that the insulating layer 33 of the respective blade 31 includes four sides 33 B that are respectively flush with four sides of the respective blade 31 .
FIG. 20 is a sectional view similar to FIG. 3 , illustrating still another modified embodiment of the structure for engaging blades with an inner frame of a plug in accordance with the present invention. In this embodiment, the inner frame 2 C includes a protruded portion 26 , thereby forming a recessed portion 27 in an outer side of the inner frame (now designated by 2 C). The inner frame 2 C has a plurality of through-holes 271 (preferably two rectangular through-holes in this embodiment) extending through a bottom wall of the recessed portion 27 and thus communicating with the recessed portion 27 . The through-holes 271 provide a passage through which air passes during the injection molding procedure for forming the housing 4 , 5 of the plug. Further, the molten plastic material may rapidly fill the recessed portion 27 via the through-holes 271 . After hardening of the plastic material, the bonding strength between the inner frame 2 C and the housing 4 , 5 of the plug is improved.
Conclusively, the blades 31 and 32 are reliably positioned when they are disposed in the inner frame 2 , 2 C through provision of the flange 331 of the insulating layer 33 of the respective blade 31 , the engaging hole 321 of the blade 32 , and the resilient hook members 23 , 24 of the inner frame 2 . Further, provision of the separation wall 25 between the positioning holes 21 of the inner frame 2 eliminates the risk of short circuit resulting from a contact between the blades 31 when in a conductive state. Further, the inner frame 2 C may include a recessed portion 27 having a plurality of through-holes 271 allowing passage of air during the injection molding procedure for forming a housing 4 , 5 of the plug. The through-holes 271 also allow molten plastic material to rapidly fill the recessed portion 27 via the through-holes 271 . The bonding strength between the inner frame 2 C and the housing 4 , 5 of the plug is improved after hardening of the plastic material.
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed. | A combination of an inner frame and at least two blades for a plug is provided. The combination includes an inner frame and at least two blades. The inner frame includes at least two positioning holes and at least two hook members respectively located adjacent to the positioning holes. Each blade extends through an associated one of the positioning holes of the inner frame. Each blade includes a portion engaged with an associated one of the hook members, thereby retaining the blades in the inner frame during formation of a housing of a plug by injection molding. | 7 |
This application claims priority from prior copending provisional application Serial No. 60/241,944, filed Oct. 20, 2000.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
This invention was made with government support in the form of grant nos. CA30206, CA77544 and CA33572 from the United States Department of Health and Human Services, National Cancer Institute. The government may have certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to human cytomegalovirus (HCMV), and in particular to peptide fragments from a protein that produces T-cell epitopes of HCMV in human beings. The peptide fragment epitopes are capable of directing human cytotoxic T lymphocytes (CTL) to recognize and lyse human cells infected with HCMV.
2. Description of the Background Art
The HCMV genome is relatively large (about 235,000 base pairs) and can encode more than two hundred proteins. HCMV comprises a nuclear complex of double-stranded DNA surrounded by capsid proteins having structural or enzymatic functions, and an external glycopeptide- and glycolipid-containing membrane envelope.
HCMV infection is relatively common and is usually self-limiting in the healthy, immunocompetent child or adult (L. Rasmussen, Curr. Top. Microbiol. Immunol. 154:221-254 (1990)). However, the virus can cause severe disease in the fetus or infant. For example, HCMV is a common cause of congenital mental retardation in children who acquire the infection in utero from mothers carrying an active infection. Other newborn infants can carry cytomegalovirus for some time before they show symptoms of the disease. Approximately 10% of all newborn infants carry HCMV.
Patients with an active HCMV infection often suffer impairment of at least some of their vital organs, including salivary glands, brain, kidney, liver and lungs. Furthermore, HCMV is associated with a wide spectrum of classical syndromes including mononucleosis and interstitial pneumonia. HCMV also has an oncogenic potential and a possible association with certain types of malignancies, including Kaposi's sarcoma.
Persistent and apparently asymptomatic HCMV infection in an otherwise healthy adult also may pose health risks in certain individuals. For example, individuals who have undergone coronary angioplasty sometimes subsequently develop restenosis as a result of arterial remodeling. In one study, about one third of such patients with restenosis had detectable HCMV DNA in their arterial lesions (E. Speir et al., Science 265:391-394 (1994)), whereas in another study HCMV seropositive patients were five times more likely to develop restenosis than their seronegative counterparts (Y. F. Zhou et al., New England J. Med. 335:624-630 (1996)). These studies suggest that decreasing the number of HCMV infected host cells can benefit certain individuals.
HCMV also has been associated with morbidity and mortality in immunocompromised patients. HCMV is an important consideration in the treatment of patients suffering from Acquired Immunodeficiency Syndrome (AIDS). The defining complication of HCMV is viral retinitis, which, if left untreated, can lead to blindness. Other disease manifestations of HCMV viremia include encephalitis, enteritis and pneumonia. At autopsy there is multi-organ involvement of HCMV disease in the majority of AIDS patients who had severe HCMV retinitis. Historically, HCMV disease has been one of the more devastating of the opportunistic infections that beset HIV-infected individuals whose CD4 + T cell level diminishes below 100/mm 3 .
HCMV can cause opportunistic infections in, for example, immunosuppressed organ transplant patients. Prior to the use of antiviral chemotherapy, HCMV infection had been responsible for a substantial proportion of post-bone marrow transplantation complications (J. Meyers et al., J. Infect Dis. 153:478-488 (1986)). The use of drugs such as gancyclovir with substantial anti-HCMV activity have reduced complications associated with post-bone marrow transplant HCMV infections (G. Schmidt et al. New England J. Med. 324:1005-1011 (1991); J. M. Goodrich et al., New England J. Med. 325:1601-1607 (1991)). However, prophylactic administration of gancyclovir has several negative consequences, including neutropenia and increased numbers of fatal bacterial and fungal diseases. Equally importantly, gancyclovir also delays reconstitution of cellular immunity as well as specific cellular responses to CMV. This results in a complication referred to as “late CMV disease,” which arises about 90 days post-transplant. Late CMV disease can result in morbidity or mortality and is most common in patients who have received either prophylactic or therapeutic gancyclovir treatment soon after transplant.
A CD8 + CTL response is believed to be important in a mammalian host response to acute viral infections such as HCMV. The observations that HCMV infection is widespread and persistent, and may be reactivated and become clinically evident in the immunosuppressed patient, suggest that virus-specific T-cells play an important role in the control of persistent infection and the recovery from HCMV disease.
In humans, protection from the development of HCMV disease in immunosuppressed bone marrow transplant recipients correlates with the recovery of measurable CD8 + HCMV-specific class I MHC-restricted T cell responses (Quinnan et al., N. Eng. J. Med. 307:7-13 (1982); Reusser et al., Blood 78:1373-1380 (1991)). The transfer of donor-derived HCMV-specific CD8 + CTL clones to allergenic bone marrow transplant recipients results in detectable CTL-based HCMV immunity, and statistically significant diminution of HCMV disease after bone marrow transplant (Walter et al., N. Eng. J. Med. 333:1038-1044 (1995)). Although successful in application, this approach has the disadvantage that it requires a sophisticated laboratory setup, which is also highly labor-intensive and costly, to derive the HCMV-specific CTL in vitro.
Because human cytomegalovirus is relatively common, yet is associated with some extremely serious health conditions, a vaccine which can reduce disease incidence and severity in a bone marrow transplant recipient, a solid organ transplant, a heart patient, an AIDS patient or a woman of child-bearing years would be highly desirable. Several HCMV vaccines are in development, including live attenuated CMV, CMV proteins carried in attenuated pox-viruses and soluble analogs of CMV membrane proteins. Unfortunately, the FDA has not approved any of these vaccines as safe and effective, despite the great efforts made in their development.
Vaccine development using CTL epitopes has become a widely adapted strategy to immunize individuals against infectious diseases and cancer. The specificity of CTL epitopes, and the fact that intracellular protein processing is not required, makes them an attractive alternative to the use of whole proteins as immunogens. To develop such a vaccine, the viral proteins which cause the host to recognize HCMV must be identified.
A variety of antigens, including tumor antigens, viral antigens and self-proteins are processed into peptides which are delivered to MHC Class I for presentation on the surface of antigen presenting cells (Reddehase et al., Nature 337:651-653 (1989); Rosenberg et al., Nat. Med. 4:321-327 (1998); Visseren et al., J. Immunol. 154:3991-3998 (1995)). Since the discovery that 8-12 amino acid fragments of cellular or viral proteins are embedded in the peptide binding groove of MHC Class I, there has been considerable interest in identifying the amino acid sequence of these fragments (Joyce and Nathenson 1994; Rammensee et al. 1993). Some of these peptides have been identified, formulated into vaccines, and evaluated for efficacy against certain viral diseases and cancer (Vitiello et al. 1995; Wang et al. 1990).
The viral life cycle provides insight as to the most effective time frame for targeting a vaccine to maximally disrupt virus production and spread. Following HCMV entry into the host cell and uncoating, the viral genome is expressed sequentially via immediate early (0-2 hour), early (2-24 hour) and late (>24 hour) viral proteins. However, certain viral structural proteins such as pp65 and pp150 are chaperoned into the cell because of their existence in large quantity in the viral particle.
The viral structural protein, pp150, has been identified as a target antigen for HCMV-specific class I MHC restricted CTL derived from the peripheral blood of most asymptomatic HCMV seropositive individuals. CTL against pp150 or pp65 (another matrix protein that is recognized frequently) are able to recognize and lyse HCMV-infected cells in vitro within an hour of infection and in the absence of viral gene expression (Riddell and Greenberg, Curr. Top. Microbiol. Immunol. 189:9-34 (1994)). Thus, CTL against HCMV pp150 are important effector cells to limit HCMV reactivation and progression to disease. The ability to induce such a cellular immune response in both immunocompromised and normal individuals would be extremely important in creating an effective vaccine (Li et al., Blood 83:1971-1979 (1994)). Peptides based on pp65 sequences which are useful for vaccines are described in U.S. Pat. No. 6,074,645, the disclosures of which are hereby incorporated by reference.
Individual MHC Class I molecules preferentially bind peptides of a given motif. The amino acid sequence of specific positions of the motif are invariant, allowing a given peptide to bind to MHC Class I molecules with high affinity. These invariant amino acids are referred to as “anchor positions” (Falk et al., Nature 351:290-296 (1991)). Later studies have suggested that amino acid positions other than the anchor positions also contribute to the specificity of peptide binding to MHC Class I molecules. Additionally, residues at positions within the CTL epitope which do not interact with MHC Class I molecules may interact with T cells, presumably by binding the T Cell receptor (TCR). The binding of amino acid residues to MHC or TCR structures is independently governed, so that substitution of TCR binding amino acid residues in many cases will not interfere with binding to the MHC molecule on the surface of an antigen presenting cell.
Edman degradation followed by N-terminal sequence analysis has been used to sequence the peptides which are bound to the MHC class I peptide binding groove. Mass spectrometry of HPLC-separated peptide mixtures can elucidate the primary sequence of individual peptides. In most cases, the length of these peptides is between 9 and 11 amino acids. Peptide fragments which bind to MHC are referred to as “naturally processed epitopes.”
Some workers have attempted to predict which peptides of a given length, between 9-11 amino acids, will optimally bind to individual HLA Class I alleles based solely on their conformity to a motif specific for that allele. (Falk et al., Nature 351:290-296 (1991)). However, these methods do not reliably predict either correct binding or recognition by T cells as a result of endogenous processing of viral protein.
Experience with another HCMV protein, pp65, has indicated that the available motif programs are not sufficiently adept at correctly predicting sequences which are recognized by human T-cells specific for an immunogenic viral protein. Identification of naturally processed epitopes generally requires brute-force approaches, including truncation analysis, overlapping peptides, and peptide deletions consisting of single amino acid removal from either the amino or carboxyl terminus followed by assay for recognition and binding. Therefore, epitope mapping is almost completely empirical. Andersen et al., Tissue Antigens 55:519-531 (2000).
CTL are an important means by which a mammalian organism defends itself against infection by viruses and possibly cancer. A processed form of antigen, such as a viral protein minimal cytotoxic epitope, is recognized by T cells in combination with MHC Class I molecules. Functional studies of viral and tumor-specific T cells have confirmed that a minimal cytotoxic epitope consisting of a peptide of 8-12 amino acids can prime an antigen presenting cell to be lysed by CD8 + CTL, as long as the antigen presenting cell presents the epitope in the context of the correct MHC molecule.
The route of entry of a protein into the cell determines whether it will be processed as an antigen bound to either MHC Class I or Class II molecules. The endogenous or Class I pathway of protein degradation is often used by cells when infectious viruses are present. Viral nucleoproteins are processed within the cell, and degraded portions are transported to the surface via MHC Class I molecules. Viral envelope glycoproteins, because they are cell surface molecules, do not obligatorily induce CTL recognition. Viral nucleoproteins, predominantly in the form of processed epitopes, frequently are the target antigens recognized by CD8 + CTL (Townsend et al., Philos. Trans. R. Soc. Lond. ( Biol ). 323:527-533 (1989)).
Antigens entering the cell through exogenous pathways (pinocytosis, etc.) typically are not processed and presented by Class I MHC molecules. Methods to introduce proteins directly into the cytoplasm, therefore, have become one focus of vaccine developers. Recombinant vaccinia viruses can be used to infect cells, delivering a large amount of intracellular antigen, however these viruses themselves have the potential to cause disease in immunosuppressed people, such as bone marrow transplant recipients or AIDS patients. Attenuated vaccinia viruses, such as modified vaccinia ankara or canary pox viruses offer an alternative to immunosuppressed individuals with respect to delivery of antigens and proteins. Recent published reports have advocated the use of epitope vaccines in the minimal form, whether they are delivered as proteins made from viruses, or utilizing minimal epitope in the form of peptides. Ishioka et al., J. Immunol. 162:3915-3925 (1999); Fu, J. Virol. 72(2):1469-1481 (1998); Rodriguez et al., J. Virol. 72(6):5174-5181 (1998). Another approach to vaccination is to mix an antigenic protein with an adjuvant and introduce the mixture under the skin by subcutaneous injection.
Another potential approach to elicit cytotoxic T lymphocytes is to use the minimal cytotoxic epitope defined for a specific viral antigen in the context of a particular MHC restriction element to boost a T cell memory response to the virus. The ability of a minimal cytotoxic epitope to provide protective immunity to challenge by a lethal dose of an infectious virus has been discussed in the literature. Vaccine developers have developed increasing interest in utilizing the minimal cytotoxic epitope as the vaccine because it is capable of binding to MHC Class I molecules through external binding of the cell surface molecules without the need for internalization or processing.
Minimal cytotoxic epitopes generally have been most effective when administered in the form of a lipidated peptide together with a helper CD4 epitope (Vitiello et al., J. Clin. Invest. 95:341-349 (1995) and Livingston et al., J. Immunol. 159:1383-1392, 1997)). Peptides administered alone, however, also can be highly effective. Other vaccine modifications which have been discussed include inclusion of a signal sequence such as KDEL for endoplasmic reticulum retention and targeting to attain maximum activity. There is also evidence in the literature that a minimal cytotoxic epitope presented by particular types of antigen presenting cells (e.g. dendritic cells) may cause a primary immune response to occur in the absence of viral infection or prior contact with the virus or tumor cell.
The peptides and functional sequence variants thereof can be formulated as a vaccine as a chimeric lipidated peptide or a chimeric peptide with a covalently bound HTL epitope at the amino terminus. The HTL epitope can be any peptide that has broad reactivity to human MHC class II to stimulate a classic helper response. Such molecules include but are not limited to amino acids 830-843 from tetanus toxin (P. Panina-Bordignon et al., Eur. J. Immun. 19:2237-2242 (1989)), HTL epitopes from HIV envelope protein (J. A. Berzofsky et al., J. Clin. Invest. 88:876-884 (1991)), or a synthetic version (PADRE) predicted from known anchor residues (J. Alexander et al., Immunity 1:751-761 (1994)).
The lipidation of the HTL+CTL epitope preferably is performed on the amino terminus of the HTL epitope, with the HTL epitope being amino terminal to the CTL epitope. Suitable lipid moieties are known and described in the literature. (H. Schild et al., Eur. J. Immunol. 21:2649-2654 (1991); A. Vitiello et al., J. Clin. Invest. 95:341-349 (1995); K. Deres et al., Nature 342:561-564 (1989)). Alternatively, the CTL epitope can be lipidated at its amino terminus, followed by the HTL epitope, or the lipid can be attached at the carboxyl terminus followed by either the CTL or HTL epitope(s). Unlipidated vaccines, as well as mono-, di- and tri-lipidated vaccines are contemplated for use with the present invention. A three amino acid spacer can be inserted between the HTL and CTL epitope, or the epitopes can be fused directly in frame. Alternatively the CTL epitope lipidated on its amino terminus can be administered together with the HTL epitope, without covalent attachment.
In spite of significant efforts to identify the particular HCMV antigens and epitopes that are recognized by CTL, these naturally processed epitopes, along with effective methods of preventing and treating HCMV infection are not commercially available. Therefore, a peptide-based vaccine for this clinically important disease would be of enormous value.
SUMMARY OF THE INVENTION
Accordingly, the present invention comprises peptides according to SEQ ID NOS: 1 and 2. In a further embodiment, the invention comprises vaccines against human cytomegalovirus comprising a peptide selected from the group consisting of SEQ ID NOS: 1 and 2.
In yet a further embodiment, this invention comprises a cellular vaccine against human cytomegalovirus which comprises antigen presenting cells that present a peptide selected from the group consisting of SEQ ID NO: 1 and 2.
In yet a further embodiment, the invention comprises a recombinant viral vector which expresses a gene encoding a peptide according to SEQ ID NO: 1 or 2.
In yet a further embodiment, the invention comprises methods of modulating the immune response to human cytomegalovirus infection which comprises administering a vaccine or a cellular vaccine as described above.
In yet a further embodiment, the invention provides a method of vaccinating a mammal in need thereof against human cytomegalovirus which comprises administering to said mammal a vaccine or a cellular vaccine as described above.
In yet further embodiments, the invention provides vaccines against human cytomegalovirus which comprise a peptide selected from the group consisting of SEQ ID NO: 1 and SEQ ID NO: 2 and an adjuvant, preferably a DNA adjuvant.
In yet a further embodiment, the invention provides an immunological reagent which comprises a peptide selected from the group consisting of SEQ ID NO:1 and SEQ ID NO: 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed toward peptides which are useful for creating effective vaccines against HCMV. These peptide vaccines are able to elicit a cellular immune response against HCMV-infected cells because they are the exact epitopes which are recognized by the immune cells of persons who have been infected with HCMV and have mounted a successful response to the infection. These peptides therefore are able to stimulate effective killing of HCMV infected cells and have done so in infected, asymptomatic persons. The peptides of this invention are the epitopes which are routinely and successfully presented on the surface of antigen presenting cells in the human host, guaranteeing productive binding to MHC Class I and the elicitation of a cellular immune response to HCMV in human beings.
Truncations of the pp150 protein expressed in vaccinia viruses were screened against pp150-specific T cell clones. These CTL clones were established from HCMV-seropositive volunteers using established methods. (Walter et al., N. Eng. J. Med. 333(16):1038-1044 (1995); McLaughlin-Taylor et al., J. Med. Virol. 43:103-110 (1994); Yee et al., J. Immunol. 157(9):4074-4086 (1996); Diamond et al., Blood, 90:1751-1767 (1997); LaRosa et al., Blood 97:1776-1786 (2001)). Recombinant vaccinia viruses having successive amino and carboxyl terminal deletions of approximately 100-200 nucleotides over the entire pp150 gene were tested for the ability to sensitize cells for killing by the pp150-specific T cells. Progressively smaller truncated peptides covering the length of the identified sequence were tested until a narrow area of the protein was identified as containing the peptide which mediated the cytotoxic T cell response of that clone. When a peptide no longer than 100 amino acids was identified, a series of overlapping peptides covering the length of the identified sequence were synthesized for further analysis. Using these methods, a scan of the 100 amino acid sequence using 15mer peptides overlapping by three amino acids required a total of 20 peptides.
For the test, autologous and HLA mismatched (control) lymphocyte cell lines were sensitized with the scanning peptides at a concentration of 50 μM for 1-2 hours, and washed. The relevant CTL then were incubated with chromated EBVLCL (Epstein-Barr virus transformed lymphocyte cell lines) sensitized with peptide, and a standard chromium release assay was performed. The sensitivity of lysis was determined, and any positive peptide was further truncated, both at the amino and carboxyl termini, until a minimal cytotoxic epitope that corresponds to the HLA allele of that T cell clone was defined. Table I provides peptide epitopes which are naturally processed from pp150 by persons having the indicated HLA allele.
