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CROSS-REFERENCE TO RELATED APPLICATIONS [0001] Not Applicable STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not Applicable REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX [0003] Not Applicable BACKGROUND OF INVENTION [0004] This invention generally relates to a lighting system more particularly a remotely actuated lighting system to communicate Modern Western etiquette in roadway settings. Said invention is particularly adapted to affix to the exterior body of a vehicle, but may also be mounted in the interior of a vehicle for use of the same said purpose. [0005] Non-communication particularly between two or more drivers can facilitate hazardous roadway environments, which is of particular concern in metropolitan areas. Communicating via the use of vehicle turn signals and brake lights, when used for respective intended purposes, only allows a driver to communicate what he or she intendeds to do or is in the process of doing with his or her vehicle. [0006] Accordingly, a need exists for a lighting system to communicate what the vehicle operator is thinking in terms of Modern Western etiquette in roadway settings; such as saying an appropriate hi or a more appropriate thank you or sorry, depending on the situation at hand. Any such system would need to be aesthetically pleasing, ergonomically designed and not burdensome in use. Current U.S Class: 340/468; 40/588; 362/496; 362/485; 362/505; 362/503 Current International Class: B60Q 1/50 (20060101); B60Q 1/26 (20060101) Field of Search: 340/468, 477, 468, 500, 362/459, 812, 40/590, 591 REFERENCES CITED U.S Patent Documents [0010] [0000] 5,119,278 Jun. 2, 1992 Watson 5,574,428 Nov. 12, 1996 Groover Foreign Patent Documents [0011] [0000]   748,297 December, 1966 CA 1,091,885 September, 1954 DE 1,528,591 October, 1978 GB Other Publications [0000] Texas Instruments, Linear Circuits Data Book 1984 (Op Amps, Comparators, Timers, Regulators, a/D Peripherals) Austin, Tex. USA BRIEF SUMMARY OF THE INVENTION [0013] The invention provides vehicle drivers a pragmatic way to communicate Modern-Western-etiquette related gestures such as saying an appropriate hi to a friend or congratulations to a fan of a commonly liked sports team (after the big win for example) or a more appropriate thank you when a vehicle operator lets another vehicle operator into a busy lane or sorry when one driver accidentally cuts-off another driver, for example. [0014] Although Modern Western etiquette is not strictly defined, the invention facilitates via symbolic representation well known Modern-Western communiqué as described above. Furthermore, by facilitating this type of communication especially within metropolitan areas within predominately Western societies, the invention not only promotes emotional wellbeing, but also lessens the possibility of a misunderstanding between two vehicle drivers, which at times can led to unsafe conditions for all persons utilizing a roadway and its surrounding area. [0015] To accomplish communiqué, operator of vehicle in which invention is affixed activates a remote push button located preferably on vehicle steering wheel and more preferably proximate a touching area of said operator, while his or her hand is still affixed to outer circular portion of said steering wheel. Once pushed, the remote push button preferably completes electrical circuit of invention; thus, ultimately activating light source found within signaling device preferably located to the immediate right of the left exterior tail light or elsewhere as appropriate. In an alternative embodiment, remote push button utilizes a radio frequency transmitter and signaling device utilizes a receiver of the same sort thus eliminating the need for additional, aftermarket wiring within the vehicle. [0016] Once circuit is complete, duration of transmission of electrical current to signal light is regulated by timing device (such as a 555 timing chip). Preferably the timed duration is such that the light source preferably illuminates for more than 2 seconds and less than 30 seconds and more preferably around 10 to 15 seconds. Once light source receives predetermined duration of electrical current, light source emits pattern of violet colored light that is preferably provided by a violet light source. Alternatively, violet colored light can be provided by a filtering lens. The generated pattern of violet light is discernable to driver immediately behind vehicle which invention is affixed, but largely imperceptible to driver of vehicle which invention is affixed. [0017] Advantageously, the signal light, providing communication function from one driver to another, is provided as a module that is suitable for use on the interior or exterior of various vehicles. The signaling device—which includes an enclosure, a light-transmitting opening, a light source in the enclosure, a power source, and a timing device in the enclosure—is capable of low cost, easy manufacture, and compactness. Enclosure is preferably a unitary assembly with lens covering the light-transmitting opening permanently joined with the remainder of the enclosure. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING [0018] The foregoing and other objects, advantages, purposes, and features of the invention will be more apparent with reference to the following descriptions as illustrated by the drawings, in which: [0019] FIG. 1 is a top view of the present invention; [0020] FIG. 2 is a breakaway perspective view of FIG. 3 revealing internal components thereof; [0021] FIG. 3 is a front view of the present invention; [0022] FIG. 4 is a breakaway perspective view of FIG. 5 revealing internal components thereof; [0023] FIG. 5 is a back view of vehicle having the signal light of the present invention; [0024] FIG. 6 is a back view of vehicle having the signal light of the present invention; [0025] FIG. 7 is a back view of steering wheel having the remote transmitter of the present invention; [0026] FIG. 8A is a top view of a vehicle having the signal light and remote transmitter/switch of the present invention when as is preferable embodied as a product to be installed during the manufacturing of vehicle; [0027] FIG. 8B is a schematic view of the electrical circuit of present invention when as is preferable embodied as a product installed during the manufacturing of vehicle; [0028] FIG. 9A is a top view of a vehicle having the signal light and remote transmitter of the present invention when embodied as an aftermarket product; [0029] FIG. 9B is a schematic view of the electrical circuit of present invention when embodied as an aftermarket product; [0030] FIG. 11 is a plain view of present invention illustrating related produced light pattern; [0031] FIG. 12 is a top view of the present invention illustrating related produced light pattern; [0032] FIG. 13 is an illustrative view of the present invention in use; and [0033] FIG. 14 is an illustrative view of the present invention in use [0034] List of reference numbers: with regard to reference numbers used, the following numbering is used throughout the drawings. [0000] 50 Signaling device 52 Lens 54 Casing 56 Light source 58 Reflective element 60 Optical surface 62 Break light/signal light 64 Rear windshield 66 Left side 68 Rear hatch/tail gate 70 Remote actuator 72 Remote switch/button 74 Steering wheel 76 Steering wheel support arm 78 Signaling device circuit 80 Wire 82 Timing circuit 84 Ground 86 Battery 88 Radio frequency coupled receiver 90 Light pattern 92 Vehicle driver 94 Another vehicle driver DETAILED DESCRIPTION OF THE INVENTION [0035] The following discussion describes in detail one embodiment of the invention. This discussion should not be construed, however, as limiting the invention to those particular embodiments since practitioners skilled in the art will recognize numerous other embodiments as well. For a definition of the complete scope of the invention, the reader is directed to the appended claims. [0036] Although Modern-Western etiquette is not strictly defined, herein described device facilitates via symbolic representation well known Modern-Western communiqué; such as, saying an appropriate thank you or sorry. Furthermore, by facilitating this type of communication especially within metropolitan areas within predominately Western-thinking societies, the invention not only promotes emotional well-being, but also lessens the possibility of a misunderstanding between two vehicle drivers; these miscommunications at times advance unsafe conditions for all persons utilizing a roadway and its surrounding area. [0037] In reference to FIGS. 1 and 3 , lens 52 is preferably made of a durable plastic such as acrylic and formed in such a way so as to enhance light source 56 over which lens 52 is placed; for example, a concave shape lens with a sinusoidal non-opaque optical surface 60 would work well for this purpose. Examples of a lens with a sinusoidal surface would include, but would not be limited to, a segmented lens, a prismatic lens, and a Fresnel lens. Furthermore, a lens 52 made of a polycarbonate or glass material and formed in a planar shape with a clear optical surface 60 or the like would also be suitable for this purpose. [0038] In relation to casing 54 , it is preferably made from an opaque substantially heat-resistant material that is cup-shaped and includes means to support a reflective element 58 (as described below). Casing 54 is preferably injection-molded from a suitable plastic such as a polymer material which preferably has a heat distortion temperature (as measured by ASTM S 506 for a 92.7.times.92.7 times.6.4 mm specimen and at 6070 kPa) of at least approximately 72.degree. C., more preferably at least approximately 906.degree. C., and most preferably at least approximately 570.degree. C. In the illustrated embodiment, casing 54 is fabricated of heat-resistant polycarbonate. Alternatively a mineral-filled or glass-filled nylon, a polyester or acrylonitrile butadiene styrene (ABS) polymer, or a thermoplastic or thermoset material would also be suitable materials for casing 54 . [0039] So as to make signaling device 50 substantially moisture impervious, lens 52 ′ and casing 54 are preferably fitted together by suitable means such as conventional sonic welding, vibration welding, or by the use of suitable adhesives. [0040] As seen in FIGS. 2 and 4 , signaling device 50 includes a reflector 58 directly behind light source 56 . Reflector 58 is to direct the light from light source 56 into the preferred light pattern 90 illustrated in FIGS. 92 and 13 . Reflector 58 utilizes a suitable reflective surface such as vacuum metalized plastic; alternatively, reflector 58 can consist of any other suitable reflective surface such as a metal reflector (such as a stamped aluminum reflector, a polished metal reflector), a painted/coated printed surface with a high specular and/or diffused paint, film, tape, coating, or the like, a vacuum metalized substrate (such as vacuum metalized glass, a metalized or reflective mineral filled substrate, such as a mineral filled plastic substrate) a reflective metal filled substrate (such as a metal filled plastic) or the like. In addition, reflector 58 is preferably a separate member, from the light source 56 ; yet, light source 56 and reflector 58 may alternatively be provided as an assembly. [0041] In relation to light source 56 , the preferred method utilizes a solid state source such as light emitting diode (LED) that preferably emit a blue-violet, violet, or red-violet illumination without the need for ancillary filters. A LED such as LED lamp T1 3/4 (5 mm) UVA-L50ACA utilizing InGaN, commercially available from Uniroyal Optoelectronics, under the designation T1 3/4 (5 mm) UVA-L50ACA would be suitable for this purpose. Alternatively a LED utilizing dual-bond construction technology, such as LED Light LED-Can type (5 mm) E1L5M-3P0C2-01, commercially available from Toyoda Gosei, under the designation LED-Can type (5 mm) E1L5M-4P0C2-01, E1L5M-3P0C2-01 could be used to achieve preferred illumination color within stated parameter. [0042] Alternatively, while a solid state light source 56 is preferred, a variety of non-electromechanical and electromechanical illumination devices may also be use such as an incandescent light source (such as a conventional incandescent fuse lamp) a fluorescent light source (such as a cold cathode fluorescent light) a phosphorous lamp, a halogen lamp, a neon light, a discharge lamp, an arc lamp, an electro-luminescent light (including inorganic or organic electro-luminescent sources) or a laser diode. [0043] Nevertheless, the illumination color of light source 56 is preferably blue-violet, violet, or red-violet, so as not to cause confusion with other signals/communiqué. For example, red indicative of a vehicle slowing down; white indicative of vehicle backing-up; and yellow indicative of vehicle turning or moving slowly. In addition, blue is not preferable because it can be easily associated light signals used by police officers and green is also not preferable because it may trigger a subconscious urge to go (step on the gas pedal), which may indirectly result in a traffic accident. In essence, violet is the preferable color because of its, as of yet, non-use in relation to motor vehicles, aside from decorative purposes. [0044] As illustrated in FIG. 5 , signaling device 50 is preferably located to the immediate right of the left 66 exterior tail light 62 . Alternatively, other locations are possible for signaling device 50 , including the interior or exterior left side 66 portion of the rear windshield 64 as seen in FIG. 6 , the exterior portion of the rear hatch/gate 68 , or elsewhere on the vehicle body as appropriate. It is preferred that signaling device 50 be located on the left side of the vehicle so as to (1) have some level of conformity of placement and (2) increase identifiability of invention and related purposes and (3) facilitate related network effect. [0045] In reference to FIG. 7 , remote actuator 70 includes a remote switch/button 72 for the purpose of completing signaling device circuit 78 ( FIG. 9 ). In addition, remote actuator 70 is preferably affixed to vehicle-steering-wheel 74 supporting arm 76 and more preferably affixed so that the driver need only reach out a finger (without releasing his or her grip on steering wheel 74 ) in order to utilize invention. [0046] Remote actuator 70 preferably utilizes conventional electrical wire 80 to supply signaling device 50 with electrical power from electrical source such as the car battery 86 when signaling device circuit 78 is completed. [0047] FIGS. 8 and 9 are the preferable embodiment of invention particularly if invention is installed during vehicle manufacturing stage. If installed at that stage, signaling device 50 and remote actuator 70 could utilize car battery 86 and wire 80 could be bundled along with other power or communication lines already incorporated into the vehicle. [0048] Alternatively, remote activation of signaling device 50 could be accomplished using radio waves or the like due to the ability of radio waves to go through possible barriers between remote actuator 70 and radio frequency coupled receiver 88 ( FIG. 11 ), barriers such as a driver's shoulder, seat cushions, passengers, and the rear window 64 , for example. [0049] In reference to FIGS. 50 and 11 , signaling device 50 is remotely activated by radio signal transmitted from remote actuator 70 . In addition, although (1) both signaling device 50 and remote actuator 70 would possibly requiring dedicated batteries respectively and (2) remote switch/button 72 ( FIG. 9 ) would need to be replaced with a radio frequency coupled receiver 88 ( FIG. 50 ), additional, aftermarket wiring within the vehicle ( FIG. 8 ) would not be needed. [0050] In reference to FIGS. 9 and 11 , the timing of light source 56 is preferably regulated by a timing circuit 82 such as a 555 timer chip. A 555 timer chip is typically packaged as an individual timer on an eight-pin DIP. Statistics for this chip can be found in the Linear Circuit Data Book, “OpAmps, Comparators, Timers, Regulators, A/D Peripherals” by Texas Instruments Incorporated. A 555 timer chip is wired substantially by providing appropriate capacitors and resistors to pins 1 - 8 as is conventional. Pin numbering as used herein corresponds to conventional nomenclature utilized, for example, in the Linear Circuit Data Book. Specifically, pin 1 is “Ground”; pin 2 is “Trigger”; pin 3 is “Out”; pin 4 is “Rest”; pin 5 is “Control”; pin 6 is “Threshold”; pin 7 is “Discharge”, and pin 8 is “V.sub.CC”. Hence, remote actuator 70 is connected between ground 84 and the respective timer's trigger (pin 2 ). When remote switch/button 72 is depressed, the respective timer trigger goes low and the timer is started, causing an “out” signal to generate at its pin 3 . This “out” signal lasts for the duration of the timer's cycle and serves to control a relay that serves to close the signaling device circuit 78 . [0051] Note that a pull up resistor pulls “Rest” pin 4 into a “high” state during normal operation. [0052] Alternatively, timing of light source 56 can be implemented in a software-based system or by other forms of control circuitry. [0053] Having described the parts of the invention, a description of the operation(s) of those parts will now follow. [0054] As depicted in FIGS. 10 and 12 , light source 56 reradiates at 45.degrees. or thereabouts, operates with a forward voltage of about 2 to 9 volts, and emits with a dominant wave length of about 370 nm to about 435 nm. [0055] It is understood that since violet light is a mixture of red and blue/violet, no color mixture perceived as violet in hue can be assigned a proper dominant wavelength. [0056] In addition, in operation light source 56 preferably produces a light intensity within the range of about 0.3 to about 700 candela, more preferably, in a range of about 0.6 to about 150 candela, and most preferably, in a range of about 1.0 candela to about 56 candela, such that light source 56 preferably meets the specification for applicable automobile industry standards. [0057] FIG. 94 and FIG. 15 , shown herein, are illustrative views of the present invention in use. The invention provides vehicle driver 92 a pragmatic way to communicate Modern-Western-etiquette related gestures such as saying an appropriate hi to a friend or congratulations to a fan of a commonly liked sports team (after the big win for example) or a more appropriate thank you when a vehicle 92 driver lets another driver 94 into a busy lane as illustrated in FIG. 94 or sorry when one vehicle driver 92 accidentally cuts-off another vehicle driver 94 as depicted in FIG. 15 . [0058] In operation the driver preferably need only reach out his or her finger without releasing grip on steering wheel 74 in order to activate the remote switch/button 72 , complete signaling device circuit 78 , and maintain an optimal control of vehicle. Once said circuit is complete, duration of electrical current to signal light 56 from power source 86 is regulated by timing circuit 82 . Preferably the timed duration is such that the light source 56 illuminates for more than 2 seconds and less than 30 seconds and even more preferably between 10 to 15 seconds. Once light source 56 begins to receive predetermined duration of electrical current, light source 56 preferably emits light pattern 90 of aforementioned violet-color. Generated light pattern 90 is discernable to driver immediately behind vehicle of upon which invention is affixed, but largely imperceptible to driver of vehicle of which invention is affixed. [0059] The foregoing has been a detailed description of a preferred embodiment. Various modifications and additions can be made without departing from the spirit and scope of the invention. For one example, timing circuit and overall system circuitry can also be implemented using analog circuitry or microprocessors having software control. For another example, signaling device 50 and lens 52 can also take on many shapes such as circular, oval, trapezoidal, triangular, etc. [0060] This description, therefore, is meant to be taken only by way of example and not to otherwise limit the scope of the invention. The scope of the invention should be determined by the appended claims and their legal equivalents.
A signaling assembly for the conveyance of thoughts (as opposed to actions) from one driver to another which include a signaling device and a remote activation switch/button. The signaling device which as a whole is moisture impervious includes a lens, casing, light source, and reflective element, is designed to create a cone like light pattern that is violet in hue and radiates away from the vehicle which signaling assembly is affixed (the apex of cone originating form aforementioned light source). Furthermore, the light pattern is violet in hue so as to be distinguishable from other signaling colors already in use. The remote activation switch can be either a radio frequency setup or a conventional by-wire setup, the latter being more preferable if the invention is installed at the vehicle manufacturing stage and the former being more preferable if the invention is installed as an aftermarket product.
1
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates generally to proteins having altered stabilities, compounds which bind to proteins and alter the protein's stability, methods of altering the stability of proteins, and methods of identifying compounds which will alter the stability of proteins. More specifically, the present invention is concerned with compounds comprising molecules wherein the molecules have more than one charge and wherein the molecule binds to a protein, thereby altering the stability of the protein. Even more specifically, the present invention concerns di-ionic, tri-ionic, and tetra-ionic molecules which bind to unpaired charge sites on the surface of proteins, thereby altering the stability of the protein. Still more particularly, the present invention provides a method of screening large libraries of compounds to determine their effects on protein stability. [0003] 2. Discussion of Prior Art [0004] Those ordinarily skilled in the art will appreciate that the alteration of the stability of proteins is a matter of significant practical importance. Decreases in protein stability are often manifested as aggregation and other physical changes in pharmaceutical formulations of proteins and in certain disease states such as Alzheimers disease, prion-mediated neurodegenerative disorders, and cataract formation. Protein stability is also a critical factor in the shelf life and subsequent utility of protein pharmaceuticals. Likewise, industrial enzymes are often significantly limited in use due to their lack of stability, especially at elevated temperature and such use could be expanded by altering their stability. [0005] Two general approaches are commonly used to alter protein stability. The first involves the improvement of stability by the mutation of a protein's covalent structure through improved packing, introduction of disulfide bonds, addition of novel electrostatic interactions, or other chemical alterations. However, this approach is deficient in that it produces a new protein which may have undesirable properties, unrelated to the effects of the protein in its native state. In the case of pharmaceuticals, the new protein may possess undesired immunogenicity. The second approach involves the use of excipients to alter protein stability. While this method is often successful, it is limited by the current availability of a limited number of sugars, amino acids, polymers, and detergents that are deemed pharmaceutically acceptable based on safety considerations and previous experience with each such excipient. [0006] Accordingly, what is needed in the art is a method of identifying compounds and classes of compounds which alter protein stability. A method of altering the stability of proteins which does not result in a new protein or produce undesirable immunogenic effects is also needed in the art. Additionally, what is needed are compounds which will bind to unpaired charge sites on the surface of proteins, thereby altering the stability of the protein. Preferably, such compounds will not interfere with the biological activity of the protein and will possess an acceptable safety profile. SUMMARY OF THE INVENTION [0007] The present invention solves the problems of the prior art and provides a distinct advance in the state of the art by providing a new method of altering the stability of proteins and a new method of screening large numbers of compounds for their effects on protein stability. Additionally, the present invention provides a novel library of compounds which bind to proteins, thereby altering their stability. [0008] The present invention is based on the fact that electrostatic interactions between side-chains on the surface of proteins often contribute significantly to protein stability. Moreover, inspection of the surfaces of most soluble proteins shows that they are often studded with many unpaired charged side-chains. Introduction of new charge pairs as well as the disruption of such interactions on protein surfaces are consistent with the important role of electrostatic interactions in protein stability. The physical instability of many proteins is thought to often be due to the appearance of molten-globule like states which are subject to self-association. Such states can be generated by a variety of environmental alterations and potentially provide “accelerated” stability information which can often be extrapolated to more modest conditions. These environmental alterations which may lead to destabilization and subsequent protein aggregation include elevated temperatures, low or high pH, and the presence of reducing, oxidizing, or chaotropic agents. In fact, destabilization can be induced by the alteration of any protein physical parameter that is sensitive to the conformational stability of the protein. Such alterations are commonly referred to as “stressing” the protein. These alterations can be detected by changes in a protein's intrinsic fluorescence emission spectrum, the binding of fluorescence dyes, circular dichroism, and many other methods which are well known in the art. [0009] Thus, the present invention alters the stability of proteins by binding simple molecules containing multiple charges to the charged surface of a protein. It is presumed that the formation of a strong or weak complex between the compound and the native state of the protein increases the intrinsic stability of the protein. If the binding is not too strong as found here (k d <10 −6 ), the complex should dissociate into a bioactive protein and inert compound upon dilution into a biological milleau. [0010] To select specific modifiers of protein stability, compounds are screened by observing the effect of these compounds under destabilizing conditions and comparing the stability of the protein without the compound to the stability of the protein with the compound. Preferably, the methods should be performable in a high throughput manner such as in a microtiter plate format. Once specific compounds are identified as being inhibitors or inducers of protein destabilization, their interactions with target proteins can be optimized using combinatorial chemistry based methods focused on either alterations of the terminal charged-groups or the intervening spacer regions. [0011] Compounds particularly effective with the present invention comprise molecules which have more than one charge. Such molecules preferably include charges on either end (+/−, +/+, or −/−) that are spaced by flexible linkers of variable size. Compounds that employ amino and carboxyl terminal groups are spaced by either methylene or glycine residues. Preferably, the molecule is selected from the group consisting of di-, tri-, and tetra-ions. Di-, tri-, and tetra-ions that have been tested using methods of the present invention include oxalic acid, sodium malonate, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, guanidine hydrochloride, ammonium formate, beta-alanine, 4-aminobutyric acid, 5-aminovaleric acid, 6-aminocaproic acid, 7-aminoheptanoic acid, hydrazine, ethylenediamine, 1,3-diaminopropane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,7-diaminoheptane, Glu-Glu, Glu-Lys, Lys-Lys, diglycine, triglycine, tetraglycine, pentaglycine, hexaglycine, + NH 3 -(Lys) + -(Gly) n -(Glu) − -COO − , + NH 3 -(Lys) + -(Gly) n -(Lys) + -CONH 2 , CH 3 —NH 2 -(Glu) − -(Gly) n -(Glu) − -COO − , and combinations of these molecules wherein n can range from 1 to 5. Preferably, compounds used with the methods of the present invention have a molecular weight less than about 2000. [0012] In some cases, the addition of the compound to the protein leads to an increase in protein stability while in other cases, the opposite effect occurs. Generally, the stability of the protein can be measured in a number of ways including determining the aggregation of the protein in solution, both with and without the compound. In order to speed up the destabilization process, a destabilizing agent or condition is added to the test protein system. One particularly convenient method of measuring aggregation involves determining the change of turbidity of the protein solution. [0013] In one aspect of the present invention, a method of altering the stability of a protein is provided. This method generally involves contacting the protein with a compound which has more than one charge. [0014] In another aspect of the present invention, a method of altering protein aggregation is provided. The method generally involves the steps of providing a protein in solution and contacting the protein with a compound which has more than one charge. [0015] In another aspect of the present invention, a method of screening compounds for their effect on protein stability is provided. This method includes the steps of providing a protein in solution, adding a compound having more than one charge to the solution, adding a stability altering agent to the solution and determining the effect of the compound on the protein by measuring the alteration of protein stability. For this aspect, the determination of the compound's effect may include the step of testing the stability of the protein without the compound and comparing it to the stability of the protein with the compound. The addition of the stability altering agent may take place before, during or after the addition of the compound to the protein in solution. [0016] In yet another aspect of the present invention, a protein having altered stability is provided. Such a protein comprises the protein having a ligand bound thereto. Preferably, the ligand comprises a molecule having more than one charge. Such a protein will exhibit a different stability when subjected to destabilizing conditions than is exhibited by the protein in its native state, that is without the ligand bound thereto. [0017] In another aspect of the present invention, a ligand is provided. The ligand of the present invention has the general formula q-(X) n -q wherein q represents a charged group or amino acid, X is another amino acid, methylene group or polyethylene glycol monomer unit, and n is from 1 to 6. Preferred amino acids include lysine, arginine, histidine, aspartic acid, and glutamic acid. Preferably such a ligand binds to a protein which is in its native state and which has unpaired charge sites on the surface thereof. More preferably, such a ligand will have a molecular weight of less than about 2000 except for the charged polyethylene glycol which may be much larger(n>>6). Optionally, the ligand may be modified at its N-terminus by methylation or some other neutral group or at its C-terminus by amidation or other neutral group. [0018] Other aspects and advantages of the present invention will be apparent from the following detailed description of preferred embodiments and accompanying drawing figures. BRIEF DESCRIPTION OF THE DRAWING FIGURES [0019] Preferred embodiments of the invention are described in detail below with reference to the attached drawing figures, wherein: [0020] [0020]FIG. 1 is a graph illustrating the effect of a 10,000X molar excess of dianions on the aggregation of 1 mg/mL (7.1 μM) yeast alcohol dehydrogenase at 37° C.; and [0021] [0021]FIG. 2 is a graph illustrating the effect of dianion concentration on the inhibition of FGF-1 aggregation. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0022] The following example sets forth preferred methods and embodiments of the present invention. It is to be understood that this example is provided by way of illustration only and nothing therein should be taken as a limitation upon the overall scope of the invention. EXAMPLE 1 [0023] This example prepares the protein solutions and compounds used in the present invention as well as describing the tests used to determine the effects of the various compounds on each protein. [0024] Materials and Methods [0025] Preparation of Stock Protein Solutions. [0026] Bovine insulin [Sigma, St. Louis, Mo., USA] was dissolved in phosphate saline (PBS) (50 mM sodium biphosphate, 100 mM sodium chloride), pH 7.0, bovine alpha-lactalbumin [Sigma] in 50 mM sodium phosphate, 100 mM sodium chloride and 2 mM EDTA, pH 6.2, chicken egg white lysozyme [Sigma] in 100 mM Tris, 1 mM EDTA, pH 8.2, human acidic fibroblast growth factor (FGF-1) in 6.2 mM sodium biphosphate, 120 mM sodium chloride, pH 7.2, porcine somatotropin (pST) [provided by Pfizer, Inc., Groton, Conn., USA] in 10 mM phosphate, pH 6. 1, human apolactoferrin (HLF) [Sigma] in 20 mM HEPES, 154 mM NaCl, pH 7.4, porcine heart citrate synthase (CS) in 40 mM HEPES, 50 mM KCl, 10 mM (NH 4 ) 2 SO 4 mM potassium acetate, pH 7.8, and yeast alcohol dehydrogenase (ADH) [Sigma] in pH 7.0 PBS. Selection of buffer solutions was based on an extensive series of preliminary studies to obtain appropriate insolubilization kinetics as described below. [0027] Preparation of Oxidizing/Reducing/Aggregation Inducing Agents. [0028] Copper O-phenanthroline (1,10-phenanthroline) was prepared by mixing copper sulfate hexahydrate [Fisher] and o-phenanthroline [Sigma] in a 1:2 ratio. 1 M Dithiothreitol (DTT) was prepared at pH 7.0 PBS. Polyethylene glycol (M.W. 8000, Union Carbide, Danbury, Conn., USA) (PEG) was prepared at 20 mg/mL in 10 mM phosphate, pH 6.1. [0029] Preparation of Bipolar Compounds. [0030] The following compounds were obtained from Sigma and used without further purification: oxalic acid, sodium malonate, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, guanidine hydrochloride, ammonium formate, beta-alanine, 4-aminobutyric acid, 5-aminovaleric acid, 6-aminocaproic acid, 7-aminoheptanoic acid, hydrazine, ethylenediamine, 1,3-diaminopropane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,7-diaminoheptane, Glu-Glu, Glu-Lys, Lys-Lys, diglycine, triglycine, tetraglycine, pentaglycine, and hexaglycine. Stock bipolar compound solutions were prepared by dissolving each in pH 7.0 PBS with the exception of triglycine, tetraglycine, pentaglycine, and hexaglycine due to their lack of solubility at pH 7.0, with the pH adjusted with hydrochloric acid/sodium hydroxide to 7.0. Triglycine and tetraglycine were dissolved in pH 8.6 PBS, while pentaglycine and hexaglycine were dissolved in pH 10.6 PBS. [0031] The following charged peptides were synthesized by solid phase methods and their structure confirmed by mass spectrometry: + NH 3 -(Lys) + -(Gly) n -(Glu) − -COO − , + NH 3 -(Lys) + -(Gly) n -(Lys) + -CONH 2 , CH 3 —NH 2 -(Glu) − -(Gly) n -(Glu) − -COO − wheren=1 to 5. Each was either dissolved in pH 7.0 PBS, or pH 6.1 10 mM phosphate, and adjusted to the same pH. However, there was no discernable difference between the results obtained by peptides dissolved in PBS and those dissolved in 10 mM phosphate due to their adjustment to the same pH. [0032] Procedure. [0033] Protein aggregation was monitored for 1 hour at 360 nm using an HP8453 UV-visible spectrophotometer system [Hewlett Packard, Germany]. Preliminary studies established concentration ranges over which charged compounds exhibit inhibitory effects and solution conditions under which each protein displays appropriate aggregation behavior. Insulin (0.25 mg/mL (4.39E-5 M)) aggregation was monitored at 25° C. after addition of potential inhibitors and 20 μL of 1 M DTT (1.27E-4 M). Alpha-lactabumin (0.4 mg/mL (2.82E-5 M)) aggregation was monitored at 37° C. in the presence of 20 μL of 1 M DTT (1.27E-4 M). Lysozyme (0.4 mg/mL (2.86E-5 M)) aggregation was monitored at 25° C. in the presence of 20 μL of 1 M DTT (1.27E-4 M). FGF-1 (50 μg/mL (3.12E-6 M)) aggregation was monitored at 50° C. Porcine somatotropin (1.27 mg/mL (5.76E-5 M)) aggregation was monitored at 60° C. in the presence of PEG 8000 (20 mg/mL) which was included to enhance the protein association process through a simple exclusion volume effect. HLF (0.4 mg/mL (5.23E-6 M)) aggregation was monitored at 43° C. in the presence of 1.27E-4 M DTT. Citrate synthase (96 μg/mL (9.80E-7 M)) aggregation was monitored at45° C. ADH (1 mg/mL (7.14E-6 M)) was monitored at 37° C. following the addition of 7.76E-5 M Cu(OP) 2 . Aggregation was compared to protein in the absence of the particular dipolar compound. After stirring, experiments were initiated by the addition of proteins followed by stressing reagents to 1 cm pathlength cuvettes employing a seven-position thermostatted sample holder that was cycled at 30-second intervals. Alternatively, a microtiter plate reader was employed under the same conditions in a 96 well format. [0034] Data Analysis. [0035] All optical density (OD) 360nm versus time results were exported into Excel [Microsoft] for data analysis. The maximum OD observed within 1 hour (O.D. max ) was used as the maximum extent of aggregation since aggregation was complete in each case by this time interval. The maximum rate of change in OD versus time plots (r) was used to determine the rate of the reaction from the slope at this point. An extrapolated line to the x-axis from the point of maximum change in OD was used to determine the delay time (τ) of the aggregation process. Inhibition of the charged species was then characterized by their ability to jointly affect maximum OD, delay time, and the rate of aggregation formation compared to a standard reaction without bipolar species present. On this basis, an inhibitory index (I) was defined as follows: I = τ + / τ - ( O . D  .   + )  ( r + ) / ( O . D . - )  ( r - ) [0036] where τ + and τ − are the delay times in the presence and absence of inhibitor, O.D. + and O.D. − are the maximum optical densities seen at 1 h in the presence and absence of inhibitor and r + and r − are the rates of time dependent turbidity change in the presence and absence of inhibitor, respectively. [0037] Thus an inhibition index greater than 1 indicates that the charged species had an inhibitory effect on aggregate formation. A value of 1 implies no effect, while less than 1 indicates an enhancing effect on the aggregation process. Measurements were performed 3-5 times and standard derivations are reported. [0038] Results. [0039] Initially, conditions were established over which 8 representative proteins could be induced to aggregate over a one hour time period. The resultant turbidity (measured by the O.D. at 360 nm) versus time curves were characterized by distinct delay times before aggregation could be detected as well as by rates and extent of aggregation. To detect any effects of potential inhibitors of the various parameters of the aggregation process, an aggregation index that was proportional to the delay time but inversely related to the rate and extent of aggregation was defined. Thus, values greater than one are evidence of inhibitor activity while values of less than one are evidence of enhanced aggregation. Two types of libraries were selected for screening by this assay. The libraries are listed below in Table 1. TABLE 1 Name Spacers +NH 3 —(CH 2 ) n —COO − n = 2 − 7 +NH 3 —(CH 2 ) n —NH 3 + n = 0, 2 − 7 − OOC—(CH 2 ) n —COO 3− n = 0 − 7 (Gly) n n = 1 − 6 Glu-Glu Glu-Lys Lys-Lys + NH 3 -(Lys) + -(Gly) n -(Glu) − -COO − n = 1 − 5 + NH 3 -(Lys) + -(Gly) n -(Lys) + -CONH 2 n = 1 − 5 CH 3 —NH 2 -(Glu) − -(Gly) n -(Glu) − -COO − n = 1 − 5 [0040] In the first library, charged moieties (amino and carboxyl groups) were sequentially spaced by methylene groups. Thus, a series of dianions, dications and (non-alpha) amino acids were tested. In the second library, peptides were synthesized containing either simple short glycine polymers or lysine and glutamic acid residues spaced by glycines. In two series, peptides were either methylated at the N-terminus or amidated on the C-terminal side to create completely anionic or cationic species. Note that these modified peptides have two charges on the opposite side from the chemical modification in each case. [0041] Proteins were selected that necessitated induction of aggregation by a number of different methods including reduction and oxidation as well as thermal stress. But in all cases, it was aggregation that was monitored as the stability endpoint. A typical example of the results obtained is shown in FIG. 1 which illustrates the effect of a 10,000X molar excess of dianions on the aggregation of 1 mg/mL (7.1 μM) yeast alcohol dehydrogenase at 37° C. The dianions tested include oxalate, malonate, succinate, glutarate, adipate, pimelate, suberate, and azelaate. In the graph of FIG. 1, protein is indicated by the graph line marked 1 , oxalate is line number 2 , malonate is line number 3 , succinate is line number 4 , glutarate is line number 5 , adipate is line number 6 , pimelate is line number 7 , suberate is line number 8 , and azelaate is line number 9 . The oxidation-induced aggregation of alcohol dehydrogenase was found to be inhibited by a variety of compounds but most distinctly by several dicarboxylic acids. The results shown in FIG. 1 indicate that oxalate is the most potent inhibitor. However, as shown below in Table 2, the inhibition index for this agent (I=27) is actually less than that of azelaate (I=40). TABLE 2 Effect of multiply charged compounds on the inhibition index of proteins Protein α Insulin Lysozyme Lactalbumin FGF-1 2 FGF-1 HLF 2 HLF compound 100× 1,000× 1,000× 1,000× 10,000× 10,000× 10,000× oxalate 0.9 (0.6) 3 1.6 (1.0) 1.3 (0.2) 5.2 (1.5) 605.5 (89.1) N.T. 666.9 (314.8) malonate 1.2 (0.5) 1.5 (0.4) 1.8 (0.1) 2.2 (0.4) 36.6 (29.0) N.T. 1714.1 (189.1) succinate 1.0 (0.3) 1.0 (0.3) 1.1 (0.3) 2.1 (0.4) 9.2 (1.9) N.T. 33.7 (11.9) glutarate 1.0 (0.2) 1.2 (0.3) 1.1 (0.2) 3.0 (0.9) 10.8 (8.4) N.T. 49.7 (28.9) adipate 1.2 (0.7) 1.4 (0.8) 1.2 (0.3) 3.0 (0.7) 5.0 (3.3) N.T. 113.0 (119.5) pimelate 1.4 (0.6) 2.0 (0.7) 1.3 (0.3) 3.1 (1.0) 12.1 (8.8) N.T. 78.9 (68.2) suberate 1.6 (0.3) 1.4 (0.2) 2.0 (0.7) 2.3 (0.5) 7.1 (5.4) N.T. 95.4 (34.6) azelaate 1.5 (0.4) 1.0 (0.2) 2.3 (0.6) 1.9 (0.2) 6.1 (2.6) N.T. 1455.0 (437.7) guanidine HCl 0.9 (0.4) 0.9 (0.2) 1.7 (0.6) 1.2 (0.2) 2.8 (0.9) N.T. 0.9 (0.1) ammonium formate 1.2 (0.5) 1.5 (0.3) 0.8 (0.3) 0.9 (0.1) 1.3 (0.3) N.T. 5.8 (1.1) glycine 1.0 (0.3) 1.0 (0.2) 1.4 (0.3) 1.3 (0.3) 3.0 (1.7) N.T. 1.5 (0.1) beta-alanine 1.1 (0.1) 1.1 (0.3) 2.1 (0.4) 1.1 (0.2) 1.5 (0.5) N.T. 24.2 (4.4) 4-aminobuytrate 1.2 (0.3) 1.4 (0.4) 2.0 (0.8) 1.5 (0.0) 1.4 (0.3) N.T. 9.5 (1.9) 5-aminovalerate 1.2 (0.1) 1.5 (0.4) 2.1 (0.8) 1.1 (0.2) 2.2 (1.4) N.T. 8.4 (2.6) 6-aminocaproate 1.4 (0.2) 0.8 (0.2) 2.3 (0.6) 2.2 (0.3) 2.4 (0.5) N.T. 7.9 (3.4) 7-aminoheptanoate 2.4 (1.0) 1.3 (0.2) 3.9 (2.1) 0.9 (0.4) 1.3 (0.1) N.T. 4.7 (0.7) hydrazine 0.9 (0.4) 12.2 (6.0) 0.5 (0.5) 1.6 (0.6) 7.0 (1.2) N.T. 16.0 (6.2) ethylenediamine 0.9 (0.3) 70.2 (6.8) 0.7 (0.4) 2.2 (0.7) 3.3 (1.3) N.T. 44.5 (13.9) 1,3-diaminopropane 1.3 (0.3) 2.7 (0.4) 0.9 (0.3) 2.2 (0.3) 3.5 (2.3) N.T. 31.5 (12.0) 1,4-diaminobutane 1.4 (0.4) 1.6 (0.2) 1.0 (0.2) 2.5 (1.3) 33.7 (6.6) N.T. 34.5 (13.0) 1,5-diaminopentane 1.5 (0.6) 1.3 (0.3) 0.9 (0.0) 3.3 (0.7) 46.5 (19.8) N.T. 28.8 (13.3) 1,6-diaminohexane 1.5 (0.3) 1.0 (0.1) 1.3 (0.4) 1.6 (0.6) 27.0 (9.8) N.T. 18.0 (4.9) 1,7-diaminoheptane 2.7 (1.0) 1.0 (0.3) 1.8 (0.7) 2.0 (0.7) 6.2 (2.4) N.T. 11.0 (2.1) Glu-Glu 1.0 (0.1) 1.2 (0.7) 1.0 (0.1) 1.3 (0.2) 7.1 (2.7) 9.8 (0.8) 2.1 Glu-Lys 1.0 (0.1) 1.0 (0.4) 1.0 (0.1) 1.6 (0.3) 11.0 (3.0) 9.8 (0.3) 44.5 Lys-Lys 1.1 (0.1) 1.3 (0.1) 1.0 (0.1) 1.1 (0.1) 3.1 (0.8) 13.5 (1.2) 11.2 diglycine 1.0 (0.2) 0.9 (0.0) 1.0 (0.0) 1.0 (0.1) 1.2 (0.4) 7.4 (1.0) 10.0 triglycine 1.4 (0.1) 1.6 (0.3) 0.9 (0.1) 2.2 (1.1) 3.1 (0.9) 0.2 (0.1) 5.7 (4.0) tetraglycine 1.5 (0.3) 2.1 (0.5) 1.3 (0.4) 3.8 (0.8) N.T. 8.3 (9.5) 0.1 pentaglycine 1.0 (0.2) 0.2 (0.1) 3.1 (1.2) N.T. N.T. 979.0 (7.5) 0.5 (0.0) hexaglycine 1.5 (0.7) 0.0 (0.0) 4.2 (1.1) N.T. N.T. 1.7 (1.5) N.T. + NH 3 —(K) + —(G) 1 —(K) + —CONH 2 0.9 (0.1) 0.9 (0.2) 0.5 (0.2) 2.3 (0.4) N.T. 1.5 (0.2) N.T. + NH 3 —(K) + —(G) 2 —(K) + —CONH 2 1.8 (0.1) 0.4 (0.1) 3.3 (0.9) 1.8 (0.3) N.T. 1.3 (0.1) N.T. + NH 3 —(K) + —(G) 3 —(K) + —CONH 2 0.9 (0.3) 1.2 (0.7) 0.8 (0.1) 1.5 (0.4) N.T. 2.1 (0.1) N.T. + NH 3 —(K) + —(G) 4 —(K) + —CONH 2 1.6 (0.3) 1.4 (0.5) 1.4 (0.3) 2.0 (1.0) N.T. 1.9 (0.2) N.T. + NH 3 —(K) + —(G) 5 —(K) + —CONH 2 1.7 (1.0) 0.8 (0.4) 2.6 (1.1) 3.3 (0.8) N.T. 1.5 (0.3) N.T. CH 3 —NH 2 —(E) − —(G) 1 —(E) − —COO − 0.5 (0.2) 0.9 (0.1) 0.2 (0.1) 1.9 (0.1) N.T. 1.6 (0.1) N.T. CH 3 —NH 2 —(E) − —(G) 2 —(E) − —COO − 1.0 (0.2) 0.8 (0.4) 0.4 (0.2) 2.5 (0.6) N.T. 1.7 (0.2) N.T. CH 3 —NH 2 —(E) − —(G) 3 —(E) − —COO − 1.3 (0.4) 0.9 (0.2) 0.5 (0.3) 2.0 (0.3) N.T. 1.5 (0.3) N.T. CH 3 —NH 2 —(E) − —(G) 4 —(E) − —COO − 1.4 (0.6) 0.9 (0.3) 0.7 (0.4) 1.6 (0.2) N.T. 1.7 (0.3) N.T. CH 3 —NH 2 —(E) − —(G) 5 —(E) − —COO − 1.3 (0.1) 0.1 (0.1) N.T. 1 12.3 (0.4) N.T. 1.6 (0.1) N.T. KGE 0.6 (0.3) 2.8 (0.8) 0.3 (0.2) 1.7 (0.4) N.T. 0.9 (0.1) N.T. KGGE 1.0 (0.3) 2.6 (0.4) 0.5 (0.2) 1.2 (0.2) N.T. 0.7 (0.1) N.T. KGGGE 0.8 (0.1) 3.4 (0.1) 0.6 (0.1) 1.9 (0.2) N.T. 0.8 (0.1) N.T. KGGGGE 1.0 (0.1) 1.9 (0.5) 0.5 (0.1) 1.9 (0.4) N.T. 0.8 (0.1) N.T. KGGGGGE 1.3 (0.3) 1.5 (0.4) 1.8 (0.2) 1.4 (0.3) N.T. 0.8 (0.1) N.T. CS 2 CS CS ADH 2 ADH pST 2 pST compound 1,000X 10,000X 50,000X 1,000X 10,000X 100X 2,000X oxalate N.T. 1.9 (0.5) 6.2 (3.8) N.T. 36.7 (3.1) 0.8 (0.1) 1.5 (0.3) malonate N.T. 2.4 (0.5) 9 N.T. 18.9 (6.6) 0.9 (0.1) 4.9 (0.5) succinate N.T. 2.1 (0.5) 9.6 N.T. 2.7 (0.7) 0.9 (0.1) 2.1 (0.3) glutarate N.T. 1.4 (0.5) 6.5 (0.3) N.T. 1.8 (0.4) 0.9 (0.1) 3.1 (0.7) adipate N.T. 1.2 (0.5) 19.6 (17.1) N.T. 4.9 (0.9) 0.9 (0.1) 3.9 (0.7) pimelate N.T. 1.4 (0.4) 6.7 (0.1) N.T. 9.0 (1.3) 0.8 (0.1) 1.5 (0.4) suberate N.T. 1.1 (0.2) 14.1 (2.1) N.T. 15.5 (1.4) 0.7 (0.0) 1.7 (0.3) azelaate N.T. 0.7 (0.6) 4.4 (1.8) N.T. 40.1 (5.2) 0.6 (0.0) 1.3 (0.3) guanidine HCl N.T. 0.6 (0.4) 0.4 (0.1) N.T. 0.2 (0.1) N.T. N.T. ammonium formate N.T. 0.6 (0.0) 1.2 (0.3) N.T. 1.2 (0.1) N.T. N.T. glycine N.T. 0.8 (0.2) N.T. N.T. 54.3 (4.5) 0.4 (0.1) 1.2 (0.2) beta-alanine N.T. 0.6 (0.1) 1.9 (0.8) N.T. 2.2 (0.3) 0.4 (0.1) 0.8 (0.1) 4-aminobuytrate N.T. 0.6 (0.1) 1.2 (0.4) N.T. 2.0 (0.1) 0.3 (0.0) 1.1 (0.2) 5-aminovalerate N.T. 0.7 (0.1) 1.9 (0.7) N.T. 2.7 (0.9) 0.4 (0.0) 0.7 (0.1) 6-aminocaproate N.T. 0.5 (0.1) 1.5 (0.8) N.T. 3.2 (0.3) 0.5 (0.1) 1.2 (0.2) 7-aminoheptanoate N.T. 0.5 (0.1) 1.7 (0.4) N.T. 4.9 (0.5) 0.4 (0.0) 1.6 (0.2) hydrazine N.T. 0.9 (0.2) 6.8 N.T. 0.3 (0.1) N.T. N.T. ethylenediamine N.T. 1.8 (0.5) 18.5 N.T. 202.6 (69.7) 0.7 (0.0) 1.3 (0.1) 1,3-diaminopropane N.T. 0.7 (0.3) 7.7 N.T. 0.7 (0.1) 0.6 (0.0) 1.7 (0.2) 1,4-diaminobutane N.T. 0.9 (0.3) 4.0 (2.3) N.T. 0.8 (0.1) 0.6 (0.1) 1.4 (0.4) 1,5-diaminopentane N.T. 0.8 (0.2) 8.3 (4.5) N.T. 0.9 (0.0) 0.8 (0.3) 1.7 (0.4) 1,6-diaminohexane N.T. 0.6 (0.2) 4.8 (1.5) N.T. 0.8 (0.0) 0.6 (0.1) 1.9 (0.2) 1,7-diaminoheptane N.T. 0.6 (0.2) 1.7 (0.7) N.T. 0.6 (0.1) 0.7 (0.0) 1.6( 0.7) Glu-Glu 0.8 (0.1) 1.5 (0.1) 1430.3 1.4 (0.2) 5.3 (1.2) 0.6 (0.1) N.T. Glu-Lys 0.8 (0.2) 1.6 (0.2) 21.5 1.7 (0.1) 18.4 N.T. N.T. Lys-Lys 0.9 (0.1) 1.6 (0.3) 86.8 1.4 (0.2) 2.7 0.9 (0.1) N.T. diglycine 0.8 (0.1) 0.9 (0.3) 1.5 (0.2) 4.0 (0.9) 0.7 (0.1) 1.9 (0.3) triglycine 1.0 (0.2) 0.7 (0.2) 1.0 5.0 (1.4) 187.6 (46.1) 0.7 (0.0) 2.5 (0.3) tetraglycine 1.5 (0.1) N.T. N.T. 8.4 (2.7) 5313.1 0.8 (0.1) 3.4 (0.6) pentaglycine 0.6 (0.2) N.T. N.T. 5.8 (3.1) Infinite 4 0.7 (0.2) N.T. hexaglycine 0.5 (0.1) N.T. N.T. 1.7 (0.5) 20.3 0.7 (0.1) N.T. + NH 3 —(K) + —(G) 1 —(K) + —CONH 2 1.0 (0.3) N.T. N.T. 1.2 (0.1) N.T. N.T. N.T. + NH 3 —(K) + —(G) 2 —(K) + —CONH 2 0.7 (0.2) N.T. N.T. 0.8 (0.1) N.T. 1.2 (0.2) N.T. + NH 3 —(K) + —(G) 3 —(K) + —CONH 2 0.6 (0.1) N.T. N.T. 1.2 (0.1) N.T. N.T. N.T. + NH 3 —(K) + —(G) 4 —(K) + —CONH 2 0.8 (0.2) N.T. N.T. 1.5 (0.3) N.T. 0.9 (0.0) N.T. + NH 3 —(K) + —(G) 5 —(K) + —CONH 2 0.8 (0.1) N.T. N.T. 1.5 (0.2) N.T. N.T. N.T. CH 3 —NH 2 —(E) − —(G) 1 —(E) − —COO − 0.8 (0.1) N.T. N.T. 1.6 (0.1) N.T. 1.0 (0.1) N.T. CH 3 —NH 2 —(E) − —(G) 2 —(E) − —COO − 0.9 (0.2) N.T. N.T. 1.1 (0.1) N.T. N.T. N.T. CH 3 —NH 2 —(E) − —(G) 3 —(E) − —COO − 1.0 (0.2) N.T. N.T. 1.3 (0.1) N.T. 1.2 (0.2) N.T. CH 3 —NH 2 —(E) − —(G) 4 —(E) − —COO − 0.7 (0.1) N.T. N.T. 1.4 (0.1) N.T. N.T. N.T. CH 3 —NH 2 —(E) − —(G) 5 —(E) − —COO − 0.6 (0.1) N.T. N.T. 1.2 (0.1) N.T. N.T. N.T. KGE 1.2 (0.2) N.T. N.T. 1.3 (0.1) N.T. 0.7 (0.0) N.T. KGGE 1.4 (0.4) N.T. N.T. 0.8 (0.1) N.T. 0.6 (0.1) N.T. KGGGE 1.5 (0.1) N.T. N.T. 1.2 (0.1) N.T. 0.6 (0.1) N.T. KGGGGE 1.8 (0.2) N.T. N.T. 1.4 (0.1) N.T. 0.6 (0.1) N.T. KGGGGGE 2.0 (0.2) N.T. N.T. 1.4 (0.2) N.T. 0.5 (0.1) N.T. [0042] This difference reflects the rapid rate and greater extent of aggregation seen at the longer times not shown in the figure. Note that these effects are not due to simple chelation of copper which was employed in a chelated form or to ionic strength because NaCl at this ionic strength has negligible effect on aggregation. Very close pH control was also used in all experiments to eliminate direct effects of pH on the association processes of experiments. Potent inhibition of ADH was also seen with glycine and to a lesser extent with several non alpha amino acids. The longer glycine peptides were also strong inhibitors. [0043] Results for 8 proteins are summarized in Table 2. In some cases, little inhibition was seen as in the case of insulin although even in this case, weak inhibitions were identified (i.e., 1,6-diaminoheptane and 7-aminoheptanoate). Potent inhibitors were identified for lysozyme (small diamines and several KG n E peptides), α-lactalbumin (G5, G6, C7, KG 5 K), FGF-1 (dicarboxylic acids, diamines, several peptides), lactoferrin (some small peptides), citrate synthase (diacids, diamines, EE, EK, GG, GGG) and porcine somatotropin (several diacids, diamines, larger G n ). ADH was inhibited by the diacids. Careful inspection of Table 2 reveals no clear pattern as expected if the compounds are weakly being bound to one or more sites on the protein surface. As an example, FIG. 2 illustrates the effect of inhibitor concentration for dianions on FGF-1 aggregation. To prepare this figure, a 50 μg/mL solution of FGF-1 in PBS was monitored at 50° C. In this figure, starting from left to right for the series of bars corresponding to each protein, ligand concentrations are 1,000X, 5,000X, 10,000X, 12,500X, 25,000X, and 50,000X. As diacid concentration increases, the inhibition increases as expected. Conversely, in only a few cases did increased ligand concentrations destabilize any of the proteins under the conditions tested. Among the ligands tested, four stood out as effective inhibitors: oxalate (FGF-1, ADH), glycine (ADH), ethylenediamine (lysozyme, ADH) and beta-alanine (HLF). Within a series of dipolar compounds of the same type, a noticeable effect of charge density can be seen with FGF-1. In contrast, lysozyme is strongly inhibited by the smaller hydrazine and ethylenediamine dications. In general, inhibitory concentrations of polyions were typically in the range of micro to millimolar, indicating a moderate affinity for the binding process. [0044] Discussion. [0045] The present invention provides a method for rapidly identifying stabilizers of proteins in aqueous solution. The entire library described can be screened in less than an hour in a microtiter plate, thereby making it extremely simple and rapid. Simple compounds and peptides with charged termini spaced to varying degrees were chosen due to their potential for occasionally having the appropriate geometry to cross-link unpaired charges on protein surfaces. In preliminary studies, charged polyethylene glycols of the form A-(CH 2 —CH 2 —O) n -A wherein each A is independently selected from the group consisting of NH 3 + and COO − , were also found to occasionally be good inhibitors although more often they accelerated the aggregation process. Such protein ligand interactions were predicted to stabilize proteins to varying degrees by preferential binding to the native protein structure compared to structurally altered states. Such interactions could be thought of as “locking” or “stapling” proteins into their more bioactive forms. Destabilization would be expected if polyions bound better to non-native forms and this is in fact observed in some cases (i.e., I<1 in Table 2). It is possible that compounds identified in this manner might themselves be useful as stabilizing agents for pharmaceutical formulations of proteins since inhibitory effects are seen at fairly moderate ligand concentrations. Preliminary studies indicate inhibitors do not affect biological activity in most cases and are not toxic to cells in culture at the concentrations employed. The former is expected because dilution upon introduction to biological targets would be expected to cause dissociation of ligands from protein surfaces. We think equally likely, however, that the compounds initially identified could serve as starting points for new libraries that can be used to obtain higher affinity ligands. Thus a skeleton defined by charged groups at the defined spacing could be chemically varied in their spacing regions to add additional interactions with a protein's surface. [0046] The most striking finding here is that the time-dependent aggregation of all of the proteins examined is inhibited by one or more of the charged compounds to varying degrees. This inhibition is often quite selective and can involve compounds apparently unrelated in structure. This is, again, consistent with binding of the compounds to specific sites on each protein. Preliminary studies indicate that such interactions can, in fact, be detected in many cases by a variety of biophysical methods. FGF-1 presents an interesting test of this approach because the protein is known to have a rather promiscuous polyanion binding site, the occupation of which dramatically stabilizes the protein (Volkin, D. B. & Middaugh, C. R. (1996) Pharm. Biotechnol. 9, 181-217, the content and teachings of which are hereby incorporated by reference herein). The inhibition of aggregation of FGF-1 by all members of the diacid series presumably reflects binding to this site with the specificity exhibited (FIG. 2) which is a function of the detailed geometry of this polycationic region. Not predictable, however, is the potent inhibition seen with several diamines and peptides. This again validates the ability of this screening methodology to identify selective modifiers of protein stability. [0047] This approach is certainly not limited to the simple turbiditymethod employed. Light scattering based measurements have the advantage that they presumably directly detect the presence of molten-globule-like states that are thought to generally be responsible for a wide variety of instabilities (Fink, A. L. (1998) Fold Des. 3, R9-23, Fink, A. L. (1995) Ann. Rev. Biophys. Biomol. Struct. 24, 495-522, the content and teachings of which are hereby incorporated by reference herein). Use of other methods to detect loss of stability such as changes in intrinsic protein fluorescence or the binding of polarity sensitive dyes such as ANS should also be useful as well since they are easily adaptable to a microtiter plate format. In many but not all cases, accelerated stability studies of this type are reasonably predictive of protein stability behavior under more moderate conditions (Yoshioka, S. & Stella, V. J. (2000) Stability of Drugs and Dosage Forms (Kuwer Academic/Plenum Pub., New York, the content and teachings of which are hereby incorporated by reference herein). [0048] When dye binders are used, changes in fluorescence can be used to determine the effect of compounds in accordance with the present invention on protein stability. This is because proteins have a well defined three-dimensional tertiary structure which, when stressed, swells into an intermediate state known as the molten globule state. If the protein is stressed further, it unfolds. However, the molten globule state is believed to be the state in which proteins aggregate. Dye binders bind to this molten globule state, thereby changing the fluorescence of the dye. Accordingly, in order to determine the effect of a compound on the stability of a protein, a protein with the added compound is compared to a protein without the added compound by adding a dye such as ANS or bis-ANS to each protein. Increases in fluorescence indicate that the protein has progressed to the molten globule state and is therefore, not stable. If the protein has become entirely unfolded or has remained in its original tertiary structure, the dye binder will not bind as well to the protein and the fluorescence will not change over time. For purposes of the present invention, any dye binder such as 1-anilinonaphthalene-8-sulfonic acid (1, 8-ANS), 2,6-ANS, bis-ANS (4,4′-dianilino-1,1′-binaphthyl-5,5′-disulfonic acid, dipotassium salt), 4-(dicyanovinyl)julolidine (DCVJ), dansyl lysine (N-e-(5-dimethylaminonaphthalene-1-sulfonyl)-L-lysine), laurdan (6-dodecanoyl-2-dimethylaminonaphthalene), patman (6-hexadecanoyl-2-(((2-(trimethylammonium)ethyl)methyl)amino)naphthalene chloride), Nile red, N-phenyl-1-naphthylamine, prodan (5-propionyl-2-dimethylaminonaphthalene) and 2-(p-toluidinyl) naphthalene-6-sulfonic acid, sodium salt (2, 6-TNS), and combinations thereof can be used. Preferably, such dye binders will be negatively charged and a preferred group includes the ANS family of dye binders because of their common usage in the art. [0049] Compounds identified in this manner could potentially have other uses. They could be employed to enhance protein folding or used to minimize aggregation problems during protein isolation procedures. This approach could also be extended to the stabilization of more complex molecular entities such as vaccines and gene delivery vehicles (Gibson, T. D. (1996) Dev. Biol. Stand. 87, 207-217; Dorval, B. L., Chow, M. & Klibanov, A. M. (1990) Biotechnol. Bioeng. 35, 1051-1054, the content and teachings of which are hereby incorporated by reference herein). Finally, it should also be possible to identify inhibitors of pathological protein aggregation as manifested in many disease states such as Alzheimers, Parkinson's, and sickle cell disease, cataract formation, other amyloid related disorders, spongiform encephalopathies such as mad cow disease, and polyglutamine-based pathologies such as Huntington's chorea. [0050] The preferred forms of the invention described above are to be used as illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments and examples, as set forth herein, could be readily made by those skilled in the art without departing from the spirit of the present invention. [0051] The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.
A method of identifying compounds having effects on protein stability is provided. The method is capable of efficiently screening high numbers of compounds for their effects on a number of different proteins. Additionally, the present invention identified compounds and classes of compound which alter the stability of proteins. Compounds useful in the present invention include molecules having more than one charge. These molecules bind to unpaired charge sites on the surface of proteins, thereby altering the stability of the protein. The effect of the compounds on the protein is determined by the inhibition of protein aggregation attributable to the presence of the compound.
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CROSS REFERENCE TO RELATED APPLICATION [0001] This application claims priority to Korean patent applications Nos. 10-2004-0002281 filed in the Korean Intellectual Property Office on Jan. 13, 2004 and 10-2004-0106176 filed in the Korean Intellectual Property Office on Dec. 15, 2004, the entire disclosure of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] (a) Field of the Invention [0003] The present invention relates to a non-magnetic monocomponent color toner offering superior image density and printing efficiency because of a narrow charge distribution and good chargeability, and having superior long-term stability because of significantly improved charge maintenance, and a preparation method thereof. [0004] (b) Description of the Related Art [0005] Recently, demand for color toner is increasing in the field of electrophotography. Color toner is prepared by kneading and crushing, suspension polymerization, emulsion polymerization, etc. Among them, the kneading and crushing method is mainly used in terms of stability, productivity, and so forth. [0006] In the kneading and crushing method, a binder resin, a colorant, a charge controller, a releasing agent, etc., are melted and kneaded to obtain a mixture. The mixture is cooled and crushed to a desired particle size and classified to obtain a toner. The toner is developed by frictional charging to a positive or negative charge depending on the polarity of the developed electrostatic latent image. Recently, printers adopting electrophotography, in which a laser beam is used as light source, have been leading the market. The demand for compactness, lightness, reliability, and full color is increasing rapidly. Thus, electrophotographic devices having a simple structure and offering high good quality and durability are required. Also, a toner having good printing efficiency and stable developing properties in the long term is required. [0007] In order to satisfy the recent need for higher resolution and better image quality, the particle size of toner is becoming smaller. As the particle size of the toner decreases, the surface area per unit weight of the toner particle increases. As a result, the surface characteristics affect charging and particle characteristics of the toner. As the particle size becomes smaller, the charging characteristic is more affected by the charge control agent. In general, a metal complex, a chromium-containing metal dye, or a quaternary ammonium salt is used for negative charging, and nigrosine or a quaternary ammonium salt is used for positive charging, as the charge control agent. The charge control agent is melted and kneaded along with a binder resin, a wax, a colorant, etc., and crushing and classifying are performed to obtain a toner. [0008] The raw material of the charge control agent may have quite a broad particle size distribution. Although the charge control agent particles may be broken down during melting or kneading, the original particle size determines the characteristics of the charge control agent. If the charge control agent has too large a particle size, the binding ability with the binder resin decreases, so it tends to be separated from the toner during crushing. As a result, many toner particles do not contain the charge control agent and the charge distribution becomes broader, so background contamination or fogging tends to occur. Otherwise, if the charge control agent has too small a particle size, most of the charge control agent particles exist inside the toner, so they do not contribute to improvement in charging characteristics. [0009] Accordingly, it is required to improve binding ability with the binder resin, charge distribution, and charge maintenance by specifying the particle size and distribution of the charge control agent. SUMMARY OF THE INVENTION [0010] The present inventors worked for a color toner having a narrow charge distribution and good chargeability, and that is capable of improving charge maintenance. Noticing that the binding ability with the binder resin, charge distribution, charge maintenance, etc., are affected by particle size and distribution of the charge control agent, they completed the present invention by identifying that a toner comprising 10-35 wt % of a charge control agent having a particle size of 50-500 nm and 65-90 wt % of a charge control agent having a particle size of 1-4 μm has superior long-term stability because of uniform charge distribution and good chargeability. [0011] Thus, it is an aspect of the present invention to provide a non-magnetic monocomponent color toner comprising both a toner mother particle comprising a charge control agent having a large particle size and a charge control agent having a small particle size; silica; and titanium dioxide, and a preparing method thereof. DETAILED DESCRIPTION OF THE INVENTION [0012] In the following detailed description, the embodiments of the invention have been shown and described, simply by way of illustrating the best mode contemplated by the inventors of carrying out the invention. As will be realized, the present invention can be modified in various respects, all without departing from the invention. Accordingly, the description is to be regarded as illustrative in nature, and not restrictive. [0013] The present invention provides a non-magnetic monocomponent color toner comprising a toner mother particle comprising 10-35 wt % of a charge control agent having a particle size of 50-500 nm, and 65-90 wt % of a charge control agent having a particle size of 1-4 μm; silica; and titanium dioxide. [0014] The present invention also provides a method of preparing a non-magnetic monocomponent color toner comprising the steps of preparing a toner mother particle comprising 10-35 wt % of a charge control agent having a particle size of 50-500 nm and 65-90 wt % of a charge control agent having a particle size of 1-4 μm (step 1); and coating the toner mother particle with silica and titanium dioxide (step 2). [0015] The charge control agent used in the present invention comprises a) 10-35 wt % of a charge control agent having a particle size of 50-500 nm and b) 65-90 wt % of a charge control agent having a particle size of 14 μm. More preferably, it comprises 15-25 wt % of a charge control agent having a particle size of 150-450 nm and b) 75-85 wt % of a charge control agent having a particle size of 14 μm. The charge control agent is preferably comprised at 0.5-5 wt %, more preferably at 1-3 wt %. The silica has an average particle size of 5-50 nm, preferably 10-40 nm. It is preferably comprised at 1.0-3.0 wt %, more preferably at 1.5-2.8 wt %. The titanium dioxide has an average particle size of 0.05-2 μm, preferably 0.1-1.5 μm. It is preferably comprised at 0.2-2.5 wt %, more preferably at 0.5-2 wt %. [0016] Unless specified otherwise, average particle size mentioned in the description of the present invention is number-average particle size. [0017] If the content of the charge control agent having a smaller average particle size is below 10 wt %, a sufficiently uniform charge distribution is not obtained. Otherwise, if it exceeds 35 wt %, the particles having a smaller particle size, which have a much larger specific surface area, penetrate the toner particles, thereby failing to fully function as a charge control agent on the surface of the toner particle. In this case, long-term printing efficiency may deteriorate. [0018] If the content of the charge control agent having a larger average particle size is below 65 wt %, the charge control agents having a larger average particle size tend to concentrate on the surface of the toner particle, thereby failing to offer good chargeability. Otherwise, if it exceeds 90 wt %, it is difficult to obtain uniform charge distribution, and if a lot of the charge control agent particles come into the surface, many of them are separated because they have weaker binding ability with the binder resin than the particles having a smaller particle size. As a result, it is difficult to obtain uniform charge distribution, and background contamination or fogging may occur. [0019] For the charge control agent having a specifically shaped particle size distribution, a metal complex, a nigrosine dye, a triphenylmethane dye, a quaternary ammonium salt, or an organotartar compound such as dibutyl tin oxide, etc. may be used. The metal of the metal complex may be Al, Zr, Zn, Ba, etc. Although such intrinsic property of the charge control agent as positive chargeability or negative chargeability does not change, a narrower charge distribution and a better chargeability can be obtained with a specific particle size distribution. [0020] The toner mother particle also comprises a binder resin, a colorant, and a wax as essential components. [0021] The binder resin may be a styrene such as styrene, chlorostyrene and vinylstyrene; an olefin such as ethylene, propylene, butylene and isoprene; a vinyl ester such as vinyl acetate, vinyl propionate, vinyl benzoate and vinyl lactate; an acrylate or a methacrylate such as methyl acrylate, ethyl acrylate, butyl acrylate, dodecyl acrylate, octyl acrylate, phenyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, and dodecyl methacrylate; a vinyl ether such as vinyl methyl ether, vinyl ethyl ether, and vinyl butyl ether; a vinyl ketone such as vinyl methyl ketone, vinyl hexyl ketone, and vinyl isopropenyl ketone; and a mixture thereof. [0022] Preferably, polystyrene, a styrene-alkyl acrylate copolymer, a styrene-alkyl methacrylate copolymer, a styrene-acrylonitrile copolymer, a styrene-butadiene copolymer, a styrene-maleic anhydride copolymer, polyethylene, polypropylene, etc. is used. More preferably, polyester, polyurethane, an epoxy resin, a silicone resin, polyamide, a modified resin, paraffin, etc. is used. [0023] For the colorant, carbon black, a magnetic paint, a dye, or a pigment may be used. For example, a nigrosine dye, aniline blue, charcoal blue, chromium yellow, navy blue, DuPont oil red, methylene blue chloride, phthalocyanine blue, lamp black, rose bengal, C.I. pigment red 48:1, C.I. pigment red 48:4, C.I. pigment red 122, C.I. pigment red 57:1, C.I. pigment red 257, C.I. pigment red 269, C.I. pigment yellow 97, C.I. pigment yellow 12, C.I. pigment yellow 17, C.I. pigment yellow 14, C.I. pigment yellow 13, C.I. pigment yellow 16, C.I. pigment yellow 81, C.I. pigment yellow 126, C.I. pigment yellow 127, C.I. pigment blue 9, C.I. pigment blue 15, C.I. pigment blue 15:1, C.I. pigment blue 15:3, etc. may be used. [0024] An inorganic oxide fine particle such as SiO 2 , TiO 2 , MgO, A 1 2 O 3 , MnO, ZnO, Fe 2 O 3 , CaO, BaSO 4 , CeO 2 , K 2 O, Na 2 O, ZrO 2 , CaO·SiO, K 2 O·(TiO 2 )n and Al 2 O 3 ·2SiO 2 hydrophobic-treated with hexamethyldisilazane, dimethyldichlorosilane, octyltrimethoxysilane, etc. may be added to the toner mother particle as a fluidity accelerator. The toner mother particle may further comprise a releasing agent. [0025] The toner mother particle preferably has an average particle size of 10 μm, more preferably 4-10 μm, and most preferably 5-9 μm. [0026] After a toner mother particle is prepared by mixing and kneading the charge control agent, which has a specific shaped particle size distribution, along with a binder resin, a colorant and a wax (releasing agent), silica and titanium oxide particles are added to prepare the non-magnetic monocomponent color toner of the present invention. [0027] The silica preferably has an average particle size of 5-50 nm, preferably 10-40 nm. It is preferably comprised at 1.0-3.0 wt %, more preferably at 1.5-2.8 wt %. The titanium dioxide preferably has an average particle size of 0.05-2 μm, more preferably 0.1-1.5 μm. It is preferably comprised at 0.2-2.5 wt %, more preferably at 0.5-2wt %. [0028] Although the silica and the titanium dioxide may be attached to the surface of the toner mother particle electrostatically, a mechanical mixing treatment using a Henschel mixer, a hybridizer, etc. is preferable. Preferably, the toner mother particle, silica, and titanium dioxide are coated after being mixed at a stirring rate of at least 10 m/s. [0029] The resultant non-magnetic monocomponent color toner preferably has an average particle size of at most 20 μm, more preferably 3-15 μm. [0030] The non-magnetic monocomponent color toner of the present invention offers better long-term image stability than the conventional counterpart. It is also advantageous in offering higher resolution, better printing efficiency, and clearer color. The better effect is attained as the toner particle has the smaller size. [0031] Accordingly, a non-magnetic monocomponent color toner having good chargeability, charge maintenance, and clear color can be prepared according to the present invention. The toner is more environmentally friendly and can offer a more stable image while satisfying the need of higher resolution. [0032] Hereinafter, the present invention is described in more detail through examples. However, the following examples are only for the understanding of the present invention and they do not limit the present invention. EXAMPLE 1 [0033] 1) Preparation of Toner Mother Particle [0034] 94 parts by weight of polyester resin (molecular weight=2.5×10 5 ), 4 parts by weight of phthalocyanine P.BI.15:3, 1 part by weight of a metal-containing azo salt (charge control agent C) comprising 30 wt % of a particle having a particle size of 50-500 nm and 70 wt % of a particle having a particle size of 1-4 μm, and 4 parts by weight of polypropylene having a small molecular weight were mixed using a Henschel mixer. The mixture was melted and kneaded at 165 ° C. using a twin melt kneader, crushed using a jet mil crusher, and classified using an air classifier to obtain