TABLE 1
HLA Restriction and Sequence of CTL Epitopes
from HCMV pp150.
HLA Allele
SEQ
Location
Number of
Restriction
Sequence of
ID
of CTL
Individuals
Element
HLA Epitope
NO.
Epitope
Tested
HLA A*0301
TTVYPPSSTAK
1
945-955
2/2
HLA A*6801/2
QTVTSTPVQGR
2
792-802
2/2
The vaccine epitopes, regardless of primary structure, may be injected s.c. into the forearm or other body location in a standard formulation buffer (PBS/10% DMSO or higher concentration/0.01% triflouroacetic acid or other acid or alcohol of the same or different concentration) once. Vaccines may be administered in PBS or any other pharmaceutically compatible vehicle. Three to six weeks later, a booster injection of the same material may be administered. Multiple booster injections spaced three to six weeks apart can be subsequently administered, if necessary.
Vaccines can be administered to a patient or at-risk individual, or to the donor of a bone marrow transplant, who is either positive or negative for the virus. Illustrative examples of vaccine peptides include:
N-terminal
C-terminal
(Pam) 2 -KSS QYIKANSKFIGITE AAA TTVYPPSSTAK
(SEQ ID NO: 3)
(Pam) 2 -KSS AKXVAAWTLKAAA TTVYPPSSTAK
(SEQ ID NO: 4)
(Pam) 1 -KSS QYIKANSKFIGITE AAA QTVTSTPVQGR
(SEQ ID NO: 5)
(Pam) 1 -KSSQTVTSTPVQGR GGG QYIKANSKFIGITE
(SEQ ID NO: 6)
TTVYPPSSTAK AAA AKXVAAWTLKAAA
(SEQ ID NO: 7)
KDELQTVTSTPVQGR QYIKANSKFIGITE
(SEQ ID NO: 8)
QYIKANSKFIGITE TTVYPPSSTAKKDEL
(SEQ ID NO: 9)
AKXVAAWTLKAAA QTVTSTPVQGR
(SEQ ID NO: 10)
VSTIVPYIGPALNI AAA TTVYPPSSTAK
(SEQ ID NO: 11)
TTVYPPSSTAK AAA VSTIVPYIGPALNI
(SEQ ID NO: 12)
VSTIVPYIGPALNI AAA QTVTSTPVQGR
(SEQ ID NO: 13)
QTVTSPVQGR AAA VSTIVPYIGPALNI
(SEQ ID NO: 14)
TTVYPPSSTAK
(SEQ ID NO: 1)
QTVTSTPVQGR
(SEQ ID NO: 2)
wherein X is cyclohexylalanine or phenylalanine and “Pam” is palmitic acid. The three-A or alternative structural spacer (underlined) may be interchanged among vaccine peptides. The format of the peptides shown above can be described (from the amino terminus) as: lipid-KSS—HTL epitope (italics)—amino acid spacer (underlined)—CTL epitope. The positions of the CTL and HTL epitopes may be interchanged. The CTL epitope (or a functional sequence variant thereof) may be further modified by adding a leader sequence and/or the amino acids KDEL may be appended to the carboxyl terminus to assist retention and targeting into the endoplasmic reticulum as exemplified in SEQ ID NO: 8. Palmitic acid or any suitable lipid may be used, including but not limited to stearic acid, myristic acid, lauric acid, capric acid and decanoic acid. Preferred lipid moieties include palmitic acid. Alternatively, forms of the vaccine without lipids may be used, choosing the appropriate T-helper epitope that causes immunogenicity either with or without accompanying adjuvants. Sequences such as KSS may be included at the amino terminus of unlipidated peptides to aid in solubility. Other vaccine formulations include peptides having the dextro form of the amino acid on the N-terminus. Unlipidated vaccines do not require the KSS linker sequence.
Adjuvants may form part of the vaccine formulation. Adjuvants such as complete or incomplete Freund's adjuvant, aluminum hydroxide or the like are contemplated, however a preferred adjuvant, particularly for use in humans, is a DNA adjuvant. Single-stranded DNA adjuvants comprising specific sequences including Cytosine-phosphate-Guanosine (CpG) are known in the art and are contemplated for use with this invention. DNA adjuvants lacking these CpG sequences also are useful with the invention. An exemplary DNA adjuvant may comprise a 20mer of nucleotides with 2 CpG motifs, or any DNA oligomer, generally about 20 to about 25 nucleotides long. Increased stability of the sequence may be obtained by substituting phosphate groups in the nucleotide backbone with thioate groups to create a phosphoro-thioate backbone rather than a phosphoro-diester backbone.
Vaccines of this invention also may be formulated as DNA vaccine. Suitable vaccines include recombinant viral vectors, for example pox virus, which express a gene encoding one or more HCMV peptides or analogs of the invention. These vaccines may be constructed according to methods known in the prior art. In summary, these peptides may be administered as a vaccine, alone or combined with other peptide sequences, in the presence or absence of an adjuvant. Alternatively, a minimal CTL epitope from an immunogenic protein that is delivered utilizing a virus or DNA construct may also induce CTL responses which have been shown to be important for virus reduction and elimination.
The peptides of this invention also may be used in immunological methods to detect pp150-reactive CTL in a patient or a sample from a patient. Assays such as chromium release assays as described below or any known assay is suitable. Specific T cell clones which recognize pp150 peptide may be detected using an immunological reagent comprising the peptides according to SEQ ID NO: 1 or 2, for example, tetramer reagents such as those described in Altman et al., Science 274:94-96, 1996 or U.S. Pat. No. 5,734,023, the disclosures of which are hereby incorporated by reference, or dimer reagents such as those described in La Rosa et al., Blood 97(6):1776-1786, 2001 and Greten et al., Proc. Natl. Acad. Sci. USA 95:7568-7573, 1998, the disclosures of which are hereby incorporated by reference.
MHC tetramers generally are known in the art and consist of tetrameric complexes of beta-2 microglobulin, a biotinylated MHC class I molecule conjugated to streptavidin linked to a fluorescent marker, and an antigenic peptide such as, for example, a pp150 peptide or the like. The MHC class I allele and the peptide in combination allow specific recognition of T cells which recognize that peptide antigen in the context of the class I allele. Multiple complexes are often linked together to increase binding, since the affinity of the individual complex is generally low. Using a fluorescently labeled tetramer, specifically binding T cells may be separated using known techniques, such as fluorescent activated cell sorting and the like. Dimeric complexes of the same diagnostic reagents taking advantage of pp150 peptide antigens also may be used.
Those of skill in the art are familiar with the use of such dimer and tetramer reagents and are fully able to construct and use such reagents for use in various diagnostic methods known in the art. As well, those of skill in the art can readily synthesize useful reagents or variants of these reagents.
The following examples are intended to illustrate rather than limit the appended claims.
EXAMPLES
Example 1
Derivation of HCMV-Specific T-cell Clones
Forty to fifty milliliter samples of whole peripheral blood were obtained from HCMV seropositive volunteers (detected by standard antibody methods). Whole blood was sedimented for 10 minutes at 1400 rpm in a tabletop centrifuge and red blood cells removed. The white blood cells (WBCs) were separated using Ficoll-HyPaque (DuPont) density gradient centrifugation as follows. The buffy coat was diluted to 12 ml with phosphate buffered saline, and 6 ml were layered on top of Ficoll-HyPaque. After centrifugation at 2000 rpm in a tabletop centrifuge for 15-30 minutes, the interface containing the white blood cells was removed, diluted in PBS and pelleted for 8-12 minutes at 1000 rpm. The cells were again resuspended in PBS and washed as above one additional time. The white blood cells were resuspended at 4-5 million cells/ml in T cell medium (TCM) containing human serum obtained from pooled AB+ (blood group) HCMV seronegative donors.
Example 2
Derivation of LCL Antigen-Presenting Cells
Simultaneously, an autologous antigen presenting cell line was prepared by Epstein Barr virus immortalization of peripheral blood leukocytes according to methods in Current Protocols in Immunology, Unit 7.22, Wiley-Liss Press (1993). The cytotoxic T lymphocytes and antigen presenting cells were derived from the same individual to ensure HLA matching between the cell lines.
Example 3
In vitro Stimulation of T Cell Clones by HCMV
To initiate the in vitro stimulation of the T cells, a monolayer of autologous dermal fibroblasts obtained from the same volunteers as the white blood cells was established by plating the cells in 12-well plates at 10 5 cells/ml/well in DMEM containing 10% human AB+ serum for 24 hours. After 24 hours in culture, the fibroblasts were infected with HCMV virions (AD169 or Towne strain) for 2 hours at a multiplicity of infection of between 1 and 5. The medium and virus were aspirated from the monolayer, and 1 ml of fresh medium was added. The monolayer was incubated in the medium for an additional 4 hours, following which time the medium was aspirated. Two milliliters of medium containing 8-10 million white blood cells were added to each well containing HCMV infected fibroblasts. The white blood cells and fibroblasts were cultured in RPMI-1640 (Irvine Scientific) containing 50 U/ml penicillin, 50 μg/ml streptomycin, 4 mM L-glutamine, 25 μM 2-mercaptoethanol, 10 mM HEPES and 10% human AB+ serum. The cells were co-incubated for 7 days. Serum was replaced if it became spent, or the culture expanded if there was vigorous cell growth.
The white blood cells were re-stimulated on day 7 by plating onto a fresh monolayer of HCMV-infected autologous fibroblasts prepared as described above. In addition, γ-irradiated (2500 rad) autologous peripheral blood leukocytes (5-fold over WBC) were added as feeder cells, and the medium was supplemented with recombinant IL-2 (10 IU/ml, Chiron-Cetus) on days 2 and 4 of this second stimulation. Wells that exhibited rapid cell growth were supplied with new medium containing IL-2 as the medium became spent. After 12-16 days in culture, the cells were harvested and assayed for recognition of HCMV matrix proteins in a chromium release assay.
Example 4
Chromium Release Assay
Autologous or HLA-mismatched (control) target antigen presenting cells by infection with recombinant vaccinia viruses containing the DNA for HCMV pp150 or wild-type virus, strain WR, were prepared. After overnight infection, the antigen presenting cells were incubated with chromium-51, and the assay was carried out according to known methods. In the chromium release assay, the vaccinia-infected target cells were loaded with chromium-51 and then mixed with T-cells (effector cells). Preferably, the cells were mixed at a series of effector:target (E:T) cell ratios varying from 20:1 to 1:1. After a 4 hour incubation period, the medium in which the cells were incubated was harvested. The release of radioactivity into the medium (R e ) was quantitated with a gamma scintillation counter. The extent to which infected antigen presenting cells exhibit spontaneous lysis and the release of radioactivity (R s ) in the absence of cytotoxic T lymphocytes was established for each virus vector. The maximum amount of radioactivity incorporated into and releasable by the target cells (R max ) was established by lysis of target cells in a detergent (1% Triton X100; Sigma) solution. Percentage cytotoxicity was expressed as:
100×(( R e )−( R s ))/(( R max )−( R s )).
Assays were deemed unacceptable and were repeated unless spontaneous release (R s ) was less than 30%. A positive result for pp150 indicates that, in the tested polyclonal population, there are T cells which recognize the pp150 HCMV protein expressed by the virus.
Example 5
Derivation of CTL Clones Utilizing pp150 Infected Fibroblasts
An additional method to derive CTL is to create autologous antigen presenting cells, expressing a recombinant form of HCMV proteins, including pp150. A mono-layer of fibroblasts as described in Example 1 is infected with pp150 Vac and the virus is allowed to propagate on the cells for several hours. The monolayer is washed and irradiated using a Stratalinker™ apparatus (Stratagene, LaJolla, Calif.). This procedure inactivates further growth of the vaccinia virus however, allowing expression to continue. White blood cells are added to the monolayer as described in Example 3. This stimulation is directed at one HCMV protein and focuses the immune response specifically to pp150.
Example 6
Identification of the CTL Epitope
White blood cells stimulated two times by HCMV on dermal fibroblasts or by pp150Vac-infected fibroblasts were cloned by limiting dilution in 96 well U-bottom plates. The white blood cells were depleted of CD4 + T cells using paramagnetic beads conjugated to anti-CD4 antibodies. The resulting population was generally between 90-95% CD8 + , a reliable T cell subset marker, and generally 99% CD3 + , a marker for most peripheral blood T cells, as assayed by either flow cytometry or fluorescence microscopy. This final population was plated at a concentration between 0.3-3 cells per well in a final volume of 150 μl. Each well also contained γ-irradiated 1.0-3.0×10 5 allogeneic peripheral blood mononuclear cells in T cell medium containing human AB+ serum supplemented with 50-100 IU/ml recombinant IL-2 (Chiron-Cetus) and 0.5 μg/ml PHA (Murex).
After 3 days of culture, the PHA was diluted 2-fold by exchanging 75 μl with fresh culture medium supplemented with rIL-2. The wells were supplemented with fresh rIL-2 every 3-4 days, and medium was replaced as necessary. The cells were restimulated at between 12-14 days with fresh allogeneic peripheral blood mononuclear cells as described above, and the plates were carefully observed for growth in individual wells. Visible cell growth indicated the need to transfer the expanding T cells to larger wells. T cells were restimulated every two weeks, and were transferred to progressively larger wells.
At the stage of accumulation of several million cells, some were cryopreserved, and others were used for chromium release assays. The target cells were HCMV infected fibroblasts, uninfected fibroblasts, or autologous lymphocyte cells lines infected with either wild type vaccinia or vaccinia virus expressing pp150 or truncated pp150. HLA mismatched fibroblasts and lymphocytes were used as controls. T cell clones which were both HCMV and pp150-specific, and reactive only to autologous targets were selected as positive. T cell clones with different HLA phenotypes were isolated in the same way, using initial peripheral blood samples from volunteers having different HLA genotypes. By repeating this method using target cells presenting smaller and smaller portions of pp150, including synthetic 15-20 amino acid peptides taken from pp150 and deletions thereof, the minimal cytotoxic epitope for that particular HLA allele was discovered.
The purity of all peptides was confirmed by HPLC on a Vydac C 18 column using acetonitrile/TFA as the moving phase. Preferably, peptides should be 70-80% pure or more and the CD8 + status, characteristic of CTL which recognize Class I restricted peptides, should be confirmed.
Example 7
Immunization of Bone Marrow Transplant Patients
A therapeutically active form of an antigenic peptide according to the present invention is administered to an HCMV-seropositive bone marrow transplant donor at a sufficient time before donation of the tissue (six to eight weeks, for example) in single or multiple doses separated by a given number of days or weeks prior to bone marrow transplant to enable the development of an anti-HCMV cellular immune response. The antigenic peptide can be made in accordance with the parameters described in the specification or according to any known method, and administered with or without an adjuvant. Preferably, multiple doses are given. If an unmanipulated bone marrow graft is to be given to the recipient, such a graft will contain 25% or more of mature T cells. The T cells present in the immunized donor's bone marrow will confer active immunity to the bone marrow transplant recipient. Alternatively, when a T cell-depleted bone marrow graft is to be employed, an aliquot of T cells from the immunized donor can be administered to the patient following (for example, approximately 21 to 35 days) transplantation in order to provide the recipient patient with HCMV immunity.
Example 8
Immunization of Healthy Adult Women of Child-bearing Years
A therapeutic form of antigenic peptide according to the present invention is administered to a HCMV-negative or HCMV-positive women of child-bearing years either before or after conception. A vaccine comprising a single or multi-epitope vaccine prevents or reduces primary HCMV infection of the fetus and of children who may come in contact with the woman. The vaccine is used to prevent new HCMV infection, or to limit existing infection which may be damaging to the developing fetus.
Example 9
Recognition of Modified Vaccinia Ankara (MVA) Infected EBV-LCL
Recombinant modified Vaccinia Ankara (MVA) expressing HCMV pp150 were used to infect EBV LCL from individuals who had the HLA A*0301 allele or the A*68xx allele. T-cell clones specific for the epitopes of SEQ ID NOS: 1 and 2 were able to recognize these targets in a chromium release assay performed as described for Example 3. Very substantial lysis (>60% specific cytotoxicity) was seen, with specificity more than 5 fold greater than that seen with targets expressing wild-type MVA.
Example 10
Screening for CMV Immunity with HLA Tetramer Reagents Complexed to CMV Peptides
Peripheral blood is collected from human donors and recipients of allogeneic hematopoietic stem cell transplant (HSCT) after obtaining consent. Study participants conveniently may be related sibling donors and recipients undergoing allogeneic HSCT for hematologic malignancies including myelodysplasia. The donors and/or the recipients are CMV seropositive, and all are HIV-negative. Donor samples are drawn prior to administration of granulocyte colony stimulating factor (GCSF), and 3-5 days later, at the time of cell harvest for transplant. Recipient blood samples are taken 40, 90, 120, 150 and 180 days after transplant (stem cell infusion). Monitoring for CMV reactivation is done twice weekly as part of routine patient management by both PCR and blood culture shell vial assay on plasma samples. When CMV reactivation is detected (defined as two positive PCR assays or one positive blood culture result) the patient is treated with prophylactic gancyclovir for 6 weeks.
Peripheral mononuclear cells (PBMC) are isolated by standard density gradient centrifugation from heparinized blood, washed, resuspended in FCS (Hyclone, Logan, TU) with 10% DMSO, aliquoted and cryopreserved in liquid N 2 . Studies are performed on PBMC that have been thawed and assayed directly with no cultivation or stimulation in vitro. Cells are labeled with HLA A*0301 (A3) or HLA A*6801 (A68) tetrameric reagents prepared as follows. Tetrameric reagents are refolded and purified using known methods. Conveniently, the reagents may be prepared using a minor modification of the procedure used by the NIAID Tetramer Core Facility (www.emory.edu/WHSC/YERKES/VRC/tetramer.html). Briefly, A3 or A68 heavy chain and beta-2-microglobulin (β 2 M), cloned in the vector pHN1, are expressed in E. coli XA90 and refolded with the peptides SEQ ID NO:1 or 2, respectively. The refolded HLA-A3 or A68/β 2 M/peptide complexes are biotinylated using the enzyme BirA (Avidity Inc.) and then purified by FPLC using a Sephacryl S300 gel filtration column, followed by a MonoQ ion exchange column. The purified biotinylated HLA-A3 or A68/β 2 M/peptide complexes are conjugated to either streptavidin-PE (Pharmingen) or to streptavidin-APC (Molecular Probes). Labeling of cells typically is performed using 0.5 μg tetramer to stain 0.5-1.0 million cells in a 50-100 μl volume of PBS/0.5% BSA for 20 minutes. The cells then are washed and analyzed on a FACScalibur™ (BDIS) flow cytometer. A lymphocyte gate is set based on forward and side scatter and a minimum of 30,000 gated events captured. Quadrants are set based on the negative controls and the number of tetramer-positive cells is expressed as a percentage of the lymphocyte population.
Example 11
Detection of IFN-γ Production by Lymphocytes on Peptide Stimulation
Thawed aliquots of PBMC are washed with cold buffer (PBS/0.5% BSA) and labeled with tetrameric reagents prepared as described in Example 10 or by any convenient method for 20 minutes. The cells then are washed, resuspended in 1 ml RPMI-1640 (Irvine Scientific) supplemented with 10% FCS and incubated overnight at 37° C. in a 5% CO 2 incubator. Brefeldin A (GolgiPlug™, Pharmingen) is added to 1 μM after 1 hour. To some aliquots, viral epitope peptides (SEQ ID NO:1 or 2) are added at 10 μg/ml and to others, an irrelevant HLA-restricted peptide is added as a negative control. The following day, the cells are washed and sub-aliquoted into individual 12×75 mm tubes at 1×10 6 cells per aliquot. The cells are labeled with FITC-conjugated antibody to CD8 (Pharmingen) by incubation for 20 minutes at 4° C. in 50 μl buffer. The cells then are washed, fixed and permeabilized (Cytofix/Cytoperm, Pharmingen, La Jolla, Calif.) before labeling with 5 μl APC-conjugated antibody to IFN-γ for 20 minutes at 4° C. The labeled cells are washed and analyzed by flow cytometry.