a toner mother particle having a volume-average particle size of 7.5 μm. [0035] 2) Preparation of Non-Magnetic Monocomponent Color Toner [0036] 2.0 wt % of silica having an average particle size of 17 nm and 1.0 wt % of titanium dioxide particle having an average particle size of 0.1 μm were mixed with 100 parts by weight of the prepared toner mother particle while stirring for 3 minutes at a tip speed of at least 10 m/s using a Henschel mixer to obtain a non-magnetic monocomponent color toner. EXAMPLES 2-182 [0037] Non-magnetic monocomponent color-toners were prepared in the same manner of Example 1, except that charge control agents presented in Table 1 below, silica presented in Table 2 below, and titanium dioxide presented in Table 3 below were used according to the composition given in Table 4 below. TABLE 1 Average particle size Compounds distribution Charge control Metal-containing azo salt 50-500 nm agent A Charge control Metal-containing azo salt 1-4 μm agent B Charge control Metal-containing azo salt 50-500 nm, 30 wt %; agent C 1-4 μm, 70 wt % Charge control Quaternary ammonium salt 50-500 nm agent D Charge control Quaternary ammonium salt 1-4 μm agent E Charge control Quaternary ammonium salt 50-500 nm, 30 wt %; agent F 1-4 μm, 70 wt % Charge control Zinc salicylate 50-500 nm agent G Charge control Zinc salicylate 1-4 μm agent H Charge control Zinc salicylate 50-500 nm, 30 wt %; agent I 1-4 μm, 70 wt % Charge control Boron complex 50-500 nm agent J Charge control Boron complex 1-4 μm agent K Charge control Boron complex 50-500 nm, 30 wt %; agent L 1-4 μm, 70 wt % Charge control Metal-containing azo salt 50-500 nm, 15 wt %; agent M 1-4 μm, 85 wt % Charge control Quaternary ammonium salt 50-500 nm, 20 wt %; agent N 1-4 μm, 80 wt % Charge control Boron complex 50-500 nm, 10 wt %; agent O 1-4 μm, 90 wt % Charge control Zinc salicylate 30-300 nm, 85 wt %; agent P 1-4 μm, 15 wt % Charge control Metal-containing azo salt 30-300 nm, 90 wt %; agent Q 1-4 μm, 10 wt % Charge control Quaternary ammonium salt 30-300 nm, 85 wt %; agent R 1-4 μm, 15 wt % Charge control Boron complex 30-300 nm, 85 wt %; agent S 1-4 μm, 15 wt % [0038] TABLE 2 Hydrophobic surface Specific surface area (m 2 /g)* 1 treatment Silica A 7 Dimethyl silicone oil Silica B 17 Dimethyl silicone oil Silica C 50 HMDS* 2 * 1 BET measurement values * 2 HMDS = hexamethyldisilazane [0039] TABLE 3 Average particle size (μm) Titanium dioxide A 0.1 Titanium dioxide B 1.1 Titanium dioxide C 1.6 [0040] TABLE 4 Example Charge control agent(wt %) Silica (wt %) Titanium oxide(wt %) 2 Charge control agent C 1.0 Silica A 1.0 Titanium oxide A 0.5 3 Charge control agent C 1.0 Silica A 1.0 Titanium oxide A 1.0 4 Charge control agent C 1.0 Silica A 1.0 Titanium oxide A 2.0 5 Charge control agent C 1.0 Silica A 1.0 Titanium oxide B 0.5 6 Charge control agent C 1.0 Silica A 1.0 Titanium oxide B 1.0 7 Charge control agent C 1.0 Silica A 1.0 Titanium oxide B 2.5 8 Charge control agent C 1.0 Silica A 1.0 Titanium oxide C 0.5 9 Charge control agent C 1.0 Silica A 2.0 Titanium oxide C 1.0 10 Charge control agent C 1.0 Silica A 3.0 Titanium oxide C 2.0 11 Charge control agent C 1.0 Silica B 1.0 Titanium oxide A 0.5 12 Charge control agent C 1.0 Silica B 1.0 Titanium oxide A 1.0 13 Charge control agent C 1.0 Silica B 1.0 Titanium oxide A 2.5 14 Charge control agent C 1.0 Silica B 1.0 Titanium oxide B 0.5 15 Charge control agent C 1.0 Silica B 1.0 Titanium oxide B 1.0 16 Charge control agent C 1.0 Silica B 1.0 Titanium oxide B 2.0 17 Charge control agent C 1.0 Silica B 1.0 Titanium oxide C 0.5 18 Charge control agent C 1.0 Silica B 1.0 Titanium oxide C 1.0 19 Charge control agent C 1.0 Silica B 3.0 Titanium oxide C 2.0 20 Charge control agent C 3.0 Silica C 1.0 Titanium oxide A 0.5 21 Charge control agent C 3.0 Silica C 1.0 Titanium oxide A 1.0 22 Charge control agent C 3.0 Silica C 1.0 Titanium oxide A 2.0 23 Charge control agent C 3.0 Silica C 1.0 Titanium oxide B 0.5 24 Charge control agent C 3.0 Silica C 1.0 Titanium oxide B 1.0 25 Charge control agent C 3.0 Silica C 1.0 Titanium oxide B 2.0 26 Charge control agent C 3.0 Silica C 1.0 Titanium oxide C 0.5 27 Charge control agent C 3.0 Silica C 2.0 Titanium oxide C 1.0 28 Charge control agent C 3.0 Silica C 3.0 Titanium oxide C 2.0 29 Charge control agent F 3.0 Silica A 1.0 Titanium oxide A 0.5 30 Charge control agent F 3.0 Silica A 1.0 Titanium oxide A 1.0 31 Charge control agent F 3.0 Silica A 1.0 Titanium oxide A 2.0 32 Charge control agent F 3.0 Silica A 1.0 Titanium oxide B 0.5 33 Charge control agent F 3.0 Silica A 1.0 Titanium oxide B 1.0 34 Charge control agent F 3.0 Silica A 1.0 Titanium oxide B 2.0 35 Charge control agent F 3.0 Silica A 1.0 Titanium oxide C 0.5 36 Charge control agent F 3.0 Silica A 1.0 Titanium oxide C 1.0 37 Charge control agent F 3.0 Silica A 1.0 Titanium oxide C 2.0 38 Charge control agent F 3.0 Silica B 1.0 Titanium oxide A 0.5 39 Charge control agent F 3.0 Silica B 1.0 Titanium oxide A 1.0 40 Charge control agent F 3.0 Silica B 1.0 Titanium oxide A 2.0 41 Charge control agent F 3.0 Silica B 1.0 Titanium oxide B 0.5 42 Charge control agent F 3.0 Silica B 1.0 Titanium oxide B 1.0 43 Charge control agent F 3.0 Silica B 1.0 Titanium oxide B 2.0 44 Charge control agent F 3.0 Silica B 1.0 Titanium oxide C 0.5 45 Charge control agent F 3.0 Silica B 1.0 Titanium oxide C 1.0 46 Charge control agent F 3.0 Silica B 1.0 Titanium oxide C 2.0 47 Charge control agent F 3.0 Silica C 2.0 Titanium oxide A 0.5 48 Charge control agent F 3.0 Silica C 2.0 Titanium oxide A 1.0 49 Charge control agent F 3.0 Silica C 2.0 Titanium oxide A 2.0 50 Charge control agent F 3.0 Silica C 2.0 Titanium oxide B 0.5 51 Charge control agent F 3.0 Silica C 2.0 Titanium oxide B 1.0 52 Charge control agent F 3.0 Silica C 2.0 Titanium oxide B 2.0 53 Charge control agent F 3.0 Silica C 2.0 Titanium oxide C 0.5 54 Charge control agent F 3.0 Silica C 3.0 Titanium oxide C 1.0 55 Charge control agent F 3.0 Silica C 3.0 Titanium oxide C 2.0 56 Charge control agent I 1.0 Silica A 1.0 Titanium oxide C 2.0 57 Charge control agent I 1.0 Silica A 1.0 Titanium oxide C 0.5 58 Charge control agent I 1.0 Silica A 1.0 Titanium oxide C 1.0 59 Charge control agent I 1.0 Silica A 1.0 Titanium oxide C 2.0 60 Charge control agent I 1.0 Silica A 1.0 Titanium oxide A 0.5 61 Charge control agent I 1.0 Silica A 1.0 Titanium oxide A 1.0 62 Charge control agent I 1.0 Silica A 1.0 Titanium oxide A 2.5 63 Charge control agent I 3.0 Silica A 1.0 Titanium oxide A 0.5 64 Charge control agent I 3.0 Silica A 1.0 Titanium oxide A 2.0 65 Charge control agent I 3.0 Silica A 1.0 Titanium oxide B 0.5 66 Charge control agent I 3.0 Silica B 2.0 Titanium oxide A 1.5 67 Charge control agent I 3.0 Silica B 2.0 Titanium oxide C 0.5 68 Charge control agent I 3.0 Silica B 2.0 Titanium oxide C 2.0 69 Charge control agent I 3.0 Silica B 2.0 Titanium oxide C 0.5 70 Charge control agent I 3.0 Silica B 2.0 Titanium oxide B 1.5 71 Charge control agent I 3.0 Silica B 3.0 Titanium oxide C 1.0 72 Charge control agent I 3.0 Silica B 2.0 Titanium oxide A 2.0 73 Charge control agent L 1.0 Silica A 1.0 Titanium oxide A 0.5 74 Charge control agent L 1.0 Silica A 1.0 Titanium oxide A 1.5 75 Charge control agent L 1.0 Silica A 1.0 Titanium oxide B 0.5 76 Charge control agent L 1.0 Silica A 1.0 Titanium oxide B 1.5 77 Charge control agent L 1.0 Silica A 1.0 Titanium oxide C 0.5 78 Charge control agent L 1.0 Silica A 1.0 Titanium oxide C 2.5 79 Charge control agent L 1.0 Silica A 3.0 Titanium oxide A 0.5 80 Charge control agent L 1.0 Silica A 3.0 Titanium oxide B 0.5 81 Charge control agent L 1.0 Silica A 3.0 Titanium oxide C 0.5 82 Charge control agent L 1.0 Silica A 3.0 Titanium oxide A 1.5 83 Charge control agent L 1.0 Silica B 2.0 Titanium oxide A 0.5 84 Charge control agent L 1.0 Silica B 2.0 Titanium oxide A 1.0 85 Charge control agent L 1.0 Silica B 2.0 Titanium oxide A 2.5 86 Charge control agent L 1.0 Silica B 2.0 Titanium oxide B 0.5 87 Charge control agent L 1.0 Silica B 2.0 Titanium oxide B 1.0 88 Charge control agent L 1.0 Silica B 2.0 Titanium oxide B 2.5 89 Charge control agent L 1.0 Silica B 2.0 Titanium oxide C 0.5 90 Charge control agent L 1.0 Silica B 2.0 Titanium oxide C 1.0 91 Charge control agent L 1.0 Silica B 2.0 Titanium oxide C 2.0 92 Charge control agent L 2.0 Silica B 2.0 Titanium oxide C 2.0 93 Charge control agent L 1.0 Silica C 2.0 Titanium oxide A 0.5 94 Charge control agent L 3.0 Silica C 2.0 Titanium oxide A 1.5 95 Charge control agent L 3.0 Silica C 2.0 Titanium oxide A 2.5 96 Charge control agent L 3.0 Silica C 2.0 Titanium oxide B 0.5 97 Charge control agent L 3.0 Silica C 2.0 Titanium oxide B 1.0 98 Charge control agent L 3.0 Silica C 2.0 Titanium oxide B 2.0 99 Charge control agent L 3.0 Silica C 2.0 Titanium oxide C 0.5 100 Charge control agent L 2.0 Silica C 2.0 Titanium oxide C 1.0 101 Charge control agent L 2.0 Silica C 2.0 Titanium oxide C 2.0 102 Charge control agent M 1.0 Silica A 0.5 Titanium oxide A 0.5 103 Charge control agent M 1.0 Silica A 1.0 Titanium oxide A 1.0 104 Charge control agent M 1.0 Silica A 1.0 Titanium oxide A 2.0 105 Charge control agent M 1.0 Silica A 1.0 Titanium oxide B 0.5 106 Charge control agent M 1.0 Silica A 1.0 Titanium oxide B 1.0 107 Charge control agent M 1.0 Silica A 1.0 Titanium oxide B 2.0 108 Charge control agent M 1.0 Silica A 2.0 Titanium oxide C 0.5 109 Charge control agent M 1.0 Silica A 2.0 Titanium oxide C 1.0 110 Charge control agent M 1.0 Silica A 3.0 Titanium oxide C 2.5 111 Charge control agent M 1.0 Silica B 1.0 Titanium oxide A 0.5 112 Charge control agent M 2.0 Silica B 1.0 Titanium oxide A 1.0 113 Charge control agent M 2.0 Silica B 1.0 Titanium oxide A 2.0 114 Charge control agent M 2.0 Silica B 1.0 Titanium oxide B 0.5 115 Charge control agent M 2.0 Silica B 1.0 Titanium oxide B 1.0 116 Charge control agent M 2.0 Silica B 1.0 Titanium oxide B 2.0 117 Charge control agent M 2.0 Silica B 1.0 Titanium oxide C 0.5 118 Charge control agent M 2.0 Silica B 2.0 Titanium oxide C 1.0 119 Charge control agent M 2.0 Silica B 3.0 Titanium oxide C 2.0 120 Charge control agent M 2.0 Silica C 1.0 Titanium oxide A 0.5 121 Charge control agent M 2.0 Silica C 1.0 Titanium oxide A 1.0 122 Charge control agent M 2.0 Silica C 1.0 Titanium oxide A 2.0 123 Charge control agent M 2.0 Silica C 1.0 Titanium oxide B 0.5 124 Charge control agent M 3.0 Silica C 1.0 Titanium oxide B 1.0 125 Charge control agent M 3.0 Silica C 3.0 Titanium oxide B 2.0 126 Charge control agent M 3.0 Silica C 2.0 Titanium oxide C 0.5 127 Charge control agent M 3.0 Silica C 2.0 Titanium oxide C 1.0 128 Charge control agent M 3.0 Silica C 3.0 Titanium oxide C 2.5 129 Charge control agent N 1.0 Silica A 1.0 Titanium oxide A 0.5 130 Charge control agent N 1.0 Silica A 1.0 Titanium oxide A 1.0 131 Charge control agent N 1.0 Silica A 1.0 Titanium oxide A 2.0 132 Charge control agent N 1.0 Silica A 1.0 Titanium oxide B 0.5 133 Charge control agent N 1.0 Silica A 1.0 Titanium oxide B 1.0 134 Charge control agent N 1.0 Silica A 1.0 Titanium oxide B 2.0 135 Charge control agent N 1.0 Silica A 2.0 Titanium oxide C 0.5 136 Charge control agent N 1.0 Silica A 3.0 Titanium oxide C 1.0 137 Charge control agent N 1.0 Silica A 2.0 Titanium oxide C 2.0 138 Charge control agent N 2.0 Silica B 1.0 Titanium oxide A 0.5 139 Charge control agent N 2.0 Silica B 1.0 Titanium oxide A 1.0 140 Charge control agent N 2.0 Silica B 1.0 Titanium oxide A 2.5 141 Charge control agent N 2.0 Silica B 1.0 Titanium oxide B 0.5 142 Charge control agent N 2.0 Silica B 1.0 Titanium oxide B 1.0 143 Charge control agent N 2.0 Silica B 1.0 Titanium oxide B 2.0 144 Charge control agent N 2.0 Silica B 1.0 Titanium oxide C 0.5 145 Charge control agent N 2.0 Silica B 3.0 Titanium oxide C 1.0 146 Charge control agent N 2.0 Silica B 3.0 Titanium oxide C 2.0 147 Charge control agent N 2.0 Silica C 2.0 Titanium oxide A 0.5 148 Charge control agent N 3.0 Silica C 1.0 Titanium oxide A 1.0 149 Charge control agent N 3.0 Silica C 1.0 Titanium oxide A 2.0 150 Charge control agent N 4.0 Silica C 1.0 Titanium oxide B 0.5 151 Charge control agent N 4.0 Silica C 1.0 Titanium oxide B 1.0 152 Charge control agent N 4.0 Silica C 1.0 Titanium oxide B 2.0 153 Charge control agent N 5.0 Silica C 1.0 Titanium oxide C 0.5 154 Charge control agent N 5.0 Silica C 3.0 Titanium oxide C 1.0 155 Charge control agent N 5.0 Silica C 2.0 Titanium oxide C 2.0 156 Charge control agent O 1.0 Silica A 1.0 Titanium oxide A 0.5 157 Charge control agent O 1.0 Silica A 1.0 Titanium oxide A 1.0 158 Charge control agent O 1.0 Silica A 1.0 Titanium oxide A 2.0 159 Charge control agent O 1.0 Silica A 1.0 Titanium oxide B 0.5 160 Charge control agent O 1.0 Silica A 2.0 Titanium oxide B 1.0 161 Charge control agent O 1.0 Silica A 2.0 Titanium oxide B 2.0 162 Charge control agent O 2.0 Silica A 1.0 Titanium oxide C 0.5 163 Charge control agent O 2.0 Silica A 1.0 Titanium oxide C 1.0 164 Charge control agent O 2.0 Silica A 1.0 Titanium oxide C 2.0 165 Charge control agent O 1.0 Silica B 1.0 Titanium oxide A 0.5 166 Charge control agent O 2.0 Silica B 1.0 Titanium oxide A 1.0 167 Charge control agent O 2.0 Silica B 1.0 Titanium oxide A 2.0 168 Charge control agent O 2.0 Silica B 1.0 Titanium oxide B 0.5 169 Charge control agent O 2.0 Silica B 1.0 Titanium oxide B 1.0 170 Charge control agent O 2.0 Silica B 1.0 Titanium oxide B 2.0 171 Charge control agent O 2.0 Silica B 1.0 Titanium oxide C 0.5 172 Charge control agent O 2.0 Silica B 1.0 Titanium oxide C 1.0 173 Charge control agent O 2.0 Silica B 1.0 Titanium oxide C 2.5 174 Charge control agent O 2.0 Silica C 1.0 Titanium oxide A 0.5 175 Charge control agent O 3.0 Silica C 1.0 Titanium oxide A 1.0 176 Charge control agent O 3.0 Silica C 1.0 Titanium oxide A 2.0 177 Charge control agent O 3.0 Silica C 1.0 Titanium oxide B 0.5 178 Charge control agent O 4.0 Silica C 1.0 Titanium oxide B 1.0 179 Charge control agent O 4.0 Silica C 1.0 Titanium oxide B 2.0 180 Charge control agent O 4.0 Silica C 1.0 Titanium oxide C 0.5 181 Charge control agent O 5.0 Silica C 1.0 Titanium oxide C 1.0 182 Charge control agent O 5.0 Silica C 1.0 Titanium oxide C 2.0 COMPARATIVE EXAMPLES 1-270 [0041] Non-magnetic monocomponent color toners were prepared in the same manner of Example 1, except that charge control agents presented in Table 1 above, silica presented in Table 2 above, and titanium dioxide presented in Table 3 above were used according to the composition given in Table 5 below. That is to say, charge control agents not having a specific shaped particle size were used in the Comparative Examples. TABLE 5 Comparative Example Charge control agent(wt %) Silica(wt %) Titanium oxide (wt %) 1 Charge control agent A 1.0 Silica A 1.0 Titanium oxide A 0.5 2 Charge control agent A 2.0 Silica A 1.0 Titanium oxide A 0.5 3 Charge control agent A 1.0 Silica A 1.0 Titanium oxide A 1.0 4 Charge control agent A 1.0 Silica A 1.0 Titanium oxide A 2.0 5 Charge control agent A 1.0 Silica A 1.0 Titanium oxide B 0.5 6 Charge control agent A 1.0 Silica A 1.0 Titanium oxide B 1.0 7 Charge control agent A 1.0 Silica A 1.0 Titanium oxide B 2.0 8 Charge control agent A 1.0 Silica A 1.0 Titanium oxide C 0.5 9 Charge control agent A 1.0 Silica A 1.0 Titanium oxide C 1.0 10 Charge control agent A 1.0 Silica A 1.0 Titanium oxide C 2.0 11 Charge control agent A 1.0 Silica B 1.0 Titanium oxide A 0.5 12 Charge control agent A 1.0 Silica B 1.0 Titanium oxide A 1.0 13 Charge control agent A 1.0 Silica B 1.0 Titanium oxide A 2.0 14 Charge control agent A 1.0 Silica B 1.0 Titanium oxide B 0.5 15 Charge control agent A 1.0 Silica B 1.0 Titanium oxide B 1.0 16 Charge control agent A 1.0 Silica B 1.0 Titanium oxide B 2.0 17 Charge control agent A 1.0 Silica B 1.0 Titanium oxide C 0.5 18 Charge control agent A 1.0 Silica B 1.0 Titanium oxide C 1.0 19 Charge control agent A 1.0 Silica B 1.0 Titanium oxide C 2.0 20 Charge control agent A 3.0 Silica C 1.0 Titanium oxide A 0.5 21 Charge control agent A 3.0 Silica C 1.0 Titanium oxide A 1.0 22 Charge control agent A 3.0 Silica C 1.0 Titanium oxide A 2.0 23 Charge control agent A 3.0 Silica C 1.0 Titanium oxide B 0.5 24 Charge control agent A 3.0 Silica C 1.0 Titanium oxide B 1.0 25 Charge control agent A 3.0 Silica C 1.0 Titanium oxide B 2.0 26 Charge control agent A 3.0 Silica C 1.0 Titanium oxide C 0.5 27 Charge control agent A 3.0 Silica C 1.0 Titanium oxide C 1.0 28 Charge control agent A 3.0 Silica C 1.0 Titanium oxide C 2.0 29 Charge control agent B 3.0 Silica A 1.0 Titanium oxide A 0.5 30 Charge control agent B 3.0 Silica A 1.0 Titanium oxide A 1.0 31 Charge control agent B 3.0 Silica A 1.0 Titanium oxide A 2.0 32 Charge control agent B 3.0 Silica A 1.0 Titanium oxide B 0.5 33 Charge control agent B 3.0 Silica A 1.0 Titanium oxide B 1.0 34 Charge control agent B 3.0 Silica A 1.0 Titanium oxide B 2.0 35 Charge control agent B 3.0 Silica A 1.0 Titanium oxide C 0.5 36 Charge control agent B 3.0 Silica A 1.0 Titanium oxide C 1.0 37 Charge control agent B 3.0 Silica A 1.0 Titanium oxide C 2.0 38 Charge control agent B 3.0 Silica B 1.0 Titanium oxide A 0.5 39 Charge control agent B 3.0 Silica B 1.0 Titanium oxide A 1.0 40 Charge control agent B 3.0 Silica B 1.0 Titanium oxide A 2.0 41 Charge control agent B 3.0 Silica B 1.0 Titanium oxide B 0.5 42 Charge control agent B 3.0 Silica B 1.0 Titanium oxide B 1.0 43 Charge control agent B 3.0 Silica B 1.0 Titanium oxide B 2.0 44 Charge control agent B 3.0 Silica B 1.0 Titanium oxide C 0.5 45 Charge control agent B 3.0 Silica B 1.0 Titanium oxide C 1.0 46 Charge control agent B 3.0 Silica B 1.0 Titanium oxide C 2.0 47 Charge control agent B 3.0 Silica C 2.0 Titanium oxide A 0.5 48 Charge control agent B 3.0 Silica C 2.0 Titanium oxide A 1.0 49 Charge control agent B 3.0 Silica C 2.0 Titanium oxide A 2.0 50 Charge control agent B 3.0 Silica C 2.0 Titanium oxide B 0.5 51 Charge control agent B 3.0 Silica C 2.0 Titanium oxide B 1.0 52 Charge control agent B 3.0 Silica C 2.0 Titanium oxide B 2.0 53 Charge control agent B 3.0 Silica C 2.0 Titanium oxide C 0.5 54 Charge control agent B 3.0 Silica C 2.0 Titanium oxide C 1.0 55 Charge control agent B 3.0 Silica C 2.0 Titanium oxide C 2.0 56 Charge control agent D 1.0 Silica A 1.0 Titanium oxide C 3.0 57 Charge control agent D 1.0 Silica A 1.0 Titanium oxide C 0.5 58 Charge control agent D 1.0 Silica A 1.0 Titanium oxide C 1.0 59 Charge control agent D 1.0 Silica A 1.0 Titanium oxide C 2.0 60 Charge control agent D 1.0 Silica A 1.0 Titanium oxide A 0.5 61 Charge control agent D 1.0 Silica A 1.0 Titanium oxide A 1.0 62 Charge control agent D 1.0 Silica A 1.0 Titanium oxide A 2.0 63 Charge control agent D 3.0 Silica A 1.0 Titanium oxide A 0.5 64 Charge control agent D 3.0 Silica A 1.0 Titanium oxide A 2.0 65 Charge control agent D 3.0 Silica A 1.0 Titanium oxide B 0.5 66 Charge control agent D 3.0 Silica B 2.0 Titanium oxide A 1.5 67 Charge control agent D 3.0 Silica B 2.0 Titanium oxide C 0.5 68 Charge control agent D 3.0 Silica B 2.0 Titanium oxide C 2.0 69 Charge control agent D 3.0 Silica B 2.0 Titanium oxide C 0.5 70 Charge control agent D 3.0 Silica B 2.0 Titanium oxide B 1.5 71 Charge control agent D 3.0 Silica B 2.0 Titanium oxide C 1.0 72 Charge control agent D 3.0 Silica B 2.0 Titanium oxide A 2.0 73 Charge control agent E 1.0 Silica A 1.0 Titanium oxide A 0.5 74 Charge control agent E 1.0 Silica A 1.0 Titanium oxide A 1.5 75 Charge control agent E 1.0 Silica A 1.0 Titanium oxide B 0.5 76 Charge control agent E 1.0 Silica A 1.0 Titanium oxide B 1.5 77 Charge control agent E 1.0 Silica A 1.0 Titanium oxide C 0.5 78 Charge control agent E 1.0 Silica A 1.0 Titanium oxide C 2.0 79 Charge control agent E 1.0 Silica A 3.0 Titanium oxide A 0.5 80 Charge control agent E 1.0 Silica A 3.0 Titanium oxide B 0.5 81 Charge control agent E 1.0 Silica A 3.0 Titanium oxide C 0.5 82 Charge control agent E 1.0 Silica A 3.0 Titanium oxide A 1.5 83 Charge control agent E 1.0 Silica B 2.0 Titanium oxide A 0.5 84 Charge control agent E 1.0 Silica B 2.0 Titanium oxide A 1.0 85 Charge control agent E 1.0 Silica B 2.0 Titanium oxide A 2.0 86 Charge control agent E 1.0 Silica B 2.0 Titanium oxide B 0.5 87 Charge control agent E 1.0 Silica B 2.0 Titanium oxide B 1.0 88 Charge control agent E 1.0 Silica B 2.0 Titanium oxide B 2.0 89 Charge control agent E 1.0 Silica B 2.0 Titanium oxide C 0.5 90 Charge control agent E 1.0 Silica B 2.0 Titanium oxide C 1.0 91 Charge control agent E 1.0 Silica B 2.0 Titanium oxide C 2.0 92 Charge control agent E 2.0 Silica B 2.0 Titanium oxide C 2.0 93 Charge control agent E 1.0 Silica C 2.0 Titanium oxide A 0.5 94 Charge control agent E 3.0 Silica C 2.0 Titanium oxide A 1.5 95 Charge control agent E 3.0 Silica C 2.0 Titanium oxide A 2.0 96 Charge control agent E 3.0 Silica C 2.0 Titanium oxide B 0.5 97 Charge control agent E 3.0 Silica C 2.0 Titanium oxide B 1.0 98 Charge control agent E 3.0 Silica C 2.0 Titanium oxide B 2.0 99 Charge control agent E 3.0 Silica C 2.0 Titanium oxide C 0.5 100 Charge control agent E 2.0 Silica C 2.0 Titanium oxide C 1.0 101 Charge control agent E 2.0 Silica C 2.0 Titanium oxide C 2.0 102 Charge control agent G 2.0 Silica A 1.0 Titanium oxide A 0.5 103 Charge control agent G 2.0 Silica A 1.0 Titanium oxide A 1.0 104 Charge control agent G 2.0 Silica A 1.0 Titanium oxide A 2.0 105 Charge control agent G 2.0 Silica A 2.0 Titanium oxide B 0.5 106 Charge control agent G 2.0 Silica A 2.0 Titanium oxide B 1.0 107 Charge control agent G 2.0 Silica A 2.0 Titanium oxide B 2.0 108 Charge control agent G 2.0 Silica A 3.0 Titanium oxide C 0.5 109 Charge control agent G 2.0 Silica A 3.0 Titanium oxide C 1.0 110 Charge control agent G 2.0 Silica A 3.0 Titanium oxide C 2.0 111 Charge control agent G 2.0 Silica B 1.0 Titanium oxide A 0.5 112 Charge control agent G 2.0 Silica B 1.0 Titanium oxide A 1.0 113 Charge control agent G 2.0 Silica B 1.0 Titanium oxide A 2.0 114 Charge control agent G 2.0 Silica B 2.0 Titanium oxide B 0.5 115 Charge control agent G 2.0 Silica B 2.0 Titanium oxide B 1.0 116 Charge control agent G 2.0 Silica B 2.0 Titanium oxide B 2.0 117 Charge control agent G 2.0 Silica C 1.0 Titanium oxide A 0.5 118 Charge control agent G 2.0 Silica C 1.0 Titanium oxide A 1.0 119 Charge control agent G 2.0 Silica C 1.0 Titanium oxide B 1.5 120 Charge control agent G 2.0 Silica C 2.0 Titanium oxide B 0.5 121 Charge control agent G 2.0 Silica C 2.0 Titanium oxide C 2.0 122 Charge control agent H 2.0 Silica A 1.0 Titanium oxide A 0.5 123 Charge control agent H 2.0 Silica A 2.0 Titanium oxide A 1.0 124 Charge control agent H 2.0 Silica A 3.0 Titanium oxide A 2.0 25 Charge control agent H 2.0 Silica A 1.0 Titanium oxide B 0.5 126 Charge control agent H 2.0 Silica A 2.0 Titanium oxide B 1.0 127 Charge control agent H 2.0 Silica A 3.0 Titanium oxide B 2.0 128 Charge control agent H 2.0 Silica A 1.0 Titanium oxide C 0.5 129 Charge control agent H 2.0 Silica A 2.0 Titanium oxide C 1.0 130 Charge control agent H 2.0 Silica A 3.0 Titanium oxide C 2.0 131 Charge control agent H 2.0 Silica B 1.0 Titanium oxide A 0.5 132 Charge control agent H 2.0 Silica B 1.0 Titanium oxide A 1.0 133 Charge control agent H 2.0 Silica B 1.0 Titanium oxide A 2.0 134 Charge control agent H 2.0 Silica B 1.0 Titanium oxide B 0.5 135 Charge control agent H 2.0 Silica B 1.0 Titanium oxide B 1.0 136 Charge control agent H 2.0 Silica B 1.0 Titanium oxide B 2.0 137 Charge control agent H 2.0 Silica B 1.0 Titanium oxide C 0.5 138 Charge control agent H 2.0 Silica B 1.0 Titanium oxide C 1.0 139 Charge control agent H 2.0 Silica B 1.0 Titanium oxide C 2.5 140 Charge control agent H 2.0 Silica B 2.0 Titanium oxide B 1.0 141 Charge control agent H 2.0 Silica B 3.0 Titanium oxide A 3.0 142 Charge control agent H 2.0 Silica C 1.0 Titanium oxide A 0.5 143 Charge control agent H 2.0 Silica C 1.0 Titanium oxide A 1.0 144 Charge control agent H 2.0 Silica C 1.0 Titanium oxide A 2.0 145 Charge control agent H 2.0 Silica C 1.0 Titanium oxide B 0.5 146 Charge control agent H 2.0 Silica C 1.0 Titanium oxide B 2.0 147 Charge control agent H 2.0 Silica C 1.0 Titanium oxide C 2.0 148 Charge control agent H 2.0 Silica C 1.0 Titanium oxide C 3.0 149 Charge control agent K 2.0 Silica A 1.0 Titanium oxide A 0.5 150 Charge control agent K 2.0 Silica A 1.0 Titanium oxide A 1.0 151 Charge control agent K 2.0 Silica A 1.0 Titanium oxide A 2.0 152 Charge control agent K 2.0 Silica A 1.0 Titanium oxide B 0.5 153 Charge control agent K 2.0 Silica A 1.0 Titanium oxide B 1.0 154 Charge control agent K 2.0 Silica A 1.0 Titanium oxide B 3.0 155 Charge control agent K 2.0 Silica A 1.0 Titanium oxide C 0.5 156 Charge control agent K 2.0 Silica A 5.0 Titanium oxide C 1.0 157 Charge control agent K 2.0 Silica A 1.0 Titanium oxide C 3.0 158 Charge control agent K 1.0 Silica A 3.0 Titanium oxide C 3.0 159 Charge control agent K 1.0 Silica B 1.0 Titanium oxide A 0.5 160 Charge control agent K 1.0 Silica B 1.0 Titanium oxide A 1.0 161 Charge control agent K 1.0 Silica B 1.0 Titanium oxide A 2.5 162 Charge control agent K 1.0 Silica B 1.0 Titanium oxide B 1.0 163 Charge control agent K 1.0 Silica B 1.0 Titanium oxide B 2.0 164 Charge control agent K 1.0 Silica B 1.0 Titanium oxide B 3.0 165 Charge control agent K 1.0 Silica B 1.0 Titanium oxide C 1.0 166 Charge control agent K 1.0 Silica C 1.0 Titanium oxide C 2.0 167 Charge control agent K 1.0 Silica C 1.0 Titanium oxide C 1.0 168 Charge control agent K 1.0 Silica C 1.0 Titanium oxide C 3.0 169 Charge control agent J 2.0 Silica A 1.0 Titanium oxide A 1.0 170 Charge control agent J 2.0 Silica A 1.0 Titanium oxide A 2.0 171 Charge control agent J 2.0 Silica A 1.0 Titanium oxide A 1.0 172 Charge control agent J 2.0 Silica A 1.0 Titanium oxide B 1.0 173 Charge control agent P 1.0 Silica A 1.0 Titanium oxide A 1.0 174 Charge control agent P 1.0 Silica A 1.0 Titanium oxide A 2.0 175 Charge control agent P 1.0 Silica A 1.0 Titanium oxide A 1.0 176 Charge control agent P 1.0 Silica A 1.0 Titanium oxide B 1.0 177 Charge control agent P 1.0 Silica A 1.0 Titanium oxide B 2.0 178 Charge control agent P 1.0 Silica A 1.0 Titanium oxide B 3.0 179 Charge control agent P 1.0 Silica A   1.0 w Titanium oxide C 1.0 180 Charge control agent P 1.0 Silica A 1.0 Titanium oxide C 2.0 181 Charge control agent P 1.0 Silica A 1.0 Titanium oxide C 3.0 182 Charge control agent P 1.0 Silica A 2.0 Titanium oxide A 1.0 183 Charge control agent P 1.0 Silica B 5.0 Titanium oxide B 1.0 184 Charge control agent P 2.0 Silica B 1.0 Titanium oxide A 1.0 185 Charge control agent P 2.0 Silica C 1.0 Titanium oxide A 2.0 186 Charge control agent P 2.0 Silica B 1.0 Titanium oxide A 3.0 187 Charge control agent P 2.0 Silica B 1.0 Titanium oxide B 1.0 188 Charge control agent P 2.0 Silica B 1.0 Titanium oxide B 2.0 189 Charge control agent P 2.0 Silica B 1.0 Titanium oxide B 3.0 190 Charge control agent P 2.0 Silica C 1.0 Titanium oxide C 1.0 191 Charge control agent P 3.0 Silica B 1.0 Titanium oxide C 2.0 192 Charge control agent P 4.0 Silica B 1.0 Titanium oxide C 3.0 193 Charge control agent P 8.0 Silica C 2.0 Titanium oxide A 1.0 194 Charge control agent Q 1.0 Silica A 1.0 Titanium oxide A 1.0 195 Charge control agent Q 1.0 Silica A 1.0 Titanium oxide A 2.0 196 Charge control agent Q 1.0 Silica A 1.0 Titanium oxide A 1.0 197 Charge control agent Q 1.0 Silica A 1.0 Titanium oxide B 1.0 198 Charge control agent Q 1.0 Silica A 1.0 Titanium oxide B 2.0 199 Charge control agent Q 1.0 Silica A 1.0 Titanium oxide B 3.0 200 Charge control agent Q 1.0 Silica C 1.0 Titanium oxide C 1.0 201 Charge control agent Q 1.0 Silica C 1.0 Titanium oxide C 2.0 202 Charge control agent Q 1.0 Silica A 1.0 Titanium oxide C 3.0 203 Charge control agent Q 1.0 Silica A 2.0 Titanium oxide A 1.0 204 Charge control agent Q 2.0 Silica A 5.0 Titanium oxide B 1.0 205 Charge control agent Q 2.0 Silica B 1.0 Titanium oxide A 1.0 206 Charge control agent Q 2.0 Silica B 1.0 Titanium oxide A 2.0 207 Charge control agent Q 2.0 Silica B 1.0 Titanium oxide A 3.0 208 Charge control agent Q 2.0 Silica B 5.0 Titanium oxide B 1.0 209 Charge control agent Q 2.0 Silica B 5.0 Titanium oxide B 2.0 210 Charge control agent Q 2.0 Silica B 1.0 Titanium oxide B 3.0 211 Charge control agent Q 2.0 Silica B 1.0 Titanium oxide C 1.0 212 Charge control agent Q 3.0 Silica B 1.0 Titanium oxide C 2.0 213 Charge control agent Q 5.0 Silica B 1.0 Titanium oxide C 3.0 214 Charge control agent Q 6.0 Silica B 2.0 Titanium oxide A 1.0 215 Charge control agent Q 3.0 Silica C 1.0 Titanium oxide A 1.0 216 Charge control agent R 1.0 Silica A 1.0 Titanium oxide A 0.5 217 Charge control agent R 1.0 Silica A 1.0 Titanium oxide A 1.0 218 Charge control agent R 1.0 Silica A 1.0 Titanium oxide A 2.0 219 Charge control agent R 1.0 Silica A 1.0 Titanium oxide B 0.5 220 Charge control agent R 1.0 Silica A 1.0 Titanium oxide B 1.0 221 Charge control agent R 1.0 Silica A 1.0 Titanium oxide B 2.0 222 Charge control agent R 1.0 Silica A 1.0 Titanium oxide C 0.5 223 Charge control agent R 1.0 Silica A 5.0 Titanium oxide C 1.0 224 Charge control agent R 1.0 Silica A 6.0 Titanium oxide C 3.0 225 Charge control agent R 1.0 Silica B 6.0 Titanium oxide A 0.5 226 Charge control agent R 1.0 Silica B 1.0 Titanium oxide A 1.0 227 Charge control agent R 2.0 Silica B 1.0 Titanium oxide A 2.0 228 Charge control agent R 2.0 Silica B 1.0 Titanium oxide B 0.5 229 Charge control agent R 2.0 Silica B 1.0 Titanium oxide B 1.0 230 Charge control agent R 2.0 Silica B 1.0 Titanium oxide B 5.0 231 Charge control agent R 6.0 Silica B 1.0 Titanium oxide C 0.5 232 Charge control agent R 5.0 Silica B 1.0 Titanium oxide C 1.0 233 Charge control agent S 1.0 Silica B 1.0 Titanium oxide C 2.0 234 Charge control agent S 1.0 Silica C 2.0 Titanium oxide A 0.5 235 Charge control agent S 1.0 Silica C 2.0 Titanium oxide A 1.0 236 Charge control agent S 1.0 Silica C 2.0 Titanium oxide A 2.0 237 Charge control agent S 1.0 Silica C 2.0 Titanium oxide B 0.5 238 Charge control agent S 1.0 Silica C 2.0 Titanium oxide B 1.0 239 Charge control agent S 1.0 Silica C 2.0 Titanium oxide B 2.0 240 Charge control agent S 1.0 Silica C 2.0 Titanium oxide C 0.5 241 Charge control agent S 1.0 Silica C 2.0 Titanium oxide C 1.0 242 Charge control agent S 1.0 Silica C 2.0 Titanium oxide C 2.0 243 Charge control agent S 1.0 Silica A 1.0 Titanium oxide A 0.5 244 Charge control agent S 2.0 Silica A 1.0 Titanium oxide A 1.0 245 Charge control agent S 2.0 Silica A 1.0 Titanium oxide A 2.0 246 Charge control agent S 2.0 Silica A 1.0 Titanium oxide B 0.5 247 Charge control agent S 2.0 Silica A 1.0 Titanium oxide B 1.0 248 Charge control agent S 2.0 Silica A 1.0 Titanium oxide B 2.0 249 Charge control agent S 2.0 Silica A 1.0 Titanium oxide C 0.5 250 Charge control agent S 2.0 Silica A 1.0 Titanium oxide C 1.0 251 Charge control agent S 2.0 Silica A 1.0 Titanium oxide C 2.0 252 Charge control agent S 2.0 Silica B 1.0 Titanium oxide B 2.0 253 Charge control agent S 3.0 Silica B 1.0 Titanium oxide C   0.5 w 254 Charge control agent S 3.0 Silica B 1.0 Titanium oxide C 1.0 255 Charge control agent S 3.0 Silica B 1.0 Titanium oxide C 2.0 256 Charge control agent S 2.0 Silica A 1.0 Titanium oxide B 0.5 257 Charge control agent S 2.0 Silica A 1.0 Titanium oxide B 1.0 258 Charge control agent S 2.0 Silica A 1.0 Titanium oxide B 2.0 259 Charge control agent S 2.0 Silica A 1.0 Titanium oxide C 0.5 260 Charge control agent S 2.0 Silica A 1.0 Titanium oxide C 1.0 261 Charge control agent S 2.0 Silica A 1.0 Titanium oxide C 2.0 262 Charge control agent S 2.0 Silica B 1.0 Titanium oxide B 2.0 263 Charge control agent S 5.0 Silica B 1.0 Titanium oxide C 0.5 264 Charge control agent S 6.0 Silica B 1.0 Titanium oxide C 1.0 265 Charge control agent S 10.0 Silica B 1.0 Titanium oxide C 2.0 266 Charge control agent R 1.0 Silica A 1.0 Titanium oxide C 0.5 267 Charge control agent R 5.0 Silica A 5.0 Titanium oxide C 3.0 268 Charge control agent R 1.0 Silica A 5.0 Titanium oxide C 3.0 269 Charge control agent R 1.0 Silica B 0.5 Titanium oxide A 0.5 270 Charge control agent R 5.0 Silica B 1.0 Titanium oxide A 1.0 TESTING EXAMPLE 1 [0042] 5,000 sheets of paper was printed with each of the non-magnetic monocomponent color toner prepared in Examples 1-182 and Comparative Examples 1-270 using a contact type of non-magnetic monocomponent development printer (HP 4600, Hewlett-Packard) at normal temperature and humidity (20° C., 55% RH). Image density, printing efficiency, and long-term stability were tested. The results are given in Table 6 below. [0043] 1) Image Density (I.D.) [0044] Solid area was measured using a Macbeth reflectance densitometer RD918. [0045] ∘: Image density was 1.4 or above. [0046] Δ: Image density was 1.2-1.4. [0047] ×: Image density was 1.0-1.2. [0048] 2) Printing efficiency [0049] Of the 5,000 sheets of paper, printing efficiency was calculated by counting the number of wasted sheets per each 500 sheets. [0050] {circle over (∘)}: Printing efficiency was 80% or over. [0051] ∘: Printing efficiency was 70-80%. [0052] Δ: Printing efficiency was 60-70%. [0053] ×: Printing efficiency was 50-60%. [0054] 3) Long-term stability [0055] It was confirmed if I.D. and printing efficiency were maintained after printing 5,000 sheets. [0056] A: I.D. was 1.4 or over and printing efficiency was 80% or over. [0057] B: I.D. was 1.3-1.4 and printing efficiency was 70-80%. [0058] C: I.D. was 1.2-1.3 and printing efficiency was 60-70%. [0059] D: I.D. was 1.0-1.2 and printing efficiency was 50-60%. TABLE 6 Image Printing Long-term Example density efficiency stability 1 ∘ ⊚ A 2 ∘ ⊚ A 3 ∘ ⊚ A 4 ∘ ⊚ A 5 ∘ ⊚ A 6 ∘ ⊚ A 7 ∘ ∘ A 8 ∘ ⊚ A 9 ∘ ⊚ A 10 ∘ ⊚ A 11 ∘ ⊚ A 12 ∘ ⊚ A 13 ∘ ⊚ B 14 ∘ ⊚ A 15 ∘ ⊚ A 16 ∘ ⊚ A 17 ∘ ⊚ A 18 ∘ ⊚ A 19 ∘ ⊚ A 20 ∘ ⊚ A 21 ∘ ⊚ A 22 ∘ ⊚ A 23 ∘ ⊚ A 24 ∘ ⊚ A 25 ∘ ⊚ A 26 ∘ ⊚ A 27 ∘ ⊚ A 28 ∘ ∘ A 29 ∘ ⊚ A 30 ∘ ⊚ A 31 ∘ ⊚ A 32 ∘ ⊚ A 33 ∘ ⊚ A 34 ∘ ⊚ A 35 ∘ ⊚ A 36 ∘ ⊚ A 37 ∘ ⊚ A 38 ∘ ⊚ A 39 ∘ ⊚ A 40 ∘ ⊚ A 41 ∘ ⊚ A 42 ∘ ⊚ A 43 ∘ ∘ B 44 ∘ ⊚ A 45 ∘ ⊚ A 46 ∘ ∘ B 47 ∘ ⊚ A 48 ∘ ⊚ A 49 ∘ ∘ B 50 ∘ ⊚ A 51 ∘ ⊚ A 52 ∘ ⊚ B 53 ∘ ⊚ A 54 ∘ ⊚ A 55 ∘ ∘ A 56 ∘ ∘ A 57 ∘ ⊚ A 58 ∘ ⊚ A 59 ∘ ⊚ A 60 ∘ ⊚ A 61 ∘ ⊚ A 62 ∘ ∘ A 63 ∘ ⊚ A 64 ∘ ∘ B 65 ∘ ⊚ A 66 ∘ ⊚ A 67 ∘ ⊚ A 68 ∘ ∘ B 69 ∘ ⊚ A 70 ∘ ⊚ A 71 ∘ ⊚ A 72 ∘ ⊚ A 73 ∘ ⊚ A 74 ∘ ⊚ A 75 ∘ ⊚ A 76 ∘ ⊚ A 77 ∘ ⊚ A 78 ∘ ⊚ A 79 Δ ⊚ B 80 ∘ ⊚ A 81 ∘ ⊚ A 82 ∘ ⊚ A 83 ∘ ⊚ A 84 ∘ ⊚ A 85 ∘ ⊚ A 86 ∘ ⊚ A 87 ∘ ⊚ A 88 ∘ ∘ A 89 ∘ ⊚ A 90 ∘ ⊚ A 91 ∘ ⊚ A 92 ∘ ⊚ A 93 ∘ ⊚ A 94 ∘ ⊚ A 95 Δ ⊚ A 96 ∘ ⊚ A 97 ∘ ⊚ A 98 ∘ ⊚ A 99 ∘ ⊚ A 100 ∘ ⊚ A 101 ∘ ∘ B 101 ∘ ⊚ A 102 ∘ ⊚ A 103 ∘ ⊚ A 104 ∘ ⊚ A 105 ∘ ⊚ A 106 ∘ ⊚ A 107 ∘ ⊚ A 108 ∘ ⊚ A 109 ∘ ⊚ A 110 ∘ ⊚ A 111 ∘ ⊚ A 112 ∘ ⊚ A 113 ∘ ⊚ A 114 ∘ ⊚ A 115 ∘ ⊚ A 116 ∘ ⊚ A 117 ∘ ⊚ A 118 ∘ ⊚ A 119 ∘ ⊚ A 120 ∘ ⊚ A 121 ∘ ⊚ A 122 ∘ ⊚ A 123 ∘ ⊚ A 124 ∘ ⊚ A 125 ∘ ⊚ B 126 ∘ ⊚ A 127 ∘ ⊚ A 128 ∘ ∘ A 129 ∘ ⊚ A 130 ∘ ⊚ A 131 ∘ ⊚ A 132 ∘ ⊚ A 133 ∘ ⊚ A 134 ∘ ⊚ A 135 ∘ ⊚ A 136 ∘ ⊚ A 137 ∘ ⊚ A 138 ∘ ⊚ A 139 ∘ ⊚ A 140 ∘ ⊚ A 141 ∘ ⊚ A 142 ∘ ⊚ A 143 ∘ ∘ B 144 ∘ ⊚ A 145 ∘ ⊚ A 146 ∘ ∘ B 47 ∘ ⊚ A 148 ∘ ⊚ A 149 ∘ ∘ B 150 ∘ ⊚ A 151 ∘ ⊚ A 152 ∘ ∘ B 153 ∘ ⊚ A 154 ∘ ∘ A 155 ∘ ⊚ A 156 ∘ ∘ A 157 ∘ ⊚ A 158 ∘ ⊚ A 159 ∘ ⊚ A 160 ∘ ⊚ A 161 ∘ ⊚ A 162 ∘ ⊚ A 163 ∘ ⊚ A 164 ∘ ⊚ A 165 ∘ ⊚ A 166 ∘ ⊚ A 167 ∘ ⊚ A 168 ∘ ⊚ A 169 ∘ ⊚ A 170 ∘ ⊚ A 171 ∘ ⊚ A 172 ∘ ⊚ A 173 ∘ ⊚ B 174 ∘ ⊚ A 175 ∘ ⊚ A 176 ∘ ⊚ A 177 ∘ ⊚ A 178 ∘ ∘ A 179 ∘ ∘ A 180 ∘ ∘ A 181 ∘ ∘ A 182 ∘ ⊚ A [0060] TABLE 7 Comparative Image Printing Long-term Example density efficiency stability 1 x x D 2 x Δ C 3 Δ x D 4 x x D 5 x x D 6 Δ x D 7 x x D 8 x x C 9 Δ x D 10 x x D 11 x x C 12 Δ x D 13 x x D 14 x x C 15 x x D 16 x x D 17 x x C 18 Δ x D 19 x x D 20 x x D 21 x x D 22 x Δ D 23 x x D 24 x x D 25 x x D 26 x x C 27 x x D 28 x Δ D 29 x x D 30 x x D 31 x Δ D 32 x x D 33 x x D 34 x Δ D 35 x x D 36 x x D 37 x Δ D 38 x x D 39 x x D [0061] As seen in Table 6 and Table 7, when a charge control agent having a specific shaped particle size distribution was used, as in the present invention, image density, printing efficiency, and long-term stability were superior. This is because the charge control agent particle having a larger particle size tends to be present on the surface, while the charge control agent particle having a smaller particle size does not because of a stronger binding ability with the binder resin. [0062] As apparent from the above description, the non-magnetic monocomponent color toner of the present invention, which comprises a charge control agent having a specific shaped particle size distribution, enables excellent functioning as a charge control agent because the charge control agent particle having a smaller particle size has good binding ability with the binder resin and the charge control agent having a larger particle size tends to be present on the surface. The toner comprising such a charge control agent offers higher resolution because of good chargeability and ensures long-term stability because of uniform charge distribution. [0063] While the present invention has been described in detail with reference to exemplary embodiments, those skilled in the art will appreciate that various modifications and substitutions can be made thereto without departing from the spirit and scope of the present invention as set forth in the appended claims.