14
1
11
PRT
Human cytomegalovirus
1
Thr Thr Val Tyr Pro Pro Ser Ser Thr Ala Lys
1 5 10
2
11
PRT
Human cytomegalovirus
2
Gln Thr Val Thr Ser Thr Pro Val Gln Gly Arg
1 5 10
3
31
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
3
Lys Ser Ser Gln Tyr Ile Lys Ala Asn Ser Lys Phe Ile Gly Ile Thr
1 5 10 15
Glu Ala Ala Ala Thr Thr Val Tyr Pro Pro Ser Ser Thr Ala Lys
20 25 30
4
27
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
4
Lys Ser Ser Ala Lys Xaa Val Ala Ala Trp Thr Leu Lys Ala Ala Ala
1 5 10 15
Thr Thr Val Tyr Pro Pro Ser Ser Thr Ala Lys
20 25
5
31
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
5
Lys Ser Ser Gln Tyr Ile Lys Ala Asn Ser Lys Phe Ile Gly Ile Thr
1 5 10 15
Glu Ala Ala Ala Gln Thr Val Thr Ser Thr Pro Val Gln Gly Arg
20 25 30
6
31
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
6
Lys Ser Ser Gln Thr Val Thr Ser Thr Pro Val Gln Gly Arg Gly Gly
1 5 10 15
Gly Gln Tyr Ile Lys Ala Asn Ser Lys Phe Ile Gly Ile Thr Glu
20 25 30
7
27
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
7
Thr Thr Val Tyr Pro Pro Ser Ser Thr Ala Lys Ala Ala Ala Ala Lys
1 5 10 15
Xaa Val Ala Ala Trp Thr Leu Lys Ala Ala Ala
20 25
8
29
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
8
Lys Asp Glu Leu Gln Thr Val Thr Ser Thr Pro Val Gln Gly Arg Gln
1 5 10 15
Tyr Ile Lys Ala Asn Ser Lys Phe Ile Gly Ile Thr Glu
20 25
9
29
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
9
Gln Tyr Ile Lys Ala Asn Ser Lys Phe Ile Gly Ile Thr Glu Thr Thr
1 5 10 15
Val Tyr Pro Pro Ser Ser Thr Ala Lys Lys Asp Glu Leu
20 25
10
24
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptice
10
Ala Lys Xaa Val Ala Ala Trp Thr Leu Lys Ala Ala Ala Gln Thr Val
1 5 10 15
Thr Ser Thr Pro Val Gln Gly Arg
20
11
28
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
11
Val Ser Thr Ile Val Pro Tyr Ile Gly Pro Ala Leu Asn Ile Ala Ala
1 5 10 15
Ala Thr Thr Val Tyr Pro Pro Ser Ser Thr Ala Lys
20 25
12
28
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
12
Thr Thr Val Tyr Pro Pro Ser Ser Thr Ala Lys Ala Ala Ala Val Ser
1 5 10 15
Thr Ile Val Pro Tyr Ile Gly Pro Ala Leu Asn Ile
20 25
13
28
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
13
Val Ser Thr Ile Val Pro Tyr Ile Gly Pro Ala Leu Asn Ile Ala Ala
1 5 10 15
Ala Gln Thr Val Thr Ser Thr Pro Val Gln Gly Arg
20 25
14
27
PRT
Artificial Sequence
misc_feature
()..()
Human cytomegalovirus vaccine peptide
14
Gln Thr Val Thr Ser Pro Val Gln Gly Arg Ala Ala Ala Val Ser Thr
1 5 10 15
Ile Val Pro Tyr Ile Gly Pro Ala Leu Asn Ile
20 25 | The invention provides peptides which are immunogenic epitopes recognized by CD8 + class I MHC restricted cytotoxic T-lymphocytes of patients harboring latent cytomegalovirus (HCMV) infection. The peptides are capable of activating CTL in the absence of active viral replication, and thus are useful for eliciting a cellular immune response against HCMV by normal and immunodeficient subjects. Vaccines against HCMV, with and without adjuvants, and immunological and diagnostic reagents are disclosed. | 0 |
The present application is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 12/985,389 filed on Jan. 6, 2011, which is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 12/639,872 filed on Dec. 16, 2009, now U.S. Pat. No. 7,930,910 B2, which is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 12/267,457 filed Nov. 7, 2008, currently pending, which is a 37 C.F.R. §1.53(b) continuation of U.S. patent application Ser. No. 10/461,451 filed Jun. 16, 2003, now U.S. Pat. No. 7,533,548 B2, which claims priority to Korean Patent Application No. 85521/2002, filed Dec. 27, 2002, the entire contents of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a drum type washing machine, and more particularly, to a drum type washing machine which can maximize a capacity of a drum without changing an entire size of a washing machine.
2. Description of the Related Art
FIG. 1 is a side sectional view showing a drum type washing machine in accordance with the conventional art, FIG. 2 is a front sectional view showing the drum type washing machine in accordance with the conventional art.
The conventional drum type washing machine comprises: a cabinet 102 for forming an appearance; a tub 104 arranged in the cabinet 102 for storing washing water; a drum 106 rotatably arranged in the tub 104 for washing and dehydrating laundry; and a driving motor 110 positioned at a rear side of the tub 104 and connected to the drum 106 by a driving shaft 108 thus for rotating the drum 106 .
An inlet 112 for inputting or outputting the laundry is formed at the front side of the cabinet 102 , and a door 114 for opening and closing the inlet 112 is formed at the front side of the inlet 112 . The tub 104 of a cylindrical shape is provided with an opening 116 at the front side thereof thus to be connected to the inlet 112 of the cabinet 102 , and a balance weight 118 for maintaining a balance of the tub 104 and reducing vibration are respectively formed at both sides of the tub 104 .
Herein, a diameter of the tub 104 is installed to be less than a width of the cabinet 102 by approximately 30-40 mm with consideration of a maximum vibration amount thereof so as to prevent from being contacted to the cabinet 102 at the time of the dehydration.
The drum 106 is a cylindrical shape of which one side is opened so that the laundry can be inputted, and has a diameter installed to be less than that of the tub 104 by approximately 15-20 mm in order to prevent interference with the tub 104 since the drum is rotated in the tub 104 .
A plurality of supporting springs 120 are installed between the upper portion of the tub 104 and the upper inner wall of the cabinet 102 , and a plurality of dampers 122 are installed between the lower portion of the tub 104 and the lower inner wall of the cabinet 102 , thereby supporting the tub 104 with buffering.
A gasket 124 is formed between the inlet 112 of the cabinet 102 and the opening 116 of the tub 104 so as to prevent washing water stored in the tub 104 from being leaked to a space between the tub 104 and the cabinet 102 . Also, a supporting plate 126 for mounting the driving motor 110 is installed at the rear side of the tub 104 .
The driving motor 110 is fixed to a rear surface of the supporting plate 126 , and the driving shaft 108 of the driving motor 110 is fixed to a lower surface of the drum 106 , thereby generating a driving force by which the drum 106 is rotated.
In the conventional drum type washing machine, the diameter of the tub 104 is installed to be less than the width of the cabinet 102 with consideration of the maximum vibration amount so as to prevent from being contacted to the cabinet 102 , and the diameter of drum 106 is also installed to be less than that of the tub 104 in order to prevent interference with the tub 104 since the drum is rotated in the tub 104 . According to this, so as to increase the diameter of the drum 106 which determines a washing capacity, a size of the cabinet 102 has to be increased.
Also, since the gasket 124 for preventing washing water from being leaked is installed between the inlet 112 of the cabinet 102 and the opening 116 of the tub 104 , a length of the drum 106 is decreased as the installed length of the gasket 124 . According to this, it was difficult to increase the capacity of the drum 106 .
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a drum type washing machine which can increase a washing capacity without changing an entire size thereof, in which a cabinet and a tub is formed integrally and thus a diameter of a drum can be increased without increasing a size of the cabinet.
Another object of the present invention is to provide a drum type washing machine which can increase a washing capacity by increasing a length of a drum without increasing a length of a cabinet, in which the cabinet and a tub are formed integrally and thus a location of a gasket is changed.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a drum type washing machine comprising: a cabinet for forming an appearance; a tub fixed to an inner side of the cabinet and for storing washing water; a drum rotatably arranged in the tub for washing and dehydrating laundry; and a driving motor positioned at the rear side of the drum for generating a driving force by which the drum is rotated.
The tub is a cylindrical shape, and a front surface thereof is fixed to a front inner wall of the cabinet.
Both sides of the tub are fixed to both sides inner wall of the cabinet.
A supporting plate for mounting the driving motor is located at the rear side of the tub, and a gasket hermetically connects the supporting plate and the rear side of the tub, in which the gasket is formed as a bellows and has one side fixed to the rear side of the tub and another side fixed to an outer circumference surface of the supporting plate.
A supporting unit for supporting an assembly composed of the drum, the driving motor, and the supporting plate with buffering is installed between the supporting plate and the cabinet.
The supporting unit comprises: a plurality of upper supporting rods connected to an upper side of the supporting plate towards an orthogonal direction and having a predetermined length; buffering springs connected between the upper supporting rods and an upper inner wall of the cabinet for buffering; a plurality of lower supporting rods connected to a lower side of the supporting plate towards an orthogonal direction and having a predetermined length; and dampers connected between the lower supporting rods and a lower inner wall of the cabinet for absorbing vibration.
The drum is provided with a liquid balancer at a circumference of an inlet thereof for maintaining a balance when the drum is rotated.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a side sectional view showing a drum type washing machine in accordance with the conventional art;
FIG. 2 is a front sectional view showing the drum type washing machine in accordance with the conventional art;
FIG. 3 is a side sectional view showing a drum type washing machine according to one embodiment of the present invention;
FIG. 4 is a front sectional view showing the drum type washing machine according to one embodiment of the present invention;
FIG. 5 is a lateral view showing a state that a casing of the drum type washing machine according to one embodiment of the present invention is cut;
FIG. 6 is a front sectional view of a drum type washing machine according to a second embodiment of the present invention;
FIG. 7 is a front sectional view showing a drum type washing machine according to a third embodiment of the present invention;
FIG. 8 is a longitudinal sectional view of the drum type washing machine according to the third embodiment of the present invention; and
FIG. 9 is a rear sectional view showing the drum type washing machine according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 3 is a side sectional view showing a drum type washing machine according to one embodiment of the present invention, and FIG. 4 is a front sectional view showing the drum type washing machine according to one embodiment of the present invention.
The drum type washing machine according to one embodiment of the present invention comprises: a cabinet 2 for forming an appearance of a washing machine; a tub 4 formed integrally with the cabinet 2 and for storing washing water; a drum 6 rotatably arranged in the tub 4 for washing and dehydrating laundry; and a driving motor 8 positioned at the rear side of the drum 6 for generating a driving force by which the drum 6 is rotated.
The cabinet 2 is rectangular parallelepiped, and an inlet 20 for inputting and outputting laundry is formed at the front side of the cabinet 2 and a door 10 for opening and closing the inlet 20 is formed at the inlet 20 .
The tub 4 is formed as a cylinder shape having a predetermined diameter in the cabinet 2 , and the front side of the tub 4 is fixed to the front inner wall of the cabinet 2 or integrally formed at the front inner wall of the cabinet 2 . Both sides of the tub 4 are contacted to both sides inner wall of the cabinet 2 or integrally formed with both sides inner wall of the cabinet 2 thus to be prolonged.
Herein, since both sides of the tub 4 are contacted to both sides inner wall of the cabinet 2 , a diameter of the tub 4 can be increased.
Also, the supporting plate 12 is positioned at the rear side of the tub 4 and the gasket 14 is installed between the supporting plate 12 and the rear side of the tub 4 , thereby preventing washing water filled in the tub 4 from being leaked.
The gasket 14 is formed as a bellows of a cylinder shape and has one side fixed to the rear side of the tub 4 and another side fixed to an outer circumference surface of the supporting plate 12 .
The supporting plate 12 is formed as a disc shape, the driving motor 8 is fixed to the rear surface thereof, and a rotation shaft 16 for transmitting a rotation force of the driving motor 8 to the drum 6 is rotatably supported by the supporting plate 12 . Also, a supporting unit for supporting the drum 6 with buffering is installed between the supporting plate 12 and the inner wall of the cabinet 2 .
The supporting unit comprises: a plurality of upper supporting rods 22 connected to an upper side of the supporting plate 12 and having a predetermined length; buffering springs 24 connected between the upper supporting rods 22 and an upper inner wall of the cabinet 2 for buffering; a plurality of lower supporting rods 26 connected to a lower side of the supporting plate 12 and having a predetermined length; and dampers 28 connected between the lower supporting rods 26 and a lower inner wall of the cabinet 2 for absorbing vibration.
Herein, the buffering springs 24 and the dampers 28 are installed at a center of gravity of an assembly composed of the drum 6 , the supporting plate 12 , and the driving motor 8 . That is, the upper and lower supporting rods 22 and 26 are prolonged from the supporting plate 12 to the center of gravity of the assembly, the buffering springs 24 are connected between an end portion of the upper supporting rod 22 and the upper inner wall of the cabinet 2 , and the dampers 28 are connected between an end portion of the lower supporting rod 26 and the lower inner wall of the cabinet 2 , thereby supporting the drum 6 at the center of gravity.
A diameter of the drum 6 is installed in a range that the drum 6 is not contacted to the tub 4 even when the drum 6 generates maximum vibration in order to prevent interference with the tub 4 at the time of being rotated in the tub 4 .
Operations of the drum type washing machine according to the present invention are as follows.
If the laundry is inputted into the drum 6 and a power switch is turned on, washing water is introduced into the tub 6 . At this time, the front side of the tub 6 is fixed to the cabinet 2 and the gasket 14 is connected between the rear side of the tub 6 and the supporting plate 12 , thereby preventing the washing water introduced into the tub 6 from being leaked outwardly.
If the introduction of the washing water is completed, the driving motor 8 mounted at the rear side of the supporting plate 12 is driven, and the drum 6 connected with the driving motor 8 by the rotation shaft 16 is rotated, thereby performing washing and dehydration operations. At this time, the assembly composed of the drum 6 , the driving motor, and the supporting plate 12 is supported by the buffering springs 24 and the dampers 28 mounted between the supporting plate 12 and the inner wall of the cabinet 20 .
FIG. 6 is a front sectional view of a drum type washing machine according to a second embodiment of the present invention.
The drum type washing machine according to the second embodiment of the present invention has the same construction and operation as that of the first to embodiment except a shape of the tub.
That is, the tub 40 according to the second embodiment has a straight line portion 42 with a predetermined length at both sides thereof. The straight line portion 42 is fixed to the inner wall of both sides of the cabinet 2 , or integrally formed at the wall surface of both sides of the cabinet 2 .
Like this, since the tub 40 according to the second embodiment has both sides fixed to the cabinet 2 as a straight line form, the diameter of the tub 40 can be increased. Accordingly, the diameter of the drum 6 arranged in the tub 40 can be more increased.
FIG. 7 is a front sectional view showing a drum type washing machine according to a third embodiment of the present invention, FIG. 8 is a longitudinal sectional view of the drum type washing machine according to the third embodiment of the present invention, and FIG. 9 is a rear sectional view showing the drum type washing machine according to the third embodiment of the present invention.
The drum type washing machine according to the third embodiment of the present invention comprises: a cabinet 2 for forming an appearance of a washing machine; a tub 50 formed integrally with the cabinet 2 and for storing washing water; a drum 6 rotatably arranged in the tub 50 for washing and dehydrating laundry; and a supporting unit positioned at the rear side of the tub 50 and arranged between the supporting plate 12 to which the driving motor 8 is fixed and the cabinet 2 for supporting the drum 6 with buffering.
The tub 50 is composed of a first partition wall 52 fixed to the upper front inner wall and both sides inner wall of the cabinet 2 ; and a second partition wall 54 integrally fixed to the lower front inner wall and both sides inner wall of the cabinet 2 .
The first partition wall 52 of a flat plate shape is formed at the upper side of the cabinet 2 in a state that the front side and both sides are integrally formed at the inner wall of the cabinet 2 or fixed thereto. Also, the second partition wall 54 of a semi-circle shape is formed at the lower side of the cabinet 2 in a state that the front side and both sides are integrally formed at the inner wall of the cabinet 2 or fixed thereto.
The supporting unit comprises: a plurality of upper supporting rods 56 connected to the upper side of the supporting plate 12 and having a predetermined length; buffering springs 58 connected between the upper supporting rods 56 and the upper inner wall of the cabinet 2 for buffering; a plurality of lower supporting rods 60 connected to the lower side of the supporting plate 12 and having a predetermined length; and dampers 62 connected between the lower supporting rods 60 and the lower inner wall of the cabinet 2 for absorbing vibration.
Herein, the upper supporting rods 56 are bent to be connected to the upper side of the supporting plate 12 and positioned at the upper side of the first partition wall 52 , and the buffering springs 58 are connected to the end portion of the upper supporting rods 56 . Also, the lower supporting rods 60 are bent to be connected to the lower side of the supporting plate 12 and positioned at the lower side of the second partition wall 54 , and the dampers 62 are connected to the end portion of the lower supporting rods 56 .
In the drum type washing machine according to the present invention, a size of the drum can be maximized by fixing the tub in the cabinet, thereby increasing washing capacity of the drum without increasing a size of the cabinet.
Also, since the front surface of the tub is integrally formed at the inner wall of the cabinet and the gasket is installed between the rear surface of the tub and the supporting plate, a length of the drum can be increased and thus the washing capacity of the drum can be increased.
As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims. | A drum type washing machine is provided. The drum type washing machine may include a cabinet, a tub fixed to an inner side of the cabinet, a drum rotatably arranged in the tub, and a driving motor positioned at a rear side of the drum for generating a driving force that rotates the drum. The washing machine may also include a supporting plate to rotatably support a rotational shaft extending between the motor and the drum, and a plurality of supporters connected between the supporting plate and the cabinet. Such an arrangement may increase washing capacity by increasing a diameter of the drum without increasing an external size of the cabinet. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for placing electronic components onto circuit boards, and a component placement method executed by the apparatus.
2. Description of the Related Art
The variety of kinds of electronic components to be placed on circuit boards has increased recently. Accordingly, an apparatus that can handle various electronic components from micro-chip components to long connectors, etc. is strongly demanded. An example of a conventional apparatus of the above type will be described below with reference to FIG. 10 . FIG. 10 shows a total view of a conventional component placement apparatus 20 . In FIG. 10, reference numeral 1 indicates a transfer device for carrying in and out an electronic circuit board 2 with respect to the component placement apparatus 20 and positioning the circuit board 2 when electronic components are placed on the circuit board 2 . Reference numeral 3 indicates a reel-type component feed device including reels 4 to which a tape temporarily securely holding the electronic components is wound. The feed device sends the tape from the reel 4 thereby feeding the electronic components one by one. A tray-type component feed device 5 is also set in the apparatus 20 to feed electronic components, and the electronic components are aligned in a grid pattern on a tray 6 . Reference number 7 indicates a placement head having a component hold part 8 for holding a hold member 13 which sucks so as to hold the electronic components supplied from the reel-type component feed device 3 and the tray-type component feed device 5 . According to the component placement apparatus 20 , the hold member 13 is a nozzle that can suck the electronic component. Reference numeral 9 indicates an XY-robot for moving the placement head 7 in X, Y-directions orthogonal to each other with a plant to an optional position and positioning the placement head 7 . Reference numeral 10 indicates a component recognition camera for measuring a suction attitude of the electronic component held by the hold member 13 . Reference numeral 11 indicates a tool change part equipped with one or a plurality of hold members 13 replaced with the hold member 13 set at the component hold part 8 . Reference numeral 12 indicates a control device connected to the above transfer device 1 , reel-type component feed device 3 , tray-type component feed device 5 , placement head 7 , XY-robot 9 , component recognition camera 10 , and tool change part 11 for controlling operations of these devices and the entire component placement apparatus 20 .
In the above component placement apparatus 20 , the hold member 13 sucks so as to hold the electronic components. However, the apparatus may be adapted to hold the electronic components, for instance, mechanically by a chuck mechanism. Although only one component hold part 8 is shown at the placement head 7 in FIG. 10, actually, a plurality of component hold parts 8 are arranged which are omitted in the illustration. Needless to say, the placement head 7 may be designed to keep only one component hold part 8 .
The conventional component placement apparatus 20 of the above constitution operates in a manner as will be described below.
The hold members 13 of the placement head 7 are set as the component feed device 3 or component feed device 5 by the XY-robot 9 . Each of the hold members 13 is lowered by the component hold part 8 in a Z direction orthogonal to the X, Y-directions to suck an electronic component to be placed on the circuit board 2 . After the sucking, each hold member 13 is moved up by the component hold part 8 . A plurality of electronic components held by the hold members 13 are sequentially moved by the XY-robot 9 over the component recognition camera 10 . The component recognition camera 10 picks up the suction attitude of each electronic component at the hold member 13 . Information on the recognized images is sent to the control device 12 . The control device 12 , after taking the information on the recognized images, calculates an amount of correction for each electronic component on the basis of an amount of displacement of the suction attitude from a placement attitude on the circuit board 2 , and rotates the hold member 13 based on the correction amount about an axis in the Z direction. The control device 12 moves the XY-robot 9 to position the placement head 7 over the circuit board 2 and moves each component hold part 8 so that the electronic components are correctly placed sequentially at predetermined positions on the circuit board 2 .
In the case where the hold member 13 not corresponding to the electronic component to be placed on the circuit board 2 is accidentally set at the component hold part 8 , the XY-robot 9 is moved to move the placement head 7 over the tool change part 11 and this hold member 13 not corresponding to the electronic component to be placed is detached and retained at a vacant tool hold portion at the tool change part 11 . The component hold part 8 is then moved to a tool hold portion, where the other hold member 13 corresponding to the electronic component to be placed is caught. The hold member 13 corresponding to the electronic component to be placed is thus set to the component hold part 8 .
The component hold part 8 with the correct hold member 13 is moved to a feed position for the electronic component to be placed next and the above-described sequence of operations from suction to placement is repeated.
Electronic components of various kinds are sequentially placed in this manner on the circuit board 2 .
The tool change part 11 will be depicted with reference to FIGS. 11 and 12. The tool change part 11 includes a holding mechanism (not shown) capable of holding the hold members 13 . Each hold member 13 is inserted at a predetermined tool hold portion 14 corresponding to each hold member 13 . Sensors 15 are installed at the tool hold portions 14 to detect the presence/absence of the hold member 13 . Each sensor 15 is connected electrically to the control device 12 . Thus the control device 12 can recognize whether or not the predetermined hold members 13 are set at the tool hold portions corresponding to the predetermined hold members 13 . The sensor 15 is, specifically, a proximity sensor, a limit switch or the like known sensor.
The conventional tool change part 11 constituted as above has drawbacks. According to the related art, before starting the component placement apparatus 20 , necessary hold members 13 are on standby at the predetermined tool hold portions 14 at the tool change part 11 , and information on the presence/absence of the hold members 13 from the sensors 15 is recognized by the control device 12 . That is, the sensor 15 is installed for each of the tool hold portions 14 , thereby raising costs and making the wiring complicated. In order to distinguish the types of hold members 13 kept at the component hold parts 8 , an increasing number of sensors 15 or a plurality of expensive sensors are necessitated at the tool change part.
SUMMARY OF THE INVENTION
The present invention is devised to solve the above problems and has for its object to provide a component placement apparatus that can obtain information on the presence/absence of hold members inexpensively and easily, and a component placement method carried out by the component placement apparatus.
In order to achieve the aforementioned objective, a component placement apparatus is provided according to a first mode of the present invention. The apparatus includes a placement head having a hold member that is detachable and replaceable corresponding to a component to be held for placing the component held by the hold member at an object to be placed. A hold member change part has a replacement hold member that can be fitted to the placement head where the hold member and the replacement hold member are exchanged by the placement head. The replacement hold member holds another component to place the other component at the object. The placement head has a replacement hold member detector for detecting presence/absence of the replacement hold member at the hold member change part.
Further, the replacement hold member detector detects the type of replacement hold member (type information) in addition to detecting the presence/absence of the replacement hold member.
Further, the component placement apparatus comprises a control device for making a judgement whether or not the replacement hold member corresponding to the other component to be placed at the object to be placed is present at the hold member change part on the basis of the type information of the replacement hold member corresponding to the other component to be placed at the object to be placed. The type information is sent out from the replacement hold member detector.
The type information is attached to the replacement hold member in the form of a type information indicator, and the replacement hold member detector optically reads the type information indicator.
The control device further makes a location and a type of each replacement hold member at the hold member change part correspond to each other on the basis of the information sent out from the replacement hold member detector.
A component placement method according to a second mode of the present invention includes scanning a replacement hold member set at a hold member change part so as to detect the presence/absence of the replacement hold member. It is then decided whether or not a hold member is exchangeable with the replacement hold member corresponding to a component to be held on the basis of the scanning. The hold member is exchanged with the replacement hold member corresponding to the component to be held and the component to be held with the replacement hold member is held. The component held with the replacement hold member is placed at an object to be placed.
According to the component placement apparatus in the first mode of the present invention and the component placement method in the second mode of the present invention, the replacement hold member detector is installed at the placement head to detect the presence/absence of replacement hold members at the hold member change part. The presence/absence of the replacement hold members is detected through scanning over the hold member change part. A sensor is thus eliminated from the hold member change part holding many kinds of components. A simple and inexpensive constitution is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become clear following description taken in conjunction with the preferred embodiment thereof with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a placement head and a tool change part of a component placement apparatus according to a preferred embodiment of the present invention;
FIG. 2 is a diagram explanatory of a state in which a replacement hold member at the tool change part is detected by a replacement hold member detector installed at the placement head of FIG. 1;
FIG. 3 is a diagram explanatory of a state in which information on the type of replacement hold member of the tool change part is detected by the replacement hold member detector installed at the placement head of FIG. 1;
FIG. 4 is a plan view of the replacement hold member of FIG. 3;
FIG. 5 is a diagram showing examples of type information marked at the replacement hold member of FIG. 3;
FIG. 6 is a perspective view of the entire component placement apparatus in the embodiment of the present invention;
FIG. 7 is a flow chart of the detection operation for the replacement hold member at the tool change part in the component placement apparatus of FIG. 6;
FIG. 8 is a perspective view showing in detail the structure of the tool change part of the component placement apparatus of FIG. 1;
FIG. 9 is a side view of the tool change part of FIG. 8;
FIG. 10 is a perspective view of a conventional component placement apparatus;
FIG. 11 is a perspective view of a tool change part shown in FIG. 10; and
FIG. 12 is a sectional view taken along the line I—I of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A component placement apparatus in a preferred embodiment of the present invention, and a component placement method executed by the component placement apparatus will be described hereinbelow with reference to the drawings. The same parts in the drawings are denoted by the same reference numerals. In the embodiment, an electronic component is discussed by way of example to function as the “component” described in the above “SUMMARY OF THE INVENTION”. Likewise, a circuit board and a tool change part are exemplified, respectively, as the “object to be placed” and “hold member change part”
As shown in FIG. 6, an essential construction of a component placement apparatus 101 in the embodiment is similar to the above-described conventional apparatus 20 . More specifically, the component placement apparatus 101 includes a transfer device 111 for a circuit board 2 , a reel-type component feed device 113 , a tray-type component feed device 115 , a placement head 117 , an XY-robot 119 , a component recognition camera 120 , a hold member change part 121 , and a control device 130 . The transfer device 111 corresponds to the conventional transfer device 1 . Similarly, the reel-type component feed device 113 corresponds to the conventional reel-type component feed device 3 , the tray-type component feed device 115 corresponds to the conventional tray-type component feed device 5 , the XY-robot 119 corresponds to the conventional XY-robot 9 , and the component recognition camera 120 corresponds to the conventional component recognition camera 10 . These devices have the same constitution and function as the conventional corresponding ones. Therefore, the description of these devices will be omitted here. A characteristic part of the component placement apparatus 101 in the embodiment is the placement head 117 , hold member change part 121 , and control device 130 which will be detailed below.
The placement head 117 has hold members 151 for sucking, similar to the related art, so as to hold electronic components, has component hold parts 161 for holding the hold members 151 removably and replaceably, and has a replacement hold member detector 171 . The placement head 117 is loaded on the XY-robot 119 and made movable in X, Y-directions, similar to the conventional placement head 7 . The hold members 151 can be moved by the component hold parts 161 in the Z direction. According to the embodiment indicated in the drawing, the placement head 117 has four hold members 151 and four component hold parts 161 corresponding to the hold members 151 . However, the number of the hold members is not limited to this, and an optional count not smaller than one is possible. The hold members 151 can be driven independently separately by the corresponding component hold parts 161 , the operation of which is controlled by the control device 130 .
Although the electronic components are held through suction by the hold members 151 in the embodiment, a mechanical mechanism or the like may be adopted or the suction and mechanical operation may be mixedly executed at the placement head 117 .
For the sake of description, the hold member set at the placement head 117 will be designated as the hold member 151 , and the hold member kept at the hold member change part 121 to be described later will be denoted as a replacement hold member 191 .
Tool hold portions 181 in which the replacement hold members 191 are inserted are arranged in a grid pattern on a flat plate of the hold member change part 121 . Some of the tool hold portions 181 do not contain replacement hold members 191 so as to catch the hold members 151 from the placement head 117 .
The hold member change part 121 is constructed as shown in detail in FIG. 8 . Specifically, the hold member change part 121 has a holding mechanism 201 for each array of the tool hold portions 181 . The holding mechanism detaches the hold members 151 set at the placement head 117 and keeps them at the tool hold portions 181 . In the holding mechanism 201 , a pair of opening levers 204 are opened or closed in response to an up or down movement of a wedge-shaped cam 202 by a cylinder 203 which has an open sensor 209 to indicate the opening or closure of the opening levers 204 . The cylinder 203 is controlled in operation by the control device 130 and the open or closure signal sent from the open sensor 209 is supplied to the control device 130 .
The above holding mechanism 201 operates in a manner as follows. Generally, the cam 202 is at an up position, with the opening levers 204 opened as shown in FIG. 8 . When the cam 202 is lowered by the cylinder 203 after the hold member 151 is installed in the tool hold portion 181 of the tool change part 121 so as to be exchanged with the replacement hold member 191 , the pair of opening levers 204 are closed. In consequence, as indicated in FIG. 9, the opening levers 204 are engaged with a groove 205 formed in the loaded hold member 151 , thereby holding the groove 205 between the opening levers 204 . The placement head 117 is raised in a state while the groove 205 is caught between the opening levers 204 , whereby a ball plunger 206 is disengaged from a groove 207 of the hold member 151 . Only the placement head 117 is allowed to move up while the hold member 151 is retained at the tool hold portion 181 . Incidentally, the ball plunger 206 is set at a hold part 210 of the component hold part 161 of the placement head 117 for holding the hold member 151 , which is engaged with the groove 207 of the hold member 151 when the hold member 151 is held with the hold part 210 .
The replacement hold member detector 171 has a sensor part installed at a casing of the placement head 117 to confront X, Y-planes. As indicated in FIG. 2, when the placement head 117 is moved in the X, Y-directions above the tool change part 121 by the XY-robot 119 , the detector 171 detects whether or not the replacement hold member 191 which is to replace the above hold member 151 is present at the tool hold portion 181 of the tool change part 121 . Moreover, according to the embodiment as shown in FIG. 3, the replacement hold member detector 171 detects type information attached to the replacement hold member 191 correspondingly to the electronic component to be held with the replacement hold member 191 . The replacement hold member detector 171 is arranged at a set position of the placement head 117 to make a movement distance of the placement head 117 as small as possible in view of the placement operation for the electronic components to the circuit board 2 . The replacement hold member detector 171 of the embodiment is a reflecting type detector that irradiates light to a part to be detected and optically recognizes the part from the reflecting wave of the irradiated light. Although the presence/absence of the replacement hold member 191 and the type information are both detected by one replacement hold member detector 171 according to the embodiment, this information may be detected separately by different detectors.
Position information obtained by the XY-robot 119 , presence/absence information of the replacement hold member 191 , and type information obtained from the replacement hold member detector 171 are fed to the control device 130 . Before the electronic component is started to be placed on the circuit board 2 , the control device 130 stores in a memory part 131 the presence/absence information and type information correspondingly for each tool hold portion 181 of the holding member change part 121 based on the above position information.
Referring to FIGS. 3 and 4, the above type information indicator 212 , which represents the type of hold member 151 and the type of replacement hold member 191 , is a mark of five spots formed in the same configuration as a five of a die on flange parts 211 of the hold member 151 and the replacement hold member 191 . As shown in FIG. 5, each spot is colored with white or black so that the type information indicator 212 can represent 32 types of information in combination of white and black spots. Every replacement hold member 191 is stored at the hold member change part 121 such that the type information indicators of each replacement hold member 191 are arranged at the same position. For instance, every replacement hold member 191 is stored at the tool hold portion 181 so that the type information indicator assumes an angle of 30 o in the counterclockwise direction to a center line 213 passing through the center of the replacement hold member 191 aligned in the X-direction and extending in the X-direction.
The operation of the component placement apparatus 101 constituted as above will be discussed now.
In FIG. 7, when an automatic operation is ordered in step (denoted by “S” in the drawing) 1 , the placement head 117 is moved by the XY-robot 119 so as to be positioned over the tool change part 121 in step 2 . In steps 3 - 6 , while the placement head 117 is moved in the X, Y-directions, the replacement hold member detector 171 installed at the placement head 117 scans the hold member change part 121 and detects whether the replacement hold members 191 are stored at the tool hold portions 181 of the tool change part 121 , and scans the type information indicator attached to each replacement hold member 191 .
Through the scanning, information on a movement amount in the X, Y-directions of the XY-robot 119 , and the presence/absence information and type information of the replacement hold members are supplied to the control device 130 via a generated information signal. Based on the supplied information, the control device 130 stores position information of each tool hold portion 181 of the hold member change part 121 correspondingly to the presence/absence information and type information of the replacement hold member 191 at each tool hold portion 181 into the memory part 131 .
According to the above operation, recognition is executed for each tool hold portion 181 (step 6 ). The control device 130 controls the placement of the electronic components on the basis of the recognized and stored information. Meanwhile, when the replacement hold members 191 are to be aligned beforehand at the hold member change part 121 to meet the order of types of electronic components to be placed, the control device 130 checks in step 7 whether or not the replacement hold members 191 are aligned in an order agreeing with the order of types of the electronic components. If the replacement hold members 191 are arranged wrong, the sequence from step 1 is tried again, after the arrangement is corrected. On the other hand, when the arrangement is correct, the placement of electronic components is started.
In executing the placement operation for the electronic components, information in which a placement position of the electronic component on the circuit board 2 and the electronic component to be placed are made to correspond to each other is supplied preliminarily to the control device 130 , and information on the hold member 151 that can hold the electronic component to be placed is supplied as well. Therefore, the control device 130 automatically fits the hold member 151 that can hold the electronic component to be placed to the placement head 117 in the order of placement. When the need for replacing the hold member 151 of the placement head 117 arises, the control device 130 moves the placement head 117 to above the hold member change part 121 , moves the component hold part 161 in the Z-direction, drives the holding mechanism 201 as depicted earlier to retreat the hold member 151 to a predetermined tool hold portion 181 , and attaches the required replacement hold member 191 to the component hold part 161 .
The electronic components are sucked from the component feed device 113 or 115 and placed on the circuit board 2 by using the hold members 151 corresponding to the electronic components placed on the circuit board 2 in the same manner as in the related art.
In the present embodiment as above, the replacement hold member detector 171 installed at the placement head 117 scans over the hold member change part 121 before the electronic components are started to be placed on the circuit board 2 , thereby recognizing the presence/absence of the replacement hold members 191 . When the hold members 151 are to be exchanged with the replacement hold members, they are prevented from being interfered with or forgotten to be replaced, etc. The location and type of the replacement hold members 191 at the tool change part 121 can be recognized by reading the type information attached to the replacement hold members by means of the scanning of the replacement hold member detector, thus enabling automatic exchange of the hold members.
Although the replacement hold member detector is adapted to recognize even the type information of the replacement hold members 191 according to the embodiment, it may be enough to detect at least the presence/absence of the replacement hold members 191 .
As described herein, every time the automatic operation is ordered (that is, every time a circuit board is started to be produced), the presence/absence of the replacement hold members 191 and the type of the members 191 are confirmed in steps 3 through 6 .
However, productivity might decrease sometimes when the above confirmation is conducted at every start time of the production. For solving this, the presence/absence of the replacement hold members 191 and the type of replacement hold members 191 may be adapted to be recognized only when any one of the following events (i)-(iv) occurs, whereby an amount of time necessary for the confirmation is saved and production efficiency is improved accordingly.
(i) Turning on the component placement apparatus 101 ;
(ii) Sending the open or closure signal from the open sensor 209 of the hold member change part 121 ;
(iii) Artificially exchanging the hold member 151 , which leads to disagreement between the information stored in the memory part 131 of the control device 130 showing at which of the four points in the embodiment of the placement head 117 the hold member 151 is loaded and which type of hold member 151 is loaded and, the information on the location and type of hold member 151 actually fitted to the placement head 117 ; and
(iv) Causing a malfunction of the component placement apparatus 101 .
Although the present invention has been fully described in connection with the preferred embodiment thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications are apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims unless they depart therefrom. | The present invention includes a component placement apparatus that can obtain information on the presence/absence of hold members inexpensively and easily, and a component placement method carried out by the component placement apparatus. A replacement hold member detector for detecting the presence/absence of replacement hold members at a hold member change part is installed at a placement head. The presence/absence is detected by moving an XY-robot so as to scan the hold member change part equipped with the replacement hold member detector. At the same time, type information attached to the replacement hold members is rendered readable by the replacement hold member detector. One replacement hold member detector is enough according to the apparatus and method of the present invention. The presence/absence information of the hold members can be obtained inexpensively and easily. | 8 |
FIELD OF THE INVENTION
The present invention relates to an electronic jacquard, in particular for controlling warp selection in a weaving loom.
BACKGROUND OF THE INVENTION
In conventional electromagnetic jacquards, see for example EP 0188074, the jacquard selectively controls raising and lowering of warp yams between upper and lower shed positions.
In EP 0188074 a pair of hooks are connected via a pulley to one or more harness cords which in turn is (are) connected to healds through which the warp yarns pass.
The jacquard is provided with selection devices which selectively operate to capture one or other of a pair of hooks when that hook is at its uppermost position. This action, in co-operation with the pulley, results in the harness cord raising or retaining the heald and warp yarn at the top of the V shaped shed opening on the warp bed on the loom. Not to select/capture the hook results in the heald/warp lowering or remaining at the bottom of the V shaped shed opening.
In other types of jacquard, a single hook is connected to the harness cord such that raising/lowering of the single hook directly results in raising/lowering of the heald.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided an electronic jacquard including a plurality of elongate heald hooks movable longitudinally between upper and lower shed positions and a plurality of electrically operable selection devices for co-operation with the heald hooks for selectively retaining the heald hooks at one of said shed positions, each selection device including a latch movable between a latched position and a non-latched position, the latch when at said latched position being capable of latching engagement with the heald hook in order to retain it at said shed position, and an ultrasonic cyclic motor, preferably a piezo-electric motor, drivingly arranged to move the latch from its non-latched position to its latched position.
Preferably the latch is biased to its non-latched position so as to be capable of moving from its latched position to its non-latched position under the influence of said bias.
Preferably the latch is mounted on a support arm which is formed of a resilient material, preferably spring steel, the arm being fixedly mounted at one end to a body of the selection device and carrying said latch at its opposite end.
Preferably the piezo-electric motor is arranged to move an actuator member which engages the support arm, preferably at a location intermediate the ends of the arm, in order to move the latch to its latched position.
Preferably, the hooks are arranged in pairs for raising/lowering a harness pulley, and each selection device preferably includes a pair of latches and a single motor arranged to control movement of both latches to their respective latched positions.
Preferably each latch is arranged to be rotated upon retaining engagement with a hook when at its latch position, biasing mans being provided to resist said rotation.
According to another aspect of the present invention there is provided an electronic jacquard including a plurality of elongate heald hooks movable longitudinally between upper and lower shed positions and a plurality of electrically operable selection devices for co-operation with the heald hooks for selectively retaining the heald hooks at one of said shed positions, each selection device including a latch movable between a latched position and a non-latched position, the latch when at said latched position being capable of latching engagement with the heald hook in order to retain it at said latch position, the latch when at said latched position being movable between a retention position and a release position, biasing means being provided to resiliently bias the latch to its release position, the hook and latch co-operating such that the hook on engagement with the latch causes the latch to move to its retention position against said resilient bias, and an electrically operable actuator for selectively moving the latch to its latched position.
Preferably the actuator is an ultrasonic cyclic motor, preferably a piezoelectric motor.