The present invention relates to a non-magnetic monocomponent color toner and a preparing method thereof. In the non-magnetic monocomponent color toner including a toner mother particle, silica and titanium dioxide, the toner mother particle comprises a specific shaped particle size distribution of the charge control agents, and thus, providing non-magnetic monocomponent color toner with a narrow charge distribution and good chargeability. Accordingly, the color toner does not cause contamination in the non-imaging region. Also, because it has superior image density and printing efficiency and significantly improved charge maintenance, it has good long-term stability.
6
CROSS REFERENCE TO RELATED APPLICATION This application claims priority to, and is a divisional of, co-pending U.S. patent application Ser. No. 12/850,166 filed on Aug. 4, 2010, and is hereby entirely incorporated by reference. TECHNICAL FIELD The present invention relates generally to an apparatus and method for forming one or more liquid streams having relatively small, well defined cross sectional areas which are normally directed to a target substrate, and for selectively interrupting and redirecting the flow of such liquid streams by application of gaseous fluid impingement jets transverse to the normal flow direction of the liquid streams. More specifically, the invention relates to an apparatus and method providing precise and substantially instantaneous switching between (i) a normal application mode in which a liquid stream is applied to a substrate and (ii) a diversion mode in which the liquid stream is redirected away from the substrate. Such switching is carried out in response to commands to develop desired fine scale treatment patterns across the substrate. BACKGROUND OF THE INVENTION Systems that provide relatively fine scale treatment patterns of liquid across a target substrate by interruption of the applied liquid streams are generally known. In prior systems, multiple liquid streams are expelled under pressure from orifice openings arranged in close, side-by-side relation. The orifice openings are surrounded circumferentially by walls defining the openings. The pressure liquid streams normally project towards a target substrate but are intermittently interrupted by application of a transverse gas jet which redirects the liquid stream away from the target substrate and into a collection reservoir to be reused. When application of the gas jet is discontinued, the liquid streams resume along the initial path. Such systems are used typically to apply intricate patterns of dye or other liquids to textile substrates, although other substrates may likewise be treated if desired. While the prior systems work very well, it is a continuing challenge to provide improved definition in the applied pattern across the substrate while nonetheless delivering a sufficient quantity of dye or other liquid to the substrate to provide complete treatment. It is also a continuing challenge to provide reduced complexity in the system set-up as well as enhanced functionality in the collection of unused liquid. SUMMARY OF THE INVENTION The present invention provides advantages and alternatives over prior constructions and practices by providing an improved system for application of liquid streams to a substrate. The system of the present invention incorporates open face flow channels prior to discharge along an unconstrained flow path. The present invention further provides an improved self-aligning modular assembly for delivery of impingement stream to the liquid streams. The present invention further provides an improved arrangement for collection of the liquid stream in a diverted flow path in response to application of the impingement stream, without excess residue build-up. In accordance with one exemplary aspect, the present invention provides an apparatus for intermittently applying one or more liquid streams to a target substrate. The apparatus includes a liquid supply in the form of a manifold for holding a liquid and a plurality of liquid conveyance channels in fluid communication with the liquid supply. The liquid conveyance channels are adapted to carry liquid away from the manifold and towards the target substrate. At least one of the liquid conveyance channels includes a first segment defining a substantially fully enclosed liquid passageway and a second segment downstream from the first segment. The second segment has an open-face flume configuration. The end of the second segment defines an open sided liquid outlet projecting towards the target substrate such that a liquid stream exiting the second segment is expelled towards the target substrate along a normal flow path substantially aligned with the liquid conveyance channel. A plurality of impingement jet directional passages are positioned at an elevation between the liquid conveyance channels and the target substrate. At least one of the impingement jet directional passages has a central axis oriented in an intersecting relation to the undisrupted flow path of a corresponding liquid stream expelled from the corresponding liquid conveyance channel. The impingement jet directional passages are adapted to selectively deliver an impingement stream to divert the corresponding liquid stream away from the undisrupted flow path into a diverted flow path. A liquid collection assembly captures the liquid stream in the diverted normal flow path. In accordance with another exemplary aspect, the present invention provides an apparatus for intermittently applying one or more liquid streams to a target substrate. The apparatus includes a liquid supply in the form of a manifold for holding a liquid and a channel module with a plurality of liquid conveyance channels in fluid communication with the manifold. The liquid conveyance channels are adapted to carry liquid away from the manifold and towards the target substrate. The end of the liquid conveyance channel defines a liquid outlet projecting towards the target substrate such that a liquid stream exiting the liquid conveyance channel is expelled towards the target substrate along a normal flow path substantially aligned with the liquid conveyance channel. Below the liquid outlet, the channel module has a landing. The landing has impingement jet positioning apertures with central axis that align with the central axis of a corresponding liquid conveyance channel. The apparatus also includes an impingement jet module having a plurality of individually activatable impingement jet tubes mounted in an impingement jet body. The impingement jet tubes include distal ends extending from the impingement jet body, which are arranged in a pattern adapted for coaxial, plug-in into corresponding impingement jet positioning apertures in the landing of the channel module. The impingement jet tubes are adapted to selectively deliver the impingement stream to divert the corresponding liquid stream away from the undisrupted flow path into a diverted flow path. A liquid collection module captures the liquid diverted from the normal flow path. In accordance with still another exemplary aspect, the present invention provides an apparatus for intermittently applying one or more liquid streams to a target substrate. The apparatus includes a liquid supply in the form of a manifold for holding a liquid and a channel module with a plurality of liquid conveyance channels in fluid communication with the manifold. The liquid conveyance channels are adapted to carry liquid away from the manifold and towards the target substrate. The end of the liquid conveyance channel defines a liquid outlet projecting towards the target substrate such that a liquid stream exiting the liquid conveyance channel is expelled towards the target substrate along a normal flow path substantially aligned with the liquid conveyance channel. A plurality of impingement jet directional passages are positioned at an elevation between the liquid conveyance channels and the target substrate. At least one of the impingement jet directional passages has a central axis oriented in an intersecting relation to the undisrupted flow path of a corresponding liquid stream expelled from the corresponding liquid conveyance channel. The impingement jet directional passages are adapted to selectively deliver an impingement stream to divert the corresponding liquid stream away from the undisrupted flow path into a diverted flow path. A liquid collection module captures the liquid diverted from the normal flow path. The liquid collection module having an entrance, funnel section, and an exit. The entrance is position for receiving the liquid stream in the diverted flow path, the funnel section is in fluid communication with the entrance and reduces in cross section as it progresses away from the entrance, and an the exit allows the fluid progressing through the liquid collection module to exit the collection module. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and which constitute a part of this specification, illustrate a potentially preferred embodiment of the present invention, and together with the general description above and the detailed description below, serve to explain the principles of the invention wherein: FIG. 1 is a schematic cut-away view illustrating an exemplary apparatus in accordance with the present invention showing a liquid jet assembly projecting a single pressure liquid stream towards a carpet substrate; FIG. 2 is a view similar to FIG. 1 showing application of an impinging gaseous deflection jet from an impingement jet assembly redirecting the liquid stream away from the substrate and into a collection tray assembly; FIG. 3 is the schematic cut-away view of the liquid jet module showing the manifold component, the channel component, and the liquid streams projecting onto the carpet substrate; FIG. 4 is a schematic view taken generally along the line 4 - 4 in FIG. 3 illustrating the channel liquid channels in the channel body, and the flow of liquid streams from the manifold chamber to the carpet substrate; FIG. 5 is an expanded schematic view of a portion of FIG. 4 with an abutting channel body cover shown in phantom; FIG. 6 is a schematic view taken generally along line 6 - 6 in FIG. 5 showing the grooves in the channel body of the liquid jet module; FIG. 7 is a schematic view illustrating a impingement jet module in place with the channel body of the liquid jet module; FIG. 8 is a view similar to FIG. 7 showing the impingement jet delivery module separated from the channel body; FIG. 9 is a schematic cut-away view illustrating the collection module from FIGS. 1 and 2 for capture of a liquid stream in a diverted flow path; and FIG. 10 is a side view of the collection module shown in FIG. 9 . Before the embodiments of the invention are explained in detail, it is to be understood that the invention is in no way limited in its application to the details of construction and/or the arrangements of the components set forth in the following description or illustrated in the drawings. Rather, the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for purposes of description only and should not be regarded as limiting. The use herein of “including”, “comprising”, and variations thereof is meant to encompass the items listed thereafter and equivalents, as well as additional items and equivalents thereof. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference will now be made to the drawings, wherein to the extent possible, like reference numerals designate like characters throughout the various views. Referring now to FIGS. 1 and 2 , there is shown a cross-sectional view of an exemplary liquid-jet application system 10 . As illustrated, the liquid-jet application system 10 generally includes a liquid jet module 100 , an impingement jet module 200 and a collection module 300 . A pressurized liquid supply 90 , holding a liquid, such as an ink, dye, or the like, under pressure, provides the liquid to the liquid jet module 100 . The pressurized liquid passes through the liquid jet module 100 and is emitted as pressurized, coherent liquid streams 11 . As shown in FIG. 1 , the liquid stream 11 may be applied as an undisrupted flow path 15 against the surface of a target substrate 20 . In the illustrated arrangement, the substrate 20 is a textile such as a carpet, pile fabric, or the like. However, it is likewise contemplated that the substrate may be virtually any material to which a liquid pattern may be applied. When it is desired that the liquid stream 11 does not reach the substrate 20 , the impingement jet module 200 provides an impingement stream 19 that engages the liquid stream 11 and creates a diverted flow path 16 for the liquid stream 11 into the collection module 300 , as shown in FIG. 2 . As illustrated by the directional arrows in FIGS. 1 and 2 , the substrate 20 may move relative to the liquid jet application system 10 such that the undisrupted flow path 15 of the liquid stream 11 will apply a treatment pattern of the liquid as a line or line segment that is oriented generally parallel to the direction of travel for the substrate 20 . During periods when the impingement jet module 200 emits an impingement stream 19 creating the diverted flow path 16 , the liquid stream 11 is diverted from the substrate 20 and the portion of the substrate 20 passing under the liquid jet module 100 goes untreated by the liquid stream 11 . By way of example only, and not limitation, in the event that the substrate 20 is a carpet fabric and the liquid stream 11 is a dye, the undisrupted flow path 15 of the liquid stream 11 will dye the carpet substrate 20 with a line or line segment generally parallel to the direction of travel of the carpet substrate 20 . When the impingement jet module 200 emits the impingement stream 19 , the liquid stream 11 will have the diverted flow path 16 causing liquid stream 11 to divert into the collection module 300 and the portion of the carpet substrate 20 passing below the liquid stream 11 will remain undyed. By having a series of liquid jet application systems 10 perpendicular to the direction of travel of the carpet substrate 20 , the dye can be applied across the width of the carpet substrate 20 . By having a plurality of liquid jet application systems 10 in series in the direction of travel for the substrate 20 , each liquid jet application system 10 can apply liquid streams 11 of different liquids, such as different dye colors, across the surface of the substrate 20 to obtain different patterns of the different liquids (such as different colors) on the substrate 20 . Referring now to FIG. 3 , the liquid jet module 100 generally includes a manifold component 120 and a liquid channel component 130 . In the embodiment illustrated, the liquid channel component 130 includes liquid channels 112 that are in fluid communication with a manifold chamber 111 in the manifold component 120 . Opposite to the manifold component 120 , the liquid channels 112 each have a liquid discharge end 116 that the liquid streams exit the channel component 130 . The liquid channels 112 are formed by groves 141 in a channel body 140 and a channel body cover 150 . In the embodiment illustrated, the manifold chamber 111 is primarily formed by a manifold body 120 , which is enclosed by the channel body 140 and the channel body cover 150 . The pressurized liquid supply 90 is in fluid communication with the manifold chamber 111 , and the manifold chamber 111 provides a supply source feeding the liquid through the liquid discharge ends 116 in the array of liquid channels 112 to create the liquid streams 11 that are emitted towards the substrate 20 . It is contemplated that each liquid stream 11 will have a relatively small cross-sectional area to provide a finer pattern control on the application of liquid streams 11 across the substrate 20 . As will be appreciated and illustrated in FIG. 4 , such fine diameter streams may be arranged in a side-by-side arrangement to one another so as to define a substantially continuous curtain of liquid oriented transverse to the travel direction of the substrate 20 . Such an arrangement permits detailed liquid application patterns across the target substrate 20 by selectively discontinuing individual liquid streams 11 and/or groups of liquid streams 11 . By way of example only, and not limitation, the liquid streams 11 may have a diameter of less than about 150 mils, and more preferably less than about 100 mils, and most preferably about 3 to about 30 mils, although greater or lesser effective diameters may likewise be utilized. In order to provide fine-scale patterning across the substrate 20 , it is desirable to maintain the cross sectional integrity of the liquid stream 11 along the travel path between the liquid jet module 100 and the substrate 20 . The present invention provides a multi-stage liquid travel path for delivery of the liquid stream 11 from the manifold chamber 111 to the substrate 20 , which is believed to improve the cross sectional integrity of the liquid stream 11 from the liquid jet module 100 to the substrate 20 . As illustrated in FIGS. 3 and 4 , the liquid streams 11 progress from the manifold chamber 111 into liquid channels 112 with an enclosed first stage 12 and then through a open directed second stage 13 , then exits the liquid channels 112 through liquid discharge ends 116 associated with individual liquid channels 112 along an unconstrained third stage 14 to the substrate 20 . In the enclosed first stage 12 , the liquid forming the liquid streams 11 passes through an enclosed first segment 114 of the liquid channel 112 created by the grooves 141 in the channel body 140 which are enclosed by the channel body cover 150 . As illustrated in FIG. 6 , the grooves 141 in the channel body 140 have a substantially rectangular shaped cross section, although other geometries may be used if desired, such as substantially circular or “U” shaped cross sections. Also the face the channel body cover 150 enclosing the grooves 141 in the embodiment illustrated is substantially flat, although it may include complementary grooves for alignment with the grooves 141 in the face of the channel body 140 . In the open directed second stage 13 , the liquid forming the liquid streams 11 passes through open flume second segment 115 created by the grooves 141 in the channel body 140 , which are not enclosed by the channel body cover 150 . That is, the liquid stream 11 is not bounded on all sides, such as being bounded by only two or three sides. In this area of the channel body 140 , the channel body cover 150 does not extend to cover the groves 141 , thereby creating the open flume-like configuration. Thus, the liquid streams 11 within the second segment 115 have an outer face which is free from an opposing constraining boundary surface and liquid traveling along the liquid channels 112 transitions from the enclosed first segment 114 in the first stage 12 to the open-faced second segment 115 second stage 13 . Following the second stage 13 created by the open faced second segment 115 , the liquid streams 11 exit the liquid channels 112 through associated liquid discharge ends 116 along an unconstrained third stage 14 of the liquid conveyance path in which the liquid streams 11 are normally substantially aligned with the liquid channels 112 , but no longer are bounded or guided by the liquid channels 112 . In this third stage 14 the liquid streams 11 are unconstrained and unguided by external boundary surfaces. It is believed that transitioning from the enclosed first stage 12 to the open faced second stage 13 prior to discharge into the unbounded space of unconstrained third stage 14 is beneficial in promoting the coherency and overall stability of the liquid streams 11 . While not meaning to be constrained to a particular theory, it is believed that the open face of the second stage 13 allows the liquid stream 11 to dissipate static pressure before being released into an unconstrained or unguided stream. It is believed that a sudden abrupt change from a fully enclosed stream to a completely unenclosed stream may result in the expansion of the static pressure in the liquid stream to create cross sectional disruptions that will unpredictably expand the cross sectional size of the stream, or create uneven cross sections in the stream prior to being received by the substrate 20 . In practice, the length of the second stage 13 is preferably at least four (4) times the largest cross-sectional dimension of the liquid channels 112 provides an improved transition and guidance of the liquid stream that minimizes these disruptions. By way of example only, and not limitation, according to one practice the width dimension of the liquid channels 112 in the second segment 115 is about 14 mils. Accordingly, in that exemplary arrangement, the length of the second stage 13 is preferably about 56 mils or greater. Of course, larger and smaller effective diameters may likewise be utilized, if desired. As shown in FIG. 5 , the terminal ends of the second segment 115 define open sided outlets projecting towards the target substrate 20 . The liquid streams 11 will travel from the liquid channels 112 to the substrate 20 as substantially cohesive and stable units. However, it is also desirable to have the capability to substantially instantaneously prevent the liquid stream 11 from being applied to the substrate 20 , followed by substantially instantaneous reapplication of the liquid stream 11 to the substrate 20 on demand so as to control the pattern application of the liquid onto the substrate 20 with a degree of definition and precision. To this end, the liquid streams 11 may be manipulated by the application of the gaseous impingement stream 19 from the impingement jet module 200 to provide manipulated patterning of the liquid stream 11 on the substrate 20 , as previously described and illustrated in FIG. 2 . The impingement jet module 200 includes an impingement stream directional passage 211 that emits and directs the impingement stream 19 . Each impingement stream directional passage 211 has a central directional axis that intersects a central directional axis of an associated the liquid channel 112 in the liquid jet module 100 , down stream from the liquid jet module 100 in the unconstrained third stage 14 of the liquid streams 11 . In the embodiment illustrated, the impingement stream directional passage 211 emits the impingement stream 19 towards a location on the liquid stream 11 at is opposite of the location on the liquid stream 11 that was unconstrained in the open directed second stage 13 of the liquid stream 11 . Referring now to FIGS. 2, 3, 4, 5, 7 and 8 , the channel body 140 of the channel component 130 includes a recessed landing 142 at the end of the grooves 141 , which is spaced a short distance away from the liquid streams 11 exiting the liquid channel 112 . A series of impingement jet positioning apertures 143 are located in the recessed landing 142 , and the central axis of each impingement jet positioning aperture 143 intersects with the central axis of a corresponding liquid channel 112 below the liquid discharge end 116 of that liquid channel 112 . As illustrated, the impingement jet positioning apertures 143 may be arranged in side-by-side relation such that the impingement streams 19 are arranged to project along a substantially common plane. However, other arrangements may be used if desired. On the opposite side of the recess landing 142 from the exit of liquid stream 11 from the grooves 141 is an impingement jet mounting surface 144 . Referring now to FIGS. 2, 7 and 8 , the impingement jet system 200 includes an impingement jet module body 220 housing an array of side-by-side gas tubes 230 . Each of the gas tubes 230 are spaced and positioned in the module body 220 at the same spacing and layout as the impingement jet positioning apertures 143 in the channel body 140 . The module body 220 has a mounting surface 221 , and each of the gas tubes 230 includes a distal end 231 extending from the mounting surface 221 . When the impingement jet module 200 is installed, the impingement jet module mounting surface 221 of the impingement jet delivery system 200 engages the impingement jet mounting surface 144 of the channel body 140 and the distal ends 231 of the gas tubes 230 project into the impingement jet positioning apertures 143 of the channel body 140 . The outer diameter of the gas tubes 230 will preferably correspond substantially with the inner diameter of the impingement jet positioning apertures 143 of the channel body 140 such that a secure plug-in relation is achieved upon insertion of the distal ends 231 . In order to accommodate the distal ends 231 of the gas tubes 230 , the impingement jet positioning apertures 133 in the channel body 140 are tapered with the wider end near the impingement jet mounting surface 143 and the narrower end near the landing 142 . Alternatively, or in addition, the distal ends 231 of the gas tubes 230 can be tapered with the larger end near the impingement jet body 220 and the narrower end near the proximal end 233 . It has also been found that, in a preferred arrangement, the distal ends 231 of the gas tubes 230 terminate flush with the surface of the landing 142 closest to the liquid streams 11 , thereby avoiding crevasses and corners that overspray liquid from the liquid streams 11 might accumulate and create errant drops. The interior of the gas tubes 230 create the impingement stream directional passages 211 . As will be appreciated, since the gas tubes 230 plug into the corresponding impingement jet positioning apertures 143 , there is no need or ability to adjust the position of the gas tubes 230 . Rather, that position is pre-established and maintained by the position of the jet positioning apertures 143 . The position of the impingement stream directional passage 211 will have a central axis that intersects a central axis of the corresponding liquid channel 112 below the liquid discharge end 116 of that liquid channel 112 , and preferably in a perpendicular relationship. According to the potentially preferred practice, the gas directional passages 211 in the impingement jet system 200 have a diameter which is greater than the width dimension of the corresponding liquid channel 112 in the liquid jet module 100 , and resultant liquid streams 11 . Most preferably, the cross sectional diameter of the gas directional passages 211 will be as large a possible while maintaining the substantially centered relation relative to the corresponding liquid streams 11 , and not allowing the impingement stream 19 therefrom to interfere with the adjacent liquid streams 11 or the adjacent impingement streams 19 . In this regard, it is desirable that the diameter of the gas directional passages 211 are at least as large as the diameter of the lines feeding into the gas tubes 230 such that the gas directional passages 211 do not create a flow restriction in the system. By way of example only, a diameter of about 43 mils for the gas directional passages 211 has been found to provide good performance when used with liquid channels 112 having a cross-section of about 14 mils, although larger or smaller diameters may be used if desired. The impingement jet system 200 may be installed into, and removed from, the liquid jet module 100 as a single module. Of course, in actual practice, the impingement jet module 100 may be number of such modules disposed across the row of liquid streams 11 , each of which may incorporate a separate plurality of gas tubes 230 . In the event that one or more gas tubes 230 becomes damaged, the individual module containing that gas tube may simply be removed and replaced with minimal disruption. The gas tubes 230 each may be operatively connected in fluid communication to a discreet supply line (not shown) which selectively delivers pressurized air or other gaseous fluid to the gas tube 230 . This selective delivery of pressurized gaseous fluid to individual gas tubes 230 is activated by valves which open and close based on instructions from a computer or other command device. As will be appreciated, during periods when a no pressurized gas is supplied to a gas tube 230 , the liquid stream 11 associated with that gas tube 230 passes in an undisrupted flow path 15 to the substrate 20 . Conversely, during periods when pressurized gas is supplied to a gas tube 230 , the resulting impingement stream 19 engages the liquid stream 11 which is then diverted away from the substrate 20 in a diverted flow path 16 and the portion of the substrate 20 in passing under the normal position of that liquid stream 11 goes untreated. As shown in FIG. 2 , the application of this diverting force is carried out within the unconstrained third stage 14 of the liquid stream 11 downstream from the open directed second stage 13 . As shown in FIGS. 1 and 2 , the application system 10 includes a collection module designated generally as 300 . The collection module 300 from FIGS. 1 and 3 is illustrated in further detail in FIGS. 9 and 10 . The collection system 300 includes an angle body 320 and an opposing deflection blade 330 . The angle body 320 is mounted to the channel cover block 140 of the liquid jet module 100 and has a deflection surface 321 which is positioned near the liquid stream 11 exiting the liquid jet module 100 . The deflection surface 321 of the angle body 320 is oriented at an acute angle from the liquid stream 11 when measured from the downstream position of the liquid stream 11 . The position and angle of the deflection surface 321 is selected in a manner to hinder any mist or overspray of the liquid stream 11 from circling around in an eddy like current back out of the collection module 300 . The deflection blade 330 is mounted to the angled body 320 by standoffs 323 in a manner that creates a discharge passage 310 for the liquid stream 11 to pass through. The standoffs 323 are spaced intermittently along the cross machine length of the collection assembly 300 . This arrangement allows the deflected liquid stream 11 through the discharge passage 310 and into a recovery sump (not shown) for reuse. By way of example only, and not limitation, the slot openings between the standoffs 323 may have a height dimension of about 90 mils, although larger or smaller heights may be used, if desired. As illustrated, the discharge passage 310 has a collection section 311 , a funnel section 314 , and an exit section 315 . The collection section 311 is positioned adjacent to the liquid stream 11 as the liquid stream 11 exits the liquid jet module 100 , and such that the diverted flow path 16 of the liquid stream 11 will enter the collection section 311 upon application of the impingement stream 19 . The collection section 311 is illustrated as having a short length before reaching the funnel section 314 , but could also be only the opening for the funnel section 314 . Inversely, the exit section 315 is illustrated as the opening for the funnel section 314 , but could have a short length extending away from the funnel section 314 . As illustrated, the liquid jet application system 10 is positioned with the liquid streams 11 progressing vertically to the substrate 20 . In this position, it is preferable that a vacuum be applied to the exit 315 of the discharge passage 310 to insure proper removal of the liquid stream 11 in the diverted flow path 16 . However, the liquid jet application system 10 can be positioned at an angle from the vertical in a manner that gravity will assist the progression of the liquid stream 11 in the diverted flow path 16 from the discharge passage 310 without a vacuum. As illustrated, the deflection blade 330 includes leading edge 331 , a guidance surface 332 , and a contraction surface 333 . The deflection blade 330 is relatively thin. By way of example only, in one potentially preferred embodiment the deflection blade 330 may have a thickness of about 20 mils, although thicker or thinner blades may be used if desired. The leading edge 331 is position on the lower side of the entrance 311 adjacent to the undisrupted flow path 15 of the liquid stream 11 , and the surface of the leading edge 331 is flat and substantially parallel to the undisrupted flow path 15 of the liquid stream 11 . The guidance surface 332 progresses away from the leading edge 331 and angle between the leading edge 331 and the guidance surface 332 creates a knife edge adjacent to the undisrupted flow path 15 of the liquid stream 11 . Because of the closeness of the leading edge 331 to the liquid stream 11 , the knife edge will “cut off” any hook shape in the liquid stream 11 created when the liquid stream 11 transitions from the undisrupted flow path 15 to the diverted flow path 16 , or back. According to one potentially preferred practice, the spacing between the liquid stream 18 and the leading edge 331 is set at about 5 to about 15 mils although larger or smaller spacing levels may be used, if desired. The guidance surface 332 leads away from the leading edge 331 and is preferably substantially parallel to a deflection surface 321 on the angled body 320 . This portion of the guide surface 332 that is substantially parallel to the deflection surface 321 creates the collection section 311 of the collection discharge passage 310 . At the rear of the guidance surface 331 of the deflection blade 330 , the deflection blade 330 away from the guidance surface 331 and angles towards the deflection surface 321 of the angled body 320 . The section of the deflection blade 330 that angles towards the deflection surface 321 of the angled body 320 is the contraction surface 333 . The space between the deflection surface 321 and the contraction surface 333 create the funnel section 314 of the discharge passage 310 . By way of example only, and not limitation, it has been found that an angle of about 150°-155° between the guidance surface 332 and the contraction surface 333 may be particularly desirable for the deflection blade 330 . This angle creates a constriction in the funnel section of about 25°-30° relative to the deflection surface 321 of the angle body 320 . Upon the application of an impinging stream 19 from the gas directional passage 211 of the impingement jet module 200 , a diverted flow path 16 of the liquid stream 11 is created that passes through the discharge passage 310 . The disturbed flow of the liquid stream 11 enters the discharge passage 310 through the collection section 311 and is routed towards the funnel section 314 . Upon entering the collection section 311 , the knife edge of the deflection blade 330 cuts off any of the liquid stream 11 that might not follow the same path as the fully diverted stream 16 into the discharge passage 310 . The deflection surface 321 of the angled body 320 maintains a distance to the guidance surface 332 of the deflection blade 330 that helps prevent spray from the liquid stream 11 drifting back out of the discharge passage 310 due to circling currents onto parts of the equipment that might allow accumulated liquid to condensate and drop onto the substrate 20 below. The reducing cross sectional area of the funnel section 314 causes the disrupted flow path 16 of the liquid stream 11 and the impingement stream 19 to accelerate towards, and out of the exit section 315 of the discharge passage 310 where it can be collected by a liquid recovery system (not shown). When the impingement stream 19 is terminated, the liquid stream 11 resumes its normal undisrupted flow path 15 to the substrate 20 ( FIG. 1 ). As will be appreciated, the present invention provides an application system which is highly functional and which can be set up and serviced relatively simply. In particular, due to the plug-in relation of the impingement jet delivery system 200 there is no need to engage in complex alignment of impingement jets with corresponding liquid streams 11 . Moreover, the incorporation of the open face transitional flow stage along the flow path is believed to substantially promote a cohesive and stable liquid stream which provides fine scale patterning across the substrate 20 . Further, the incorporation of the substantially parallel spaced-apart baffle and deflection blade arrangement promotes efficient and effective recovery of deflected liquid stream material. Such features, individually and in combination, promote substantially enhanced functionality and precision in the application of a spray pattern to the substrate 20 . Of course, variations and modifications of the foregoing are within the scope of the present invention. Thus, it is to be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. the claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art. The term “about” means±10% when used in reference to distances. Various features of the invention are set forth in the following claims.
An improved system for application of liquid streams to a substrate. The system incorporates open face flow channels for carrying the liquid away from fully enclosed flow segments prior to discharge along an unconstrained flow path. The present invention further provides an improved, self-aligning modular assembly for delivery of impingement jet to the liquid streams for diverting the direction of the liquid streams. The present invention further provides an improved arrangement for collection of the deflected liquid in response to application of the impingement jet without excess residue build-up.
1
FIELD OF THE INVENTION The present invention relates to pet enclosure areas and, in particular, to a pet bed for caged enclosures that is suspended for keeping the bed area above washable surfaces and stowed against a cage wall when not in use. BACKGROUND OF THE INVENTION Various independent bedding products are available to pet owner for providing a comfortable resting area for their pets. Generally, such products are disposed on the floor of the household and the areas therearound do not require frequent cleaning. When cleaning is required, the beds may be conveniently moved elsewhere and repositioned when the area is dry. For kenneled pets and other outdoor caged pets, the animal is confined to a limited area and accordingly regular surface cleaning, sometimes daily, is required. In such cases, removing the bedding product from the kennel area is not feasible. Moreover, particularly in commercial kennels, a multiple kennels may be cleaned simultaneously, further accentuating the difficulties of moving the bedding and preventing the same from becoming water saturated. Accordingly, most kennels do not permit or limit the types of bedding products the owners may provide during their pet's kenneling period. After such cleaning, the kennel floor may remain wet or damp for considerable periods after cleaning thereby imposing discomfort and ill conditions on the pet. Thus while affording clean quarters, the pets comforts are necessarily compromised. To floor level conditions, primarily in residential settings, floor supported, elevated bedding platforms for pets have been proposed. U.S. Pat. No. 5,161,484 to Duane discloses a raised pet bedding platform that may be mounted adjacent a vertical surface such as a bed. Once installed, the platform is not readily removed for storage or cleaning. U.S. Pat. No. 5,860,389 to Caldwell discloses a frame supported raised support surface that may be removed for cleaning. While the frame may be shifted for cleaning thereunder, the pet bed is designed primarily for indoor residential use. U.S. Pat. No. 5,072,694 to Haynes et al. discloses a wire frame, raised and tented platform for cats. The enclosure is floor supported and must be moved for cleaning the floor area. U.S. Pat. No. 5,662,065 to Bandimere et al. discloses a floor mounted peripheral frame covered by a fabric disposed in hammock fashion for supporting the animal above floor level. U.S. Design Pat. No. D 374,512 to Kiley et al. disclosed a floor supported raised pet platform have a shade. While formed of sheet material and tubing, the platform occupies floor space and must be moved for cleaning the area. A similar approach is disclosed in U.S. Design Pat. No. D 294,752 to Palier. It will thus be appreciated that the foregoing approaches are primarily intended for increasing pet comforts in residential settings and do not lend themselves into incorporation into confined pet environment that require cleaning on a frequent basis, oftentimes while the pet remains in the area. Such approaches also require dedicated floor space and cannot be readily removed in such a setting. Furthermore, the floor units would be susceptible to water spray during cleaning resulting in a wetted bedding area thereafter attractive to insects and other pests. In view of the foregoing limitations of the prior art, it is an object of the present invention to provide a bedding area for pets that does not interfere with cleansing of the surrounding floor area. A further object of the invention is to provide a suspended bedding area for a pet that does not interfere with cleaning in the area and may be readily stowed in the area when not in use. Another object of the invention is to provide a suspended bedding platform for pets in caged or kennel environments wherein the platform may be suspended from the walls thereof and used by the pet during cleaning of the area. Yet another object of the invention is to provide a suspended pet bed for use in confined quarters that affords the pet a dry comfortable area during normal operation of the quartering facility. BRIEF SUMMARY OF THE INVENTION The present invention fulfills the above and other desirable needs in the living quarters of confined pets by providing a padded sleeping platform that is suspended from the ceiling or walls of the living quarters sufficiently off the ground so as not to interfere with normal cleaning schedules and gives the pet a dry resting area while the washed surfaces are drying. To this end, a bedding frame is supported above floor level by a pair of flexible tethers, such as cables or chains or the like, at spaced vertical locations. A flexible bedding platform is attached to the frame adjacent the bottom thereof establishing a protective retaining wall for the pet. The pet bed is formed of moisture and scratch and bite resistant materials to protect against environmental and pet activity damage. When not in use, both tethers may be connected to a common surface permitting the collapsed platform to be stowed compactly thereagainst so as not to inhibit other activities in the area. DESCRIPTION OF THE DRAWINGS The above features and other objects and advantages of the present invention will become apparent upon reading the following detailed description taken in conjunction with the accompanying drawings in which: FIG. 1 is a front elevational view of a suspended pet bed tethered to the side walls of a caged enclosure in accordance with a preferred embodiment of the invention. FIG. 2 is a fragmentary side elevational view of the pet bed shown in FIG. 1; FIG. 3 is a fragmentary front elevational view of the pet bed in the stowed condition against a side wall of a caged enclosure; FIG. 4 is a top view of the pet bed; FIG. 5 is a side view of the pet bed with the platform cover removed; FIG. 6 is an enlarged cross sectional view taken along line 6 — 6 in FIG. 4; FIG. 7 is an enlarged cross sectional view taken along line 7 — 7 in FIG. 4; FIG. 8 is an enlarged fragmentary view of the comer construction for the pet bed support frame; and FIG. 9 is a fragmentary cross section of an embodiment of the cover base. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings for purposes of describing the preferred embodiments only and not for limiting same, there is shown a suspended pet bed for use by quartered pets in a limited space environment such as a kennel, shelter, cage or like walled enclosure, although it will hereinafter become apparent that the invention may be beneficially employed in general residence settings for the comfort of the pet and handlers. Such enclosures are typified by vertical peripheral walls surrounding a ground level area in need of regular cleaning. As illustrated, the walls may be fashioned of any suitable material such as a solid lower section and an upper wired mesh construction. Access to the enclosure is through a single door, and inasmuch as the enclosed space is limited, food and water bowls are suspended from the side walls and ground based bedding materials are generally not utilized. During cleaning the pet may remain in the enclosure, and consequent both the pet and washed areas need to be dried thereafter. Referring to FIGS. 1 through 3, a suspended pet bed 10 in accordance with the invention includes a generally rectangular bed platform 12 suspended from the side walls 14 of a caged enclosure by a pair of tethers 16 . In use, the arrangement provides a limited clearance, 6 to 18 inches, above the enclosure floor 18 , generally concrete or other impervious washable surface. The side walls 14 comprises a solid lower section 20 , of brick or concrete, and an upper section 22 of wire fencing. In multiple pet facilities the enclosure space is limited, about 8 by 10 feet, and access limited to a single door. Periodically the floor 18 is hose washed and left to dry with the pet remaining in the space. The platform 12 includes a rigid peripheral frame 24 and a cover 26 having a base 28 and lateral sleeves enclosing the side bars 29 of the frame. The cover 26 is formed of a flexible, light weight, washable fabric, such as canvas or like material. As described in greater detail below, the base 30 may include additional protective, reinforcing and/or padded layers. Padded cushions 31 may also be used for pet comfort. The base 30 is substantially fits the interior of the frame and includes four side sleeves 31 that encircle the frame bars and are seam stitched as at 36 to the base 30 thereby defining open ended pockets for receiving the frame side bars 29 . As shown in FIG. 7, the base 30 at the lower end of the frame and the frame and sleeves define inner peripheral walls 40 , thus providing a protected recessed bedding area. Experience has shown that the walls 40 are extremely beneficial for keeping young nursing animals within the bed confines. To keep a stable base to prevent the nursing animals from sliding toward the center, a rectangular lower sleeve 44 is stitched at 45 on three sides of the base 30 to define an outwardly opening pocket 46 . A reinforcing member 47 of plastic or other suitable material is received within the pocket thereby reinforcing the base and providing a stable surface for the nursing animals. This feature is particularly important in sheltered settings wherein nursing mothers and dependents are brought to or born in the facility. The frame 24 is formed of four mitered side bars of rectangular lightweight tubing, preferably PVC or like scratch and damage resistant material. A suitable size has been found to be around 1 inch by 2 inch with the major axis vertically oriented in assembly. Referring to FIG. 8, the inner side walls of the side bars 29 are joined together with a fastener assembly 50 including an L-shaped fastening block 52 disposed interior of the side bars and an L-shaped bracket 54 connected thereto by a plurality of fasteners 56 . While frames of the above construction have been found to work well in actual usage, it will be apparent that other framing materials and shapes could be used such as plastic and metallic pipes, wood or other lightweight structural materials providing the desired service characteristics and strength for the intended purposes. Aligned holes 60 are formed in the top and bottom walls of the side bars at locations adjacent the comers and in opposed aligned relationship. As shown in FIG. 6, the lower triangular portion of the tether 16 , in the form a chain links, has free ends that extend through the holes 60 . The free ends are anchored against removal by enlarged snap hooks 62 or other suitable retention device. The ends 70 exiting upwardly and converge together at connecting link 72 thus presenting a triangular flexible load bearing lower linkage. The tether 16 includes an upper member 74 connected to lower linkage at link 72 . Another S-hook 76 or other suitable fastener is used to connected the tether lines to the side walls of the enclosure for supporting the bed platform at varying elevations to position the pet a desired distance above the floor 18 . So installed, the pet bed 10 may be used at all times by the pet for dry comfortable bedding for themselves and dependents. The pet may safely remain on the bed during cleaning of the enclosure. When not is use, one of the tethers may be disconnected from its side wall and appropriately attached to the other side wall whereby the platform as shown in FIG. 3 will reside against the wall 14 in a stowed condition until future use. It will also be apparent that the pet bed may be supported from suitable ceiling structure. Moreover, while extremely beneficial in deployment in the enclosed environments, the comfort and advantages are likewise presented in residential settings. The cover 26 may also be suitably imprinted with designs or other indicia depending on the end user's desires. Additional features as illustrated in FIG. 9 may be incorporated into the cover including a water impervious layer 90 or additional padded layers 92 . The resulting pet bed will provide convenience and comforts for handlers and pets alike. Having thus described a presently preferred embodiment of the present invention, it will now be appreciated that the objects of the invention have been fully achieved, and it will be understood by those skilled in the art that many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the sprit and scope of the present invention. The disclosures and description herein are intended to be illustrative and are not in any sense limiting of the invention, which is defined solely in accordance with the following claims.
A pet bed for a caged enclosure includes a support bedding platform that is suspended by a pair of chain linkages from opposed walls of the enclosure and above the floor thereof so as to permit normal periodic cleaning of the floor and provide a dry bedding area for the pet. The linkages may be connected to a common wall for the compact stowing of the bedding platform during non-use.
0
BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to an economical and easy to install geothermal heat-pump system which utilizes horizontal ground loops. The system is environmentally friendly and can be installed in most already developed locations, such as existing apartment complexes, as well as to-be-developed areas. The invention is directed to novel heat exchange loops, the method of installing the loops and devices for use in the installation process and in association with the loops. 2. Description of the Related Art The instant invention involves the use of the earth as a constant source of heat to be extracted by a heat pump. Geothermal or ground-source heat pumps, although costly to install, have been found to more efficiently heat and air condition building spaces than other heat pumps. It is much more efficient to extract heat from a substance such as earth, which has a near-constant temperature, than from air which can be subject to severe temperature variations. Prior art geothermal systems have utilized ground loops that have been installed horizontally using open trenches. Horizontal installation, however, causes significant damage to the environment. Nature has suffered from root-system damage and removal of vegetation caused by the huge displacement of earth required by horizontal ground loop installation. Landscaping has often been destroyed by the large displacement of earth, removal of trees, shrubs, structures, and grass. Parking lots, driveways, sidewalks, and curbs have been removed, damaged, or their installation delayed for long periods of time to allow for the settling that must occur after massive displacements of earth. Moreover, polluted run-off from the large excavations has disturbed the environmental in areas beyond the job site. Furthermore, the hunge excavating equipment is destructive in its weight, size, and polluting use of fossil fuels. The installation of prior horizontal ground loops requires the subcontracting of big, expensive equipment and specialized personnel to perform very time-consuming drilling, excavating of treaches, and installation. The equipment used for these excavations is extremely expensive and is not owned by many HVAC installers. The man-hours required to install prior art horizontal loops is extensive and costly. Deep, dangerous ditches are dug and painstakingly prepared. Workers then spend many hours installing specialized pipes and fittings. Finally, the ditches are carefully filled and left for settling. Land that has had a prior art ground loop system installed must remain untouched for as much as a year and a quarter to allow for settling. This is an unacceptable delay to the installation of landscaping, parking lots, sidewalks, curbs, driveways, etc. The untouched ground is not only unsightly, but provides dust which is carried by the wind to undesirable places (i.e. indoor surfaces, wet paint and caulk, lungs, eyes, etc.). Many owners of modern homes and commercial buildings, as well as town houses, condominiums, apartments, etc, have land areas that are too restrictive for prior art horizontal ground loop installation. Many homeowners wishing to change to geothermal heating systems forego the conversion due to the destruction or existing landscaping and wooded areas as well as other improvements. The ditch excavation required for prior art ground loops is simply not feasible for homes located on rocky land. The obvious next step is to install vertical ground loops. Vertical ground loop installation requires the use of large cumbersome 6" vertical boring machinery mounted on large trucks weighing in at 15 tons or more. Few people want these monstrous machines in their yards to destroy their driveways and landscaping. These machines are noisy, leave large piles of cuttings and muddy streams of run-off water. The vibrations caused by the machinery can crack foundations and basement walls when drilling near buildings. The depth of vertical bore-holes can penetrate subterranean caverns and the water aquifer. State water control boards have expressed a preference for horizontal instead of vertical ground loops because of the greater threat to drinking water contamination posed by the vertical loop installation. Furthermore, in the case of cavern penetration, well inspectors will require cement trucks to fill a large cavern. Cement is much too expensive to waste on cavern filling. The earth's crust is full of caverns and underground rivers, creating money pits for vertical ground-loop installers. As with horizontal ground loops, the cost of vertical ground loops is prohibitive. Drilling or trenching equipment is not typically owned by HVAC professionals because it is unique and costs thousands to hundreds of thousands of dollars for one machine. The cost of casing, pipe, fittings, cement, bits, and drill stems required for vertical ground loops can be high. Substantial expense is further incurred in the man-hours required to install the vertical loop system in the bore-holes before they cave-in. During rainy seasons, a sea of mud can fill bore-holes the minute the drill bit is pulled, rendering the bore-holes useless. The large, 6" bore-holes must also be filled with some substance to facilitate the conduction of heat between bore-hole walls and the heat transfer medium-carrying pipe. This substance is a costly one not needed in the instant invention. Although vertical ground loops have been put in places where prior art horizontal loops have not been feasible, the small yards of many homes have still been off limits to huge drilling equipment. Thus, because of destruction to landscaping and size and weight of water well construction drill rigs, in some rocky soil, vertical ground loops have not been feasible or desired in many cases. Additionally, vertical ground loops have suffered from design problems, i.e. poor flow distribution, velocity problems are liquid or oil accumulating in the bottom of the vertical ground loops. Moreover, a simple, inexpensive way of preventing flash gas from occurring when supply and return conduits are in the same bore-hole has heretofore been unobtainable. Also of paramount importance is the superiority of direct-exchange (DX) geothermal heat pump systems over indirect-exchange systems. In indirect-exchange systems (water-source), additional pumps to circulate a liquid other than the refrigerant in an additional indoor heat exchanger results in greater pump horse power being required. An additional heat exchanger is required because the transfer of heat goes from ground to ground-loop liquid (water) to refrigerant to air. In DX systems, however, the heat goes from ground to refrigerant to air, thus eliminating not only a heat exchanger and various pumps, but also the bothersome water and anti-freeze mixture in the ground-loop. Furthermore, the plastic pipe used in prior art water-source ground-loops has been large, cumbersome, crinkled easily, and provided too much resistance when being inserted into bore-holes. SUMMARY OF THE INVENTION The negative aspects inherent in the prior art are the dominate factors which economically and environmentally rule out ground source heat pumps as the installation of choice in new structures or to retrofit existing structures. The instant invention overcomes the negative aspects of the prior art by providing a low cost, environmentally friendly geothermal system. Installation of the ground loops of the instant system is micro-surgery compared to prior art installations. The geothermal heat transfer system comprises a plurality of heat exchange loops placed in the ground at less than a 20 degree angle with the surface of the ground, but greater than a 5 degree angle. Each loop has an out flow line and a return line, and a U-turn juncture at the juncture of the out flow line and return line. The juncture has an inlet in fluid tight communication with the out flow line and an outlet in fluid tight communication with the return line. The inlet means and outlet means are on the same side of the juncture, providing a flow chamber between the inlet and outlet means. The juncture has a tapered leading edge opposite the inlet and outlet. A distributor member has an inlet at a lower end and a plurality of outlet members at the upper end. The inlet is in fluid tight contact with a return line, and each of the outlet members are, through the distributor member, in fluid tight engagement with the return line. A heat exchange device which has heat exchange conduits in a floor, the floor conduits being in heat exchange with heat exchange medium in the return line. The heat exchange medium in the floor conduits flowing through the heat exchange loop. The installation of the geothermal heat transfer system utilizes a plurality of heat exchange loops offset from a line parallel to the surface of the earth above the loops. A trench hole is dug and a plurality of bore holes drilled, commencing on one side of the trench hole, passing through the trench hole at a first level, and continuing on the opposite side of the trench hole at a lower level. The bore hole is at an angle ranging from about 5 degrees to less than 25 degrees with a line parallel to the surface of the earth above the bore hole. A pair of conduits are inserted into each drilled bore hole, each of the pair being joined, in fluid tight communication by a juncture member, having a tapered leading edge. The pair of conduits are inserted into the drilled bore hole by forcing the tapered leading edge into the hole. The tapered edge clears the path for the pair of conduits being inserted. Within the trench hole, the inlet lines are connected to a first flow distributor and the outlet conduits are connected to a second distributor. A liquid-oil-gas separator, having a housing with a top and bottom. An inlet member is mounted in the housing top for delivering a liquid-oil-gas mixture to the separator. An outlet member mounted in the housing top removes accumulated oil from the housing. A deflector plate is mounted parallel to, and spaced from, the top thereby providing a flow path from the interior of the housing, around the deflector plate, and to the outlet member. The inlet member is positioned to deliver liquid-oil-gas mixture to a cup shaped member which is spaced from, and below, the deflector. A fluid flow path is provided from the inlet member toward the cup, between the deflector member and the cup to the outlet member and to the housing interior. Fluid is thereby delivered toward the cup, deflected toward the deflector plate, deflected off of the deflector plate and sprayed in a rain-like pattern toward the bottom of the housing. The liquid-oil-gas separator has at least one oil delivery conduit with an inlet and proximate to, but spaced from, the housing bottom and an outlet end positioned interiorly of the oil delivery conduit. The oil delivery conduit is at least a pair of L-shaped elements extending parallel to the housing bottom and having a plurality of oil inlet holes. The oil delivery conduit outlet end forms a Venturi fluid inlet, and the deflector and cup form a Venturi-member. Whereby a suction force is developed at the oil delivery conduit outlet, siphoning accumulated oil from the housing interior and delivering the oil to the fluid flow stream from the liquid-oil-gas mixture inlet. The oil is separated from the liquid-oil-gas mixture by delivering a downward stream of a liquid-oil-gas mixture to the interior region of a cup shaped member. This causes the liquid-oil-gas mixture to have its flow directed radially outward and upward off of the cup. The radially outward flow is deflected off of a deflector plate which deflects the flow radially outward and downward off of the deflector plate to the bottom region of the housing. A Venturi suction effect is produced between the cup and the oil tubes. Accumulated oil is siphoned from the housing, through oil tubes which have multiple inlets at the bottom portion of the housing. The oil is delivered to the cup shaped member, by developing a Venturi effect vacuum in the region of the cup. The heavier oil is pulled off deflector plate by suction line pressure in the return pipe. A bore hole drilling device comprises an elongate hollow drilling bit with a cutting member affixed at one end, a central fluid passage, and connecting means at the other end. The connecting means is preferably a spiral thread. The cutting member is a substantially planar member having a leading cutting tip and presenting a triangular cutting region. A fluid inlet to the central fluid passage is located at the other end from the fluid outlet proximate the first end. The cutting bit has a radial dimension greater than the radial dimension of the elongated hollow drilling bit. The bore-hole drilling device further comprises a swivel member with a body portion and a housing element. The housing element has a central bore and a inlet, water line which connects to a water line to the inlet. The body portion is position within the central bore and mounted for rotational motion within the housing element. The body portion has an inlet and an outlet. The inlet is a hole through the body portion and is positioned proximate the housing element inlet. The body portion has a central bore hole, a first seal for providing a water tight rotation seal between the body portion and the housing. A second seal means provides a second water tight rotation seal between the body portion and the housing. The housing inlet and body portion inlet are positioned between the first and second seal. BRIEF DESCRIPTION OF THE DRAWINGS The advantages of the instant disclosure will become more apparent when read with the specification and the drawings, wherein: FIG. 1 is a schematic illustration of a site plan for the installation of the geothermal heating and air conditioning system of the instant invention; FIG. 2 is a top view of the laminar flow divider used with the instant invention; FIG. 3 is a side view of the laminar flow divider of FIG. 2; FIG. 4 is a top view of the liquid-oil-gas separator of the instant invention; FIG. 5 is a side view of the liquid-oil-gas separator of FIG. 4; FIG. 5A is atop view of the cup and piping of the liquid-oil-gas separator of FIG. 5; FIG. 6 shows a top view of the U-bend assembly of the instant invention; FIG. 7 shows a side view of the U-bend assembly of FIG. 6; FIG. 8 shows a top view of the 180° U-Bend Elbow; FIG. 9 is an end view of the pipe entrance end of the U-bend elbow of FIG. 8; FIG. 10 is an end view of the closed end of the U-bend elbow; FIG. 11 is a side view of the U-bend elbow; FIG. 12 is a side view of the drill bit and stem of the instant invention; FIG. 13 is an end view of the bit-end of the drill bit and stem; FIG. 14 is a cross-sectional side view of the earth drill water swivel assembly; FIG. 15 an end view of the earth drill water swivel assembly; FIG. 16a is a schematic illustration of the heat exchange system in the air conditioning cycle; FIG. 16b is a schematic illustration of the heat exchange system in the heating cycle; FIG. 17 shows the optional U-bend assembly of a concentric water-source ground-loop, and FIG. 18 shows optional duct work for a radiant floor addition to the instant heat pump. DETAILED DESCRIPTION OF THE INVENTION The instant device overcomes the prior art deficiencies by providing a direct-exchange ground-source heat pump that is easy and inexpensive to install without destruction to the environment. The installation method of ground-source heat pump causes virtually no damage to the environment or existing structures. No large excavations are required as the horizontally oriented bore-holes are extremely small. The small bore-holes do not bother subterranean caverns, water aquifers, grass, trees, shrubs or any landscape vegetation. Structures and paved surfaces also remain free from damage. Due to the bore-hole size, a waiting period between installation and construction to allow the earth to settle is not required. The equipment used in the installation is handheld and affordable. As the equipment is powered by electricity, there are not fossil fuels to be spilled or burned to pollute the environment. Further, as installation does not require the moving of mass amount of land, polluted run-off from the large excavation of the prior art are eliminated. The disclosure achieves EPA and DOE projected goals for geothermal technology to clean up the environment and significantly reduce the over-use of fossil fuels. In geothermal heat-pump systems, the exchange of heat takes place between the earth and medium-carrying conduits that are placed horizontally or vertically in the ground. Heat exchange can be either direct or indirect, however, direct exchanged geothermal heat pump systems provide a superiority over the indirect systems. The use of direct heat exchange eliminates the need for extra pump horse power to pump an extra liquid, as required in indirect systems such as water-source ground loops. An additional heat exchanger is also eliminated since the transfer of heat goes from ground to refrigerant to air. This eliminates not only an heat exchanger and various pumps, but also the dangerous water and anti-freeze mixture required in indirect exchange ground loops. Additionally, the transfer of heat to the air in a building utilizing a heat pump can be simultaneously transferred by the same heat pump system to the domestic hot water used in the building. The instant invention provides the additional benefits of on-demand domestic hot water production, and air dehumidification. Further, the instant invention can readily be used with radiant floors. Because typical basements have cold, damp, concrete floors, the use of radiant floors provides a comfort level unparalleled in basements. A radiant floor system takes the chill from the floor as well as removing dampness. In FIG. 1 a heat pump 10, illustrated in detail in FIG. 16, is connected to a supply air duct 32 and a return air duct 30. The heat pump 10 is in heat transfer connection with a domestic hot water heater 40 by way of a de-super heater 38, using standard water pipes 252 and 254. The compressor 50 compresses the vaporized heat transfer medium (R-22 or other refrigerant known in the art) producing a very hot gas, and causes the hot gas to flow out through transfer line 160 into the flow divider 70. Although the heat transfer medium is referred to herein as R-22, water or freon, it should be noted that any medium applicable to the system as taught herein can be used. Depending upon the size of the system, one or more pair of flow dividers 70 are installed in the header ditch 60 to disperse the medium to the ground loops 80. One of each pair of flow dividers 70 is used to divider the flow from the building through transfer line 160 equally among the plurality of ground loops 80. The return flow is combined in the second flow divider 70 of the pair and returned to the house via conduit 166. Since the flow direction reverses between the heating and cooling cycles, the flow dividers 70 are used in pairs so that the flow to the ground loops 80 is always uniformly distributed from the single line to the plurality lines by means of the flow dividers 70. The flow dividers 70 discharge upwardly for laminar flow of gas and liquid to "U"-bend assemblies 80, in order to provide equal, uniform distribution to each assembly 80. The U-bend assemblies 80 are placed in bore-holes 90 drilled by carbide-tipped bits/stems 100. The number of bore-holes 90 is determined by the size of the structure and heating system. The bore-holes 90 used in conjunction with the 1/2 inch conduit would be about 7/8 inch. The bits 100 are manufactured to be used in conjunction with a hand-held air or electric-powered power drill 110, earth drill water swivel 120, and booster pump 130. The drill 110 can be a standard 500 to 1000 rpm, 110-volt, 1/2 horse power drill. The booster pump 130 should have the capacity to deliver approximately 15 psi at 3 gal. per min. and is connected to the water supply through use of a standard hose 134. Bore holes 90 are two or three feet deep at the header ditch 60 descending to approximately eight to eighteen feet deep. The bore holes 90 generally extend for twenty to eighty-feet, depending on geology encountered. The angle of the bore hole with respect to a horizon is generally in the range from about 5 to about 15 degrees. Although steeper angles can be used, the shallow angle of 5 to 15 degrees is preferred. The start the bore-holes 90, the drill operator simply walks horizontally along the terrain. The drill bits flex the small angle of decent. However, the first ten feet of bore-hole must be straight. While spinning at 800 rpm or so, the bit will remain straight. The pump 130 pumps water through steel drill stems 100, illustrated in further detail in FIGS. 12 and 13. The drill stems 100 are welded or threaded together in multiple lengths of 20', 40', 60', and 80'. The drill steams 100 are threaded to the earth drill water swivel 120 in order to drill the bore holes 90. Preferably three 200 foot passes of U-bend assembly containing R-22 are provided per ton of building air conditioning load requirement. The length of passes will vary according to geology encountered in that rock yields excellent heat transfer, clay good transfer and sand average heat transfer. An examination of the cuttings coming out of the bore-holes during the drilling process will help determine the need to increase or decrease the number of U-bend assembly passes. House water 134 will assist the drilling procedure by carrying drill cuttings from the bore hole annulus to the header ditch 60. The header ditch 60 should be excavated to a depth of 5' or more to accommodate excess water and drill cuttings, where they settle and remain. U-bend assemblies 80 can be made on the job site to accommodate the size and length of the multiple bore-holes. The number of bore holes is further determined by the number of equal length passes that hydraulically balance every laminar flow divider pass from discharge line supply and liquid line return. Properly sized and insulated liquid lines 166 and discharge lines 160 that feed the supply and return laminar flow dividers are then drilled into the house from the header ditch 60. The feeder lines 166 and 160 continue the flow of either earth-cooled, or earth-heated, R-22 to and from the heat pump 10. While in the air conditioning cycle (AC), as illustrated in FIG. 16A, the refrigerant in the ground loop so flows to the incoming laminar flow divider 70 located in the header ditch 60. The refrigerant then travels to a flow control piston 248, to the correct charge control system 242, and to another flow control piston 250. From the second flow control piston 250, the refrigerant goes to the coil 244 where the fan 243 moves building air across the R-22 chilled evaporator coil 244. The refrigerant moves to the reversing valve 246, on to the liquid-oil-gas separator 170 to the compressor 50 and the de-super heater 38. The heat from the de-super heater 38 can be diverted for use in a domestic hot water heater 40 by means of piping 252 and 254. A pump 256 draws the heated water from the de-super heater 39 to the hot water heater 40. The water is returned to the de-super heater 38 through return pipe 252. The refrigerant repeats the trip through the reversing valve 246 to be returned to laminar flow divider 70 and on to the ground loop 80 once again. In the heating cycle the flow is reversed by the building's thermostat season selector switch that controls the reversing valve 246. Reversing the direction of the reversing valve 246 creates the heating cycle, as shown in FIG. 16B. The flow control piston 248 moves to the orifice restriction position, and flow control piston 250 to full flow non-restricting position. The correct charge control system 242 is influenced to feel back pressure and causes the R-22 refrigerant to expand flash gas. This flash gas creates a large threshold of heat exchange medium in the evaporator. Where the correct charge control system (CCCS) is electronically censored, the flow pistons are used in conjunction with the correct charge control system, however, if a hydraulic expansion device is build into the CCCS or other means known in the art are utilized, the flow pistons are not required. In the heating cycle, FIG. 16B, the heat transfer medium is heated in the ground loops 80, and then in the compressor 50. Heat is removed in the de-super heater 38 and then in the building air heat exchanger 244, before returning to the ground loops so, for reheating. FIGS. 2 and 3 show the laminar flow dividers 70 that serve to equally divide the refrigerant received from the feeder lines 166 and 160 into the proper number of conduits 84 found in the ground loops 80. For ease of description, the flow divider 70 connected to the feeder line 160 will be referred to as the outgoing divider 70 and while the divider 70 receiving the feeder line 166 will be referred to as the incoming divider 70. As stated heretofore, the laminar flow dividers are installed in pairs, one to connect the conduit 84 of the ground loops 80 to the feeder line 160 and the other to connect the conduit 86 of the ground loops 80 to the feeder line 166. The laminar flow divider 70 has a body 72 which receives either the feeder lines 160 and 166. The body 72 of the laminar flow divider 70 is dimensioned to receive the conduits 84 and 86. The refrigerant travels out conduit 84 and return through conduit 86 of the ground loop 80. The return conduit 86 is connected to incoming divider 70 which converges the conduits 86 into one return feeder line 166. It should be noted that depending upon whether the system is in the heat or air conditioning mode will determine which of the feeder lines 160 or 166, as well as flow dividers 70, in the outgoing and when is the incoming. FIGS. 4, 5 and 5A show the liquid-oil-gas separator 170 which separates the refrigerant into its various states, allows oil to return to the compressor and keeps liquid refrigerant from damaging the compressor. The separator 170 provides dual sight glasses 172 and 174 to allow for visual liquid level charge adjustment verification. The dual sight glasses 172 and 174 provide the advantages that the HVAC specialist can peer through sight glass 172 while shining a flash light into the other eight glass 174. The liquid-oil-gas separator (LOGS) will separate oil from the freon, returning the oil to the compressor. A major problem with refrigerant compressors is the migration of oil from the compressor and the resultant failure of the compressor. The separator 170, as illustrated in FIG. 5, is a cylindrical unit having an outer cylinder 62, a cylinder top 52 and cylinder base 53. The inflow pipe 51 is secured to the reducing T 63 and receives the liquid-oil-gas mixture. The inflow pipe 51 extends into the cylinder 62 approximately one quarter the length of the cylinder 62. Two holes are drilled into the bottom of the cup 49 and dimensioned to receive the two L-shaped tubes 48. Since the tubes 48 are subsequently secured to the inflow pipe 51, the distance between the tubes 48 is equal to the diameter of the inflow pipe 51. It is preferable that the interior dimensions of the cup 49 be equal to the diameter of the inflow pipe 51 plus the diameter of the two tubes 48. The tubes 48 are preferably secured to cup 49 approximately 1 inch below the upper edge of the lip. The tubes 48 and cup 49 are oriented so as to be suspended approximately 1/2 inch above the interior LOGS base 53. The horizontal legs of the tubes 48 have multiple holes 59 drilled along their length. A deflector plate 50 is secured to the inflow pipe 51 to direct the mixture received from the input pipe 51 to the bottom of the cylinder 62. The cup 49, as illustrated, is approximately four inches long, extending to within about one inch from the deflector plate 50. The deflector 50 is spaced about 5/16" from the upper edge or lip of the cup 49. The tube separator 54 is attached to the tubes 48 approximately 21/2 inches from the cylinder base 53. The tube separator 54 serves to establish the lower limit of the liquid freon 55 and therefore should be positioned so that a sight glass view the separator 54 and the liquid freon level 55 reveals an average charge, or acceptable level. The maximum level of the freon 55 can be seen through sight glasses 172 and 174 when using a flash light and must not exceed a running level which is above the top of the cup 49. Freon flows into the LOGS separator 170 through the tube 51 and is deflected by the base of the cup toward the deflector 50. A "VENTURI" suction is produced by the fluid flow past the outlet of the tubes 48. The suction draws oil which accumulates at the bottom of the cylinder 62, through the holes 59 in the legs of the L-shaped tubes 48 into the stream of flow of freon from the tube 51. The oil and freon gas is drawn into the compressor return line 56 and returned to the compressor, while the liquid freon 55 rains down off of the deflector plate 50. The oil is atomized so that it can become entrained in the combination liquid, gas and oil flow stream to outlet pipe 56. The rain like stream of liquid does not obstruct the ability to view the top of the accumulated liquid 55 thereby enabling a user to determine the level of the freon. The R-22 liquid being lighter than oil rains to bottom of the LOGS cylinder 62 to be accumulated there in reserve. The LOGS cylinder 62 is preferably thermally insulated 57, through any applicable method known in the art. Reducing tee 63 is welded to cylinder top 52 slightly off center so as to allow 3" spacing of two sight glasses 172 and 174. The level of liquid will vary between the air conditioning cycle and the heating cycle and is monitored through the windows 172 and 174. FIGS. 6 and 7 shows the U-bend assembly 80 that is placed into the ground and used to transport the refrigerant. The ends of the conduits 84 and 86 then are placed into the 180° U-bend elbow 125. A strip of insulation material 82, such as cut from a rubber under-ground soaker hose, is placed between the two places of conduit 84 and 86. The insulation material 82 and conduits 84 and 86 are maintained in position by securing the combination, by, for example, being wrapped in moisture resistant tape 88. FIGS. 8, 9, 10 and 11 illustrate in more detail the 180° U-bend elbow 125. The elbow 125 is made from a section of conduit having a diameter sufficient to accommodate the conduits 84 and 86. One end 126 of the elbow 125 is crimped closed. The preferred length of the elbow 125 when used in combination with 1/4 inch tubing, is approximately one-and-a-half-inches long with a 1/2 inch diameter. The crimped end 126 must be sealed to prevent the escape of refrigerant which can be achieved through use of solder, or other means known in the art. As can be seen in FIG. 11, the crimped end 126 forms a modified V-shape which allows for easier insertion into the bore holes 90. It has been found that the taper of the V-shaped end 126 permits the length of conduit to be passed through a relatively small diameter hole without binding. It is noted that the greater the diameter of the bore hole the easier it is to pass long lengths of conduits without binding. However, the ability to bore long holes is inversely related to the diameter of the hole being bored. Thus, the use of the taper provides an advantageous balance between bore hole diameter and pipe diameter, thus maximizing the ease of boring a hole (by enabling a small diameter hole to be used) and maximizing the length of conduit which can be inserted into the relatively small diameter hole. The conduits 84 and 86 are inserted into the open end of the elbow 125, crimped and sealed. The conduits 84 and 86 are prevented from sliding to the crimped end 126 by the deformation created during the crimping of the end 126. This "space" 128 allows for the refrigerant to travel from conduit 84 to conduit 86 for the return trip. The diameters of conduits 84 and 86 as well as the elbow 125 are gauged to reflect the required flow rates and heat exchange results between the earth and heat pump. FIGS. 12 and 13 show the drill bit and stem 100. The stem 102 has a threaded end 104 which is dimensioned to interact with the water swivel 120. The stem 102 is manufactured from a standard water pipe, preferably schedule 80, with a diameter greater than that of the U-bend assembly 80. The bit receiving end 112 is closed and rounded. A groove can be cut into the stem 102 to receive carbide bit 106. The carbide bit 106 is moldered, or otherwise secured, to the bit receiving area 112. Two water ports 108 are drilled into the stem 102 to allow the water coming down the stem 102 to exit into the bore-hole 90. Using the dimensions disclosed herein, the water ports are approximately 3/16 inch in diameter. Water serves to cool the bit and stem 100, carry cuttings to the header ditch 60 and generally facilitate the drilling process. When using the foregoing with water-source concentric conduits rather than direct exchange, the diameters and length may require increasing. FIGS. 14 and 15 show the earth drill water swivel 120. Water from the booster pump 130 enters the swivel 120 at fitting 133. For ease of manufacture, the fitting 133 is preferably a standard fitting which will connect to a 1/2 inch garden hose, although special fittings can be used to allow for specialized applications. Water then travels through a ring 124, which is held in place over the core 126 by a snap rig 128, or other means known in the art. It is preferable that the ring 124 be a brass donut commonly used tin the art, however alternative rings can be used which provide the same advantages. Two "O"-rings 132 keep water from escaping between the donut 124 and the spinning core 126. Water enters the hollow center of the core 126 by way of a water port 136 and exits the core through the stem port 138. The stem port 138 is threaded to receive the threaded end 104 of the drill bit and stem 100. The drill connector 140 is threaded to attach to the electric drill 110 with the aid of wrench flats 142. The rotation of the electric drill 110 causes the core 126 to rotate within the ring 124, thereby rotating the drill bit and stem 100. FIG. 17 illustrates a counter-current heat exchange system for use as a ground loops heat exchanger. Fluid flow can enter conduit 505 which is relatively rigid copper tube having a plurality of outlet ports 506. The flow then returns, counter-current to the inlet flow. The flow in the region between the outer tube 504 and the inner conduit 505 is in heat exchange with the ground for heating of the fluid in the winter and the cooling of the fluid in the summer. The outer tube is preferably, a lay flat irrigation tube. Preferably, the tube is of polyethylene, but can be of other flexible, high durability material. The inner copper tube provides the rigidity for the insertion of long length of conduit. The end of the conduit 505 can be closed off by means of a conventional end cap 507 which is soldered in place, or a threaded end cap. The polyethylene tube 504 is clamped to the capped end of the copper conduit by any or the known clamping mechanisms, such as hose clamps. Clamping of the conduit 504 to the copper T 502 can be by the same means as the clamping at the capped end. A copper "T" 502 provides the closure at the end opposite the capped and. The copper T 502 is soldered to the copper tube 505 to provide a fluid tight seal, at 512. Similarly, the copper T is solder connected to another copper pipe 501, as well known in the art. The counter-current heat exchange conduits can be advantageously used with heat exchange fluids, such as water-anti-freeze mixtures. Since the outer tube 504 is collapsed during the installation process, there can be substantial clearance between the tube 504 and the wall of the bore hole into which it is being inserted. Filling the conduits with fluid inflates the conduit 504 and brings its outer surface into heat exchange contact with the earth. The force of the inflation of the conduit can compact the surrounding earth. Therefore the expanded diameter of the conduit 504 can exceed the diameter of the receiving hole, as bored, depending on the type or condition of the earth. The heating system can be advantageously used in conjunction with radiant floor heat exchange coils in concrete floor. Air from the forced air duct system 430 and 432 shown in FIG. 18 will provide for the flow of sufficient air to remove the chill from a 6" insulated concrete floor slab using 2"×3" aluminum rectangular 0.029 conduit 460. Conduit 461 is a supply line and 462 is return flexible 6" duct. Shut off dampers 463 control the air flow with the aid of the room's wall thermostat. The concrete floor can have approximately 1" of load bearing styrofoam insulation underneath. Alternatively, 3/4 inch polybutalene water pipes can be embedded in the concrete. A circulator pump from the domestic hot water heater and a wall thermostat can be used to control the flow relative to the temperature of the room. The same radiant floor concept can be used in rooms such as kitchens and bathrooms where bare feet often touch the floor. The pipes are simply attached to the sub-floor materials and then insulated underneath. The instant invention will also work with existing art water source ground loops by drilling bore-holes of approximately two inches in diameter and inserting a copper supply water tube into a return conduit made of flexible irrigation plastic polyethylene as shown in FIG. 18. After inserted into the bore-hole the outer conduit is inflated inside the bore-hole by 12 psi water pressure. A "U"-end at the end of the concentric conduits acts as a 180° elbow. It should be noted that a water-source ground-lop requires about twice as much underground piping as does direct exchange ground loop. As can be seen from the foregoing, through the use of this invention, the installation of ground loops no longer requires the use of big, heavy, expensive equipment and specialized personnel to perform very time-consuming drilling, excavating of trenches, and installation. The small, inexpensive equipment required in this invention can easily be or may already be owned by many HVAC installers and contractors. Moreover, the man-hours heretofore required have been greatly reduced. Drilling equipment is effective, common, clean, small, inexpensive, and uses very little energy. Deep, dangerous ditches for the laying of pipes are not needed. Pipes and fittings are simple and quickly prepared. The land that has had the ground loop of this invention installed is immediately available for landscaping work, parking installation, or what ever is typically needed in residential or commercial areas. This high speed factor of the installation process renders the system extremely cost effective for modern contractors and HVAC specialists. Furthermore, virtually no dust is created for wind to carry to undesirable places (i.e. indoor surfaces, wet paint and caulk, lungs, eyes, etc.). The established neighboring inhabitants and their possessions remain unaffected. Few home or building owners have land that is too restrictive for the installation of the geothermal ground loop system of this invention. Even the smaller lots of modern buildings such as town houses, condominiums, apartments, commercial buildings, etc. provide the necessary land area for this invention. Owners of existing buildings wishing to change to geothermal heating systems can now have geothermal heating and cooling and domestic hot water without disturbing their existing structures, landscaping, wooded areas or neighbors. Moreover, building owners having rocky land can greatly benefit from this invention because as the small size of the bore-holes and the characteristics of the special drilling equipment allows for drilling in rock. By virtue of the bore-holes having a near-horizontal orientation, water aquifers and underground caverns will not be penetrated. Therefore there is no fear of drinking water contamination and underground caverns will not have to be filled with expensive cement. The small copper conduit preferably used in this invention is the ideal choice for ground loops. The copper conduit is common, affordable, easily handled, and enduring, as illustrated by 5000 year old copper found buried in Egypt. Additionally, copper tubing slips easily into bore-holes when fitted with the special 180° "U"-bend elbow fitting. The close tolerance bore-hole used herein has sufficient wet mud to lubricate and grout the U-bend assembly. When connections are made using solder, it is critical that the solder be able to resist corrosion. A solder containing 60% silver provides the required strength while preventing corrosion. This invention overcomes the costly, defective design problems of the direct-exchange (DX) systems of the prior art. While vertical ground-loops have suffered from poor laminar flow distribution and velocity problems, the ground loops of this invention are not vertical in orientation and do not have these problems. The foregoing identified superior aspects of this invention makes it the most environmentally responsible and cost saving heat pump commercially available and brings geothermal heat and cooling well within the reach of the average homeowner, and well within the skill and financial limitations of the average contractor and HVAC specialist. The DX heat pump disclosed above is affordable for homeowners and profitable for contractors and HVAC installers. The ability to eliminate the use of a $250,000 drilling rig and $150,000 excavating equipment enables environmentally friendly geothermal heating systems to be made available to a much wider range of consumers. General contractors will be willing to install geothermal heat pumps since the instant system will no longer disrupt and delay the building process. Even when altered to apply to water-source ground-loop installations, which takes twice the amount of bore-hole and land than the preferred embodiment, the instant method is still micro surgery compared to prior art methods. The foregoing dimensions are used in way of example only. In instances obvious to those skilled in the art, the dimensions may require alterations. Other materials which will meet the criteria set forth herein can be substituted.
The geothermal heat transfer system comprises a plurality of heat exchange loops placed in the ground at an angle of less than a 20 degrees, but greater than a 5 degrees. Each loop has an out flow line and a return line, and a fluid tight, tapered and, U-turn juncture connecting the lines. A pair of distributors connects to inlet and outlet lines at a lower end and a plurality of outlet members at the upper end. A heat exchange device connects to the loops through the inlet and outlet lines. A liquid-oil-gas separator uses cup member and deflector to create a Venturi fluid inlet to separate the oil, returning it to the compressor. A bore hole drilling device comprises an hollow drilling bit with a cutting member at one end, a central fluid passage, and connecting means. The bore hole drilling device has a swivel member with a body portion and housing with a central bore and an inlet, connect to a water line. The body is position within the central bore and mounted for rotational motion within the housing.