DESCRIPTION OF THE DRAWINGS
Reference is now made to the accompanying drawings, in which:
FIG. 1 is a schematic side view of an embodiment according to the present intention illustrated in a first operational position;
FIGS. 2 to 7 a/b are similar views to FIG. 1 showing the embodiment in different operational positions;
FIG. 8 is a front view of an upper portion of a heald hook shown in FIG. 1; and
FIG. 9 is a schematic diagram illustrating the principle of operation of an ultrasonic motor as used in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, there is shown a selection device 50 arranged to control a pair of heald hooks 1 a , 1 b which operate to raise and lower a harness pulley (not shown).
The selection device 50 includes a body 9 made for example from plastic, having guide channels 3 a , 3 b for guiding longitudinal movement of the upper portion of the heald hooks 1 a , 1 b respectively.
The selection device 50 includes an electrically operable actuator 55 which is arranged to drive an actuator member 5 either to the left or right as required. Preferably the actuator 55 is an ultrasonic cyclic motor, preferably a piezo-electric motor having an elongate casing 11 from one end of which projects a drive output in the form of a drive finger 2 . The actuator member is preferably in the form of a block or rod of a suitable material which is connected at opposite ends to arms 58 a , 58 b of a bracket 58 . The arms 58 a , 58 b are movable to enable movement of the actuator member 5 to the left or right of casing 111 . In addition the bracket is biased by biasing means preferably in the form of a spring 7 , in order to maintain positive contact between the drive finger 2 and the actuator member 5 .
Referring initially to FIG. 9, there is shown an ultrasonic motor 110 including a casing 111 which houses a drive finger 12 . The drive finger 12 is arranged to cyclically move along a cyclic path from a retracted position A (as shown) to an extended position B (shown in broken lines) and then whilst in its extended position, to the position C and then retracted to position D and then whilst in its retracted position, to position A.
The finger 12 is driven at high speed through the cycle of positions A,B,C and D, preferably by piezo-electric elements (not shown) housed within the casing 111 .
The direction of movement through the cycle may be A to B to C to D or may be reversed, viz A to D to C to B depending upon the applied electrical current.
By placing a member 14 to be driven in the path of the finger 12 whilst it moves between positions B to C (or vice versa), it is possible for the finger 12 to drive, in a stepwise manner, the member 14 in the same direction of travel.
This type of motor operates at high speeds, typically at cycles of between 20 to 140 KHz. The motor typically has a cross-sectional dimension of about 8 mm×4 mm and a length of about 25 mm.
The selection device 50 also includes a pair of latches 4 a and 4 b which are each movable from a non-latched position (as seen in FIG. 1) to a latched position (as seen by reference to the latch co-operating with heald hook 1 a in FIG. 2 ).
Each of the latches 4 a and 4 b is mounted on one end of a resilient arm 10 , the opposite end of arm 10 being fixedly mounted to the body 9 . Accordingly the resilient arm 10 is arranged to act as biasing means for biasing each of the latches 4 a and 4 b to its non-latched position.
Preferably each of the latches 4 a and 4 b is formed from a moulded plastics material. Preferably each arm 10 is formed from a spring strip material such as spring steel.
The actuator member 5 is arranged to engage the arm 10 at a position intermediate the ends of the arm 10 and so enables a suspended latch 4 a or 4 b to be pushed through a hole 6 formed in the hook 1 (see FIGS. 1 and 8 ). Thus each selection device 50 when actuated acts to move latches 4 a and 4 b into the holes 6 in their respective hooks 1 a and 1 b and thus capture the hook when required. The length of the hook 1 above the hole 6 is not important but the hole 6 must align with the latches 4 a and 4 b when the hook is raised to its uppermost position.
In FIG. 1 the motor 2 has moved the actuator member 5 to a central position where the latches 4 a and 4 b are not required to engage with the hole 6 in either hook 1 . Hook 1 a is shown at its uppermost position and hook 1 b is at its lowest position.
FIG. 2 shows a latch 4 a at its latched position whereat it has been pushed through the hole 6 of hook 1 a by actuator member 5 following the operation of motor 2 moving the actuator member 5 to the left. Since both latches 4 a and 4 b are biased towards the centre, ie. to their non-latched position, then latch 4 b has been allowed to move towards the left moving further away from hook 1 b.
FIG. 3 illustrates an example of pre-selecting latching of a heald hook.
As required by prior art EP 0188074 at some time later in the cycle from the selection point, the hook 1 a has been captured by latch 4 a at its uppermost position and hook 1 b has been raised by its lifting member up from the lowest position of hook travel. Since in this case it is necessary to retain the second hook 1 b at its upper position, the motor 2 has been actuated to move the actuator member 5 to the right. As illustrated in FIG. 3, this has caused latch 4 b to engage the upper portion of hook 1 b and has thus pre-loaded the latch 4 b ready to engage hole 6 in hook 1 b when the hook is raised to the uppermost position (this is shown in FIG. 4 ). It is not essential but preferable that this pre-load function is used in high speed jacquards.
In accordance with the preferred embodiment of the invention, the latch 4 a has been mechanically interlocked with hook 1 a and no longer requires actuator member 5 to hold it at its latch position.
For practical reasons there may be a neutral position wherein actuator member 5 is located central to body 9 and at this position neither latch 4 a nor 4 b is pushed by member 5 ; ie. both latches are in their non-latched position. However, this neutral condition is not essential. It will be appreciated that the member 5 does not require a neutral position between latches 4 a and 4 b for the selection device to operate correctly. For example to avoid retention of hook 1 a , motor 2 is actuated to move member 5 to the right against latch 4 b whether or not latch 4 b is engaged in hook 1 b as the spring component of latch 4 b takes up the travel of block 5 to the right.
FIG. 6 illustrates the mechanical load path.
Starting with the downward force on the hook L 1 the load is transferred via the latch L 2 , arm L 3 , latch anchor L 4 , selector body L 5 , L 6 and finally the interface contact between the selector body and the frame L 7 .
Apart from friction contact between the spring arm L 3 and the actuator member 5 , the load path misses out the actuator 55 and member 5 thus avoiding any distortion of the actuator material or connecting wires. The actuator life is not effected by the selector loads allowing the selector body to be manufactured in a compact, flexible scale.
In FIGS. 7 a , 7 b there is illustrated an example of achieving impact reduction.
It is normal for jacquard hooks to be captured by stiff latches. This has the effect of suddenly stopping the harness while it is in motion causing an impact on the latch and the harness.
Similarly, when the hook is lifted from the latch there is a sudden motion of the harness which results in a steep force change in the selector device and that member of the jacquard used to lift the hook.
Both the forces produced when retaining the hook on the latch and the forces produced when the hook is lifted from the latch can be reduced by incorporating a resilient latch design. FIG. 7 a shows the position of latch 4 a before the hook 1 a has moved down onto the latch. This position is referred to as the release position. A short time later the hook 1 a has moved down and the position of the latch 4 a is changed to that shown in FIG. 7 b . This position is referred to as the retention position.
The hook 1 a has loaded the latch 4 a which due to the shape of the recess 11 in the selector body 9 and the resilience of the spring arm 10 has allowed the latch 4 a to rotate creating a torque reaction which reduces the deceleration of the hook and harness inertia and thus impact.
Similarly when the hook is raised from the latch by its lifting member on the jacquard the situation changes from diagram 7 b to that of 7 a . During this time the hook lifting is assisted by the reaction force from latch 4 a thus reducing the force on the hook lifting member and reducing the rate of change of force on the latch.
By this means the resilient construction of the latch 4 a and its recess 11 reduce the effects of capturing and releasing the hook 1 a.
It will be appreciated that the preferred embodiment of the invention enables operation of two movable latches for capturing either or both co-operating hooks at the top of their stroke utilising a single ultrasonic piezo motor driving an actuator member against the spring arm carrying the latches.
The latches have a mechanical means of interlocking with the hook such that once engaged, the actuator member may be removed from the spring arm while the latch is carrying the downward load of the hook. | An electronic jacquard including a plurality of elongate heald hooks ( 1 a , 1 b ) movable longitudinally between upper and lower shed positions and a plurality of electrically operable selection devices ( 50 ) for co-operation with the heald hooks ( 1 a , 1 b ) for selectively retaining the heald hooks ( 1 a , 1 b ) at one of said shed positions, each selection device including a latch ( 4 a , 4 b ) movable between a latched position and a non-latched position, the latch ( 4 a , 4 b ) when at said latched position being capable of latching engagement with the heald hook ( 1 a , 1 b ) in order to retain it at said shed position, and an ultrasonic cyclic motor ( 55 ), preferably a piezo-electric motor, drivingly arranged to move the latch ( 4 a , 4 b ) from its non-latched position to its latched position. | 3 |
BACKGROUND OF THE INVENTION
Polycarbonates obtained from diphenols are known and, because of their good mechanical, thermal and electrical properties, have gained acceptance in many fields of industrial use.
A certain disadvantage of the polycarbonates obtained from diphenols is that their resilience properties such as, for example, their notched impact strength and their splintering properties, are inadequate for special applications at low temperatures. A further disadvantage is that the toughness in the case of high wall thicknesses is sometimes inadequate. The tough fracture occurring at low wall thicknesses turns into a brittle fracture at higher wall thicknesses. The transition region is called the "critical thickness" (4 to 6 mm).
It is known to improve the resilience properties of polycarbonates obtained from diphenols by, for example, admixing ABS graft copolymers: compare, for example, German Pat. No. 1,170,141 and German Published Patent Specification No. 1,900,756 which corresponds to U.S. Pat. No. 3,663,471. However, disadvantages are the loss in transparency and the deterioration of some thermal properties, such as, for example, the heat distortion point according to DIN 53,460.
It has now surprisingly been found that by admixing polyether-carbonates and/or polyester-carbonates, products are obtained which are distinguished by improved resilience properties compared with known polycarbonates, especially at low temperatures and at increased critical thickness, while retaining other typical polycarbonate properties such as transparency and heat distortion point.
SUMMARY OF THE INVENTION
The present invention relates to thermoplastic molding compositions consisting of
(a) from about 80-98% by weight, preferably from about 85-95% by weight, of polycarbonates having the repeating units given by the formula I, obtained from diphenols, with a mean weight-average molecular weight M w of between about 10,000 and 200,000, preferably between about 20,000 and 80,000 ##STR1## and
(b) from about 20-2% by weight, preferably from about 15-5% by weight, relative to the total weight of the mixture, of polyester-carbonates having the repeating units given by the formula II a, polyether-carbonates having the repeating units given by the formulae II b or mixtures thereof with mean weight-average molecular weights M w of between about 50,000 and 300,000, preferably between about 70,000 and 150,000, which contain from about 50 to 70% by weight of soft polyester segments B or soft polyether segments C with mean number-average molecular weights M n of between about 10,000 and 20,000, preferably between about 12,000 and 18,000 ##STR2## wherein in the formulae I, IIa and IIb, R denotes hydrogen, chlorine, bromine or saturated alkyl substituents with 1 to 3 C atoms,
M denotes 0, 1 or 2,
X denotes a bond, C 1 -C 8 -alkylidene, C 2 -C 8 -alkylidene, C 5 -C 15 -cycloalkylene, C 5 -C 15 -cycloalkylidene, SO 2 , SO, O, CO or ##STR3## n denotes 20-400, u denotes 1-50,
p denotes 50-170,
r denotes 65-450,
Y denotes a C 2 -C 15 linear or branched alkylene and
M denotes a bond, C 1 -C 15 -alkylene, C 5 -C 12 -cycloalkylene, C 6 -C 15 -arylene or hetero-arylene.
Preferred arylene radicals M are phenylene radicals and preferred hetero-arylene radicals are 5-membered or 6-membered heterocyclic radicals.
The instant invention also relates to a process for the production of the above-mentioned thermoplastic molding compositions.
DETAILED DESCRIPTION OF THE INVENTION
Examples of aromatic dihydroxy compounds which are suitable for the preparation of the polycarbonates of the formular I which can be used according to the invention are: dihydroxydiphenyls, bis-(hydroxyphenyl)-alkanes, bis-(hydroxyphenyl)-cycloalkanes, bis-(hydroxyphenyl) sulphides, bis-(hydroxyphenyl) ethers, bis-(hydroxyphenyl) sulphoxides, bis-(hydroxyphenyl) sulphones and α,α'-bis-(hydroxyphenyl)-diisopropylbenzenes, and their nuclear-alkylated and nuclear-halogenated compounds.
These and other suitable diphenols are described, for example, in U.S. Pat. Nos. 3,028,365, 2,999,835, 3,148,172, 3,271,368, 2,991,273, 3,271,367, 3,280,078, 3,014,891 and 2,999,846; in German Published Patent Specifications Nos. 1,570,703, 2,063,050, 2,063,052, 2,211,956 and 2,211,957; French Pat. No. 1,561,518 and in the monograph "H. Schnell, Chemistry and Physics of Polycarbonates, Interscience Publishers, New York, 1964."
Examples of preferred diphenols are: 2,2-bis-(4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl-4-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, 1,1-bis-(4-hydroxyphenyl)-propane and 1,1-bis-(4-hydroxyphenyl)-butane.
Furthermore, the polycarbonates can be branched by incorporating small amounts, preferably amounts between about 0.05 and 2.0 mol % (relative to the diphenols employed), of compounds which are trifunctional or more than trifunctional, in particular those with three or more than three phenolic hydroxyl groups.
Polycarbonates of this type are described, for example, in German Published Patent Specification Nos. 1,570,533, 1,595,762, 2,116,974, 2,113,347 and 2,500,092; British Pat. No. 1,079,821 and U.S. Pat. No. 3,544,514.
The polycarbonates can essentially be prepared by two known processes (compare H. Schnell, Chemistry and Physics of Polycarbonates, Polymer Rev., Volume IX, page 27 et seq., Interscience Publishers):
1. Preparation of the polycarbonates in a heterogeneous phase system (phase boundary process) by reacting an aqueous sodium bisphenolate solution with phosgene in the presence of methylene chloride.
2. Preparation of the polycarbonates in a homogeneous phase system (pyridine process) by reacting the aromatic dihydroxy compound, dissolved in pyridine, with phosgene in the presence of methylene chloride.
Suitable polyesters for the preparation of the polyester-carbonates of the formula IIa which can be used according to the invention are polyesters which are obtained by reacting polyhydric, preferably dihydric and optionally also trihydric, alcohols with polybasic, preferably dibasic, carboxylic acids by known processes (see, for example, Houben-Weyl, Volume 8, page 516 et seq., Georg Thieme Verlag Stuttgart, 1952) and which have molecular weights M n (number-average) up to about 20,000, preferably from about 12,000 to 18,000.
Examples of suitable alcohols are low-molecular weight aliphatic diols with about 2-15 C atoms, in particular linear or branched aliphatic diols with about 2-10 C atoms, such as, for example, ethylene glycol, propylene 1,2-glycol and 1,3-glycol, butylene 1,4-glycol and 2,3-glycol, hexane-1,6-diol, octane-1,8-diol, neopentyl-glycol and decane-1,10-diol, furthermore poly(alkylene oxide)-α,ω-diols, such as diethylene glycol, triethylene glycol, polyethylene glycol and poly(tetramethylene oxide)-α,ω-diols, random or block copolymers of ethylene oxide and 1,2-propylene oxide, and also polyformals (for example from hexane-1,6-diol and formaldehyde). Suitable dicarboxylic acids are aliphatic, cycloaliphatic and aromatic dicarboxylic acids, for example oxalic acid, malonic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, decanedicarboxylic acid, terephthalic acid and isophthalic acid, and mixtures of these acids. Preferred suitable aliphatic dicarboxylic acids are those with about 2 to 12 C atoms.
Instead of the free carboxylic acids, it is also possible to use the carboxylic acid anhydrides or corresponding carboxylic acid esters of lower alcohols, or mixtures thereof, for the preparation of the polyesters.
Suitable polyethers for the preparation of the polyether-carbonates of the formula IIb which can be used according to the invention are (polyalkylene oxide)-diols with molecular weights M n (number-average) up to about 20,000, preferably from about 12,000 to 18,000, which are prepared by known processes (see, for example, Winnacker-Kuchler, Volume 4, 71, Carl Hanser Verlag, Munich 1972), such as for example polytetrahydrofurane-diols and polyethylene oxide-glycols.
The polyester-carbonates and polyether-carbonates of the general formulae IIa and IIb respectively are likewise essentially prepared by two known processes.
The preparation in a heterogeneous phase system by the phase boundary process is described, for example, by S. H. Merrill, J. Polymer Sci., 55, 343 (1961), and the preparation in a homogeneous phase system by the pyridine process is described, for example, by K. P. Perry, W. J. Jackson, Jr. and J. R. Caldwell, Ind. Eng. Chem. Prod. Res. Develop., 2, 246 (1963).
Working up is carried out by methods known for polycarbonates, for example by evaporating off the solvent in devolatilization extruders.
The molding compositions according to the invention, consisting of polycarbonates and polyester-carbonates and/or polyether-carbonates, are prepared in conventional mixing units, such as kneaders and screw extruders, or by mixing solutions of the two components and then isolating the molding composition via a devolatilization extruder.
The mixtures of polycarbonates and polyester-carbonates and/or polyether-carbonates can be employed as films and shaped articles in all cases where, on the one hand, high notched impact strengths at low temperatures, high toughness properties at relatively high wall thicknesses, and transparency are required.
The following examples are intended to illustrate the subject of the invention in more detail. The relative solution viscosities indicated are measured in methylene chloride at 25° C. and at a concentration of 5 g/l.
The properties of the molding compositions from Example 1 and of the molding compositions from Examples 5-12 are summarized in Table I.
EXAMPLES
Example 1 (Comparison Example)
About 454 parts of 4,4'-dihydroxydiphenyl-2,2-propane and 9.5 parts of p-tert.-butylphenol are suspended in 1.5 l of water. The oxygen is removed from the reaction mixture, in a 3-necked flask provided with a stirrer and gas inlet tube, by passing nitrogen through the reaction mixture for 15 minutes, while stirring. 355 parts of 45% strength sodium hydroxide solution and 1,000 parts of methylene chloride are then added. The mixture is cooled to 25° C. While maintaining this temperature by cooling, 237 parts of phosgene are passed in over a period of 120 minutes.
After 15-30 minutes, or after the absorption of phosgene has started, an additional amount of 75 parts of a 45% strength sodium hydroxide solution is added. 1.6 parts of triethylamine are added to the solution formed and the mixture is stirred for a further 15 minutes. A highly viscous solution is obtained, the viscosity of which is controlled by adding methylene chloride. The aqueous phase is separated off. The organic phase is washed with water until free from salts and free from alkali. The polycarbonate has a relative viscosity of 1.29, measured in a 0.5% strength solution of methylene chloride at 20° C. This corresponds to an approximate molecular weight, M w , of 32,000. The polycarbonate thus obtained is extruded and granulated.
Example 2 (Polyester-carbonate)
5 kg (0.38 mol) of a polyester of butanediol and adipic acid, with terminal hydroxyl groups and a molecular weight of 13,000, are dissolved in 30 l of methylene chloride. 320 ml (4.7 mols) of phosgene, dissolved in 5 l of methylene chloride, are added to this solution at 18° C. in the course of half an hour. The solution is stirred for 40 minutes and an aqueous bisphenolate solution consisting of 5 kg (22 mols) of bisphenol A and 29.5 kg (48 mols) of 6.5% strength sodium hydroxide solution is then added.
80 l of methylene chloride and 33 g (0.2 mol) of p-t-butylphenol, as a chain stopper, are added. 400 g (4 mols) of phosgene are passed into the reaction mixture at a pH value of 13 at 20° C. in the course of one hour. An additional 53.6 kg (87 mols) of 6.5% strength sodium hydroxide solution are required to maintain the pH value. After passing in the phosgene, 500 ml of 4% strength triethylamine solution are added as a condensation catalyst and the mixture is stirred for 1 hour in order to carry out a post-condensation reaction. The polyester-carbonate is worked up by evaporating off the solvent. A polyester-carbonate with a relative viscosity of 1.998 is obtained.
Example 3a (Polyester-carbonate)
A polyester comprising 10.5 kg (1.27 mols) of a polyester of hexanediol and sebacic acid, and a molecular weight of 18,000, and 4.5 kg (19.7 mols) of bisphenol A are reacted with phosgene in accordance with the process described in Example 2, without a chain stopper, to give a polyester-carbonate with a relative solution viscosity of 2.305.
Example 3b (Polyester-carbonate)
A polyester comprising 10.5 kg (0.58 mol) of a polyester of hexane-1,6-diol and adipic acid, with a molecular weight of 14,000, and 4.04 kg (17.7 mols) of bisphenol A are reacted with phosgene in accordance with the process described in Example 2 to give a polyester-carbonate with a relative solution viscosity of 2.16.
Example 3c (Polyester-carbonate)
A polyester comprising 7.5 kg (0.75 mol) of a polyester of octane-1,8-diol/propylene 1,3-glycol (1:1) and suberic acid, with a molecular weight of 10,000, and 6.87 kg (24.2 mols) of tetramethylbisphenol A are reacted with phosgene in accordance with the process of DT-OS No. 2211 957 (Le A 14 240) to give a polyester-carbonate with a relative solution viscosity of 1.75.
Example 3d (Polyester-carbonate)
A polyester comprising 7.5 kg (0.75 mol) of a polyester of ethylene glycol/butane-1,4-diol and adipic acid, with a molecular weight of 10,000, and 6.1 kg (26.6 mols) of bisphenol A and 0.7 kg (1.9 mols) of tetrachlorobisphenol A are reacted with phosgene in accordance with the process described in Example 2 to give a polyester-carbonate with a relative solution viscosity of 1.85.
Example 3e (Polyester-carbonate)
A polyester comprising 9.0 kg (0.56 mol) of hexane-1,6-diol/butane-1,4-diol (75:25) and sebacic acid, with a molecular weight of 16,000, and 4.6 kg (20.1 mols) of bisphenol A and 0.9 kg (1.58 mols) of tetrabromobisphenol A are reacted with phosgene in accordance with the process described in Example 2 to give a polyester-carbonate with a relative solution viscosity of 2.02.
Example 4a (Polyether-carbonate)
5.25 kg (0.33 mol) of a polyethylene oxide-glycol with a molecular weight of 16,000 and 4.5 kg (19.7 mols) of bisphenol A are reacted with phosgene in accordance with the process described in Example 2 to give a polyether-carbonate with a relative solution viscosity of 1.89.
Example 4b (Polyether-carbonate)
9.0 kg (0.90 mol) of a polyethylene oxide-glycol with a molecular weight of 10,000, with 5.4 kg (23.6 mols) of bisphenol A are reacted with phosgene in accordance with the process described in Example 2 to give a polyether-carbonate with a relative solution viscosity of 1.93.
Example 4c (Polyether-carbonate)
7.5 kg (0.47 mol) of a poly-(1,2-propylene oxide)-glycol, with a molecular weight of 16,000, and 6.7 kg (29.5 mols) of bisphenol A are reacted with phosgene in accordance with the process described in Example 2 to give a polyether-carbonate with a relative solution viscosity of 1.84.
Example 4d (Polyether-carbonate)
9.0 kg (0.6 mol) of a poly-(1,2-butylene oxide)-glycol, with a molecular weight of 15,000, and 5.5 kg (19.4 mols) of bisphenol A are reacted with phosgene in accordance with the process described in Example 2 to give a polyether-carbonate with a relative solution viscosity of 1.78.
Example 4e (Polyether-ester-carbonate)
10.5 kg (1.05 mols) of a polyether-ester comprising 96.46% by weight of a polybutanediol (M n 2,000) and 4.69% by weight of adipic acid and with a molecular weight of 10,000, and 4.0 kg (17.5 mols) of bisphenol A are reacted with phosgene in accordance with the process described in Example 2 to give a polyether-ester-carbonate with a relative solution viscosity of 2.43.
Example 5
85 Parts by weight of the polycarbonate from Example 1 are mixed with 15 parts by weight of the polyester-carbonate from Example 2, as a solution in methylene chloride, and the mixture is extruded through a devolatilization extruder at 320° C. and under 0.1 mm Hg. The relative solution viscosity is 1.322.
Example 6
95 Parts by weight of the polycarbonate from Example 1 and 5 parts by weight of the polyester-carbonate from Example 2 are mixed, in the form of granules, and the mixture is extruded through a twin-screw extruder at 320° C. The relative solution viscosity is 1.297.
Example 7 90 Parts by weight of the polycarbonate from Example 1 and 10 parts by weight of the polyester-carbonate from Example 3a are mixed, in the form of granules, and the mixture is extruded through a twin-screw extruder at 320° C. The relative solution viscosity is 1.333.
Example 8
92 Parts by weight of the polycarbonate from Example 1 and 8 parts by weight of the polyether-carbonate from Example 4a are mixed, in the form of solutions in methylene chloride, and the mixture is extruded through a devolatilization extruder at 320° C. and under 0.1 mm Hg. The relative solution viscosity is 1.298.
Example 9
96 Parts by weight of a polycarbonate from Example 1 and 4 parts by weight of the polyester-carbonate from Example 3c are mixed, in the form of granules, and the mixture is extruded through a twin-screw extruder at 320° C. The relative solution viscosity is 1.31.
Example 10
88 Parts by weight of a polycarbonate from Example 1 are mixed with 12 parts by weight of a polyester-carbonate from Example 3d, in the form of granules, and the mixture is extruded through a twin-screw extruder at 320° C. The relative solution viscosity is 1.33.
Example 11
90 Parts by weight of a polycarbonate from Example 1 and 10 parts by weight of a polyether-ester-carbonate from Example 4e are mixed, in the form of granules, and the mixture is extruded through a twin-screw extruder at 320° C. The relative solution viscosity is 1.35.
Example 12
85 Parts by weight of a polycarbonate from Example 1 and 15 parts by weight of a polyether-carbonate from Example 4c are mixed, in the form of solutions in methylene chloride, and the mixture is extruded through a devolatilization extruder at 320° C. and under 0.1 mm Hg. The relative solution viscosity is 1.31.
Table I__________________________________________________________________________ Content of polyester- carbonate or Molecular Notched impact polyether- weight of strength + kJ/m.sup.2 Critical Carbonate the soft room thickness in the segment tempera- Vicat B ++ +++ mixture M.sub.n ture -20 -40° C. °C. mm__________________________________________________________________________Example 1(Comparison Example) -- -- 35 22 10 150 5.7-6Example 5 15 13,000 40 39 20 145 >9Example 6 5 13,000 44 30 15 148 7.1-7.4Example 7 10 18,000 42 35 18 146 >9Example 8 8 16,000 41 35 20 147 >9Example 9 4 10,000 46 34 16 148 7.4-7.7Example 10 12 10,000 42 38 19 145 >9Example 11 10 10,000 43 36 18 146 7.4-7.7Example 12 15 16,000 40 32 20 145 >9__________________________________________________________________________ +DIN 53,453 ++DIN 53,460 +++Izod, ASTM0256
It is to be understood that any of the components and conditions mentioned as suitable herein can be substituted for its counterpart in the foregoing examples and that although the invention has been described in considerable detail in the foregoing, such detail is solely for the purpose of illustration. Variations can be made in the invention by those skilled in the art without departing from the spirit and scope of the invention except as is set forth in the claims. | Thermoplastic molding compositions are provided comprising from about 80 to 98% by weight of a polycarbonate obtained from diphenols, having a mean weight-average molecular weight M w from about 10,000 to 200,000 and from about 20 to 2% by weight of a polyester-carbonate and/or polyether-carbonate with mean weight-average molecular weights M w of from about 50,000 to 300,000, which contain between about 50 and 70% by weight of soft polyester segments or soft polyether segments with mean number-average molecular weights M n of from about 10,000 to 20,000. The instant invention also relates to a process for the production of said thermoplastic molding compositions. These thermoplastic molding compositions show markedly improved resilience properties compared with known polycarbonates and can be employed as films and shaped articles in all cases where, on the one hand, high notched impact strength at low temperatures, high toughness properties at relatively high wall thicknesses, and transparency are required. | 2 |
BACKGROUND
Presently, food servers, such as containers for serving french fries in a fast food restaurant, are manufactured using a two stage process. The first stage of the process consists of several steps each of which is performed to a web of paper board in order to produce a stack of identical blanks therefrom. Shown in FIG. 1 is the typical blank 10 formed by the first stage of the process. To form the blanks from the web of paper board, the web is first unwound from a roll and sent to one or more printing stations where indicia such as a logo and an associated design is printed thereon. After the printing, the paper board is forwarded to a punch die-cutting station where the paper board is die cut, creased and perforated using a flat steel rule die to form several fold lines 12, 14 and 16 onto the paper board and to define a front panel 18, a back panel 20, glue flaps 22, bottom panels 24 and side panels 26 thereon. After being die cut, the die cut web, which has several blanks 10 nicked together, is forwarded through a rotary stripping station which automatically removes the die cut trim away from the die cut and creased paper board blanks. The nicked together, die cut blanks are then forwarded to a set of speed up rolls which break the nicks and then feed the separated blanks onto a slow down belt in a shingled fashion. The blanks are then manually removed from the shingle belt onto a pellet where they are stored awaiting the ensuing operation of folding, gluing and packing.
The punch press die cutting step requires that the paper board being cut and creased be of sufficient stiffness to allow for stopping the web in the punch press, die cutting the paper board with a minimum number of nicks and accelerating the cut web into the rotary stripper. The above-described first stage of the process will not work on light weight paper.
The second stage of the process consists of folding and gluing the glue flaps 22 of each blank 10. The folding and gluing is performed in a way that will only provide glue flaps 22 adhered to the outside surface 28 of the back panel 20. The process does not provide that the glue flaps 22 can be adhered to the inside surface of the back panel 20. The second stage of the process provides that a person folds the die cut blanks into a folder/gluer. The person selects a small stack of blanks 10 and hand folds the small stack along score line 12 so that the flat stack becomes an angled stack. This pre-bent stack is then placed into the feeder section of the folder/gluer where blanks 10 are fed off the bottom of the pre-bent stack and each blank 10 is first folded along fold line 12. Glue is applied to glue flaps 22, and then the blank 10 is folded with flat twisted belts along fold lines 14 which completes the folding. The paper board containers are then fed into a pressure belt system that sets the glue. After glue is applied to the glue flaps 22, food server 30 is formed, the rear 32 of which is shown in FIG. 2. As shown, the rear 32 of the food server 30 is defined by two side panels 26, a bottom panel 24, and two glue flaps 22 each of which is adhered to the outside surface 28 of the back panel 20. After gluing, the food servers 30 are ready for packing.
The above-described two stage process requires that a paper board having a high stiffness be used in order to achieve efficient high speed non-parallel fold lines (for example, fold lines 14). Additionally, the folder/gluer requires that a very stiff paper board be used (for example, 0.012 to 0.014 inches thick) in order to be able to feed a single blank at a time into the folder/gluer. Even if one were to adapt the abovedescribed two stage process to run lighter weight paper board, a significant cost savings would not be realized because paper board mills normally sell their paper board with calipers below twelve to thirteen for about the same price per square foot.
After the food server 30 is manufactured, the food server 30 is shipped to the food vendor, such as to a fast food restaurant. When food, such as french fries, is to be placed in the food server 30 and served by the food vendor, the sides 34 of the food server are urged toward each other to cause the bottom panels 24 to shift upward thereby locking the food server 24 into a position which provides an opening for the food. The glue flaps 22 essentially render the rear 32 of the food server 30 less practical for printing any attention-grabbing graphics thereon. Preferably, a folder carton (paper board) product is formed and glued with the glue flaps on the inside so that one can better use the full panel for graphics.
Because the first stage of the two stage process described above consists of stopping a moving web of paper board to perform certain steps (for example, punch die-cutting scrap therefrom), the first stage of the process severely limits the speed at which food servers can be produced. Additionally, the fact that one must hand fold small stacks of blanks prior to placing them in the folder/gluer infeed station adds substantial extra labor to the process.
Additionally, as mentioned, one of the steps performed to the web of paper board during the first stage of the above-described process includes punch die-cutting scrap from the paper board. Because the paper board is punch die-cut, it is imperative that a relatively heavy paper board, such as one hundred thirty pound paper board, be used so that the paper board does not jam during the punch die-cutting step. Of course, the heavier the paper board used, the higher the cost of producing a food server therefrom. Additionally, using heavier paper board is presently undesirable in light of recent worldwide efforts to conserve materials and limit the amount of material dumped into landfills.
Still further, as shown in FIG. 1, the blank 10 formed during the first stage of the above-described process includes four side panels 26 and two glue flaps 22 located adjacent the front panel 18. Therefore, to provide that scrap is kept to a minimum, the blanks must be "reverse nested" side-by-side on the web. In other words, the layout of the individual blanks on the web must be such that several blanks are aligned and staggered side-by-side on a single web rather than merely aligned front to back in a single file line. As a result of having to provide that the blanks are reverse nested, not only must the web of paper be relatively wide, but the gluing and folding steps of the process must be performed after the individual blanks are cut from the web, as a secondary operation, thus necessitating using the two stage process described above rather than utilizing a single stage process as is provided by the present invention.
The present invention provides a novel food server and a novel method of producing a food server, each directed to solve the problems discussed hereinabove.
OBJECTS OF THE INVENTION AND SUMMARY OF THE DISCLOSURE
A general object satisfied by the claimed invention is to provide a single stage method of producing a food server which significantly reduces the amount of material used.
Another object satisfied by the claimed invention is to provide a method of producing a food server whereby food servers can be produced at an extremely fast rate.
A related objective satisfied by the claimed invention is to provide a method of producing a lightweight paper food server in a continuous operation from a roll of paper to a finished, folded, flat product that can be opened and filled in the same manner as prior art paper board servers.
Still another object satisfied by the present invention is to provide a method of producing a food server whereby lighter weight paper can be used.
Still yet another object satisfied by the present invention is to provide a method of producing a food server using a layout that does not require reverse nesting to achieve material usage efficiency.
A related object satisfied by the present invention is to provide a method of producing a food server using a relatively narrow web of paper to achieve material usage efficiency.
Still another object satisfied by the present invention is to provide a method of producing a food server in a more cost efficient manner.
A still yet further object satisfied by the present invention is to provide a method of producing a food server which minimizes land fill waste.
Still yet another object satisfied by the present invention is to provide a method of producing a food server which eliminates frequent job setups commonly experienced in producing "reverse nested" prior art food servers.
Still yet a further object satisfied by the present invention is to provide a method of producing a food server which reduces stock inventories and permits just-in-time deliveries.
A still further object satisfied by the present invention is to provide a food server having glue flaps that assist in the opening and locking of the food server.
Still yet a further object satisfied by the present invention is to provide a food server having glue flaps that maintain the rear of the food server more practical for printing attention-grabbing graphics thereon such as advertising icon imagery.
Briefly, and in accordance with the foregoing, the present invention envisions a method of producing a food server. The method includes the steps of providing a continuous web of paper, moving the continuous web, printing on at least one surface of the web, scoring fold lines on and die-cutting the moving web, plow folding the moving web to form glue panels thereon, applying glue to the glue panels of the moving web, cutting across the moving web to form a blank separate from the web of moving paper where the blank includes the glue panels, and folding the blank to cause portions of the blank to contact and adhere to the glue panels, thereby forming the food server from the blank.
A preferred, envisioned method of the present invention includes the steps of providing a continuous web of lightweight paper, moving the continuous web at a constant speed until the web is cross cut, printing on both surfaces of the moving web, rotary scoring curved fold lines on and rotary die-cutting and scoring the moving web, using rotary timing belts to pre-bend along score lines on the moving web to define the glue panels before plow folding the moving web, after pre-bending score lines on the moving web to define the glue panels, plow folding the moving web at an angle relative to the direction the web is moving to form angled glue panels thereon, applying glue to the glue panels of the moving web, simultaneously rotary cutting across the moving web to form a blank separate from the web of moving paper where the blank includes the glue panels and vacuum folding the blank to cause portions of the blank to contact and adhere to the angled glue panels, thereby forming the food server from the blank.
The present invention also envisions a food server that includes a first panel having two side flaps where each of the side flaps is defined by a score line on the first panel, and a second panel having two side flaps where each of the side flaps is defined by a score line. Each of the side flaps on the second panel has an outside portion and an inside portion defined by a score line. Adhesive is provided between each of the outside portions of the side flaps on the second panel and each of the side flaps on the first panel to provide that the first panel is adhered to the second panel, thereby forming the food server.
A preferred apparatus according to the present invention envisions a food server comprised of lightweight paper that includes a first panel having two side flaps where each of the side flaps is defined by a score line on the first panel, and a second panel having two side flaps where each of the side flaps is defined by a score line. Both the first panel and the second panel are formed from a single web of paper and have a bottom panel therebetween. Between the bottom panel and the first panel and between the bottom panel and the second panel are curved score lines. Each of the side flaps on the second panel has an outside portion and an inside portion defined by a score line. Adhesive is provided between each of the outside portions of the side flaps on the second panel and each of the side flaps on the first panel to provide that the first panel is adhered to the second panel, thereby forming the food server. When the food server is opened, it provides an opening for receiving food, and each of the outside portions of the side flaps on the second panel has a first surface and an opposing, second surface, where the first surface of each outside panel contacts the food and the second surface of each outside panel is adhered to a side flap of the first panel. The second surface of each outside panel assists in urging the food server into a locked, open position for receiving food when the sides of the food server are urged toward each other.
BRIEF DESCRIPTION OF THE DRAWINGS
The organization and manner of the structure and function of the invention, together with further objects and advantages thereof, may be understood by reference to the following description taken in connection with the accompanying drawings, wherein like reference numerals identify like elements, and in which:
FIG. 1 is a top plan view of a prior art blank formed using the typical process of producing a food server;
FIG. 2 is a side, elevational view of the rear of the prior art food server formed from the blank shown in FIG. 1;
FIG. 3a is a top plan view of a blank configured on a web produced within a method in accordance with the present invention;
FIG. 3b is a side, elevational view of the rear of a first embodiment food server formed from the blank shown in FIG. 3a;
FIG. 4a is a top plan view of a second blank configured on a web produced within a method in accordance with the present invention;
FIG. 4b is a side, elevational view of the rear of a second embodiment food server formed from the blank shown in FIG. 4a; and
FIG. 5a is a nonscaled, top plan view of either the first or second embodiment food servers of FIGS. 3b and 4b, showing the sides of the food server being pressed together to urge the food server into an open position;
FIG. 5b is a nonscaled, top plan view of either the first or second embodiment food servers of FIGS. 3b and 4b, showing the food server in an open position; and
FIG. 6a is a schematic view of a machine which can be used to practice a method in accordance with the present invention to produce the first and second embodiment food servers shown in FIGS. 3b and 4b ; and FIG. 6b is a schematic view of the sequential operations performed on the web by the machine shown in FIG. 6a.
DESCRIPTION
While the present invention may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, certain embodiments with the understanding that the present description is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to that as illustrated and described herein.
The present invention envisions a novel food server and a novel method of producing a food server, both of which provide several advantages over the prior art. A method in accordance with the present invention will now be described referring to the machine 40 depicted in FIG. 6a and a web 48 shown in FIG. 6b. As shown, initially a roll 42 of paper 44 is provided, and preferably the paper 44 is of lightweight stock such as sixty pound paper. It is desirable to use lightweight stock because lighter paper is less expensive. Additionally, should the food server produced by the machine 40 not be reclaimed, lighter paper lessens the amount of garbage deposited into landfills. Minimizing the amount of garbage deposited into landfills is necessary in light of present day environmental concerns.
Roller 46 initially unwinds a web 48 of paper 44 from the roll 42. The paper 44 may be relatively narrow stock and may have a width 49 of, for example, six and three-eighths inches. However, the roll 42 may be even narrower than six and three-eighths inches wide, or may be substantially wider than six and three-eighths inches wide. For example, it is possible to provide that two or more blanks of the food server are aligned side-by-side on the web 48. In this case, the width of the paper 44 would most likely be greater than six and three-eighths inches.
As shown, the web 48 of paper 44 is essentially two-sided with a first surface 52 of the web 48 opposing a second surface 54 of the web 48. Shown in FIG. 6b is a general schematic of the first surface 52 of the web 48 as the web 48 proceeds through the machine 40. As the roller 46 unwinds the web 48, the roller 46 forwards the web 48 to a first printing station 50. The first printing station 50 comprises a plurality of printing rolls 56 which pull the web 48 from the roller 46 and print different colors onto the first surface 52 of the web 48. While the printing rolls 56 print onto the first surface 52 of the web 48, the web 48 keeps moving.
From the first printing station 50, the web 48 is forwarded to a second printing station 58. The second printing station 58 also comprises a plurality of printing rolls 60. The printing rolls 60 of the second printing station 58 pull the web 48 from the first printing station 50 and print different colors onto the second surface 54 of the web 48. Similar to the first printing station 50, while the printing rolls 60 of the second printing station 58 print onto the web 48, the web 48 keeps moving. Therefore, the first and second printing stations 50 and 58 provide that the web 48 gets printed on both sides thereof while the web 48 keeps moving from the roll 42. Preferably, the web 48 proceeds from the roll 42 and though both printing stations 50 and 58 at a constant speed with the web 48 never having to stop.