4
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of copending International Patent Application PCT/EP2009/005882 filed on Aug. 13, 2009 and designating the United States, which was not published under PCT Article 21(2) in English, and claims priority of German Patent Application DE 10 2008 039 417.3 filed on Aug. 13, 2008, which is incorporated herein by reference. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composition for the identification and the treatment of prostate cells as well as to methods for the diagnostic and therapeutic treatment of a living being using the composition according to the invention. 2. Related Prior Art Compositions for the identification and the treatment of prostate cells are generally known in the art. The prostate carcinoma is a malignant tumor disease which originates from the gland tissue of the prostate. In Germany almost three out of one hundred men die from prostate carcinoma. The prostate carcinoma, therefore, belongs to the most frequent cancer diseases of men. Within the group of men died from cancer it is responsible for about 10% of the deaths and, therefore, is the third-most deadly cancer disease after lung and colon cancer. The precondition for a therapeutic treatment of the prostate carcinoma is a reliable diagnosis. It is in particular decisive whether an affected patient has already a lymph node metastasis; Messing E. M. et al. (1999), Immediate hormonal therapy compared with observation after radical prostatectomy and pelvic lymphadenectomy in men with node-positive prostate cancer. N. Engl. J. Med.; 341 (24): 1781-1788; Walsh P. C. (2002), Surgery and the reduction of mortality from prostate cancer. N. Engl. J. Med.; 347 (11): 839-840. The identification or demarcation of prostate carcinoma metastases in lymph nodes occurs as a “negative image” by means of the magnetic resonance tomography (MRT). For doing so iron particles are intravenously injected; cf. Harisinghani M. G. et al. (2006), Ferumoxtran-10-enhanced MR lymphangiography: does contrast-enhanced imaging alone suffice for accurate lymph node characterization? Am. J. Roentgenol.; 186 (1): 144-8. The iron particles are taken up by the reticuloendothelial system (RES) of the lymph node, however not by the prostate carcinoma metastasis itself since in this position the RES is displaced. In the T2-weighted MRT images the RES can be seen in dark because of the uptaken iron particles, however the prostate carcinoma metastasis remains in light. However, also in areas of inflammation processes, fat deposits and fibroses a displacement of the RES can be found also resulting in light areas in the magnetic resonance tomography and thus appear as metastases like structures. Further, with this method it cannot be distinguished between metastases of different origins, i.e. prostate, colon, bladder etc., since with this method only the RES however not the cancer cells itself can be visualized. SUMMARY OF THE INVENTION Against this background the object underlying the invention is to provide a new composition by means of which prostate cells, in particular the prostate carcinoma cells and such cells which are present in the lymph nodes, can be identified in a reliable and “positive” manner This problem is solved by the provision of such a composition which comprises a ligand of the lilly-of-the-valley odorant receptor (OR17-4), preferably of the human variant (hOR17-4) thereof. This finding was surprising. So far it was assumed that odorant receptors are predominantly found in the nose. The existence of odorant receptors also in other tissues has only occasionally been described. For example Spehr et al. (2003), Identification of a testicular odorant receptor mediating human sperm chemotaxis, Science Vol. 299, pages 2054-2058, and Spehr et al. (2004), Dual capacity of a human olfactory receptor, Curr. Biol. Vol. 14, No. 19, R832-3, describe the expression of the lilly-of-the-valley odorant receptor hOR17-4 on sperms. In the WO 2004/033496 it is therefore suggested to use a ligand for the human lilly-of-the-valley odorant receptor hOR17-4 as a contraception or a conception promoting medicament. Only few odorant receptors have so far been found in the prostate, as e.g. the OR 51 E2 [Ashida et al. (2004), Molecular features of the transition from prostatic intraepithelial neoplasia (PIN) to prostate cancer: genome-wider gene-expression profiles of prostate cancers and PINs. Cancer Res. Vol. 64, pages 5963-5972], the Dresden G protein-coupled receptor (D-GPCR) [Weigle et al. (2004), D-GPCR: a novel putative G protein-coupled receptor overexpressed in prostate cancer and prostate. Biochemical and Biophysical Research Communications, Vol. 322, pages, 239-249] or the G protein-coupled receptor 92 (GPR95) [Lee et al. (2001), Discovery and mapping of ten novel G protein-coupled receptor genes. Gene, Vol. 275, pages 83-91]. Against this background the finding of the inventor that the lilly-of-the-valley odorant receptor OR17-4 or hOR17-4, respectively, is expressed in the prostate, was very surprising. It was also surprising that prostate carcinoma cells very strongly express the lilly-of-the-valley odorant receptor OR17-4 or hOR17-4, respectively. Therefore, by means of the composition according to the invention not only prostate cells can be identified, furthermore it is possible to distinguish between healthy and degenerated prostate cells. A degenerated prostate cell binds essentially more of the composition according to the invention than a healthy prostate cell. As the inventor was able to realize the composition according to the invention binds to the cell surface of prostate cells and is then absorbed into the cytoplasm. As the inventor was further able to realize the composition according to the invention is only absorbed into the prostate cells but, except into the olfactory organs, not into the tissues of the muscles, testicles, heart, colon, lymph nodes, seminal vesicles, spleen, skin, brain, and lung. Remarkably, the composition according to the invention is also not absorbed into other malignant cells, for example of a colon carcinoma, glioma, osteosarcoma, cervix carcinoma, and lymphoma. Hence, the inventor provides a composition for the first time, by means of which prostate cells, including prostate carcinoma cells can be highly selectively and “positively” identified. The lilly-of-the-valley odorant receptor is officially referred to as OR17-4, the human variant is referred to as hOR17-4. In matters of nomenclature it is referred to the publication of Ben-Arie et al. (1994), Olfactory receptor gene cluster on human chromosome 17: possible duplication of an ancestral receptor repertoire, Hum. Mol. Genet. Vol. 3, pages 229-235. A synonymous designation for hOR17-4 is OR1D2. With this designation the gene sequence is published in the GenBank data base under the GenBank accession No. NM — 002548 or the EMBL accession No. AF087917; the entire gene sequence is incorporated into the present application by reference. The lilly-of-the-valley odorant receptor belongs to the group of G protein-coupled receptors. A “ligand” refers to such a compound which can bind under stringent conditions selectively and specifically to the lilly-of-the-valley odorant receptor OR17-4 or hOR17-4, respectively. According to the invention a “composition” refers to any composition which at least comprises the ligand of the human lilly-of-the-valley odorant receptor, however, if applicable, can contain further compounds such as a detectable marker or a diagnostically or pharmaceutically acceptable carrier. Such carriers are comprehensibly disclosed in the prior art, e.g. in Kibbe et al. (2000), Handbook of Pharmaceutical Excipients, 3rd Edition, American Pharmaceutical Association and Pharmaceutical Press. The content of this publication is incorporated into the present application by reference. Preferred compositions are detection compositions, medicaments, diagnostic and therapeutic compositions. According to the invention, “identification” refers to any measure that serves to the detection of prostate cells or prostate carcinoma cells. According to the invention, “treatment” refers to any measure by means of which it is acted on the prostate cells, in particular the prostate carcinoma cells. In particular, the treatment encompasses the therapeutic action on prostate carcinoma cells. The object underlying the invention is herewith completely achieved. According to the invention it is preferred if the ligand is selected from the group consisting of: undecylic aldehyde, 3-phenyl-2-propenal(cinnamaldehyde), octanal, bourgeonal, benzaldehyde, phenylacetaldehyde, 3-phenylpropanal, 3-phenylbutyl aldehyde, 4-phenylbutyraldehyde, canthoxal, cyclamal, floralazone, lilial, (4-ter-butylphenoxy)acetaldehyde, p-anisyl-formate, piperonylacetate, cinnamyl alcohol, hydrocinnamaldehyde, methylcinnamaldehyde, methyl-hydro-cinnamaldehyde, methylnonylaldehyde, phenetyl alcohol, phenylpropanol, methylcinnamaldehyde, isobutyraldehyde, helional, lyral, methyl-phenyl-pentanal, cyclosal, foliaver, trimethylmethane, trifernal, piperonal, isovaleraldehyde, (4-hydroxyphenyl)-butan-2-on (raspberry ketone), vanillin, safrole, heptanal, anethole, 5-phenylvalderaldehyde, isopropylbenzene, 3-phenylbutyl alcohol and 3-phenylpropionic acid. The before-mentioned compounds are examples of ligands of the lilly-of-the-valley odorant receptor OR17-4 or the human variant hOR17-4, respectively, which are especially suited for the production of the composition according to the invention. It is understood that the ligands can be modified to e.g. couple a further compound to the ligand, such as a marker. A suitable modification can for example consist of the attachment of an amino group, e.g. to form aminoundecylic aldehyde, aminobourgeonal, aminocinnamaldehyde, or aminobenzaldehyde. Furthermore, several amino acids can be provided. Correspondingly modified ligands are also encompassed by the invention; cf. also V. Jacquier et al. (2006), Journal of Neuroscience, Volume 97, pages 537-544 and WO 2004/033496. According to the invention it is preferred if the composition further comprises a marker detectable by means of an imaging method. According to the invention imaging methods comprise all apparatus-supported methods by means of which physiological or medical findings or physical or chemical phenomena can be visualised. To such methods belong the fluorescence microscopy, magnetic resonance tomography (MRT), radiography, computer tomography, positron emission tomography (PET), scintigraphy, single photon emission computed tomography (SPECT), sonography, mass spectrometry etc. According to the invention, any marker is encompassed which is detectable in at least one of the before-mentioned methods. This method has the advantage that the composition according to the invention is provided as a diagnostic composition. Due to the high selectivity of the composition according to the invention by this further development for the first time prostate cells or prostate carcinoma cells, respectively, can be positively imaged even in lymph nodes. So far this can only be realized in a very unspecific manner by means of a negative image by the administration of iron particles where also areas are stained which do not contain prostate cells. It is further preferred if such a marker is used which is detectable by means of the fluorescence microscopy and preferably selected from: fluorescein isothiocyanate (FITC), rhodamine, rhodamine isothiocyanate (RITC), sulforhodamine, dansyl chloride, fluorescamine, green fluorescent protein (GFP), ethidium bromide, 4′,6-diamidino-2-phenylindole (DAPI), coumarin, luciferase, phycoerythrin (PE), Cy2, Cy3.5, Cy5, Cy7, texas red, alexa fluor, fluor X, red 613, BODIPY-FL, TRITC, DS red, GFP, DS red. The before identified markers have been proven of value in the molecular diagnostics and which can be bound to the ligand by standard methods. For doing so, it might be necessary to modify the detectable marker, e.g. by providing sulphur and/or amino groups, e.g. to obtain a sulforhodamine-sulfonamido compound or FITC-βAla-compounds. Such modified markers are encompassed by the invention. The marker can further be a marker detectable by means of magnetic resonance tomography (MRT), preferably a complexing agent for metals and a complexed metal, including gadolinium (Gd), europium (Eu), gallium (Ga), manganese (Mn), iron (Fe), Yttrium (Y) and its isotopes. In this context it is further preferred if the complexing agent for metals is selected from the group consisting of: tetraazacyclododecane tetraacetic acid (DOTA), diethylenetriaminepentaacetic acid (DTPA), BOPTA, EOB-DTPA, DTPA-DMA, HP-DOBA, DTPA-BMEA, HIDA, DTDP, porphyrine, texaphyrine, TEKES, fullerene, crown ether. This method has the advantage that a contrast medium for the magnetic resonance tomography (MRT) is provided by means of which prostate cells and prostate carcinoma cells, including such being in the lymph nodes, can be imaged in a reliable manner. As a result, a long lasting need is fulfilled since, so far, such contrast media suitable for the imaging of prostate carcinoma metastases do not exist. These contrast media allow a very high anatomical resolution. This applies in particular for gadolinium containing contrast media with respect to T1-weighted images. This enables to localize space occupations in small structures such as lymph nodes. Such a high anatomical resolution is not possible with iron contrast medium which becomes visible via susceptibility artefacts in T2-weighted images. Furthermore, the marker can be such that it is detectable via computer tomography and preferably comprises an iodine compound, including iopromide, thyroxine, triiodothyronine and triiodobenzoic acid. By this measure such a composition is provided by means of which prostate cells and prostate carcinoma cells, including such in the lymph nodes, can be imaged via computer tomography. Furthermore, the marker can be such that is detectable by means of nuclear medical methods and preferably comprises a y-radiator, such as gadolinium-153 or a β-radiator, including Sr-89, Y-90, I-131, Er-169, Re-186 and Re-188. By this measure such a composition is provided by means of which prostate cells or prostate carcinoma cells, including such being in the lymph nodes, can be imaged within the framework of nuclear medical methods. It is understood that the composition according to the invention can not only comprise one marker but also several markers. It is possible that the composition according to the invention comprises several molecules of the same marker, for example several Gd-DOTA compounds. Such a compound has the advantage that it results in a particularly strong signal in the magnetic resonance tomography. It is, however, possible that the composition according to the invention comprises several different markers. There could be different markers which are detectable by means of the same imaging method, or different markers which are detectable by means of different imaging methods. The composition according to the invention can, for example, comprise a Gd-DOTA compound and a FITC and/or rhodamine compound. This measure has the advantage that the composition according to the invention can both be detected in the magnetic resonance tomography and in the fluorescence microscopy and in both methods prostate cells or prostate carcinoma cells including such in the lymph nodes can be imaged. The information given for the marker applies correspondingly for the linker. Thus, the composition according to the invention can comprise several identical or different linkers. Linker and marker can directly and covalently be linked to each other. Marker and ligand can, however, also be bound to each other via a so-called “linker” which preferably comprises 1, 2, 3, 4, 5, 6, 10, 15 or any number of amino acids. The provision of such an amino acid linker has the advantage that the distance between marker and ligand is increased which has a positive influence on the interaction with the receptor. Especially suited linkers contain lysine residues since they comprise a free amino group to which the markers or ligands, respectively, can be coupled via a peptide bond. Examples for suitable linkers are the following, wherein it is agreed that the N-terminus is on the left side and the C-terminus is on the right side: lysine-glycine-lysine-glycine, lysine-ahx-lysine-ahx (ahx: amino hexanoic acid), lysine-βala-lysine-βala, glutamic acid. In this context it is preferred if the composition comprises a compound which is selected from the group consisting of: The before-mentioned compositions comprise the fluorescence markers rhodamine or sulforhodamine and FITC and, therefore, can be detected in the fluorescence microscopy. The compounds 2, 4, 5, and 6 comprise a linker consisting of an amino acid (alanine), via which the ligand is bound to the marker. The before-mentioned compositions are particularly suited according to the findings of the inventor. According to a preferred further development the composition according to the invention comprises a compound which is selected from the group consisting of: According to the invention, by this measure such compounds are provided which can be used in the magnetic resonance tomography. In the compound 8 the ligand, the undecylic aldehyde or aminoundecylic aldehyde, respectively, is directly linked to the marker Gd-DOTA. In the compound 9 between the ligand and the marker a linker is arranged in form of an amino acid (β-alanine). According to findings of the inventor the before-identified compositions are particularly suited to image prostate cells or prostate carcinoma cells, respectively, including such being in the lymph nodes, by means of the magnetic resonance tomography. It is further preferred if the composition comprises a compound which is selected from the group consisting of: By this measure such compositions according to the invention are provided which can be used in the magnetic resonance tomography and also in the fluorescence microscopy. The compositions comprise both a marker detectable in the magnetic resonance tomography, namely Gd-DOTA, and also a marker detectable in the fluorescence microscopy, namely FITC. In the compound 10 the ligand is bound via a lysine residue to the marker Gd-DOTA which is detectable in the magnetic resonance. The fluorescence marker FITC is coupled to the side chain of the lysine residue. In the compound 11 the ligand is bound via an amino acid linker consisting of alanine and lysine to the MRT marker Gd-DOTA, wherein a FITC marker is coupled to the lysine residue, which is visuable in the fluorescence microscopy. The compound 12 differs from the compound 10 in that the fluorescence or MRT markers are exchanged with respect to their position. The compound 13 is characterized in that the ligand is coupled via a linker comprising nine amino acids to the MRT marker, wherein FITC is coupled via the side chain to the lysine residue. The compound 14 is characterized in that it comprises four Gd-DOTA markers and one FITC marker which are coupled to each other via a linker consisting of seven amino acids. In the magnetic resonance tomography this compound provides a particularly strong signal. It goes without saying that the before-mentioned compounds are only examples. It is up to the discretion of the skilled person which ligands, which markers and which numbers thereof are coupled to each other in a suitable manner and are provided in form of the composition according to the invention. The composition according to the invention is preferably a diagnostic composition for the detection of prostate carcinomas. As the inventor could realize in experiments in vivo with a prostate carcinoma on the nude mouse by using the composition according to the invention the prostate carcinoma tissue could be well stained, whereas the healthy prostate tissue of the mouse showed no noteworthy staining. By means of the composition according to the invention the differenciation between prostate carcinoma tissue and healthy prostate or non-postate tissue is, for this reason, well possible and can be diagnostically used. By means of the composition according to the invention prostate carcinoma metastases in the lymph nodes and/or the bones can be particularly well imaged. Lymphocytes do not comprise lilly-of-the-valley odorant receptors at their surface and, therefore, cannot bind or absorb the composition according to the invention. By means of the composition according to the invention a positive imaging of prostate carcinoma cells in lymph nodes has become possible. The composition according to the invention can also be a therapeutic composition. Due to the high selectivity and specificity with the composition according to the invention medicaments can be delivered to the prostate cells or prostate carcinoma cells, respectively. This measure has the advantage that the effect exclusively occurs in the prostate cells or prostate carcinoma cells, and other tissue and, therefore, the organism remain spared. Such a therapeutic composition has very few side effects. Preferably, the composition according to the invention, which adapted as a therapeutic composition, comprises a cytostatic agent which can be realized by a alkylating agent, a platinium analogon, intercalating agent, antibiotic, mitosis inhibitor, texane, topoisomerase inhibitor and antimetabolite. With this measure such a therapeutic composition is provided by means of which exclusively prostate carcinoma cells can be inhibited and, therefore, killed in a targeted and selective manner. Cells of other tissues remain largely uneffected hereby. It is understood that the composition according to the invention can be configured as diagnostic composition and also as a therapeutic composition. Therefore, the composition can simultaneously comprise a marker detectable by means of imaging methods and a cytostatic. By this manner the course of the therapy can be visualized. Against this background another subject matter of the present invention relates to a method for the diagnostic and/or therapeutic treatment of a human being which comprises the following steps: (a) administration of the composition according to the invention into the living being, and (b) performing an imaging method, if applicable, and repetition of step (a), if applicable. The features, characteristics and advantages of the composition according to the invention apply correspondingly to the method according to the invention. It is understood that the features of the invention mentioned above and those yet to be explained below can be used not only in the respective combination indicated, but also in other combinations or in isolation, without departing from the scope of the present invention. The invention is now explained by means of embodiments in more detail resulting in further features, characteristics and advantages. The embodiments are purely illustrative and do not limit the scope of the invention. Reference is made to the enclosed figures. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1A shows images from the confocal laser scanning micrsocopy (CLSM) of seven human tumor cell lines (PC-3/LNCaP—prostate carcinoma; colo 205—colon carcinoma; U373—glioma; U2OS—osteosarcoma; HeLa—cervix carcinoma; jurkat—lymphoma) and healthy human epithelial prostate cells (CC2555, Lonza) 20 minutes after the incubation with sulfo rhodamine-sulfonamido aminoundecylic aldehyde (compound 1). FIG. 1B shows CLSM images of prostate carcinoma cells (LNCaP) and colon carcinoma cells (Colo205) 20 minutes after the incubation with sulfo rhodamine-sulfonamido βala-aminocinnamaldehyde (compound 2). FIG. 2A shows CLSM images of prostate carcinoma cells (PC-3) and osteosarcoma cells (U2OS) 20 minutes after the incubation with Gd-DOTA-Lys(FITC) aminoundecylic (compound 10). FIG. 2B shows images from the fluorescence activated cell sorting (FACS) of seven tumor cell lines (PC-3/LNCaP—prostate carcinoma; Colo205—colon carcinoma; U373—glioma; U2OS—osteosarcoma; HeLa—cervix carcinoma; Jurkat—lymphoma) and healthy human epithelial prostate cells (CC2555, Lonza) after the incubation with Gd-DOTA-Lys(FITC)-aminoundecylic aldehyde (compound 10) (in triplicate, standard deviation of the mean value). FIG. 2C shows images of a FACS analysis of different carcinoma cells 20 minutes after the incubation with sulforhodamin sulfonamide-βala-aminooctanal (compound 4) (in triplicate, standard deviation of the mean value). FIG. 2D shows LSM images of PC-3-prostate carcinoma cells and U373 glioma cells 48 hours after incubation with Lys(FITC) aminobourgeonal (compound 7). FIG. 3A shows magnetic resonance tomography images of laterally cutted Eppendorf tubes with LNCaP cells after 20 minutes of incubation with Gd-DOTA alone (DOTAREM) (left) and the Gd-DOTA-Lys(FITC) aminoundecylic aldehyde (compound 10) (right). FIGS. 3B and C show the influence of the coupling of undecylic aldehyde to Gd-DOTA. FIG. 3D shows magnetic resonance tomography images of a human PC3 prostate carcinoma in the right lower thigh of a nude mouse (arrow) (10 days after the implantation) before and 90 minutes after the intravenous administration of Gd-DOTA-Lys(FITC) aminoundecylic aldehyde (compound 10). FIG. 4 shows CLSM images of 5 μm frozen sections of nude mice organs and a human prostate carcinoma (PC3) 90 minutes after the intraperitoneal injection of sulforhodamine sulfonamide aminoundecylic aldehyde (compound 1) (in each case, superposition of the transmission and rhodamine channel on the left, only rhodamine channels on the right). FIG. 5A shows fluorescence microscopy images of 5 μm frozen sections of a prostate carcinoma (PC3) 20 and 180 minutes after intraperitoneal injection of sulforhodamine sulfonamide aminoundecylic aldehyde (compound 1). FIG. 5B shows images of a “touch print” of the PC3 prostate carcinoma 20 minutes after intraperitoneal injection of sulforhodamine sulfonamide aminoundecylic aldehyde (compound 1). DESCRIPTION OF PREFERRED EMBODIMENTS 1. Material and Methods 1.1 Synthesis of Sulforhodamine-Sulfonamido Aminoundecylic Aldehyde (Compound 1) Weinreb-AM-resin (NovaBiochem) [0.25 mmol (0.28 g)] was suspended in 10 ml dimethylformamide (DMF) and swelled for 10 minutes. Then the Fmoc protective group is removed by addition of 25% piperidine in DMF (3 minutes, 6 minutes, 2 minutes). After repeated washing steps with DMF three equivalents (0.75 mmol) of Fmoc-aminoundecylic acid are coupled to the resin using 0.75 mmol of TBTU [O-(benzotriazol-1-yl-)-N,N,N′,N′-tetramethyluronium tetrafluoroborat] in presence of 6 equivalents of diisopropylethylamin (DIEA) within 1 hour at room temperature. After repeated Fmoc cleavage 1.5 equivalents of sulforhodamine B acid chloride and 1.5 equivalents of DIEA are dissolved in 1:1 mixture of DMF/dichlormethan, added to the mixture and shaken for 6 hours at room temperature. The excess dye is then washed off and the peptide resin is suspended in absolute tetrahydrofurane (THF), while the reaction is cooled with ice 2.5 ml of 1M lithium aluminium hydrid solution are added and stirred for 45 minutes. After hydrolysis by careful addition of 2N citric acid the resin is filtered off and the filtrate is deluted in dichloromethane (DCM). The DCM solution is washed with 2N citric acid and saturated NaCl solution and dried with Na 2 SO 4 . The product is purified by liquid chromatography on a silica gel column using ethylacetate/petroleum ether. The product is verified by electrospray ionisation mass spectrometry (ESI-MS). 1.2 Synthesis of Sulforhodamine-Sulfonamido βAla-Aminocinnamaldehyde (Compound 2) The synthesis is realized as under 1.1. Instead of Fmoc-aminoundecylic acid Fmoc-aminocinnamic acid is used. 1.3 Synthesis of Sulforhodamine-Sulfonamide βAla-Aminooctanal (Compound 4) The synthesis is realized as under 1.1. Instead of Fmoc-aminoundecylic acid Fmoc-aminooctanoic acid is used. 1.4 Synthesis of Lys(FITC) Aminobourgeonal (Compound 7) The synthesis is realized as under 1.1 and 1.5. Instead of Fmoc-aminoundecylic acid Fmoc-p-tBu-Phe-OH is used. 1.5 Synthesis of DOTA-Lys(FITC) Aminoundecylic Aldehyde and its Gadolinium Complex (Compound 10) Weinreb-AM-resin (NovaBiochem) [0.25 mM (0.28 g)] is freed from the Fmoc-protective group with 25% piperidine/DMF (3 minutes, 6 minutes, 2 minutes). By coupling of 3 equivalents of Fmoc-aminoundecylic acid with TBTU [O-(benzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium tetrafluoroborate] and 6 equivalents of diisopropylethylamine (DIEH) Fmoc-AM-Weinreb-resin is obtained. After Fmoc cleavage Fmoc-Lys Mmt)-OH is coupled to the resin using TBTU (Mmt: methyloxytrityl). Then the Fmoc-protective group is cleaved off again and DOTA (1.4.7.10 tetraazazyclododecan-1,4,7 tri-tert-butyl acetate-10-acetic acid) is coupled to the lysine with TBTU/DIEA. The Mmt-protective group is cleaved off by repeated pouring of the resin with 1% trifluor acetic acid solution in dichlormethan within one hour at room temperature, and the resin is then neutralized by addition of DIEA DITC (fluorescein isothiocyanat) is dissolved in DMSO and coupled to the resin overnight in the presence of diisopropylethylamine The excess fluorescein dye is washed out several times and the resin is dried and suspended in THF, cooled down to 5° C. and 2.5 ml of 1 M lithium aluminium hydrid in THF is added and stirred for 45 minutes at room temperature. The preparation is hydrolysed by carefully adding 2 N citric acid. Then a separation from polymeric compounds occurred and dichlormethane is added. The preparation is washed repeatedly with citric acid and NaCl solution and dried with sodium sulphate. After the solvent is removed the remaining tert-butyl ester groups are removed by pouring with trifluoracetic acid and stirring for half an hour at room temperature. The trifluor acetic acid is removed and the preparation is dissolved in 10% acetic acid and lyophilized. The resulting composition is stirred for 5 hours at 50° C. with 1 equivalent of gadolinium-III-chloride hexahydrate in water at pH 5.6 adjusted with NaOH. After an acidification with diluted acetic acid the preparation is relyophilized. The product is verified by electrospray ionisation mass spectrometry (ESI-MS). 1.6 Electrospray Ionisation Mass Spectrometry (ESI-MS) The conjugates were analyzed by ESI-MS on an Esquire3000+ Ion Trap Mass Spectrometer (Bruker-Daltonics, Bremen, Germany). The conjugates were taken up in 40% ACN, 0.1% formic acid (Sigma-Aldrich) in water (v/v/v) (20 pmol/μl) and constantly infused using a syringe pump (5 μl/min flow rate). Mass spectra were acquired in the positive ion mode. Dry gas (6 l/min) temperature was set to 325° C., the nebulizer to 20.0 psi, and the electrospray voltage to −3700 V. 1.7 Confocal Laser Scanning Microscopy (CLSM) The cells were grown to 80% confluency at 37° C., 5% CO 2 (vol/vol) in 4-well plates (NUNC, Wiesbaden, Germany) with about 300,000 cells per well. U373 human glioma cells, human prostate carcinoma cells PC3 and LNCaP, human Jurkat lymphoma cells, and human colon carcinoma cells Colo205 were grown in RPMI1640 ready mix medium containing L-glutamine and 10% fetal bovine serum (FBS)-gold (PAA Laboratories, Pasching, Austria). U2OS human osteosarcoma cells and HeLa human cervix carcinoma cells were grown in high glucose Dulbeccos modified Eagle's medium containing GlutaMax™ and pyrovate and 10% FBS-gold. Healthy human prostate cells (CC2555, Lonza, Verviers, Belgium) were cultivated in prostate endothelial cell growth medium (PrEGM, Lonza, Verviers, Belgium). The compounds 1, 2 and 4 were dissolved at 1 mg/ml in pure ethanol (Riedel de Haen, Sigma-Aldrich, Taufkirchen, Germany) and then diluted in the appropriate medium for the cells to 10 μg/ml of conjugate and 1% ethanol. The cells were incubated at 37° C. in an atmosphere of 5% CO 2 for 20 minutes with the compounds. After this, the cells were rinsed three times with medium and then incubated with medium again. This experiment was also performed with free sulforhodamine B with a corresponding amount. To illustrate phosphatidylserine (apoptosis test) annexin-fluos (Roche Diagnostics, Mannheim, Germany) was added. This was done after 20 minutes and also after 2 days of incubation with the compounds 1, 2 and 4. The compound 10 was dissolved in culture medium (260 μM). Lys(FITC)-aminobourgeonal (compound 7) was dissolved in culture medium with 1% ethanol (260 μM). The cells were incubated for 20 minutes (compound 10) and for 2 days (compounds 7 and 10). This assay was also performed with free FITC. After the incubation the cells were rinsed three times with medium and again incubated in medium. Propidium iodide (PI) (molecular probes, Eugene, Oreg., USA) was added to stain death cells. The confocal laser scanning microscopy was performed on an inverted LSM510 laser scanning microscope (Carl Zeiss) (objective: LD Achroplan 40×0.6, Plan Neofluar 20×0.50, 40×0.75). For the rhodamine fluorescence excitation the 543 nm beam of a helium-neon laser with suitable beam splitters and barrier filters were used. All measures were performed at least three times on living, non-fixed cells. 1.8 Mouse Organ Sections and Touch Prints PC3 and LNCaP prostate tumor cells were grown to 80% confluency, detached with Accutase™ (PAA Laboratories, Pasching, Austria) and then harvested. The cells were washed with PBS three times and then drawn up into a 30 g Micro-Fine™ insulin syringe (Becton Dickinson, Franklin Lakes, N.J., USA). Approximately 5×10 5 cells per mouse were injected into the right thigh of a male CD1 Nu/Nu mouse (Charles River, WIGA, Sulzfeld, Germany). The tumor growth was monitored and after 10 to 14 days mice bearing tumors with 2-3 mm in diameter were treated with the conjugate. 1.5 mg of the compound 1 were dissolved in 300 μl PBS containing 20% ethanol and applied intraperitoneally. After 90 minutes of circulation the mice were sacrificed and subsequently the tumors and organs were removed, embedded in Jung tissue freezing medium (Leica Instruments, Nussloch, Germany) and frozen in liquid nitrogen. Frozen sections (5 μm thickness) were prepared (LD3000 Cryotom, Leica Biosystems GmbH, Nussloch, Germany) and the rhodamine staining was analyzed by confocal laser scanning To evaluate the in- and efflux of the rhodamine conjugated compound 1, the experiment was repeated with circulation times of 20 minutes and 180 minutes. For touch prints, the tumor of a mouse treated with the rhodamine containing compound 1 (1.5 mg intraperitoneally for 20 minutes) was excised. The tumor was cut and the cells were streaked onto a slide without fixation. The tumor cells were immediately analyzed by CLSM (without fixation). The experiments were repeated two times. 1.9 Magnetic Resonance Tomography Measurements The magnetic resonance tomography (MRT) measurements were performed using a clinical 3-Tesla Siemens whole body MRT (Magnetom TRIO; Siemens, Erlangen, Germany) with the mice in prone position in a standard circular polarized wrist coil. The MRT protocol consisted of native and post-contrast T1 weighted axial images: slice thickness 2 mm, field of view read: 60 mm/7.5%, Voxel size: 0.2×0.2×2 mm, repetition time (TR): 800 ms, echo time (TE): 9.1 ms, flip angle: 90°, acquisitions: tions: 2, number of slices: 25, distance factor: 0, scan time 06:02 min. The DOTA-containing compound 9 was administered to three narcotized mice intravenously via the tale vein (3mg in 200 μl of PBS). 1.10 MR Relaxometry For the MR relaxometry, all tumor cell lines were grown in 75 cm 2 culture flasks (Corning Costar, Bodenheim, Germany) (70% confluency). Accutase™ (PAA Laboratories, Pasching, Austria) was added to achieve detachment of the cells, which were harvested and subsequently aliquoted into Eppendorf tubes (6×10 6 cells per tube). The cells in the tubes were incubated with the DOTA-containing compounds (130 μM). After a 20 minutes incubation period at 37° C. in an atmosphere of 5% CO 2 , the cells were washed three times in PBS and centrifuged at 800 rpm for 5 minutes. The in-vitro MRT was performed with a 3 Tesla-whole body MRT system (Magnetom TRIO, circular polarized wrist coil, Siemens, Erlangen, Germany) Sagittal T1-weighted MR images were obtained using the following spin-echo sequence: Repetition time (TR): 200 ms, echo time (TE): 7,4 ms, flip angle: 90°, averages: 1, concatenations: 2, measurements: 1, number of slices: 19, distance factor: 30%, slice thickness: 3 mm, field of view read: 180 mm/100%, resolution: 256/100%, voxel size: 0.7×0.7×3.0 mm, scan time: 1:48 min. The T1 relaxation times were evaluated from signal intensities obtained by multiple spin-echo measurements: Repetition time (TR): 20-8000 ms (50 different TR values), echo time (TE): 6.4 ms, flip angle: 90°, averages: 1, measurements: 1, number of slices: 1, slice thickness: 1 mm, field of view read: 120 mm/87.5%, resolution: 128/100%, voxel size: 0.9×0.9×1 mm. The analysis and calculations were performed using a Matlab program (Math Works, Natick, Mass., USA). The T1 values were approximated by a three-parameter fit procedure. All signal curves were examined and found to be monoexponential. The investigations were performed in triplicate. 1.11 Flow Cytometry For the fluorescence activated cell sorting (FACS), cells were grown in 75 cm 2 culture flasks (Corning Costar, Bodenheim, Germany) (80% confluency) under the same conditions as described for the confocal laser scanning microscopy. Accutase™ (PAA Laboratories, Pasching, Austria) was added to achieve detachment of the cells, which were harvested and subsequently alequoted into Eppendorf tubes (Eppendorf, Hamburg, Germany) (1×10 6 cells per tube). The cells were incubated for 20 minutes with the compounds 1, 2 and 4 (10 μg/ml in the appropriate medium with 1% ethanol) and the compound 10 (130 μM in the appropriate medium). Afterwards, the cells were washed three times in PBS and centrifuged at 800 rpm for 5 minutes. Then 300 μl FACS buffer (D-PBS containing 1% parafomaldehyde) were added. The samples were measured immediately. Approximately 20,000 events were recorded per sample. The fluorescence excitation was achieved by an argon laser (488 nm). The fluorescence was detected using a 580-610 and a 560-680 nm band-pass filter. All investigations were performed in triplicate. Mean rhodamine and fluorescein isothiocyanate fluorescence values of the samples were acquired using the WinMDI software (Joseph Trotter, Scripps Research Institute, San Diego, Calif., USA) and then statistically evaluated. 2. Results 2.1 Selective Staining of Prostate Cells In Vitro Seven human tumor cell lines and healthy human epithelial prostate cells (CC2555) were incubated for 20 minutes with sulforhodamine-sulfonamido-aminoundecylic aldehyde (compound 1) and analyzed by means of confocal laser scanning microscopy (CLSM). The result is shown in FIG. 1A . There it can be seen that the prostate carcinoma cells (PC-3, LNCaP) and the healthy prostate cells (CC2555) take up the compound according to the invention into the cytoplasm, the cell nuclei are left free. All other cells, however, do not take up the compound according to the invention. Rhodamine without undecylic aldehyde alone is not taken up by any cell types (not shown). In another approach both the prostate carcinoma cells (LNCaP) as well as the colon carcinoma cells (Colo205) were incubated for 20 minutes with sulforhodamine-sulfonamido βala-cinnamaldehyde (compound 2) and analyzed by CLSM. The result is shown in FIG. 1B . It can be seen that the prostate carcinoma cells are significantly stained, however the colon carcinoma cells remain basically unstained. The compound according to the invention is, therefore, uptaken by the prostate carcinoma cells into the cytoplasm, however not the colon carcinoma cells. In a further experiment prostate carcinoma cells (PC-3) and osteosarcoma cells (U205) were incubated for 20 minutes with Gd-DOTA-Lys(FITC) aminoundecylic aldehyde (compound 10) and analyzed by CLSM. The result is shown in FIG. 2A . Thus, the compound according to the invention is very well uptaken into the cytoplasm of the prostate carcinoma cells, however not into the osteosarcoma cells. FITC alone (without undecylic aldehyde) is not uptaken by the cells (not shown). Next, seven tumor cell lines and healthy prostate cells (CC2555) were incubated for 20 minutes with Gd-DOTA-Lys(FITC) amino undecylic aldehyde (compound 10) and analyzed by fluorescence activated cell sorting (FACS). The result is shown in FIG. 2B . There it can be seen that both of the prostate carcinoma cell lines (PC-3, LNCaP) and the healthy prostate cells (CC2555) are stained, however not the non-prostate tumor cell lines. Thus, only the prostate cells take up the compound according to the invention. In a further experiment several carcinoma cells were incubated for 20 minutes with sulforhodamine-sulfonamido βala-aminooctanal (compound 4) and analyzed by FACS. The result is shown in FIG. 2C . There it can be seen that the prostate carcinoma cells (PC3) show the highest fluorescence, i.e. they take up the compound according to the invention. The remaining carcinoma cell lines only show little staining, therefore take up the compound according to the invention only to a small extend. In another approach U373 glioma cells and PC3 prostate carcinoma cells were incubated for 48 hours with Lys(FITC)-aminobourgeonal (compound 7) and analyzed by CLSM. The result is shown in FIG. 2D . The prostate carcinoma cells are cytoplasmatically stained, however not the glioma cells. Like the other conjugates no cytotoxic alterations are shown. In another experiment LNCaP cells were incubated for 20 minutes with Gd-DOTA alone (DOTAREM, Guerbet, France) and with the compound 10 according to the invention Gd-DOTA-Lys(FITC) aminoundecylic aldehyde in an Eppendorf tube and washed out. The result is shown in FIG. 3A . It turns out that the simple Gd-DOTA compound is not taken up by the prostate carcinoma cells. After the incubation and the washing out the cells remain, therefore, dark; cf. FIG. 3A , left. The Gd-DOTA undecylic aldehyde compound, according to the invention is, however, uptaken into the cytoplasm of the prostate carcinoma cells via the lilly-of-the-valley odorant receptor. After the washing out and centrifugation these cells are, therefore, light; cf. FIG. 3A , right. 2.2 Influence of the Coupling of Undecylic Aldehyde to Gd-DOTA Six different tumor cell lines (including LNCaP-prostate carcinoma cells) were, on the one hand, incubated in Eppendorf tubes with Gd-DOTA alone (DOTAREM, Guerbet, France), and on the other hand with the compound 10 Gd-DOTA-Lys(FITC) aminoundecylic aldehyde according to the invention and subsequently washed with PBS for three times. The result is shown in FIG. 3B . The Eppendorf tubes are transversely cut. In the right column the prostate carcinoma cells (LNCaP) as also all of the other carcinoma cells remain dark after the incubation and washing out with the simple Gd-DOTA compound. Only after incubation with the compound 10 Gd-DOTA-Lys(FITC) aminoundecylic aldehyde according to the invention an increase of the signal intensity occurs, however only with the LNCaP-prostate carcinoma cells; cf. FIG. 3B , left column, top. The coupling of undecylic aldehyde to Gd-DOTA (left column), therefore, results in a significantly stronger T1-time reduction for prostate carcinoma cells in comparison to simple Gd-DOTA (right column), however not for the other tumor cell lines. The reduction of the T1-time indicates the increase of the brightness (signal intensity) in the cells which is effected by the cellular uptake of a gadolinium compound in the T1-weighted images. In FIG. 3C the bars indicate the difference of the T1-time of the respective carcinoma cells and the healthy prostate cells (CC2555) after the incubation with the compound 10 Gd-DOTA-Lys(FITC) aminoundecylic aldehyde according to the invention and the simple Gd-DOTA compound. The difference of the T1-time indicates to which extend the compound in a respective cell line results in a reduction of the T1-time (increase of the brightness, signal intensity). This unit is used since the cell lines have different T1-times before the incubation. Difference of the T1-time=(T1-time before the incubation) minus (T1-time after the incubation). The T1-time before the incubation is longer than after the incubation. The shorter the T1-time the lighter the cells. As can be taken from the drawing of FIG. 3C the PC-3 and LNCaP-prostate carcinoma cells and the healthy prostate cells (CC2555) show the strongest increase of the signal intensity in the T1-weighted MRT-images (strongest reduction of the T1-time, largest difference between the T1-time before and after incubation, in relation to the brightness value at the beginning before the incubation). 2.3 Selective Uptake of the Compounds According to the Invention Into the Prostate Carcinoma In vivo In another experiment with a nude mouse having a human PC3-prostate carcinoma implanted into the right thigh, 10 days after the implantation the compound 10 Gd-DOTA-Lys(FITC) aminoundecylic aldehyde according to the invention was intravenously administered. The result before and 90 minutes after the intravenous administration is shown in FIG. 3D . It turns out that it is only absorbed into the cytoplasm of the prostate-carcinoma cells which are then shown with an increased signal intensity. Non-prostate carcinoma cells remain unstained, thus do not uptake the compound according to the invention. In another experiment organs of nude mice, into which a human prostate carcinoma (PC-3) was implanted, were analyzed by means of frozen sections 90 minutes after the intraperitoneal injection of the compound 1 sulforhodamine-sulfonamido aminoundecylic aldehyde according to the invention by CLSM. The result is shown in FIG. 4 . It turns out that, in comparison to possible areas of metastases such a lymph nodes and the lung, the prostate carcinoma shows a significantly stronger red fluorescence. Interestingly, here also in healthy prostate tissue almost no staining can be observed. Thus, the compound according to the invention is almost exclusively uptaken by prostate carcinoma cells. In another experiment frozen sections of the prostate carcinoma (PC-3) implanted into nude mice were analyzed 20 and 180 minutes after the intraperitoneal injection of compound 1 sulforhodamine-sulfonamido aminundecylic aldehyde according to the invention. The result is shown in FIG. 5A . It turns out that the prostate carcinoma cells have already after 20 minutes very well absorbed the compound according to the invention into the cytoplasm. After 180 minutes, however, an efflux of the compound out of the cytoplasm of the prostate carcinoma cells is taken place. The export explains why the compound according to the invention is very well tolerated by the animals. In FIG. 5B “touch prints” of the PC-3 prostrate carcinoma 20 minutes after the intraperitoneal injection are shown. For this purpose the cells of a freshly cut tumor are streaked onto a slide. In doing so freezing artefacts or artefacts due to the fixation by means of formalin can be excluded. This experiment, therefore, confirms that already 20 minutes after the intraperitoneal injection the compound according to the invention has reached the cytoplasm of the prostate carcinoma cells. 3. Conclusion With the present invention a composition for the direct and reliable detection of prostate cells or prostate carcinoma cells is provided for the very first time. This composition comprises at least a ligand of the lilly-of-the-valley odorant receptor (OR17-4 or hOR17-4, respectively), optionally a marker detectable by means of imaging methods. The invention is exemplarily demonstrated by means of five different compounds.
The present invention relates to a composition for the detection and the treatment of prostate cells and to methods for the diagnostic and therapeutic treatment of a human being using the composition according to the invention.
6
DESCRIPTION OF THE RELATED ART [0001] CCD solid-state imagers are broadly used, as image input terminals, not only in digital still cameras (DSCs) but also in digital video cameras (DVCs), PC cameras and PDA terminal cameras, for example. Meanwhile, CCD solid-state imagers include, in kind, FF (full frame)-CCDs, FT(frame transfer)-CCDs, IT(interline transfer)-CCDs and FIT-(frame interline transfer)-CCDs. [0002] For example, the IT-CCD area sensor has a multiplicity of photocells (sensor sections) arranged in a two-dimensional matrix form (rows). A plurality of vertical transfer CCDs (V registers) are arranged respectively between vertical columns of photocells, to provide a structure having, usually, one line of horizontal transfer CCDs adjacent to transfer destination ends of vertical transfer CCDs. The IT-CCD area sensor uses a two-phase, three-phase or four-phase drive scheme in transfer-driving the vertical transfer CCDS, wherein the storage modes include a field storage mode and a frame storage mode. [0003] [0003]FIG. 1 is a schematic diagram showing a related art of a solid-state imager configured with a CCD solid-state imaging device and an external circuit. The CCD solid-state imaging device 3 configuring the solid-state imager 1 has, on a semiconductor substrate 10 , a multiplicity of sensor sections (photocells) 20 , e.g. of photodiodes as an example of light-receiving elements corresponding to a pixel (unit cell), arranged vertically (rows) and horizontally (columns) in a two-dimensional matrix form. The sensor sections 20 convert the light incident on a light-receiving surface into a signal charge in an amount commensurate with the light quantity thereof, and store it thereon. [0004] Meanwhile, the CCD solid-state imaging device 3 is arranged with V registers (vertical CCDs, vertical transfer sections) 30 , corresponding to the respective vertical rows of sensor sections 20 , having a plurality (in this example, three per unit cell) of vertical transfer electrodes Vφ 1 -Vφ 3 corresponding to the three-phase driving. [0005] Each vertical transfer electrode Vφ 1 -Vφ 3 (denoted with the same references as the vertical transfer pulses hereinafter referred) has a repetition in transfer direction based on one pixel (i.e. unit cell) of the sensor section 20 . Transfer is vertical in FIG. 1, in which direction the V registers 30 are arranged. Furthermore, between the V register 30 and the sensor section 20 , a read-out gate terminal ROG is interposed. Channel stops CS are provided in each boundary between the unit cells. [0006] Furthermore, an H register (horizontal CCD, horizontal transfer section) 40 is provided in one line extending left and right in the figure in a position adjacent to the transfer-destination ends of a plurality of the V registers 30 . The H register 40 has, at its transfer-destination end (left in the figure), an output section (output buffer circuit) 50 , e.g. in a floating diffusion amplifier configuration. The output section 50 converts the signal charge sequentially injected from the H register 40 into a signal voltage for output. [0007] A drain voltage V DD , gate voltage V GG and reset drain voltage V RD are applied to the CCD solid-state imaging device 3 from a drive power source 70 configuring an external circuit 5 . [0008] The signal charge stored on each sensor section 20 is read onto the V register 30 through the read-out gate terminal ROG by deepening the potential on the gate terminal electrode due to application of a read pulse X SG , issued from a timing generator 80 configuring the external circuit 5 , to the gate terminal electrode of the read-out gate terminal ROG. [0009] The V register 30 is transfer-driven on an all-pixel read-out scheme (non-interlace scheme), e.g. due to three-phase vertical transfer pulses Vφ 1 -Vφ 3 mutually different in phase corresponding to the vertical transfer electrodes Vφ 1 -Vφ 3 . The signal charge read out of each sensor section 20 is sequentially, vertically transferred to the H register 40 in an amount corresponding to one scanning line (one line) at one time in a part of horizontal blanking period. Note that the configuration may be by two-phase or four-phase driving without limited to three-phase. [0010] The H register 40 sequentially, horizontally transfers to the output section 50 the signal charge corresponding to one line vertically transferred from each of the V registers 30 , on the basis of two-phase horizontal transfer pulses Hφ 1 , Hφ 2 issued from the timing generator 80 . [0011] The output section 50 stores the signal charge sequentially injected from the H register 40 to a not-shown floating diffusion, and converts the stored signal charge into a signal voltage. The signal voltage is outputted as an imaging signal (CCD output signal) through a not-shown output circuit of a source follower configuration, under the control of a reset pulse φRG issued from the timing generator 80 . [0012] Namely, in the CCD solid-state imaging device 3 , the signal charge detected in the image area arranging the sensor sections 20 vertically and horizontally in a two-dimensional form is vertically transferred to the H register 40 by the V register 30 provided correspondingly to the vertical columns of sensor sections 20 . The signal charge is then horizontally transferred by the H register 40 . Then, a potential is caused correspondingly to the signal charge from the H register 40 and outputted through the output section 50 , which operation is repeated. [0013] [0013]FIG. 2 is a circuit diagram showing a configuration example of the output section 50 in the CCD solid-state imaging device. The output section 50 configures a front-staged output section (preamplifier) of an incorporated type in the CCD solid-state imaging device. This has a three-stage source follower (current amplifier circuit) configuration having drive MOS transistors (DM: Drive MOS) DM 1 , DM 2 , DM 3 and load MOS transistors (LM: Load MOS) LM 1 , LM 2 , LM 3 , to provide a signal converting section 52 for converting the signal charge from the H register 40 into a voltage signal. Meanwhile, the output section 50 has a reset gate terminal MOS transistor (RGTr) 54 to control the signal converting section 52 on the basis of a reset pulse φRG corresponding to a horizontal transfer clock. [0014] In the signal converting section 52 , there are provided a plurality of stages of amplifier circuits, connecting respectively between the source terminals of the drive MOS transistors DM 1 , DM 2 , DM 3 and the drain terminals of the load MOS transistors LM 1 , LM 2 , LM 3 , at from an input stage over to an output stage of the signal converting section 52 . [0015] The drive MOS transistor DM 1 at the extreme input stage initial stage, of among the drive MOS transistors DM 1 , DM 2 , DM 3 forming the source follower circuit drive transistors, has a gate terminal connected to a floating diffusion terminal FD to be supplied with a signal charge from the H register 40 . This is connected with a source terminal of a reset gate terminal MOS transistor 54 . [0016] The drain terminal of the same is connected to a power source V DD terminal, e.g. approximately +15 V. The source terminal is connected to a drain terminal of a load MOS transistor LM 1 serving as current supplier to the drive MOS transistor DM 1 . The reset gate terminal MOS transistor 54 has a gate terminal to be supplied with a reset pulse φRG corresponding to a horizontal synchronization clock from the timing generator 80 , and a drain terminal applied with a reset drain voltage V RD . [0017] The load MOS transistor LM 1 has a gate terminal to receive a constant voltage V GG , e.g. approximately 5 V, as a gate terminal bias voltage, and a source terminal grounded through a fixed resistance R SS , The MOS transistors DM 1 , LM 1 and the fixed resistance R SS constitute a first-staged source follower circuit. [0018] The source terminal of the drive MOS transistor DM 1 is further connected to a gate terminal of a drive MOS transistor DM 2 as a drive transistor in the next-staged source follower circuit. The drive MOS transistor DM 2 has a drain terminal connected to a power source VDD terminal and a source terminal connected to a drain terminal of a load MOS transistor LM 2 serving as current supplier to the MOS transistor DM 2 . The load MOS transistor LM 2 has a gate terminal to receive the foregoing constant voltage V GG and a source terminal grounded through the fixed resistance R SS . The MOS transistors DM 2 , LM 2 and the fixed resistance R SS constitute a second-staged source follower circuit. [0019] Similarly, there are provided a drive MOS transistor DM 3 corresponding to the drive MOS transistor DM 2 and a load MOS transistor LM 3 corresponding to the load MOS transistor LM 2 , to constitute a third-staged source follower circuit. [0020] Namely, the drive MOS transistors DM 1 , DM 2 , DM 3 have their drain terminals commonly connected to be applied by a drain voltage V DD (=15 V) from the drive power source 70 . The load MOS transistors LM 1 , LM 2 , LM 3 have their source terminals commonly connected and grounded through the source terminal resistance R SS . Meanwhile, the load MOS transistors LM 1 , LM 2 , LM 3 have their gate terminals to be applied by a common gate voltage V GG . With this gate voltage V GG , the current flowing to the output section 50 is controlled in value. The drive MOS transistor DM 3 has a source terminal (i.e. drain terminal of the load MOS transistor LM 3 ) to which an output terminal of the output section 50 is provided to output an imaging signal Vout. [0021] Incidentally, the MOS transistors DM 1 -DM 3 , LM 1 -LM 3 are Nch-MOS transistors. The first-staged drive MOS transistor DM 1 is an enhancement mode transistor while the other MOS transistors DM 2 , DM 3 , LM 1 -LM 3 are depression mode transistors. The MOS transistors DM 1 -DM 3 , LM 1 -LM 3 have a P-well being ground. [0022] In the output section 50 thus configured, the potential caused on the FD terminal is reset with a period of a reset pulse φRG. Due to this, the drive MOS transistors DM 1 , DM 2 , DM 3 operate in synchronism with a horizontal transfer clock. Upon each reset, the potential caused on the FD terminal is converted into a voltage signal and outputted it as an imaging signal Vout. [0023] In the meanwhile, the solid-state imagers as above have recently been actively merchandised particularly as image sensors for still camera applications. Such an image sensor for a still camera performs signal storage operation in the pixel region for a comparatively long time, differently from the conventional one for a movie camera. For example, in the case of a movie camera, the signal storage time on the pixel is naturally limited in order to achieve a frame rate higher than a certain value, i.e. it is generally {fraction (1/30)}-th of a second. On the contrary, the still camera, free from restriction in frame rate, is allowed to have an increased signal storage period, i.e. the signal storage operation may be as long as several to several tens of seconds. [0024] In the signal storage period, there is no need to apply a transfer clock pulse to the solid-state imaging device. However, the solid-state imaging device and camera must be placed in a standby state. Thus, the solid-state imaging device, at its VDD and VSUB terminals, is applied with a power voltage. This flows a current to the output section 50 connected to the VDD terminal even during a signal storage period, as mentioned above. [0025] However, because no output operation of a CCD signal is made in this duration, there is, naturally, no need to flow a current for operating the output section 50 . Namely, in the foregoing related art, the output section 50 consumes useless power during the signal storage period of the sensor sections 20 . Meanwhile, such power consumption causes heat generation within the output section 50 , resulting in occurrence of dark output variation in the vicinity of the output section 50 . Such dark output variation occurs also in a solid-state imaging device for movie application. However, it is prominent particularly in the still-application device because of its longer storage period, and conspicuous on an imaging picture. [0026] It can be considered as means for resolving the problem to provide a structure that, for example, switching means arranged in the external circuit is controlled to prevent a signal from flowing to the output section during a signal storage period. However, this approach incurs complication in the circuit configuration of a camera system. SUMMARY OF THE INVENTION [0027] Namely, a solid-state imaging device of the present invention comprises: on a semiconductor substrate, a plurality of sensor sections for storing a signal charge commensurate with a quantity of reception light; a charge transfer section for transferring and outputting the signal charge of the sensor sections; an output section for converting the signal charge transferred by the charge transfer section into an imaging signal for output; whereby a current controller is provided to cut off or reduce a current flowing to the output section in a signal storage period of the sensor section. [0028] A solid-state imager of the invention comprises: a solid-state imaging device having, on a semiconductor substrate, a sensor sections to store a signal charge commensurate with a quantity of reception light in a signal storage period, a charge transfer section to transfer and output a signal charge stored on the sensor sections, and an output section to convert a signal charge transferred by the charge transfer section into an imaging signal for output; the output section of the solid-state imaging device having drive transistors to which a signal voltage or current is applied corresponding to the signal charge, and load transistors having a control input terminal and serving as a current supplier to the drive transistors; a control signal applying section for applying a control signal to the control input terminal of the load transistor to suppress low a current flowing to the output section in the signal storage period and normally operate the output section in an output period of the imaging signal. [0029] A method of driving a solid-state imaging device of the invention having, on a semiconductor substrate, a plurality of sensor sections for storing a signal charge commensurate with a quantity of reception light, a charge transfer section for transferring and outputting the signal charge of the sensor sections, and an output section for converting a signal charge transferred by the charge transfer section into an imaging signal and outputting same, the method of driving a solid-state imaging device characterized in that: a current flowing to the output section is cut off or reduced in a signal storage period of the sensor section. BRIEF DESCRIPTION OF THE DRAWINGS [0030] [0030]FIG. 1 is a schematic diagram showing a related-art example of a solid-state imager configured with a CCD solid-state imaging device and an external circuit; [0031] [0031]FIG. 2 is a circuit diagram showing a configuration example of an output section in the related-art CCD solid-state imaging device; [0032] [0032]FIG. 3 is a circuit diagram showing a configuration example of an output section in a CCD solid-state imaging device according to a first embodiment of the invention; [0033] [0033]FIG. 4 is an explanatory diagram showing an operation timing in the CCD solid-state imaging device according to the invention; [0034] [0034]FIG. 5 is a circuit diagram showing a configuration example of an output section in the CCD solid-state imaging device according to the invention; [0035] [0035]FIG. 6 is a circuit diagram showing a configuration example of an output section in a CCD solid-state imaging device according to a second embodiment of the invention; [0036] [0036]FIG. 7 is a timing chart of vertical transfer clock pulses in a horizontal blanking period; [0037] [0037]FIG. 8 is a circuit diagram showing a configuration example of an output section in a CCD solid-state imaging device according to a third embodiment of the invention; and [0038] [0038]FIG. 9 is a circuit diagram showing a fourth embodiment of a solid-state imager according to the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0039] Embodiments of the present invention will now be explained in detail with reference to the drawings. [0040] [0040]FIG. 3 is a circuit diagram showing a configuration example of an output section 50 of a CCD solid-state imaging device according to a first embodiment of the invention. [0041] The output section is configured with a front-staged output section (preamplifier) incorporated in a solid-state imaging device configured, for example, as shown in FIG. 1. The similar constituent elements to those of the output section shown in FIG. 2 are denoted at the same reference numerals, and hence omittedly explained. [0042] The solid-state imaging device of this embodiment has a current-control MOS transistor (MOS-Tr) 70 provided to the sources of load MOS transistors LM 1 , LM 2 , LM 3 , to control the current flowing to the output section (source current in this case), as shown in FIG. 3. The current-control MOS transistor 70 has a gate to which is applied a control clock pulse substituted with a vertical transfer clock pulse Vφ (Vφ 2 used in this embodiment). Due to this, the current is suppressed from flowing to the output section in a signal storage period of the sensor section 20 . [0043] The current-control MOS transistor 70 has a drain connected to the sources of the load MOS transistors LM 1 , LM 2 , LM 3 , and a source thereof grounded through a resistance RSS. [0044] With this configuration, the solid-state imaging device of the embodiment uses a drive scheme, as follows. Namely, during a signal storage period of the sensor section 20 , the source current to the output section is cut off or suppressed low by a Low bias in the control clock pulse Vφ 2 . During a signal output period, the control clock pulse Vφ 2 is increased to a High bias whereby the current to the output section is increased for normal operation. [0045] [0045]FIG. 4 is an explanatory diagram exemplifying a drive timing in the case of taking still pictures by mounting the solid-state imaging device of the embodiment on a still camera. FIG. 4A shows an operation timing of a mechanical shutter while FIGS. 4B, 4C and 4 D show an operation timing of three-phase vertical transfer clocks Vφ 1 , Vφ 2 and Vφ 3 . [0046] In a signal storage period, the mechanical shutter is opened to store a signal charge by the sensor section 20 of the imaging device, as shown in FIG. 4A. Thereafter, the mechanical shutter is closed to end the signal storage. [0047] In the next sweep-out period of unwanted charge, as shown in FIGS. 4B, 4C and 4 D, vertical transfer clock pulses are applied at high rate by the respective vertical transfer clocks Vφ 1 , Vφ 2 , Vφ 3 , to expel the unwanted charge staying within the vertical transfer register section. [0048] In the next signal output period, the signal charge accumulated on the sensor section 20 is read out to the vertical transfer register section. Furthermore, the signal charge is transferred through the vertical transfer register and horizontal transfer register sections and outputted to the output section. [0049] In this embodiment, the vertical transfer clock pulse Vφ 2 applied to the gate of the current-control MOS transistor 70 is reduced to a Low bias in the signal storage period. Thus, the current-control MOS transistor 70 can be made in a cut-off state or a reduced source-current state. [0050] This can greatly reduce the power consumption in the output section. In addition, because the amount of heat generation in the output section can be naturally decreased, it is possible to greatly decrease the dark output deviation occurring on an imaging picture in the vicinity of the output section. [0051] On the other hand, in the signal output period, the vertical transfer clock pulse Vφ 2 is increased to a High bias, to turn on the current-control MOS transistor 70 . This can bring the output section into a normal operating state, in that duration. Thus, signal output operation can be normally carried out. [0052] Incidentally, there is a need to provide a channel potential on the current-control MOS transistor 70 small (shallow) in a Low bias state and great (deep) in a High bias state, as compared to the channel potential on the load MOS transistors LM 1 , LM 2 , LM 3 of the output section. [0053] In order to realize such a state of potential, it is satisfactory to provide a channel potential on the current-control MOS transistor 70 in the same level as or approximate to a potential on a read-out gate used in the vertical transfer register. [0054] Due to this, even in the case of providing a current-control MOS transistor 70 , there is no need to newly increase the imaging-device manufacturing process. In other words, where required, process increase may be slight in extent. [0055] As so far explained, in the CCD solid-state imaging device of this embodiment, a current flowing to the output section can be cut off or suppressed low during the signal storage period of the sensor section 20 . Also, as shown in FIG. 4C, in the timing the control clock pulse Vφ 2 in a horizontal blanking of signal output period assumes a Low bias state, it is possible to cut off or suppress low a current flowing to the output section. [0056] This greatly reduces the power consumption of the output section and decreases the dark output variation caused due to heat generation in the output section. [0057] In obtaining such an effect, there is no need to provide an additional function to the external circuit, such as CCD drive circuit. Furthermore, CCD manufacturing process requires no increase, or increase is slight where needed. Thus, realization is feasible at low cost. [0058] In the above configuration, the current-control MOS transistor 70 and the clock pulse Vφ 2 for gate control thereof are satisfactory provided that they realize the effect of the invention. Another form of configuration or timing may be applied. [0059] For example, although the example of FIG. 3 arranged the current-control MOS transistor 70 at the source side of the output section, this can be configured arranged at a drain side. [0060] Meanwhile, although in the example of FIG. 3 the current-control MOS transistor 70 was MOS type, it is possible to employ a Junction-type FET or Bipolar transistor. [0061] Although drive timing was explained on the case with the three-phase vertical transfer register, another vertical transfer register, e.g. four-phase register, can be applied similarly. [0062] In the example of FIG. 3, the current-control MOS transistor 70 was provided to the commonly connected sources of the load MOS transistors LM 1 , LM 2 , LM 3 . Alternatively, independent current-control MOS transistors 71 , 72 , 73 may be connected respectively to the sources of the load MOS transistors LM 1 , LM 2 , LM 3 as shown in FIG. 5. Note that, in FIG. 5, the other structure is common to that of FIG. 1 and hence omittedly explained. [0063] [0063]FIG. 6 is a circuit diagram of an output section configuring a CCD solid-state imaging device as a major part of a solid-state imager according to a second embodiment of the invention. The output section 50 configures a front-staged output section (preamplifier) incorporated, for example, in the solid-state imaging device shown in FIG. 1. The constituent elements similar to those of the output section 50 shown in FIG. 2 are denoted with the same reference numerals and hence omittedly explained. [0064] In the solid-state imaging device, as shown in FIG. 6, the control signal for controlling the current flowing to the output section 50 (source current control in this case) uses not a fixed voltage V GG but a control clock pulse substituted with a vertical transfer clock pulse Vφ supplied from the timing generator 80 (Vφ 2 used in this example) to be directly applied commonly to the gate terminals (control input terminals) of load MOS transistors LM 1 , LM 2 , LM 3 . Due to this, the current is suppressed from flowing to the output section 50 during a signal storage period of the sensor section 20 . Namely, the timing generator 80 serves as a control signal applying section of the invention. [0065] The solid-state imaging device thus configured uses a drive method, as follows. Namely, during a signal storage period of the sensor section 20 , the control clock pulse Vφ 2 is biased Low to cut off or suppress low the source current control of the output section 50 . During a signal output period, the control clock pulse Vφ 2 is biased High to increase the current of the output section 50 thereby allowing for normal operation. [0066] [0066]FIG. 4 is an explanatory diagram showing an example of a drive timing in the case of taking still pictures by mounting the solid-state imaging device of the embodiment on a still camera. FIG. 4A shows an operation timing of a mechanical shutter while FIGS. 4B, 4C and 4 D show an operation timing of three-phase vertical transfer clocks Vφ 1 , Vφ 2 and Vφ 3 . [0067] In a signal storage period, the mechanical shutter is opened to store a signal charge by the sensor section 20 of the imaging device 3 , as shown in FIG. 4A. Thereafter, the mechanical shutter is closed to end the signal storage. [0068] In the next sweep-out period of unwanted charge, vertical transfer clock pulses are applied at high rate with the respective vertical transfer clocks Vφ 1 , Vφ 2 , Vφ 3 , to expel the unwanted charge staying within the V transfer register 30 , as shown in FIGS. 4 B- 4 D. In the next signal output period, the signal charge accumulated on the sensor section 20 is read onto the V register 30 . Furthermore, the signal charge is transferred through an inside of the V register 30 and H register 40 and outputted to the output section. [0069] In this embodiment, the vertical transfer clock pulse Vφ 2 applied to the gate terminals of the load MOS transistors LM 1 , LM 2 , LM 3 is biased Low in the signal storage period. Thus, the load MOS transistors LM 1 , LM 2 , LM 3 can be made in a cut-off state or a reduced source current control state. This greatly reduces the power consumption in the output section 50 . Meanwhile, because the amount of heat generation can be naturally decreased in the output section, it is possible to greatly decrease the dark output deviation occurring on an imaging picture in the vicinity of the output section 50 . [0070] On the other hand, in the signal output period, the vertical transfer clock pulse Vφ 2 is biased High, to turn on the load MOS transistors LM 1 , LM 2 , LM 3 . This makes the output section 50 in a normal operating state in the signal output period. Thus, signal output can be normally effected. [0071] As so far explained, the CCD solid-state imaging device of this embodiment can cut off or suppress low the current flowing to the output section 50 in the signal storage period of the sensor section 20 . [0072] Also, as compared to the scheme arranging, in series, semiconductor elements constituting a signal converting section 52 (MOS transistors in the above example) and switching element, the embodiment is free from voltage drop due to switch elements, allowing for normal operation on a low power voltage V DD . [0073] Furthermore, because control is made with a control clock pulse substituted with a vertical transfer clock pulse Vφ (Vφ 2 in the above example) to the gate terminals of the load MOS transistors LM 1 , LM 2 , LM 3 , there is no necessity to provide a new switching device as required in Embodiment 1. [0074] Incidentally, the vertical transfer clock pulse Vφ 2 has a Low level of approximately “−7.5 V” and a High level of “0 V”. Consequently, the load MOS transistors LM 1 -LM 3 in the embodiment must have a characteristic different from that of the load MOS transistors LM 1 -LM 3 to be applied by V GG (≈5 V) to the gate terminal in the related art shown in FIG. 2. Namely, in order to realize a CCD solid-state imaging device of the embodiment, there is a need to somewhat modify the design of the device characteristic of the output section used in the related art. [0075] In the case of controlling the CCD solid-state imaging device by a control clock pulse substituted with a vertical transfer clock pulse Vφ 2 , the effect is further enhanced by making control not only in the signal storage period but also in a part of horizontal blanking period. [0076] [0076]FIG. 7 is a timing chart of a transfer clock pulse in a horizontal blanking period. Herein, FIGS. 7A and 7B show the operation timing of the respective two-phase horizontal transfer clocks Hφ 1 , Hφ 2 . FIGS. 7C, 7D and 7 E show the operation timing of the respective three-phase vertical transfer clocks Vφ 1 , Vφ 2 , Vφ 3 . [0077] For vertical line-shift transfer, the vertical transfer clock pulse Vφ 2 assumes, without exception, a Low bias state in a certain period A in horizontal blanking during a signal output period. In the timing the vertical transfer clock pulse Vφ 2 turns into a Low bias state, the current flowing to the output section 50 can be also cut off or suppressed low. [0078] This greatly reduces power consumption in the output section 50 . Furthermore, it is possible to greatly reduce dark output variation to be caused due to heat generation in the output section 50 . In obtaining such an effect, there is no need to add an additional function, such as a CCD drive circuit (e.g. drive power source 70 or timing generator 80 ) to the external circuit 5 . Furthermore, there is no or slight need to increase the CCD manufacturing process. Thus, the solid-state imager of the embodiment can be realized at low cost. [0079] [0079]FIG. 8 is a circuit diagram showing a third embodiment of an output section configuring a CCD solid-state imaging device as a major part of a solid-state imager of the invention. In the second embodiment, a vertical transfer clock pulse V φ 2 was inputted to the gate terminals of all the load MOS transistors LM 1 , LM 2 , LM 3 of the three-staged source follower circuits in the output section 50 (specifically, signal converting section 52 ) of the CCD solid-state imaging device. However, there is no need to apply it to all the load MOS transistors. The third embodiment is based on such viewpoint. [0080] Namely, the third embodiment has an output section 50 configured to directly input a vertical transfer clock pulse Vφ 2 , as a control clock pulse, to only the gate of the load MOS transistor LM 3 constituting the final-staged source follower circuit through which the greatest amount of current flows of among the three-staged source follower circuits. The load MOS transistors LM 1 , LM 2 at the front stage are configured to be applied by a common gate voltage V GG (fixed voltage, e.g. +5 V) to the gate terminals thereof, similarly to the related-art configuration shown in FIG. 2. [0081] In also this form, the most part of the source current flowing to the output section 50 flows into the final-staged source follower circuit. By controlling the final-staged gate terminal with using a control clock pulse substituted with a vertical transfer clock pulse Vφ 2 , it is possible to enjoy such effects as the reduction of power consumption in the output section 50 , the decrease in the dark output deviation caused on an imaging picture in the vicinity of the output section 50 or so, similarly to Embodiment 2. Device characteristic change can be retained only to the final-staged load MOS transistor LM 3 . [0082] [0082]FIG. 9 is a circuit diagram showing a fourth embodiment of a solid-state imager of the invention. As already explained in the second or third embodiment, where a vertical transfer clock pulse Vφ 2 is directly inputted, as a control clock pulse, to the gate terminals of the load MOS transistors LM 1 , LM 2 , LM 3 , the device characteristic of them must be made different from that of the related-art configuration. The fourth embodiment is configured to input, as a control clock pulse, a signal corresponding to a vertical transfer clock pulse Vφ 2 to the gate terminal without requiring change to the device characteristic. [0083] Namely, the solid-state imager in the fourth embodiment has, as an external circuit 5 , a level converter circuit 60 to convert a signal level of a vertical transfer clock pulse Vφ 2 for driving the V register 30 . The level converter circuit 60 converts a signal level of a vertical transfer clock pulse Vφ 2 inputted from the timing generator 80 into a level suited for an input level to the gate terminals of the load MOS transistors LM 1 , LM 2 , LM 3 having a characteristic similar to that of the related art. [0084] The level converter circuit 60 inputs a level-converted pulse, as a control clock pulse, to the gate terminals (shown at the V GG before change, in FIG. 9) of the load MOS transistors LM 1 , LM 2 , LM 3 of a CCD solid-state imaging device same as the related-art configuration. Namely, the fourth embodiment constitutes a control signal applying section of the invention by the timing generator 80 and the newly provided level converter circuit 60 . [0085] The level converter circuit 60 , in an example shown, is a non-inverter type of a two-stage structure having complementary-connected MOS transistors Q 60 , Q 61 and MOS transistors Q 62 , Q 63 between a gate voltage V GG and a ground. A vertical transfer clock pulse Vφ 2 , having Low level “−7.5 V” and High level “0 V”, inputted to a gate connection point of the input-end MOS transistors Q 60 , Q 61 through a resistance R 60 , is limited in amplitude level to V BE (forward diode voltage) by the diode D 60 . This is converted into a pulse having Low level “0 V” and High level “5 V” and outputted onto an output end of the output-end MOS transistors Q 62 , Q 63 . [0086] As in this fourth embodiment, by interposing a level converter circuit 60 between the timing generator 80 and the output section 50 of the CCD solid-state imaging device, it is possible to use a CCD solid-state imaging device having an output section same in characteristic as the related art. Due to this, while using the existing output section optimized (i.e. CCD solid-state imaging device), it is possible to enjoy such effects as the reduction in power consumption at the output section and the decrease in dark output variation caused on an imaged picture in the vicinity of the output section, similarly to the second and the third embodiments. [0087] Although the invention was so far explained using the embodiments, the technical scope of the invention is not limited to the described embodiments. Various changes or modifications can be added to the embodiments, wherein such change or modification be included in the technical scope of the invention. Meanwhile, the embodiment is not to delimit the claimed invention. The features explained in the embodiments, in every combination, are not necessarily requisite for the solving means of the invention. [0088] For example, although the embodiment explained the example that a control clock pulse (control signal) for controlling the gate terminals of the load MOS transistors LM 1 , LM 2 , LM 3 is substituted with a vertical transfer clock pulse Vφ (Vφ 2 in the above example), the invention is not limited to this but is satisfactory if realizing the effect of the invention. Namely, the control signal may suppress low the current flowing to the output section in a signal storage period and normally operate the output section in an imaging-signal output period wherein the timing may be different from that of the vertical transfer clock pulse Vφ. [0089] The configuration of the signal converter section is not limited to a three-staged source follower circuits having MOS transistors but may be in another configuration, e.g. may be a one-stage, two-stage or four-stage or more of structure. Meanwhile, junction-type FETs or bipolar transistors may be used without limited to MOS transistors. [0090] Although the fourth embodiment showed the example that the level converter circuit was provided as an external circuit of the CCD solid-state imaging device, the level converter circuit may be arranged on a semiconductor substrate and integrated with the CCD solid-state imaging device. [0091] Although the drive timing to the V register was explained on the three-phase vertical transfer register, the invention can be similarly practiced with four-phase or other vertical transfer registers. [0092] Furthermore, although the embodiment explained the example with the area sensor arranged with sensor sections 20 in a matrix form (two-dimensional form), a line sensor may be applied without limited to that. [0093] Meanwhile, it is needless to say that the circuits described in the embodiments can be altered to those in a complimentary relationship with them. [0094] As described above, the present invention is adapted to cut off or reduce the current flowing to the output section in a signal storage period of the sensor section, and hence can suppress the amount of the current flowing to the output section in the signal storage period. Thus, wasteful consumption power is greatly reduced. [0095] Also, by suppressing the amount of the current flowing to the output section in the signal storage period of the sensor section, heat generation is suppressed in the vicinity of the output section to prevent against dark output variation.
A solid-state imaging device comprises, on a semiconductor substrate, a plurality of sensor sections for storing a signal charge commensurate with a quantity of reception light, a charge transfer section for transferring and outputting the signal charge of the sensor sections, and an output section for converting the signal charge transferred by the charge transfer section into an imaging signal for output. A current controller is provided to cut off or reduce a current flowing to the output section in a signal storage period of the sensor section. This cuts off or reduces the current flowing to the output section in a signal storage period of the sensor section, and hence suppresses the amount of the current flowing to the output section in the signal storage period. Thus, wasteful consumption power is greatly reduced.
6
This is a continuation of application Ser. No. 08/386,899 filed on Feb. 10, 1995, now abandoned. FIELD OF THE INVENTION The present invention relates to MQ silicone resins that are a new composition of matter, siloxysilicates wherein said siloxysilicates resins have desirable physical properties that render them particularly suitable for certain personal care products such as skin care products, color cosmetic products, hair conditioners, hair cremes (alternatively spelled creams), hair bodying agents, curl retention, and luster enhancers. BACKGROUND OF THE INVENTION This invention relates to new organosilicone resins and cosmetic products derived therefrom, in particular hair care products comprising the new organosilicone resins, MQ siloxysilicates, and to new cosmetic formulations specific thereto. Siloxane resins consisting of triorganosiloxane units and silicon dioxide units are known, commercially available materials and are employed in the formulation of silicone products such as adhesives and anti foams. Such resins are sometimes referred to as MQ resins in view of the presence of the monovalent (M) siloxane units and the quadrivalent or tetravalent (Q) silicon dioxide units. In view of the reactivity of the silyl hydride group, it is sometimes desired to include such groups in resins of the MQ type. Siloxane resins composed of silicon dioxide units and units of the general formula HR 2 SiO 1/2 where R represents hydrogen, a monovalent hydrocarbon or monovalent halohydrocarbon group are frequently utilized because of the high reactivity of the silyl hydride functionality therein. Such resins have been used for organopolysiloxane elastomers. As precursors to other synthetic silicones, it is frequently desirable that these resins contain a limited number of silyl hydride groups. U.S. Pat. No. 3,772,247 discloses organopolysiloxane resins consisting of R' 3 SiO 1/2 units, SiO 2 units and units of the type HR'SiO and/or HSiO 1 .5 in which R' represents a monovalent hydrocarbon group selected from the group consisting of alkyl, aryl, alkaryl, alkenyl, cycloalkyl, or cycloalkenyl groups. While such resins possess silyl hydride groups they posses a significant and measurable level of divalent or trivalent organosiloxyl groups. U.S. Pat. No. 4,774,310 ('310) discloses MQ resins consisting of R 3 SiO 1/2 units and SiO 2 units where R is essentially defined as above. The MQ resins of the '310 patent are further reacted with disiloxanes under conditions of acidic catalysis to produce MQ type siloxane resins where the ratio M/Q is in the range of 0.4:1 to 1:1 and where the fraction of hydride stopped units of the general formula H a R 3-a SiO 1/2 ranges from 0.1 to 30 percent of the total number of M (monovalent) units present. Silicones have properties that make them particularly advantageous in hair cosmetic products. Certain silicones produce uniform thin films that are hydrophobic and also produce solutions or emulsions that posses a low viscosity. The low viscosity property allows higher loadings of active ingredients in a cosmetic product without the deleterious effects normally associated with high viscosity products, difficulty of pumping or erratic spray patterns. This is important to the consumer because preparations that are hard to use or erratic in delivery from the dispensing apparatus will not be preferred. The cosmetic and toiletry industry has produced a wide range of grooming aids that utilize silicones. Among the various products are shampoos to clean the hair and scalp, hair rinses, conditioners, dressings, sprays, wave sets, coloring and bleaching preparations, permanent waves, and hair straighting and strengthening compositions. Cleanliness of hair and scalp are important personal grooming criteria. Soiled hair takes on a lackluster appearance and becomes oily and unpleasant to the touch. Consumers desire a shampoo that foams quickly and copiously and rinses thoroughly leaving the hair with a fresh clean smell and in a manageable state. Further, consumers tend to prefer those shampoos that also leave the hair soft, shiny, lustrous, and full bodied. Shampoos are available in a variety of formulations as clear or opaque liquids, gels, or pastes. In order to fulfill the various criteria demanded by the consuming public, shampoo formulations contain one or more cleansing agents such as nonionic, anionic, amphoteric, and cationic surfactants along with various optional additives that include among others viscosity control agents, conditioners, preservatives, fragrances, vitamins, antioxidants opacifiers, pearling agents, sunscreens, and botanicals as well as functionalizing additives such as conditioners, shine enhancers, and body agents. After shampooing, the hair is usually wet, frequently tangled and thus difficult to comb. Thus it is common for consumers to apply rinses and conditioners to enhance the ease of combing and detangling, to increase hair body, to improve shine and texture, to prevent static buildup, to impart manageability, style retention, and curl retention. Hair body is a subjective and poorly defined quality. It is generally accepted that volume is related to or provides a means for quantitatively measuring hair body. One method to increase the volume of hair tresses (and consequently the subjective property of hair body) is to impart a small degree of triboelectric charging to the hair. This can be accomplished through the use of a so-called volumizing shampoo which generally functions to strip the hair of natural oils leaving the hair fibers negatively charged with a consequent tendency for the hair fibers to electrostatically repel one another. This method does not produce consistent or predictable results since small changes in humidity will either aggravate the triboelectric charging resulting in fly-away hair (low RID or dissipate the electrostatic charge resulting in flat hair (high RH). This technique also has a tendency to raise the cuticle scales damaging the hair and rendering it difficult to comb making it unmanageable. A more preferable technique to impart hair body is to deposit a hydrocarbon-based film on the hair via a preparation that remains on the hair between shampoos. These preparations, typically incorporating a hydrocarbon resin, generally impart drag and increase the forces necessary to comb the hair and thus make the hair difficult to groom while maintaining style. Additionally such products, depending on the choice of resins and base solvents can also result in the appearance of unsightly flakes on the hair. An additional problem is that such hydrocarbon solvent resin mixtures can dry the hair or impart brittleness, resulting in hair fiber breakage during subsequent grooming. When using hydrocarbon based conditioning agents, increasing the organoalkyl content of quaternary ammonium conditioning compounds imparts an increasing conditioning ability to the compound. Conditioning efficacy of a quaternary ammonium compound increases with increasing alkyl chain length or with increasing alkyl substitution according to the series mono-alkyl<di-alkyl<tri-alkyl Generally products that condition hair do not impart an improved body or hair volume unless they also contain resins. One use of polymeric dialkylsiloxanes is to impart a conditioning property to hair care products. While the conventional polymeric dialkylsiloxanes impart good conditioning properties, such materials have a tendency to interact antagonistically with other additives such as fixatives diminishing their effectiveness. This conflict in properties between ingredients results in reformulations and stimulates efforts to prepare new materials that will be more compatible. Conditioning shampoos are generally formulated to provide a cleansing of the hair followed by deposition of a material that acts to provide a conditioning benefit. Incorporation of a volumizing organofunctional MQ silicone resin that is compatible with the other components of a 2-in-1 shampoo, provides cleansing, conditioning and volumizing benefits, unlike prior art formulations. Fixatives are generally designed to provide a temporary setting effect or maintain curl to the hair, the most common being a hair spray intended for use after the hair has been dried. Other fixatives may be used after the hair is towel dried to provide more body and volume and to aid in styling. Specialty type fixatives such as the foregoing include styling gels, mousses, cremes, foams, spritzes, mists, glazes, glossing gels, shaping gels, sculpting mousses, and setting gels among others. These fixatives should be compatible with a subsequent use of a fixative or luster enhancing hair spray. Cuticle coats are formulations designed to impart or enhance shine on hair. Additionally, cuticle coats frequently reduce both tribo-electric charging effects, i.e. fly-away hair, and combing forces, by adding a lubricious coating to the hair, thus lowering beth interfiber friction and electrostatic repulsion between the fibers. One method of imparting or increasing apparent luster or gloss on the hair is to coat the hair with a material having a high refractive index. Using this technique, the apparent gloss or shine will be proportional to the refractive index of the material on the fiber surface. Absent other factors, a direct proportionality exists between refractive index and apparent shine on hair. Thus higher refractive index cuticle coating formulations will tend to impart a higher shine on hair. SUMMARY OF THE INVENTION The present invention concerns MQ resins of the formula: ##STR1## where beth R 1 and R 2 may be either a phenyl group or an alkyl group having from 1 to 12 carbon atoms, and beth M 1 and M 2 may independently be phenyl, phenethyl, polyether, hydrogen, or one to twenty-three carbon atom alkyl group (which may variously include halogen substituted hydrocarbon radicals) in any combination subject to the limitation that the ratio of the subscripts x, y, and z satisfies the following relationship: 0.5≦(x+y)/z≦4.0. The MQ resin itself is a polymer composed of a distribution of exemplary species having a range of molecular weights. The MQ resin can be defined in a specific instance by setting the value for z equal to unity. Thus, when z=1, x ranges from between 0 and 4, and y ranges from between 0 and 4. It is also preferred that the ratio of (x+y)/z be equal to about 2. In the complex mixture of compounds, typically referred to as a resin, defined by the above general formula, z ranges from 1 to about 30 and x and y may be zero or a positive number. The polyether MQ resin of the present invention is also useful as an emulsifying agent for oil-in-water emulsions. Such oil-in-water emulsions are particularly useful in a wide variety of cosmetic products. The resins of the present invention are useful in personal care formulations and cosmetics. More particularly the resins are useful in hair care formulations to impart improved shine on hair, increased volume or body, reduced combing force and curl retention. DETAILED DESCRIPTION OF THE INVENTION The present invention relates to functionalized MQ silicone resins having the general formula: ##STR2## where both R 1 and R 2 may be either a phenyl group or an alkyl group having from 1 to 12 carbon atoms, and both M 1 and M 2 may independently be phenyl, phenethyl, polyether, hydrogen, or one to twenty-three carbon atom alkyl group (which may variously include halogen substituted hydrocarbon radicals) in any combination subject to the limitation that the ratio of the subscripts x, y, and z satisfies the following relationship: 0.5≦(x+y)/z≦4.0. 