From the second printing station 58, the web 48 is forwarded to one or more scoring stations 62 (one shown). As shown, the scoring station 62 comprises a number of rotary scoring blades 64 (two shown). At the one or more scoring stations 62, several lines 66, 68, 70, 72, 73 and 74 are scored onto the web 48, as shown in FIGS. 3a, 4a and 6. Score lines 66 and 68 define two bottom panels 76 divided by score line 70. As shown, preferably score lines 66 and 68 are curved while score line 70 is substantially straight. Score lines 72 along with score line 66 define a first panel 78 while score lines 73 along with score line 68 define a second panel 80. Score lines 72 also define side flaps 82 adjacent each side of the first panel 78, and score lines 73 also define side flaps 83 adjacent each side of the second panel 80. Each of score lines 74 essentially splits, the side flaps 83 into an inside portion 84 and an outside portion 86.
Score lines 72 may be scored onto the web 48 at an angle relative the direction the web 48 is traveling as the web travels through the one or more scoring stations 62 such that the score lines 72 are angled relative to each other as shown in FIGS. 3a and 6b. As a result, the side flaps 82 will be tapered, and provided at an angle relative to each other as shown. Additionally, score lines 73 may be scored onto the web 48 at an angle relative the direction the web 48 is traveling such that the score lines 73 are angled relative to each other. As a result, the side flaps 83 will be tapered, and provided at an angle relative to each other. For example, the angled scoring may provide that the side flaps 82 and 83 are angled at six degrees off the direction at which the web travels such that the side flaps 82 and 83 are angled at twelve degrees relative to each other.
Alternatively, score lines 72 may be scored onto the web 48 at substantially the same angle at which the web 48 is traveling as the web travels through the one or more scoring stations 62 such that the score lines 72 are substantially parallel to each other as shown in FIG. 4a. Additionally, score lines 73 may be scored onto the web 48 at substantially the same angle at which the web 48 is traveling such that the score lines 73 are substantially parallel to each other. As a result, the side flaps 82 and 83 will all be substantially parallel to each other.
Regardless of the angle at which score lines 72 and 73 are scored onto the web 48, the web 48 continues moving during the scoring by the one or more scoring stations 62. Preferably, the web 48 moves from the roll 42, through the first and second printing stations 50 and 58, and to and through the one or more scoring stations 62 at a constant rate of speed.
As shown in FIG. 6a, from the one or more scoring stations 62, the web 48 is forwarded to a die-cutting station 88. The die-cutting station 88 comprises one or more rotary die cutting blades 90. The rotary die cutting blades 90 trim away scrap portions 92 from the moving web 48. As shown in FIGS. 3a, 4a and 6b, cutting away the scrap portions 92 further defines the side flaps 82 and 83 and the bottom panels 76 on the web 48. By providing that the rotary die-cutting blades 90 perform the die-cutting, it is possible to keep the web 48 moving during the die-cutting step. Keeping the web 48 moving is important because, as a result, more food servers can be produced within a given amount of time. As shown in FIGS. 3a, 4a and 6b, the scrap portions 92 which are cut away from the web 48 are not substantial. Of course, it is desirable to minimize the amount of scrap produced, and the present method provides as such. Additionally, by providing that the rotary die-cutting blades 90 perform the die-cutting, it is possible to use lightweight paper without risking tearing of the paper during the die-cutting.
As mentioned, during the die-cutting step, the web 48 is kept moving. Preferably, the web 48 is kept moving at a constant rate speed from the roll 42, through the first and second printing stations 50 and 58, through the one or more scoring stations 62, and to and through the die-cutting station 88.
As shown in FIG. 6b, from the die-cutting station 88, the web travels to the glue flap folding station 94. As shown, the glue flap folding station 94 may comprise rotary timing belts 96 followed by a plow folder 98. The rotary timing belts 96 may be polyurethane timing belts with weld-on profiles. Alternatively, the glue flap folding station 94 may comprise only a plow folder 98 and may not include rotary timing belts 96. However, should the glue flap folding station 94 include rotary timing belts 96, the rotary timing belts 96 are located upstream from the plow folder 98, as shown in FIG. 6a. When the web 48 travels to the rotary timing belts 96, the rotary timing belts 96 fold the web 48 along the fold lines 74 such that the outside portion 86 of each side flap 83 is at a ninety degree angle relative to the inside portion 84 of each side flap 83. In this manner, the rotary timing belts 96 pre-fold the outside portions 86 of each side flap 83 before the web 48 travels to the plow folder 98 where the outside portions 86 are completely folded onto the inside portions 84 such that a first surface 95 of each outside portion 86 is contacting an inside portion 84 of each side flap 83. Typically, rotary timing belts 96 will be utilized when angled side flaps 83 are to be produced on light paper as shown in FIG. 3a. In contrast, when substantially parallel side flaps 83 are to be produced on heavier paper, typically pre-scoring or pre-folding will not be necessary, and the rotary timing belts 96 need not be utilized. In this case, the glue flap folding station 94 need not include rotary timing belts 96 and may comprise only the plow folder 98. Regardless of which components are, in fact, included within the glue flap folding station 94, the web 48 continues to move as the web 48 approaches and passes through the glue flap folding station 94. Preferably, the web 48 travels at a constant rate of speed during such movement.
As shown in FIG. 6a, from the glue flap folding station 94, the web 48 travels forward to a gluing station 100 comprising a gluer 101 where glue 102 is applied to a second, exposed surface 104 of each outside portion 86 of each of the side flaps 83. Thereafter, the web 48 travels to a rotary cross cutting and folding station 106. At the cross cutting and folding station 106, the web 48 is simultaneously cut by a rotary cutter 105 in a direction traverse to the direction the web 48 travels and is vacuum cross folded along cross line 70 so that the glued, exposed surface 104 of each outside portion 86 of each of the side flaps 83 contacts and adheres to the side flaps 82 adjacent the first panel 78 as shown in FIG. 5a. Should the one or more scoring stations 62 score the web 48 to provide that the score lines 72 and 73 are angled as shown in FIG. 3a, then the resulting food server 107, after being cross cut and cross folded, will have angled sides 108 as shown in FIG. 3b. However, should the one or more scoring stations 62 score the web 48 to provide that the score lines 72 and 73 are substantially parallel as shown in FIG. 4a, then the resulting food server 110, after being cross cut and cross folded, will have substantially parallel sides 112 as shown in FIG. 4b. Regardless of which food server 107 or 110 is produced, many of the same are typically produced at a time, and then are stacked for delivery after leaving the cross cutting and folding station 106. To this end, each food server 107 or 110 produced is forwarded from the cross cutting and folding station 106 to a delivery-stacker 114 as shown in FIG. 6a. Subsequently, the food servers are delivered flat to food vendors, such as fast food restaurants.
One having ordinary skill in the art should recognize that many different modifications can be made to the described method. For example, the scoring, die-cutting, folding and gluing steps need not be performed in the order described, and may, in fact, be performed in any order. Additionally, it is possible to apply glue 102 to the side panels 82 instead of, or in addition to, applying the glue 102 to the outside portion 86 of each side panel 83. Of course, still other modifications are possible while still remaining within the scope of the present invention.
Either of the food servers 107 or 110 shown in FIGS. 3b or 4b, respectively, provides that when the sides 108 or 112 are lightly urged toward each other, as shown in FIG. 5a, the bottom panels 76 (shown in FIGS. 3a, 3b and 4a, 4b) shift causing the food server 107 or 110 to lock into an open position as shown in FIG. 5b. When the food server 107 or 110 is locked into the open position as shown, the food server 107 or 110 provides an opening 116 for receiving food 118 such as french fries therein. When food 118 is received by the food server 107 or 110, the food 118 can contact the first surface 95 of the outside portion 86 of each of the side flaps 83 while the second, opposing surface 104 of the outside portion 86 of each of the side flaps 83 is glued to a corresponding side flap 82. By providing that each side flap 83 is glued to a side flap 82 inside the food server 107 or 110 rather than being glued to the second panel on the outside of the food server 107 and 112, either food server 107 or 110 provides that the outside portions 86 of the glue flaps 83 assist in the opening of the food server 107 or 112. As a result, either food server 107 or 110 is easier to open merely by lightly urging the sides 108 or 112 toward each other. Additionally, as shown in FIGS. 3b and 4b, by providing that each side flap 83 is glued to a side flap 82 inside the food server 107 or 110, both panels 78 and 80 are practical for providing attention-grabbing graphics thereon, such as a logo.
The above-described novel method of producing a food server provides many advantages over the prior art. As mentioned above, the web 48 is kept moving as the web proceeds from the printing stations 50 and 58, to the one or more scoring stations 62, to the die-cutting station 88, to the glue flap folding station 94, to the gluing station 100, to the rotary cross cutting and folding station 106, and finally to the delivery-stacker 114. Preferably, the web 48 moves at a constant rate of speed as it proceeds, and slows down only when reaching the delivery-stacker 114. In this manner, the described method provides a continuous, single stage method of producing food servers, and provides that the food servers can be produced extremely quickly. In fact, the method provides that 60,000 food servers can be produced in one hour. Additionally, the food servers can be produced in one stream or multiple streams with the same scrap rate. Side-by-side nesting is not necessary to provide that the amount of scrap produced is reasonable. Still further, the method provides that lighter weight paper can be used thereby providing that food servers can be produced less costly.
Wile a preferred embodiment of the present invention is shown and described, it is envisioned that those skilled in the art may devise various modifications and equivalents without departing from the spirit and scope of the invention as defined by the appended claims. The invention is not intended to be limited by the foregoing disclosure. | A novel food server and method of producing a food server is disclosed. The novel method includes moving a web of paper at a constant rate of speed, rotary perforating a plurality of lines on the moving web, using rotary timing belts to score at least two fold lines on the moving web, where the two fold lines define two glue flaps, rotary die-cutting the moving web to cut away portions of the paper adjacent the glue flaps, plow folding the moving web along the two fold lines defining the glue flaps, and applying glue to the moving web. After plow folding along the fold lines and applying the glue, the moving web is cross cut to form a blank having the glue flaps. Then, the blank is vacuum folded to cause portions of the blank to contact and adhere to the glue flaps, thereby forming the food server from the blank. The novel food server includes a first panel having two side flaps each defined by a score line, and a second panel having two side flaps each defined by a score line. Each of the side flaps on the second panel has an outside portion and an inside portion defined by a score line. There is adhesive between each of the outside portions and each of the side flaps on the first panel, thereby providing that the first panel is adhered to the second panel to form the food server. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to devices responsive to angular motion or rotation, and more particularly to an inertial reference device based on the Sagnac interferometer principle for measuring the angular rate of rotation of a platform.
Rotation rate sensors are utilized in a variety of different applications including use as a rate gyroscope and a gyroscope test turntable, as well as application to tachometers for generator speed control, inertial navigation and non-magnetic compasses. In its most common application, the device is disposed in a gimbal mounting and used in the manner of a gyroscope, stabilized about one sensitive axis or about 2 or 3 mutually perpendicular sensitive axes. The device so mounted may provide a space platform stabilized with respect to the system of fixed stars and may be used either for visual aid in navigation or to supply information for actuating automatic piloting or navigating mechanisms, or for remote control of a vehicle. Alternately, the device may be mounted directly upon the frame of a vehicle to supply information in response to the rotation of the vehicle about one or more reference axes. Such information would then be utilized to actuate a computer or other device for automatic or remotely controlled navigation, or like purposes.
It has been known for some time that the Sagnac interferometer can be used to detect the rotation rate of any rotating frame. These interferometers detect rotation rates as small as 15 degree per hour or less.
In essence, the Sagnac interferometer utilizes the principles of general relativity in order to detect angular motion by means of energy circulating in a loop path subjected to angular motion having a component in the plane of the loop. The existence of a measurable effect caused by the angular motion of a given circuit path upon the transmission of electromagnetic waves in the circuit was first verified by experiments performed by G. Sagnac and A. A. Michelson.
In order to more clearly understand the prior art and the problems pertaining thereto, reference will now be made to various of the figures in the drawings appended to this disclosure. Accordingly, a brief description of the drawings in this case will now be made:
FIG. 1 is a schematic diagram of a standard Sagnac interferometer utilizing a helically wound light fiber as the light path.
FIG. 2(a) is a graph of the theoretical normalized light power output response with respect to time of a Sagnac interferometer.
FIG. 2(b) is the actual normalized light power response with respect to time of the Sagnac interferometer.
FIG. 2(c) is a graph showing a small magnified portion of the normalized power response with respect to time of the Sagnac interferometer of the present invention.
FIG. 2(d) is a graph of a magnified portion of the ripple frequency generated if there is a rotation component in the plane of the light path circuit.
FIG. 2(e) is the normalized power vs frequency response of the system illustrating the noise window.
FIG. 3 is a simplified rotational diagram showing the difference in distances traveled by the two beams in the interferometer.
FIG. 4(a) is a graph of one possible wavelength variation with time which may be utilized to implement the present invention.
FIG. 4(b) is a graph of the normalized power response with time for the wavelength modulation shown in FIG. 4(a).
FIG. 5 is a schematic diagram of one embodiment of the interferometer of the present invention.
Referring now to the drawings, wherein like reference characters designate like or corresponding parts throughout the views, FIG. 1 shows a typical prior art Sagnac interferometer. The assembly of FIG. 1 is mounted on a platform and is designed to sense the rotation rate of that platform. A beam of light, in this case a laser beam from a laser source 10 is split by a beam splitter 12 into two beams diverging at right angles to each other. These two beams are then focused by means of the lenses 14 and 16 into the ends 18 and 20 of a helically wound optical fiber 22. The light beam focused into the end 20 of the optical fiber 22 traverses the optical fiber light path circuit in a counter-clockwise direction, while at the same time the beam focused into the end 18 traverses the optical fiber light path circuit in the clockwise direction. When these two beams have traveled through the light path circuit in their respective directions, they are collimated by the lenses 18 and 20, respectively, and impinge upon the beam splitter 12. The two beams interfere with each other at the beam splitter 12 and form an interference or fringe pattern 26 at the end of optical fiber 23. A detector 30 with a slit 28 with a width of d is then disposed to detect a portion of this fringe pattern. Accordingly, any change in this fringe pattern will be detected by the detector 30. As noted above, it is known that if the platform on which this system is located is rotated at an angular velocity Ω in the plane in which the light beams travel, then the interference fringes will be displaced from the position which they occupy when the system is at rest. The amount of the displacement of this fringe pattern is found to be proportional to the angular velocity.
In the alternative, the beam splitter 12 and the two interfering beams may be arranged in such a way that the total optical power impinging upon the detector 30 varies with the rotation rate. More specifically, if the beams are perfectly collimated and are disposed at 45° with respect to the beam splitter, then the spacing between the interference patterns becomes infinite. Thus, the measurement of the change in the total output power will yield a figure proportional to the rotation rate. This measurement may be taken by abutting the optical fiber 23 directly against the detector 30.
It should be noted that the beam splitter 12 which is shown to be a bulk-type in FIG. 1, may be replaced by a guided-wave directional coupler. With such a device the total power received by the detector 30 will again vary with the rotation rate (R. A. Bergh, H. C. Lefevre, and H. J. Shaw "All-Single-Mode Fiber-Optic Gyroscope", Optics Letters, Vol. 6, No. 4, p.p. 198-200, April 1981).
In the conventional Sagnac interferometer shown above, the wavelength λ of the optical beam is constant. If we assume that the interferometer begins to rotate at a time t=t 0 , then the optical power being measured at the detector 30 will change as shown in FIG. 2(a) due to the change in the relative phase between the two beams traveling in opposite directions. In essence, the power output at the measurement point of the interference pattern is related to the phase by the following equation: assuming a unit total output,
P=1/2,1-cos (θ+φ),
where φ is a constant and θ is the Sagnac phase. The Sagnac phase change θ causing this fringe shift and thus resulting in a change in the power output at the detector 30 can be illustrated using the circular rotation diagram of FIG. 3. To begin the analysis, assume that two beams leave the point A on the circle shown in the figure at the same time to traverse the circular path 40 in opposite directions like a standard Sagnac interferometer. The time T for the light to make a circle is
T=2πR/c (1)
where R is the radius of the circle, and c is the velocity of the light. If the frame or platform containing the circular optical path is rotating with a component of the rotation in the direction of travel having an angular rate Ω radians/second, the point A will move to the point A' by the time the two light beams have made the complete circuit around the circle. Thus, one beam will have to travel over a distance equal to (2πR+S/2), while the other beam propagating in the opposite direction around the circle will have to travel over a distance equal to (2πR-S/2) before each of these beams see the beam splitter 12 which is assumed to have moved from A to A' during the time T. Here S represents twice the distance between A and A'. Then, the phase difference θ between the two beams when they meet at A' is
θ=(2π/λ)(2πR+S/2)-(2πR-S/2)
θ=(2π/λ)S (2)
where the value of S is
S=2TΩR (3)
and the rotation rate is in radians. The foregoing equations have been derived with the simple circular path shown in FIG. 3 and are actually approximated equations. However, it can be shown that these equations are very good approximations and can be generalized to any configuration.
In conventional Sagnac interferometers, the phase difference θ will remain constant so long as Ω and S remain constant in equations (2) and (3). When Ω and S change, this change will typically be very slow.
One of the major problems with the Sagnac interferometer is that rotation-caused fringe shifts will generally only cause a change in power ΔP of on the order of 10 -6 -10 -4 P where P is the total power output. However, a significant amount of system noise will typically be present in the apparatus. This noise will frequently cause power fluctuations as large as and larger than the power change ΔP caused by the rotation fringe shift. There are a variety of potential sources of such noise in the system. For example, the laser light output is generally not constant but will fluctuate. Likewise, noise may be caused by polarization drift or from the backscattering of light as it propagates through the optical fiber. If the change in power ΔP caused by the rotation fringe shift is smaller than this drift fluctuation or other noise fluctuation, then it cannot be detected by the system. Accordingly, such noise fluctuation in the power output places a severe limitation on the use of Sagnac rotation interferometers. Furthermore, such interferometer signals are usually of low frequency ranging from a few hertz to a fraction of a hertz where noise power is relatively high.
OBJECTS OF THE INVENTION
Thus, it is an object of the present invention to significantly enhance the detectability of power changes ΔP due to rotation fringe shifts.
It is a further object of the present invention to increase the sensitivity of rotation rate interferometers in the presence of system noise.
It is yet a further object of the present invention to effectively filter out noise-caused power fluctuations at the output of a Sagnac interferometer.
Other objects, advantages and novel features of the invention will become apparent from the detailed description of the invention following the summary when considered in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
Briefly, the above and other objects are obtained in a Sagnac rotation sensing interferometer by converting the interferometer output signal from a low frequency to a high frequency. According to the invention, the wavelength of the light propagating in the light paths of the interferometer is modulated in time at a modulation frequency substantially higher than the rate of change of phase of the light beam due to rotation and the system noise frequency spectrum. Apparatus is then included for extracting a signal from the interferometer interference pattern at the modulation rate of the optical beam wavelength in order detect the phase change therefrom. The invention is based on the fact that by varying the wavelength of the beam applied to the Sagnac interferometer at a predetermined rate, it is possible to modulate the Sagnac phase and thereby detect with significantly increased sensitivity the changes in the interference pattern signal. Accordingly, this invention permits the shifting of the spectrum of gyro signal into a region where the noise spectrum for the system is minimal.
In one embodiment of the present invention, the Sagnac rotation sensing interferometer comprises a long wound optical fiber light path, a beam splitter for splitting an input light beam into two beams and directing one of the two beams to travel in a clockwise direction around the light path circuit and directing the other of the two beams to travel in a counter-clockwise direction around the light path circuit, and for recombining the two beams after having traversed through their respective directions in the light path circuit to produce electromagnetic wave interference. This apparatus further includes a plurality of light sources for generating a plurality of different beams of electromagnetic energy with each beam having a different wavelength, a gating circuit for alternately gating each of the plurality of different wavelength beams to the beam splitter at a gating frequency substantially higher than the rate of change of phase due to rotation, and an extracting circuit for extracting a signal from the interference pattern at the wavelength switching frequency in order to detect a phase change therefrom. In operation, when there is no rotation component in the plane of the light path circuit, then the wavelength modulation will not alter the normalized interference output signal. However, if the gyroscope is in a rotating frame, then the normalized interference output signal will have a ripple at the wavelength modulation frequency with the amplitude of the ripple being proportional to the Sagnac phase change caused by the rotation component in the plane of the light path circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In conventional Sagnac interferometers the rotation rate Ω and distance S are very small and change slowly. Typically, the rotation rate may be as small as 15 degrees per hour or less. Accordingly, the magnitude of the phase change θ in equation (2) is much less than a degree and changes very slowly with time.
In the present invention the fact that a change in the phase shift θ also occurs with changes in the wavelength (see equation (2)) is utilized to effectively enhance the detectability of the phase shift signal. In λ particular, the wavelength of the input optical beam is modulated at a frequency substantially higher than the speed of change of the distance S and the noise frequencies. From equation (2) it can be seen that this wavelength modulation results in the modulation of the phase of the interferometer signal at the same modulation frequency. The effect of this wavelength modulation can be more clearly understood through the following analysis. It was previously stated that the phase change Δθ caused by rotation is proportional to the change in output power ΔP, or Δθ=KΔP where K is a constant. Now by subtracting the phase shifts θ(λ 1 )-θ(λ 2 ) in accordance with equation (2) the following equation is obtained:
KΔP=Δθ=θ(λ.sub.1)-θ(λ.sub.2)=2.pi.S(1/λ.sub.1 -1/λ.sub.2) (4)
Now assume that the wavelength λ in equation (2) varies as shown in FIG. 4(a) with time. Then, the change in the power output at the detector for the system will be proportional to the change in phase Δθ, in accordance with the equation P=1/2[1-cos (θ+φ)], and will vary with time as shown in FIG. 4(b). At t<t 0 , the platform on which the system is disposed is assumed to have a zero rotational component in the plane of the light path for the Sagnac interferometer. Thus, at t<t 0 , Δθ is zero in equation (4), since S is zero. However, when the platform begins to rotate at t=t 0 , then S in equation (4) becomes non-zero, and any change in λ will induce a change in the phase θ, and thus in the power P, as shown in FIG. 4(b). Accordingly, the normalized power output will have a ripple component at the wavelength modulation frequency if there is rotation and a non-zero S (FIG. 2(c)).
Now, it should be understood that the purpose of the present invention is to determine the value of the distance S, which is directly proportional to the rotation rate of the platform on which the apparatus is located. By algebraically manipulating equation (4) the following equation may be obtained. ##EQU1##
It is understood of course that λ 1 and λ 2 are known since they will be the wavelengths utilized to modulate the system. The difference in power ΔP from the Sagnac interferometer when the different wavelengths λ 1 and λ 2 are utilized can be measured quite easily by extracting from the output interference signal the signal at the wavelength modulation frequency and measuring the amplitude thereof. From the above equation (5) it can be seen that for a given set of wavelengths λ 1 and λ 2 , the term on the right hand side of equation 5 is a constant times the measured change in power ΔP. Accordingly, the measured change in power ΔP is directly proportional to the distance S, which, in turn, is directly proportional to the rotation rate. Thus, by simply extracting and measuring the amplitude of the ripple at the wavelength modulation frequency, an extremely accurate measure of the rotation rate of the platform on which the apparatus is disposed may be obtained.
There are a wide variety of ways to implement the above recited teaching. One embodiment utilizing two laser sources and a modulating switch is shown in FIG. 5. In that figure, a laser source 40 for generating an optical beam with a wavelength λ 1 is applied via an optical fiber line 41 to one terminal of an optical switch 44. Likewise, a laser source 42 for generating an optical beam with a wavelength of λ 2 is applied via an optical fiber line 43 to a second terminal of the optical switch 44. By way of example, and not by way of limitation, the optical switch 44 could be implemented by means of an integrated optic directional coupler switch of the type disclosed in the article "Switched Directional Couplers With Alternating Δβ" by H. Kogelnik and R. V. Schmidt, IEEE Journal of Quantum Electronics, Vol. Q.E.-12, No. 7, page 396, July 1976. This optical switch 44 will operate to alternately switch or gate the light wavelengths λ 1 and λ 2 through the optical switch 44 and the beam splitter 46 to an optical fiber light path circuit 22.
The optical fiber light path circuit 22 may again be implemented by means of a wound light fiber. The beams splitter 46 may be implemented, by way of example, by a guided-wave directional coupler of the type disclosed in U.S. Pat. No. 4,264,126.
The beam splitter 46 will operate to split whichever wavelength beam is applied thereto into two beams to travel in opposite directions through the optical fiber light path circuit 22. One beam will travel in the clockwise direction around the light path 22 while the other beam will travel in the counter-clockwise direction around the light path circuit. When these light beams of the same wavelength have traversed in their respective directions through the light path circuit 22, they are recombined by the beam splitter 46 and applied to optical fiber 23, which in turn, is butted against the detector 30. The ratio between optical powers that are divided between the fiber 23 and 45 is proportional to the Sagnac phase (θ).
Since the wavelength of the input light beam is being modulated at a given rate of, for example, one KHz, by the gating circuit 44, then the normalized power output will be modulated by the same frequency, as noted above and shown in FIG. 4(b). This power output modulation at the gating frequency of the gate 44 is also shown as a ripple modulation in FIG. 2(c). This modulation signal may be extracted simply by detecting the power at the detector 30 and then extracting via an extracting circuit 48 the ripple signal present in the frequency spectrum at the position of the wavelength modulation frequency. A variety of detection techniques are available for extracting the signal at this modulation frequency. For example, the signal from the detector 30 could be applied to a spectrum analyzer or a locking amplifier. It is understood of course that the output power P must be normalized by the input power P i .
In operation, when the Sagnac interferometer is disposed on a stationary platform, the wavelength modulation will not alter the normalized power output signal detected by the frequency extracter 48 because the distance S or phase shift will be zero. However, when the interferometer platform begins to rotate with a component of the rotation in the same plane as the optical light path circuit 22, then the normalized output signal will vary at the wavelength modulation rate. Thus, even though the distance S may be very small, it can be detected easily since the phase θ and thus the normalized power is modulated at a predetermined frequency which may be extracted and its amplitude measured. This modulation frequency may be arbitrarily varied up to the GHz range, but will typically be on the order of 100-10,000 Hertz.
In essence, the present system has operated to shift the spectrum of the interference phase shift signal to a frequency significantly higher than that of the system (drift) noise. This can be seen in FIG. 2(e) where the wavelength modulation frequency and thus the spectrum location where the signal appears has been chosen as 1 KHz. Thus, the fact that the background noise of the system is greater than or equal to the signal generated by the interference phase shift caused by the rotation rate and has approximately the same frequency as the system noise, will not prevent accurate detection thereof. In essence, the interference phase shift signal has been moved to a window in the noise spectrum thereby facilitating its detection in the presence of such noise.
It should be understood that there are a variety of methods for generating light beams at a plurality of wavelengths. For example, a plurality of different wavelength light beams could be generated by generating one wavelength and the harmonics therefore. The present system could thus be implemented by generating a wavelength λ 1 and its optical second harmonic.
Obviously, many modifications and viriations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | A Sagnac rotation sensing interferometer disposed on a rotating platform use as a gyroscope comprising a wound optical fiber light path, a beam splitter for splitting a light beam into two beams directed to traverse the optical path in opposite directions, a light source circuit for generating a light beam which is switched between two wavelengths at a switching or modulation frequency substantially higher than the speed of change of the phase due to rotation, and a detector for extracting a signal from the recombined beam interference pattern at the wavelength modulation frequency, this signal being proportional to the phase shift caused by rotation. | 6 |
[0001] This application is a continuation of U.S. patent application Ser. No. 12/653,282, filed Dec. 10, 2009, which claims priority of U.S. provisional application Ser. No. 61/1201,394 filed Dec. 10, 2008, and the entire contents of each are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to directional drilling systems, and more specifically to a sonde used to transmit information concerning a drill head used in directional drilling.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to a sonde assembly. The sonde assembly comprises a sonde housing comprising a non-magnetic tube, the tube forming a non-magnetic sonde cavity, a front plug for enclosing a front end opening of the non-magnetic sonde cavity, and a sonde slidingly disposed inside the non-magnetic sonde cavity. The sonde comprises a sensor and a radio transmitter connected to the sensor to transmit a directional sensor based on sensor input. The sonde assembly further comprises a rear end cap securable in a fixed position in a rear end opening of the non-magnetic sonde cavity. Upon securing the rear end cap in a rear end opening of the sonde housing, the sonde is secured in a fixed position relative to the sonde housing.
[0004] The present invention is also directed to a second embodiment of a sonde assembly. The sonde assembly comprises a sonde housing in the form of a non-magnetic tube, the tube forming a non-magnetic sonde cavity, a means for enclosing a front end opening of the non-magnetic tube, and a sonde slidingly disposed inside the non-magnetic sonde housing. The sonde comprises a sensor and a radio transmitter connected to the sensor to transmit a directional sensor based on sensor input. The sonde assembly further comprises a means for enclosing the rear end opening of the non-magnetic sonde housing. Upon securing the rear end opening of the non-magnetic sonde housing, the sonde is secured in a fixed position relative to the non-magnetic sonde housing.
[0005] The present invention is further directed to a third embodiment of the sonde assembly. The sonde assembly comprises a sonde housing in the form of a non-magnetic tube, a front plug for enclosing a front end opening of the non-magnetic tube, a sonde slidingly disposed inside the non-magnetic tube, and a rear end cap securable in a fixed position in a rear end opening of the non-magnetic tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a side view of a drill head having a sonde assembly of the invention.
[0007] FIG. 2 is a lengthwise sectional view of the drill head of FIG. 1 along the line 2 - 2 in FIG. 1 .
[0008] FIG. 3 is an enlarged view of the circled area 3 in FIG. 2 .
[0009] FIG. 4 is an enlarged view of the circled area 4 in FIG. 2 .
[0010] FIG. 5 is an enlarged view of the circled area 5 in FIG. 4 .
[0011] FIG. 6 is a partial side view of a sonde assembly of the invention.
[0012] FIG. 7 is an end view of the rear end cap of the sonde assembly of FIG. 6 .
[0013] FIG. 8 is a top view of the sonde assembly of FIG. 6 .
[0014] FIG. 9 is a side view partly in section, of the sonde assembly of FIG. 6 .
[0015] FIG. 10 is an enlarged view of the circled area 10 in FIG. 9 .
DETAILED DESCRIPTION
[0016] Horizontal directional drilling (“HDD”) has become an effective and efficient method of installing or rehabilitating utilities with minimal surface disruption. However, accurate placement of utilities in HDD tends to require accurate tracking of a drill head as it progresses along a borepath. Thus, several methods of tracking have developed over time. One such method of tracking is called “walkover tracking”. Walkover tracking uses a wireless signal beacon disposed underground proximate or within the drill head and an above-ground tracker used to detect a signal transmitted from the beacon. The signal is used to determine the location and orientation of the drill head. Another method of tracking the drill head utilizes a wireline transmitter.
[0017] Wireline sondes (transmitters) are capable of reading the earth's magnetic field rather than gravity. These systems are capable of use underneath busy streets, rivers or other locations where a walkover transmitter may be imperiled by traffic, need for a boat, or the signal may be affected by the existence of steel rebar between the receiver and the transmitter. One potential drawback to the use of a wireline sonde is that they are generally required to be located at a distance (preferably at least about 10 feet) from any magnetic item, including alloy steel making up the housing or drill pipe. Steel alloys commonly used to make sonde housings are sufficiently magnetic to prevent the sonde from sensing the earth's magnetic field accurately. To remedy this, non-magnetic variations of stainless steel can be used.
[0018] Non-magnetic variations of stainless steel, however, can be difficult to fabricate into tooling because they have a low machinability rating. Thus, end load housings have been developed because of their simplicity of design. As used herein “end load housing” means the drill stem may be disconnected from the housing to access the sonde for loading/unloading through the end of the housing. End load housings normally restrain and clock the sonde relative to the housing with a slot in the sonde to engage a tabbed feature within the housing. The sonde is then trapped from the opposite end with a plug which maintains the tab/slot engagement and therefore the clock orientation of the sonde relative to the housing.
[0019] The action of finding and engaging the slot and the tab is risk prone as it cannot be inspected at the bottom of its blind bore, a bore possibly contaminated with dried mud. Should this engagement not be accomplished, the sonde will drift in clock position during operation and the drill head orientation signals from the sonde will be inaccurate. Inaccurate orientation readings may cause the drill head to deviate from the desired borepath.
[0020] Turning now to the Figures, and more specifically FIG. 1 , there is shown therein a sonde assembly 100 of the present invention. The sonde assembly 100 is constructed, as described herein, to reduce the risk of not engaging a housing tab into the sonde slot by rigidly bolting the sonde to a plug which threadedly retains the sonde within the housing.
[0021] The sonde assembly 100 of FIG. 1 comprises a drill bit 12 and a sonde housing 14 . The drill bit 12 may comprise a slant-faced steering bit. The slant-faced bit 12 may comprise a conventional flat bill made of non-magnetic steel. A plurality of bolts 15 are used to secure the bit 12 to the housing 14 . The bit 12 is used to bore through the ground; it should be appreciated that a variety of drill bits could be used with the current invention including drag bits, rotary bits and back reamers.
[0022] The sonde housing 14 comprises a non-magnetic housing 17 having a cavity 18 ( FIG. 2 ). The cavity 18 is vented to the outside ground pressure through at least one window 16 . Window 16 permits a directional signal to be transmitted from inside the non-magnetic housing 17 . These windows 16 may be open, or they may be sealed with putty that will yield and leak should sufficient differential pressures develop between the cavity 18 and the adjacent soil.
[0023] Wireline 19 is shown extending from the up hole end of housing 17 and may extend to the surface along the drill string (not shown). As shown in FIG. 2 , the wireline 19 is connected to the sonde 34 and passes through a yet to be described rear end plug 32 .
[0024] Turning to FIG. 2 , the sonde assembly 100 of FIG. 1 is shown in a longitudinal section view. The drill a bit adapter 20 is shown supporting dill bit 12 and connected to housing 17 . The bit adapter 20 is used to support the drill bit 12 relative to the housing. The bit adaptor 20 shown in FIG. 2 comprises an angled face 21 for mounting the bit at an angle relative to a central axis 23 ( FIG. 1 ) of the housing 17 to facilitate steering. One skilled in the art will appreciate that the bit adaptor 20 may comprise a threaded portion (not shown) at its downhole end to facilitate the connection of a rotary bit or backreamer to the housing 17 . Alternatively, the bit adaptor 20 may have a drill bit 12 formed integrally therewith.
[0025] The bit adapter 20 may comprise threads 22 , shown more clearly in FIG. 3 , at its up hole end for connecting the bit adaptor to the housing 17 . The bit adapter 20 has a central fluid passage 24 and a discharge nozzle 26 to meter drilling fluid or mud from the downhole end of the adaptor 20 . Alternatively, one skilled in the art will appreciate passage 24 may be operatively connected to a fluid passage formed in the drill bit 12 such that said fluid is expelled from the bit itself. Both the bit adapter 20 and housing 17 are preferably made of a non-magnetic metal (steel) for use in the present invention.
[0026] Continuing with FIG. 2-5 , the housing 17 has at least one fluid passage 28 that direct the drill fluid or mud along the housing 17 to the bit adaptor 20 and around the cavity 18 . One such passage 28 is shown below the cavity 18 in FIG. 2 . One skilled in the art will appreciate that a plurality of passages may be disposed about the housing without departing from the spirit of the present invention. Such passages may be arranged in a circular formation around the periphery of the cavity 18 .
[0027] Cavity 18 is sealed from the flow of pressurized mud via a front plug 30 and a rear end cap 32 . The front plug 30 attaches to the front end opening 31 of the cavity 18 and encloses the front end opening. The rear end cap is securable within the rear end opening 33 of the cavity 18 . A sonde 34 is disposed within the cavity 18 and engages the front plug 30 and the rear end cap 32 at opposite ends. The sonde 34 comprises a sensor (not shown) and a transmitter (not shown) connected to the sensor. The sonde 34 may be formed inside of a non-magnetic tube 43 . The transmitter may comprise a radio signal transmitter adapted to transmit a directional signal based on a sensor output. The front plug 30 , shown more clearly in FIG. 3 , comprises an O-ring 36 and an elastic isolator 38 to help seal and cushion the sonde 34 from shock. As shown in FIG. 9 , the end plug comprises a non-ferrous component having a series of threads 60 for threading the plug into the cavity 18 of the housing 17 . An elastic isolator 38 is positioned between the sonde 34 and the plug 30 to absorb shock during drilling operations. A sleeve 62 is formed to support the isolator 38 , plug 30 and sonde 34 . The sleeve 62 comprises a cavity 64 formed to support the sonde 34 therein.
[0028] The sensor may comprise an orientation sensor package adapted to detect the roll, pitch and/or yaw orientation of the sonde assembly. Accordingly, the sensor may comprise a sensor that senses the magnetic field of the earth such as a magnetometer. The sensor may alternatively comprise at least one accelerometer. The sensor generates an output signal indicative of an orientation component of the sonde 34 and housing 17 and transmits said output to the transmitter. The transmitter, in turn, embeds or encodes orientation information onto a communication signal that is transmitted above-ground.
[0029] Referring now to FIGS. 6-9 in addition to FIGS. 2-5 , the rear end cap 32 is securable in a fixed position in the rear end opening 33 ( FIG. 4 ) of the cavity 18 . The rear end cap 32 comprises a rear plug 40 , a flange 42 , and a connector 44 . The rear plug 40 extends into the cavity 18 and creates a tight seal via threads 48 and an O-ring 50 ( FIG. 4 ) supported in an O-ring groove. The flange 42 is connected to the connector 44 and the sonde 34 . The flange 42 has a hole (not shown) therein used to connect the flange to the tube 43 . The non-magnetic tube 43 that houses the sensor and transmitter further comprises rearwardly opening holes (not shown) that align with the holes in the flange 42 . At least two bolts 52 ( FIGS. 6 & 8 ) are used to secure the rear end cap 32 to the non-magnetic tube 43 . The bolts 52 are preferably located 180 degrees apart. Connection of the flange 42 to the non-magnetic tube 43 may seal the sonde 34 to prevent pressurized fluid from entering the sonde. FIGS. 5 and 10 show the flange 42 connected to the tube 43 . As bolts 52 are tightened to bias the flange 42 toward the tube 43 , an O-ring 53 compressed to seal the sonde where the wireline 19 enters the sonde tube 43 .
[0030] The attachment of the rear end cap 32 to the sonde 34 and cavity 18 is considered a semi-permanent installation, removable to service the cavity 18 , sonde 34 , or front plug 30 . The front plug 30 and rear plug 40 also seal a data transmission line wireline 19 ( FIG. 5 ) which extends from the rear of the sonde 34 and continues through the length of the drill stem up to the machine (not shown). The data transmission line 19 works to transmit the directional signal and other information from the sonde 34 up to the operator regarding the position, operation, and condition of the sonde assembly 100 .
[0031] FIGS. 6-9 show the sonde 34 with front plug 30 and rear end cap 32 connected on opposite ends. As shown in FIGS. 2-4 , the sonde 34 is secured within the housing 17 using front plug 30 , and rear end cap 32 via threads. The rear end cap 32 is attached to the housing via threads 48 . As shown in FIG. 7 , the rear end cap 32 comprises three geometric shaped holes 66 adapted to receive a correspondingly formed geometric tool used to rotate the rear end cap 32 to thread it into the cavity 18 to isolate the sonde 34 from the flow of fluid through the housing 17 .
[0032] The front plug 30 remains in place sealing the front end opening 31 of the cavity 18 while the rear end cap 32 seals the rear end opening 33 of the cavity 18 and secures the sonde 34 in place within the non-magnetic housing 17 . By this means the sonde 34 , housing 17 , front plug 30 , and rear end cap 32 , rotate as a unit.
[0033] While certain embodiments of the invention have been illustrated for the purposes of this disclosure, numerous changes in the method and apparatus of the invention presented herein may be made by those skilled in the art, such changes being embodied within the scope and spirit of the present invention as defined in the appended claims. | A sonde assembly of the invention includes a sonde housing in the form of a nonmagnetic tube having windows therein for permitting a radio signal to be transmitted out the tube from the inside, means such as a device enclosing a front end of the tube, a sonde disposed inside the non-magnetic tube and closely fitting in a sonde cavity thereof in engagement with a front end plug. The sonde comprises a sensor and a transmitter connected to the sensor to transmit a directional signal based on sensor output, which sensor and transmitter are disposed inside a non-magnetic sonde cavity. | 4 |
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