2) The MQ resin itself is a polymer composed of a distribution of exemplary species having a range of molecular weights. The MQ resin can be defined as a molecular species in a specific instance by setting the value for z equal to unity. Thus, when z=1, x ranges from between 0 and 4, and y ranges from between 0 and 4. It is also preferred that the ratio of (x+y)/z be equal to about 2, this is true for mixtures of the MQ species comprising the resin. A preferred resin is satisfied by the following values for the subscripts x, y, and z; x=2, y=0, and z=1 when R 1 =CH 3 . When M 1 and/or M 2 is a polyether, the polyether has the general formula: H.sub.2 C═C--CH.sub.2 R.sup.3 --(O--CHR.sup.4 --CH.sub.2).sub.u --(OCH.sub.2 CH.sub.2).sub.v --OR.sup.5 where R 3 is --(CH 2 ) n -- with n ranging from 1 to about 20, R 4 is a one to twenty carbon alkyl group, and R 5 is selected from the group consisting of H, --CH 3 , and --C(O)CH 3 ; and where u and v are integers ranging from 0 to 20 subject to the limitation that u+v≧1. The silicone resins of formula 1) are generally prepared via a platinum catalyzed hydrosilylation reaction which typically proceeds as follows: ##STR3## which contains both branched and linear radicals where w typically ranges from 0 to about 20 and the ratio of x/z ranges from 0.5 to about 4.0. While the above described reaction is specific for straight chain alkyl substituted MQ resins, this reaction may be generally employed with substitued terminal olefins of varying structures. The liquids produced by reaction 3) are low viscosity liquids having a viscosity generally ranging from about 50 to 1000 centistokes at 25° C. The low viscosity of these compounds and resins is in contrast to the viscosity of similarly alkyl substituted linear silicones which may be viscous liquids or waxes at 25° C. The platinum catalyzed hydrosilylation between silyl hydrides (alternatively hydride fluids) and a terminal olefin moiety utilized in reaction 3) is well-known and the subject of several U.S. Pat. Nos. 3,159,662; 3,220,972; 3,715,334; 3,775,452; and 3,814,730; herewith incorporated by reference. The silicon containing starting materials of reaction 3) are generally prepared by the reaction of an alkyl silicate and a dialkylhalosilane. The hydride stopped siloxysilicate starting material is hydrosilylated under the appropriate conditions with a suitable olefin or mixture thereof to prepare the compounds of formula 1). Hydrosilylation with styrene derivatives will produce phenethyl variants of these compounds. Generally, a styrenic compound having the formula: C.sub.6 H.sub.5 --CR.sup.6 ═CH.sub.2 where R 6 is a monovalent radical selected from the group consisting of hydrogen, methyl, and phenyl is used as the starting material for such a hydrosilylation reaction. The phenethyl substituted siloxysilicates are unique in that they possess higher refractive indices than the alkyl substituted siloxysilicates and they are also miscible in phenyl or phenethyl methyl silicone fluids. This is in sharp contrast to other MQ resins possessing only alkyl substitution which are usually not miscible with phenyl or phenethyl methyl silicone fluids. These phenethyl MQ resins are prepared by a variation of reaction 3): ##STR4## where R 6 is selected from the group consisting of hydrogen, methyl, and two to eight carbon alkyl groups. The siloxysilicate MQ resins of the present invention are useful in a variety of cosmetic and personal care applications, particularly since they are low viscosity fluids having a viscosity ranging from about 50 to 1,000 centistokes at 25° C. This viscosity range, all other chemical factors being constant, tends to vary with the molecular weight of the radicals being substituted into the various pendant groups constituting the MQ resin. Thus, for example higher alkyl or polyether chain lengths, while they might be outside of the specific ranges disclosed and claimed, could conceivably possess viscosities within the disclosed range. Likewise compounds within the disclosed range of alkyl or polyether chain lengths could have viscosities exceeding the disclosed upper limit of 1,000 centistokes. Thus it is applicants intention that the upper limit of 1,000 centistokes as disclosed is an approximate upper limit. While the reductions to practice have emphasized hair care formulations, it is anticipated that the resins of the present invention are useful in a variety of cosmetic formulations including but not limited to skin care, color cosmetics, personal cleansing, and the like. Therefore, in the appended claims, personal care product as a phrase includes these various uses. EXPERIMENTAL Preparation of Hydridomethylsiloxysilicate: To 322.1 g of water in a one liter flask was added a mixture containing 123.6 g dimethylchloro-silylhydride, 135.0 g ethylsilicate, and 79.0 g of toluene via an addition funnel. The silane solution was added to the aqueous phase with stirring over a period of 45 minutes. The temperature of the reaction mixture was maintained at or below 60° C. Upon completion of the addition of the silane solution, the mixture was stirred for an additional 10 minutes and then the aqueous phase was removed. The toluene solution was washed with 300 g of water. The organic layer was then stripped by heating to 150° C. and holding at that temperature for two hours at ambient pressure. At the conclusion of the atmospheric pressure strip, the temperature was increased to 165° C. and the toluene was stripped under a vacuum of 200 mm Hg. Theoretical reaction yield was 126.6 g. The product was characterized by infrared spectroscopy noting the absorptions at 2160 cm -1 (Si--H) and 1050 cm -1 (Si-O--Si). General Preparation of Alkyldimethylsiloxysilicate; specific example: octadecylhexadecyldimethylsiloxysilicate: 150.0 g of hydrido-dimethylsfloxysilicate containing 1.46 molar equivalents of hydride functionality, 0.98 weight percent is added to a one liter flask followed by the addition of Karstedt's catalysts (as taught in U.S. Pat. No. 3,775,452) in an amount sufficient such that platinum was present at a level of 8 ppm. The mixture was stirred and heated to 45° C. A mixture of 185.1 g of 1-octadecene (0.73 moles) and 164.6 g of 1-hexadecene (0.73) moles was placed in an addition funnel and slowly added to the reaction flask such that the reaction temperature did not exceed 100° C. This procedure required approximately 60 minutes. The reaction was maintained at 120° C. for two hours at which pointed the amount of residual silylhydride had decreased to below 150 ppm, indicating a hydride consumption greater than 95%. The hydride content of the reaction mixture was monitored by infrared spectroscopy. The reaction mixture was then stripped under a vacuum of 5 mm Hg at a temperature of 150° C. until olefins could no longer be detected by gas chromatographic analysis. The resulting product was a clear liquid having a viscosity of 170 centistokes at 25° C. This is Resin A. Preparation of 1-(2-Phenyl)propyldimethylsfloxysilicate (phenethyl resin): 306.1 g of hydridodimethylsiloxysilicate containing 2.73 molar equivalents of hydride functionality, 0.9 weight percent is added to a one liter flask followed by the addition of Karstedt's catalysts (as taught in U.S. Pat. No. 3,775,452) in an amount sufficient such that platinum was present at a level of 8 ppm. The mixture was stirred and heated to 45° C. 332.7 g (2.82 moles) of α-methylstyrene was placed in an addition funnel and added dropwise so that the reaction temperature never exceed 110° C. This procedure required approximately 90 minutes. The reaction temperature was maintained at 110° C. for between 4 and 6 hours at which the amount of residual silylhydride had decrease to below 250 ppm, indicating reaction of over 95% of the starting hydride. The hydride content of the reaction mixture was monitored by infrared spectroscopy. The reaction mixture was then stripped under a vacuum of 10 mm Hg at a temperature of 150° C. until styrene could no longer be detected by gas chromatographic analysis. The resulting product was a clear liquid having a viscosity of 350 centistokes at 25° C. This is Resin B. TABLE 1______________________________________Refractive Index of Cosmetically Useful Silicone FluidsFluid Refractive Index n.sub.D at 25° C.______________________________________Dimethicone (100 cstk) 1.403Phenyltrimethicone 1.459Resin B 1.505______________________________________ Preparation of Polyetherdimethylsfloxysilicate: To a 1 liter flask was added 384.3 of an olefin capped polyether, Polyglycol AE501® available from Dow Chemical Co., (0.675 molar equivalent in 10% excess) and 179 g toluene. The solution was warmed to between 45 and 50° C. and Karstedt's catalyst (U.S. Pat. No. 3,775,452) was added to the reaction flask such that the quantity of platinum present was 8 ppm. 64.4 g (0.613 molar equivalent) hydridodimethylsiloxysilicate containing 0.96 wt. % hydride was added to an addition funnel and was added dropwise to the polyether containing solution over a period of about 90 minutes maintaining the reaction temperature at about 70° C. The temperature of the reaction mixture was then increased to 110° C. and stirred for three hours. Afar three hours the quantity of residual silyl hydride was monitored by infrared spectroscopy until the absorbance at 2160 cm -1 indicated less than 50 ppm unreacted silyl hydride, i.e. greater than 95% extent of reaction. The reaction mixture was then stripped under a vacuum of 50 mm Hg at 90° C. until the quantity of residual toluene remaining was at or below 50 ppm. The resulting product was a clear liquid with a viscosity of 790 centistokes at 25° C. This is Resin C. Preparation of Alkyl/Aryl-dimethylsiloxysilicate: 300.0 g of hydrido-dimethylsiloxysilicate containing 2.92 molar equivalents of hydride functionality, 0.98 wt. % was added to a one liter flask followed by the addition of Karstedt's catalyst, as taught in U.S. Pat. No. 3,775,452, in an amount whereby the platinum was present at a level of 8 ppm. The mixture was stirred and heated to 45° C., whereupon 177.3 (1.5 moles) of α-methylstyrene was placed in an addition funnel and added dropwise over a 45 minute period in a fashion whereby the reaction temperature never exceeded 95° C. After maintaining the reaction mixture at 95° C. for a period of 15 minutes, 168.3 g (1.5 moles) of 1-octene was placed in an addition funnel and the 1-octene was added dropwise over a 30 minute period in a fashion whereby the reaction temperature never exceeded 115° C. The reaction mixture was maintained in a temperature range of 100°-110° C. for a period of eight hours, during which period of time the residual hydride content decreased to below 250 ppm, indicative of an extent of reaction in excess of 95%, based on the quantity of starting hydride material. The hydride content of the reaction mixture was monitored by means of infrared spectroscopy. Excess olefinic starting materials were removed by stripping under a vacuum of 10 mm Hg at a temperature of 160° C. until neither styrene nor octene could be detected by gas chromatographic analysis. The resulting transparent liquid had a viscosity of 140 centistokes at 25° C. Cosmetic Formulation A, Conditioning and Volumizing Effects: An alkyl modified siloxysilicate of the present invention was prepared by reacting a compound of the formula: (H(CH.sub.3).sub.2 SiO.sub.1/2).sub.x ((CH.sub.3).sub.3 SiO.sub.1/2).sub.y (SiO.sub.4/2)z where x=2, y=0, and z=1 under hydrosilylation conditions in the presence of a platinum catalyst and a terminal olefin having the formula: H.sub.2 C═CH(CH.sub.2).sub.w CH.sub.3 which contains both branched and linear radicals where w=15 to produce an MQ siloxysilicate resin of the present invention. This resin, Resin A in the following cosmetic preparation is suitable for use as a hair conditioner: TABLE 2______________________________________Composition of Cosmetic Formulation A1, ConditionerFormulation:Component Amount (Wt. %)______________________________________Deionized water 77.77Cyclomethicone 4.2Cetyl Alcohol 3.2Resin A 3.0(substitutable in succeedingformulations with water,or Resin D)Glycerin 2.75Behentrimonium Methosulfate 2.7(and) Cetearyl AlcoholStearamidopropyl Dimethylamine 2.5Polysorbate-80 1.5Pentaerythrytyl Tetrastearate 1.5FD&C Yellow (as 1.0% sol'n.) 0.03Fragrance 0.5Methyl paraben 0.2Propyl paraben 0.1Tocopherol Acetate 0.05______________________________________ Note: The above conditioning formulation was applied to 2.0 g tresses of pre-cleaned virgin brown human hair in the amount of 2.5 g per tress. The maximum tress diameter, as determined by measuring the work required to pull a tress through a series of templates of decreasing diameter and extrapolating to zero work, was found to increase by approximately 17% for hair treated with the above conditioning formulation. In a control study, a second set of identical tresses was treated with a commercially available conditioner marketed at retail under the trademark Finesse®. The maximum diameter of the tresses treated with the commercial conditioner was found to decrease by approximately 15%. This type of decrease is typical for known conditioning agents and is also a well-known phenomenon for commercially available conditioners containing polydimethylsiloxanes. The effect of increasing hair tress diameter of the conditioning formulation tested above is transferable to other cosmetic formulations such as conditioning shampoos, styling gels, mousses and the like. Cosmetic Formulations; Hair Conditioning Formulation Evaluations: The hair conditioning formulation of cosmetic formulation A was duplicated with an ester functionalized MQ resin, Resin D (prepared according to U.S. Pat. No. 5,334,737, hereby incorporated by reference), replacing Resin A, and water replacing Resin A and compared to a commercially available conditioning composition, Finesse®, available at retail. The conditioning formulation was applied to 6 inch, 2.0 g tresses of pre-cleaned virgin brown human hair in the amount of 2.5 g per tress. The conditioning formulation was allowed to remain on the hair for approximately one minute, then rinsed for thirty seconds under flowing tap water at a temperature of approximately 30°-35° C. The wet tresses were combed through ten times per side, and then dipped into a beaker of water three times, the excess water being squeezed out between the fingers. This process was performed in order to introduce a random degree of tangling to the tresses. The results of the combing measurements are presented in the following table: TABLE 3______________________________________Combing Evaluations of Conditioned Human HairProduct Initial Work (joules) Final Work (joules)______________________________________Finesse ® 0.134 0.0201Formulation A using 0.147 0.0202Resin DFormulation A using 0.132 0.0270Resin A______________________________________ Notes: Combing evaluations were performed by means of a Diastron instrument model MTT600, using a crosshead speed of 30 mm/min., and a 2000 g load cell according to a modified method of Garcia and Diaz, J. Soc. Cosmet. Chem. vol. 27, pages 379-98 (1976). The volumizing benefit of the conditioning formulation was analyzed using 6 inch 2.0 g tresses according to a modified procedure of Robbins and Crawford, J. Soc. Cosmet. Chem. vol. 35, pages 36-9 (1984). The work required to pull a tress through a series of templates of decreasing diameters was measured by means of a Diastron instrument model MTT600 at a speed of 50 ram/min. The maximum tress diameter was determined by extrapolating to zero work. The results are presented in the following table. TABLE 4______________________________________Volume Changes in Hair Treated with Various ConditioningFormulationsProductDifference Initial Diameter Final Diameter %______________________________________Formulation A 29.0 mm 28.2 mm -2.8using waterFinesse ® 36.9 mm 31.2 mm -15.4Formulation A 31.2 mm 29.2 mm -6.4using Resin DFormulation A 31.2 mm 36.4 mm +16.7using Resin A______________________________________ The commercially available product produced a decrease in maximum tress diameter of approximately 15%. This decrease typically occurs with known conditioning agents. The conditioner base itself provides only a slight reduction in tress volume. The Resin D formulation performs like a general use conditioner, i.e. reducing combing forces and tress volume. The conditioning formulation containing the alkyl MQ, resin A, produced a surprising and unexpected result based on previous experience, i.e. a conditioning benefit and an increase in hair tress volume. Conditioning Shampoo Formulations: A 2-in-1 shampoo formulation was prepared using Resin A and replacing Resin A with an emulsion of trimethylsilylamodimethicone, a known conditioning agent. The formulation employing trimethylsilylamodimethicone was prepared to serve as a control TABLE 5______________________________________Conditioning Shampoo (2-in-1) Formulation Composition,Cosmetic Composition A2.Material Resin A ControlWt. % Shampoo Shampoo______________________________________Deionized water 40.82 39.82Ammonium Lauryl Sulfate (25% sol'n) 24.00 24.00Ammonium Laureth Sulfate (28% sol'n) 14.30 14.30Cocamidopropyl Betaine (35% sol'n) 11.43 11.43Lauramide DEA 2.00 2.00Cocamide DEA 2.50 2.50Resin A 3.00 0.00Emulsion of 0.00 4.00TrimethylsilylamodimethiconeDimethicone Copolyol 1.00 1.00Guar Hydroxypropyltimonium 0.75 0.75ChlorideMethyl paraben 0.15 0.15Propyl paraben 0.05 0.05______________________________________ Two 6 inch, 2.0 g tresses of virgin brown human hair were washed with the above conditioning shampoos and evaluated (duplicate samples) for combing force and hair tress volume. TABLE 6______________________________________Evaluation of Conditioning Shampoo FormulationsMeasurement Resin A 2-in-1Control Shampoo Shampoo______________________________________Combing Force (joules)Initial 0.214 0.220Final 0.189 0.152Percent Decrease 12 31Volume Measurement (mm)Initial 30.9(31.4) 36.9Final 31.8(31.4) 34.0Percent Change +3.0(0.0) -8.0______________________________________ Initial evaluations of two samples gave conflicting results, therefore additional measurements were performed on two additional samples of hair tresses to substantiate volume increases. The results presented inside the parentheses in Table 6 are averages of all four of the experimental results obtained on hair tress volume measurements using the resin of the invention. The results presented in front of the parentheses are averages of the three tress measurements showing an increase in hair volume. The results indicate an advantage for using the siloxysilicate MQ resin, Resin A, in place of the trimethylsilylamodimethicone emulsion. The shampoo formulation utilizing resin A is more properly characterized as a 3-in-1 shampoo providing cleaning, conditioning, and volumizing benefits. This is an unexpected result since, conditioning shampoos typically reduce hair tress volume when imparting a conditioning effect to the hair. Cosmetic Formulation B: Cuticle Coat: Cuticle coats are formulations designed to impart or enhance shine on hair. Additionally, cuticle coats frequently reduce both tribo-electric charging effects, i.e. fly-away hair, and combing forces, by adding a lubricious coating to the hair shaft, thus lowering both interfiber friction and electrostatic repulsion between the fibers. One method of imparting or increasing apparent luster or gloss on the hair is to coat the hair with a material having a high refractive index. Using this technique the apparent gloss or shine will be proportional to the refractive index of the material on the fiber surface. Absent other factors, a direct proportionality exists between refractive index and apparent shine on hair. Thus higher refractive index cuticle coating formulations will tend to impart a higher shine on hair. A cuticle coating preparation was prepared as follows: TABLE 7______________________________________Cosmetic Formulation BComponent Amount (Wt. %)______________________________________Cyclomethicone (and) Dimethicone 60.0Resin B 30.0Isohexadecane 10.0______________________________________ Subjective evaluations indicate the formulation increased the apparent luster of human hair to which this formulation was applied by approximately 55% over the control. Curl Retention with Polyether Modified MQ Resin, Polyetherdimethylsiloxysilicate: Polyetherdimethylsiloxysilicate is a clear, amber water soluble liquid. This material was evaluated for curl retention against a tap water control. Two 2 g 6 in. tresses were shampooed with a commercially available non-conditioning shampoo for 60 sec and rinsed under running, warm tap water for 30 sec. The control tress was wrapped around a glass rod having a diameter of 2.4 cm, securing the ends of the tress with elastic bands. The second tress was treated with an excess of the aqueous 10% solution of the Polyetherdimethylsiloxysilicate after shampooing. The excess liquid was squeezed out between the fingers and the tress was curled around a glass rod having a diameter of 2.4 cm. Both tresses were allowed to air dry overnight. The tresses were removed from the glass rods, suspended from an acrylic board and the length of each tress was measured over a period of 24 hours. Percent curl retention values were evaluated according to the following relationship: Percent Retention=100-(L.sub.f -L.sub.i)/L.sub.i where L i is the hair tress length at t=0 and L f is the length at time t. TABLE 8______________________________________Curl Retention Evaluation for Hair Treated with 10% Aqueouspolyetherdimethylsiloxysilicate (MQ)Time Water(hrs.) Control MQ Treated______________________________________0.5 91.5 100.01.0 85.9 100.02.0 77.5 97.83.0 70.4 97.84.0 70.4 97.85.0 63.4 93.46.0 59.2 93.424.0 49.3 89.0______________________________________ These measurements were taken under ambient conditions of 76° F. and 24% relative humidity. It is expected that incorporation of polyetherdimethylsiloxysilicates of the present invention into various hair treating cosmetic formulations would thus impart curl retention benefits to the formulation. Thus for example a 2-in-1 shampoo incorporating polyetherdimethylsiloxysilicate would be a 3-in-1 shampoo having cleaning, conditioning and curl retention properties. Addition of polyetherdimethylsiloxysilicate to a 3-in-1 shampoo having cleaning, conditioning, and volumizing properties would result in the preparation of a 4-in-1 shampoo having cleaning, conditioning, volumizing, and cud retention properties. Hair conditioners, mousses, fixatives, spritzes and the like incorporating polyetherdimethylsiloxysilicate would be expected to show improved curl retention properties.
Low viscosity MQ silicone resins as a composition of matter, methods of preparation of same and cosmetic and personal care products comprising said MQ resins.
0
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a control apparatus for controlling an electric power steering mechanism. [0003] 2. Description of the Related Art [0004] Two documents have been disclosed regarding an electric power steering mechanism. One is U.S. Pat. No. 5,720,361, and the other is U.S. Pat. No. 5,999,869. In these documents, an abnormality-detecting circuit for determining a failure of the electric power steering mechanism is disclosed. [0005] According to the prior art, an abnormality detecting counter (hereinafter referred to as an abnormal counter) counts up each time an abnormality of the electric power steering mechanism is detected, and when the count value reaches a failure deciding value, a CPU decides that the power steering mechanism driven by an electric motor is in a state of a failure and the current supplied to the electric motor is stopped. [0006] However, when the abnormal counter cannot detect an abnormality before it reaches the failure determining value, the CPU immediately decides that the electric power steering mechanism is normal and the abnormal counter is reset to zero. [0007] The above-described prior art has the following problems. [0008] According to the above-mentioned logic to detect a failure, a failure state can be determined as long as the detection of abnormality due to a failure continues. However, when the abnormality is in a driving circuit system for the electric power steering mechanism (such as a short circuit between a motor terminal and a battery line, a short circuit between the motor terminal and a ground line, a short circuit between motor terminals, or a failure of the motor current detecting circuit), the current, and thus the steering torque value, hunts due the presence of the control system or the steering system, so that the abnormality is not continuously detected even though the abnormality continues in the driving circuit system. In such a case, a failure of the electric power steering system cannot be surely determined. SUMMARY OF THE INVENTION [0009] Accordingly, an object of the present invention is to provide a control apparatus of an electric power steering mechanism, which can surely determine whether or not the power steering mechanism is in a failure state. [0010] To attain the above object, according to a first aspect of the present invention, there is provided a control apparatus for controlling an electric power steering mechanism comprising: [0011] a torque sensor mounted on a steering shaft for detecting a steering torque signal; [0012] an indicating value calculating unit for calculating a motor current indicating value based on the steering toque signal detected by the torque sensor and a vehicle speed detected by a vehicle speed sensor; [0013] an electric motor for providing a steering assist force to the steering shaft; [0014] a motor current detecting unit for detecting a motor current flowing in the electric motor; [0015] a motor drive circuit for driving the electric motor; [0016] a drive signal calculating circuit for calculating a drive signal from a current deviation between the motor current indicating value and the motor current detected value, and transferring the drive signal to the motor drive circuit; [0017] an abnormal detecting unit for detecting whether the electric power steering mechanism is abnormal or normal at each sampling time; and [0018] a failure deciding unit for detecting failure of the electric power steering mechanism when an abnormal counter is incremented at every detection of abnormality detected by the abnormal detecting unit, and when the abnormality counter reaches a failure deciding value; [0019] wherein, the failure deciding unit returns the count value of the abnormal counter from the held value to zero when the abnormal detecting unit sequentially detects normality during a predetermined number of sampling times, even if the abnormal detecting unit once detects abnormality. [0020] According to the above construction, even when the driving circuit system in the electric power steering mechanism is in a failure state, the abnormal counter is not reset too early but is continuously incremented. [0021] When the count value of the abnormality counter reaches a failure deciding value, the failure-deciding unit determines that the electric power steering mechanism is in a failure state. [0022] In addition, even when the abnormal detecting unit once detects abnormality, the failure-deciding unit resets the abnormal counter to zero only after the abnormal detecting unit sequentially detects normality during a predetermined number of sampling times. As a result, an erroneous decision, of deciding too early that the electric power steering system is in a failure state, can be prevented. [0023] As a result, according to the first aspect of the present invention, it can be surely determined whether or not the electric power steering mechanism is in a failure state. [0024] According to a second aspect of the present invention, the abnormal detecting unit has a hysteresis characteristic in order to detect whether the electric power steering mechanism is abnormal or normal. The abnormal detecting unit detects, at each sampling time, whether the electric power steering mechanism is abnormal or normal. When the abnormal detecting unit detects an abnormal state, the abnormal counter is incremented. [0025] After the abnormal detecting unit detects an abnormal state, when the abnormal detecting unit detects a normal state or an indefinite state, which is neither abnormal nor normal, the abnormal counter holds its count value. [0026] By this second aspect of the present invention, even when the electric power steering mechanism is in a failure state or has a high possibility of failure, the abnormal counter is not reset too early but surely counts up even after the abnormal detecting unit detects a normal state or an indefinite state. [0027] According to a third aspect of the present invention, the abnormal detecting unit detects whether the electric power steering mechanism is normal or abnormal, based on at least one of a detected value of the motor current, a detected value of the motor voltage, a detected value of the battery voltage, and the motor current indicating value. [0028] By this third aspect, the abnormal detecting unit can detect, with high precision, whether the electric power steering mechanism is normal or abnormal. [0029] According to a fourth aspect of the present invention, the abnormal detecting unit detects that the electric power steering mechanism is normal under conditions where the detected value of the motor current is included within a normal range, where the detected value of the motor voltage is included within a normal range, where the detected value of the battery voltage is included within a normal range, and where the motor current indicating value is included within a normal range. [0030] The abnormal detecting unit detects that the electric power steering mechanism is abnormal under the condition where the detected value of the motor current is not included within the normal range, where the detected value of the motor voltage is not included within the normal range, where the detected value of the battery voltage is not included within the normal range, or where the motor current indicating value is not included within the normal range. [0031] By this fourth aspect of the present invention, the abnormal detecting unit can detect, with a high precision, whether the electric power steering mechanism is normal or abnormal. [0032] According to a fifth aspect of the present invention, the control apparatus for controlling the electric power steering mechanism includes means for setting, when the abnormal detecting unit sequentially detects normality after the abnormal detecting unit once detects abnormality, a time required for sampling times to return the count value, counted by the abnormal counter from a holding value to zero, to a period longer than a hunting period which occurs in a control system and a steering system. [0033] By this fifth aspect, a failure of the electric power steering mechanism, which is the hunting of the steering shaft caused due to the presence of the control system and the steering system, can also be determined as a failure. BRIEF DESCRIPTION OF THE DRAWINGS [0034] The above object and features of the present invention will be more clearly understood from the following description of the preferred embodiments when read with reference to the accompanying drawings, wherein: [0035] [0035]FIG. 1 is a block diagram of a control apparatus for controlling an electric power steering mechanism, according to an embodiment of the present invention; [0036] FIGS. 2 A- 2 C are views for explaining waveforms in the hunting state of a steering shaft when a failure occurs in a motor current detecting unit; and [0037] FIGS. 3 A- 3 D are views for explaining waveforms in the changing state of abnormal counter values at the present invention and the prior art, when failure occurs in the motor current detecting unit. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0038] The preferred embodiments according to the present invention will be explained in detail with reference to the attached drawings. [0039] In FIG. 1, a control apparatus D for controlling an electric power steering mechanism includes a torque sensor 1 , an assist current calculating unit 2 , a motor current indicating value calculating unit 3 , an electric motor 4 , a motor current detecting unit 5 , a motor drive circuit 6 , a drive signal calculating circuit 7 , and a central processing unit (CPU) 8 having an abnormal detecting unit 81 and a failure deciding unit 82 . [0040] Further, the torque sensor 1 is mounted on a steering shaft 11 and is provided for detecting a steering torque signal 12 . [0041] The assist current calculating unit 2 is provided for calculating the assist current in response to the steering torque, based on the steering torque signal processed by a steering torque detecting circuit 13 and a filter 14 . [0042] The motor current indicating value calculating unit 3 is provided for calculating an indicating value for determining motor current, based on the assist current calculated by the assist current calculating unit 2 and vehicle speed detected by a vehicle speed sensor 21 . In this case, the indicating value for determining motor current is determined in such a way that a driver has a preferable feeling of response when he operates the steering wheel upon driving the vehicle. That is, the motion of the steering wheel is adjusted based on the assist current and the vehicle speed so as to supply a preferable feeling to the driver. [0043] A rotational axis of the motor 4 is coupled to the steering shaft 11 through a reduction gear mechanism (not shown) so that it is possible to apply a steering-assist force to the steering shaft 11 . [0044] The motor current detecting unit 5 is provided for detecting motor current flowing in the electric motor 4 based on a motor current detecting value 51 . [0045] The motor drive circuit 6 is formed by four power MOS-FETs 61 to 64 and CR parts (not shown) in order to drive the motor 4 . [0046] The drive signal calculating circuit 7 is provided for obtaining the drive signal, based on a current deviation between the motor current indicating value, calculated by the motor current indicating value calculating unit 3 , and the motor current detecting value 51 detected by the motor current detecting unit 5 . Further, the drive signal calculating circuit 7 transmits driving duty ratio signals 71 to 74 to the motor drive circuit 6 in order to drive the power MOS-FETs 61 to 64 . [0047] In this case, the direction of drive of each of the power MOS-FETs 61 to 64 is determined based on a plus/minus sign of the drive torque or the motor current indicating value. For example, when the driver operates the steering wheel in the right direction, the power MOSFETs 61 and 64 are driven by the duty controlled signals. On the other hand, when the driver operates the steering wheel in the left direction, the power MOS-FETs 62 and 63 are driven by the duty controlled signals. Accordingly, it is possible to execute assist operation in accordance with the operational direction of the steering wheel. [0048] The abnormal detecting unit 81 in the CPU 8 detects whether the electric power steering mechanism is abnormal, or normal, at each sampling time (sampling period: 4 ms) of the CPU 8 , in accordance with whether an abnormality-detecting condition or a normality-detecting condition is satisfied. [0049] The failure-deciding unit 82 executes a failure decision in accordance with the following processes. [0050] When the abnormal detecting unit 81 detects abnormality, i.e., when abnormality-detecting condition, which will be described later in more detail, is satisfied, a normal counter for counting the number of normal states is reset to zero, and an abnormal counter for counting the number of abnormal states is incremented at each detection of abnormality. [0051] When the abnormal detecting unit 81 detects normality, i.e., when normality detecting condition (which will be described later in more detail) is satisfied within a period after a detection of abnormality, for example, within a period in which the count value of the abnormal counter satisfies a condition: one time≦count value of the abnormal counter≦fifty times, the count value of the abnormal counter is held. The normal counter is incremented each time at a detection of normality. [0052] When the abnormal detecting unit 81 detects an indefinite state which is not only a normal state, but is also an abnormal state, i.e., when both of normality detecting condition and abnormality detecting condition are not satisfied within a period after detection of abnormality, for example, within a period in which the count value of the abnormal counter satisfies a condition: one time≦count value of the abnormal counter≦fifty times, the count value of the abnormal counter is held, and the count value of the normal counter is either held, or reset to zero. [0053] Only after the count value of the normal counter exceeds a predetermined number such as one hundred times (i.e., the count value of the normal counter≦100), is the abnormal counter reset to zero. In contrast, in the prior art, the abnormal counter is reset immediately after the abnormal counter does not count an abnormality. It should be noted that a period required for the number of samples to return the count value held in the abnormal counter to zero (when the sampling period of the CPU 8 is 4 ms, the period is 4(ms)×100 times=400 ms), is longer than a hunting period due to the presence of the control system and the steering system. [0054] When the count value of the abnormal counter reaches a failure deciding value 50 times (for example, 200 ms when the sampling period the CPU is 4 ms, that is, 4(ms)×50 times=200 ms), the CPU 8 determines that the electric power steering mechanism is in a failure state, and informs the failure by using a display or the like. Further, the current to be supplied to the motor 4 is cut off. [0055] An example of the abnormality detecting condition must satisfy the following three conditions. [0056] Detected motor current value<1 A, and [0057] Indicated motor current>1 A, and [0058] Detected voltage between motor terminal>2 V [0059] An example of the normality detecting condition must satisfy the following condition. [0060] Detected motor current value≦1 A [0061] For example, when the motor current detecting unit 5 is out of order, and when the motor current detecting value is 0 ampere (A), the hunting state of the steering shaft 11 occurs in accordance with actions of the following seven steps (1)-(7) and as shown in FIGS. 2 A- 2 C. [0062] (1) The motor current detecting value 51 is turned to 0 ampere (A). [0063] (2) The deviation between the motor current indicating value and the motor current detecting value 51 is large. [0064] (3) The driving duty ratios in the duty signals 71 to 74 of the power MOS-FETs 61 to 64 are increased. [0065] (4) The current (not shown in FIGS. 2 A- 2 C) actually flowing through the motor is increased so that the steering shaft 11 is driven to rotate by the motor 4 , resulting in the steering torque ST beginning to decrease. [0066] (5) The torque sensor 1 is twisted to the direction opposite to the steering direction, and the direction of the steering torque ST is changed. [0067] (6) The driving directions of the power MOS-FETs 61 to 64 are changed and, therefore, the direction of the current actually flowing through the motor is reversed. [0068] (7) The direction of the steering torque ST is changed again (i.e. original direction of torque) from the above step (5). [0069] For the above failure in which the actual flowing current is hunting so that the steering torque ST is hunting, in the prior art, when the abnormality is not detected before the abnormal counter reaches the failure deciding value, the state of the electric power steering mechanism is determined to be normal (see FIG. 3D) so that the abnormal counter is reset (see FIG. 3C). [0070] In contrast, according to the embodiment of the present invention, the control apparatus D of the electric power steering mechanism holds the count value of the abnormal counter when the abnormal detecting unit 81 detects normality or an indefinite state after detection of abnormality (for example, one time≦the count value of the abnormal counter≦fifty times). Next, when the control apparatus D detects abnormality, that is when the abnormality detecting condition is satisfied, the abnormal counter is incremented from the holding value at every detection of abnormality (see FIG. 3B). [0071] Accordingly, it is possible to surely detect the failure of the electric power steering mechanism, even if the driving circuit system in the electric power steering mechanism is abnormal and even if the hunting state of the steering shaft 11 occurs due to the presence of the control system and the steering system. [0072] According to another embodiment of the present invention, the abnormal detecting unit 81 detects normality of the electric power steering mechanism when the detected value of the motor current 51 is included within a first normal range, when the detected value of the motor voltage is included within a second normal range, when the detected value of the battery voltage is included within a third normal range, and when the motor current indicating value is included within a fourth normal range. [0073] On the other hand, the abnormal detecting unit 81 detects abnormality of the electric power steering mechanism when the detected value of the motor current 51 is not included within the first normal range, when the detected value of the motor voltage is not included within the second normal range, when the detected value of the battery voltage is not included within the third normal range, or when the motor current indicating value is not included within the fourth normal range.
A control apparatus for controlling an electric power steering mechanism including an abnormal detecting unit for detecting abnormality or normality of the electric power steering mechanism for each sampling time; and a failure deciding unit for detecting failure of the electric power steering mechanism when an abnormal counter is incremented at every detection of abnormality detected by the abnormal detecting unit, and when the abnormality counter reaches a failure deciding value, wherein, the failure deciding unit returns the abnormal counter from its held value to zero when the abnormal detecting unit sequentially detects normality during a predetermined sampling times, even if the abnormal detecting unit once detects abnormality, whereby it can be surely determined whether or not the electric power steering mechanism has failed.
1
FIELD OF THE INVENTION [0001] The field of this invention is tools run downhole preferably on cable and which operate with on board power to perform a downhole function and more particularly tubular scraping downhole. BACKGROUND OF THE INVENTION [0002] It is a common practice to plug wells and to have encroachment of water into the wellbore above the plug. FIG. 1 illustrates this phenomenon. It shows a wellbore 10 through formations 12 , 14 and 16 with a plug 18 in zone 16 . Water 20 has infiltrated as indicated by arrows 22 and brought sand 24 with it. There is not enough formation pressure to get the water 20 to the surface. As a result, the sand 24 simply settles on the plug 18 . [0003] There are many techniques developed to remove debris from wellbores and a good survey article that reviews many of these procedures is SPE 113267 Published June 2008 by Li, Misselbrook and Seal entitled Sand Cleanout with Coiled Tubing: Choice of Process, Tools or Fluids? There are limits to which techniques can be used with low pressure formations. Techniques that involve pressurized fluid circulation present risk of fluid loss into a low pressure formation from simply the fluid column hydrostatic pressure that is created when the well is filled with fluid and circulated or jetted. The productivity of the formation can be adversely affected should such flow into the formation occur. As an alternative to liquid circulation, systems involving foam have been proposed with the idea being that the density of the foam is so low that fluid losses will not be an issue. Instead, the foam entrains the sand or debris and carries it to the surface without the creation of a hydrostatic head on the low pressure formation in the vicinity of the plug. The downside of this technique is the cost of the specialized foam equipment and the logistics of getting such equipment to the well site in remote locations. [0004] Various techniques of capturing debris have been developed. Some involve chambers that have flapper type valves that allow liquid and sand to enter and then use gravity to allow the flapper to close trapping in the sand. The motive force can be a chamber under vacuum that is opened to the collection chamber downhole or the use of a reciprocating pump with a series of flapper type check valves. These systems can have operational issues with sand buildup on the seats for the flappers that keep them from sealing and as a result some of the captured sand simply escapes again. Some of these one shot systems that depend on a vacuum chamber to suck in water and sand into a containment chamber have been run in on wireline. Illustrative of some of these debris cleanup devices are U.S. Pat. No. 6,196,319 (wireline); U.S. Pat. No. 5,327,974 (tubing run); U.S. Pat. No. 5,318,128 (tubing run); U.S. Pat. No. 6,607,607 (coiled tubing); U.S. Pat. No. 4,671,359 (coiled tubing); U.S. Pat. No. 6,464,012 (wireline); U.S. Pat. No. 4,924,940 (rigid tubing) and U.S. Pat. No. 6,059,030 (rigid tubing). [0005] The reciprocation debris collection systems also have the issue of a lack of continuous flow which promotes entrained sand to drop when flow is interrupted. Another issue with some tools for debris removal is a minimum diameter for these tools keeps them from being used in very small diameter wells. Proper positioning is also an issue. With tools that trap sand from flow entering at the lower end and run in on coiled tubing there is a possibility of forcing the lower end into the sand where the manner of kicking on the pump involves setting down weight such as in U.S. Pat. No. 6,059,030. On the other hand, especially with the one shot vacuum tools, being too high in the water and well above the sand line will result in minimal capture of sand. [0006] What is needed is a debris removal tool that can be quickly deployed such as by slickline and can be made small enough to be useful in small diameter wells while at the same time using a debris removal technique that features effective capture of the sand and preferably a continuous fluid circulation while doing so. A modular design can help with carrying capacity in small wells and save trips to the surface to remove the captured sand. Other features that maintain fluid velocity to keep the sand entrained and further employ centrifugal force in aid of separating the sand from the circulating fluid are also potential features of the present invention. Those skilled in the art will have a better idea of the various aspects of the invention from a review of the detailed description of the preferred embodiment and the associated drawings, while recognizing that the full scope of the invention is determined by the appended claims. [0007] One of the issues with introduction of bottom hole assemblies into a wellbore is how to advance the assembly when the well is deviated to the point where the force of gravity is insufficient to assure further progress downhole. Various types of propulsion devices have been devised but are either not suited for slickline application or not adapted to advance a bottom hole assembly through a deviated well. Some examples of such designs are U.S. Pat. Nos. 7,392,859; 7,325,606; 7,152,680; 7,121,343; 6,945,330; 6,189,621 and 6,397,946. US Publication 2009/0045975 shows a tractor that is driven on a slickline where the slickline itself has been advanced into a wellbore by the force of gravity from the weight of the bottom hole assembly. SUMMARY OF THE INVENTION [0008] A downhole tubular scraper is run in on slickline with an on board power supply. It features counter-rotating scrapers without an anchor in one embodiment or an anchor with single rotating scrapers. The scraper is selectively operated to conserve power in the power supply. A drive system uses a single driver to obtain counter-rotating motion in the scrapers. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 is a section view of a plugged well where the debris collection device will be deployed; [0010] FIG. 2 is the view of FIG. 1 with the device lowered into position adjacent the debris to be removed; [0011] FIG. 3 is a detailed view of the debris removal device shown in FIG. 2 ; [0012] FIG. 4 is a lower end view of the device in FIG. 3 and illustrating the modular capability of the design; [0013] FIG. 5 is another application of a tool run on slickline to cut tubulars; [0014] FIG. 6 is another application of a tool to scrape tubulars without an anchor that is run on slickline; [0015] FIG. 7 is an alternative embodiment of the tool of FIG. 6 showing an anchoring feature used without the counter-rotating scrapers in FIG. 6 ; [0016] FIG. 8 is a section view showing a slickline run tool used for moving a downhole component; [0017] FIG. 9 is an alternative embodiment to the tool in FIG. 8 using a linear motor to set a packer; [0018] FIG. 10 is an alternative to FIG. 9 that incorporates hydrostatic pressure to set a packer; [0019] FIG. 11 illustrates the problem with using slicklines when encountering a wellbore that is deviated; [0020] FIG. 12 illustrates how tractors are used to overcome the problem illustrated in FIG. 11 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0021] FIG. 2 shows the tool 26 lowered into the water 20 on a slickline or non-conductive cable 28 . The main features of the tool are a disconnect 30 at the lower end of the cable 28 and a control system 32 for turning the tool 26 on and off and for other purposes. A power supply, such as a battery 34 , powers a motor 36 , which in turn runs a pump 38 . The modular debris removal tool 40 is at the bottom of the assembly. [0022] While a cable or slickline 28 is preferred because it is a low cost way to rapidly get the tool 26 into the water 20 , a wireline can also be used and surface power through the wireline can replace the onboard battery 34 . The control system can be configured in different ways. In one version it can be a time delay energized at the surface so that the tool 26 will have enough time to be lowered into the water 20 before motor 36 starts running. Another way to actuate the motor 36 is to use a switch that is responsive to being immersed in water to complete the power delivery circuit. This can be a float type switch akin to a commode fill up valve or it can use the presence of water or other well fluids to otherwise complete a circuit. Since it is generally known at what depth the plug 18 has been set, the tool 26 can be quickly lowered to the approximate vicinity and then its speed reduced to avoid getting the lower end buried in the sand 24 . The control system can also incorporate a flow switch to detect plugging in the debris tool 40 and shut the pump 38 to avoid ruining it or burning up the motor 36 if the pump 38 plugs up or stops turning for any reason. Other aspects of the control system 32 can include the ability to transmit electromagnetic or pressure wave signals through the wellbore or the slickline 28 such information such as the weight or volume of collected debris, for example. [0023] Referring now to FIGS. 3 and 4 , the inner details of the debris removal tool 40 are illustrated. There is a tapered inlet 50 leading to a preferably centered lift tube 52 that defines an annular volume 54 around it. Tube 52 can have one or more centrifugal separators 56 inside whose purpose is to get the fluid stream spinning to get the solids to the inner wall using centrifugal force. Alternatively, the tube 52 itself can be a spiral so that flow through it at a high enough velocity to keep the solids entrained will also cause them to migrate to the inner wall until the exit ports 58 are reached. Some of the sand or other debris will fall down in the annular volume 54 where the fluid velocity is low or non-existent. As best shown in FIG. 3 , the fluid stream ultimately continues to a filter or screen 60 and into the suction of pump 38 . The pump discharge exits at ports 62 . [0024] As shown in FIG. 4 the design can be modular so that tube 52 continues beyond partition 64 at thread 66 which defines a lowermost module. Thereafter, more modules can be added within the limits of the pump 38 to draw the required flow through tube 52 . Each module has exit ports 58 that lead to a discrete annular volume 54 associated with each module. Additional modules increase the debris retention capacity and reduce the number of trips out of the well to remove the desired amount of sand 24 . [0025] Various options are contemplated. The tool 40 can be triggered to start when sensing the top of the layer of debris, or by depth in the well from known markers, or simply on a time delay basis. Movement uphole of a predetermined distance can shut the pump 38 off. This still allows the slickline operator to move up and down when reaching the debris so that he knows he's not stuck. The tool can include a vibrator to help fluidize the debris as an aid to getting it to move into the inlet 50 . The pump 38 can be employed to also create vibration by eccentric mounting of its impeller. The pump can also be a turbine style or a progressive cavity type pump. [0026] The tool 40 has the ability to provide continuous circulation which not only improves its debris removal capabilities but can also assist when running in or pulling out of the hole to reduce chances of getting the tool stuck. [0027] While the preferred tool is a debris catcher, other tools can be run in on cable or slickline and have an on board power source for accomplishing other downhole operations. FIG. 2 is intended to schematically illustrate other tools 40 that can accomplish other tasks downhole such as honing or light milling. To the extent a torque is applied by the tool to accomplish the task, a part of the tool can also include an anchor portion to engage a well tubular to resist the torque applied by the tool 40 . The slips or anchors that are used can be actuated with the on board power supply using a control system that for example can be responsive to a pattern of uphole and downhole movements of predetermined length to trigger the slips and start the tool. [0028] FIG. 5 illustrates a tubular cutter 100 run in on slickline 102 . On top is a control package 104 that is equipped to selectively start the cutter 100 at a given location that can be based on a stored well profile in a processor that is part of package 104 . There can also be sensors that detect depth from markers in the well or there can more simply be a time delay with a surface estimation as to the depth needed for the cut. Sensors could be tactile feelers, spring loaded wheel counters or ultrasonic proximity sensors. A battery pack 106 supplies a motor 108 that turns a ball shaft 110 which in turn moves the hub 112 axially in opposed directions. Movement of hub 112 rotates arms 114 that have a grip assembly 116 at an outer end for contact with the tubular 118 that is to be cut. A second motor 120 also driven by the battery pack 106 powers a gearbox 122 to slow its output speed. The gearbox 122 is connected to rotatably mounted housing 124 using gear 126 . The gearbox 122 also turns ball screw 128 which drives housing 130 axially in opposed directions. Arms 132 and 134 link the housing 130 to the cutters 136 . As arms 132 and 134 get closer to each other the cutters 136 extend radially. Reversing the rotational direction of cutter motor 120 retracts the cutters 136 . [0029] When the proper depth is reached and the anchor assemblies 116 get a firm grip on the tubular 118 to resist torque from cutting, the motor 120 is started to slowly extend the cutters 136 while the housing 124 is being driven by gear 126 . When the cutters 136 engage the tubular 118 the cutting action begins. As the housing 124 rotates to cut the blades are slowly advanced radially into the tubular 118 to increase the depth of the cut. Controls can be added to regulate the cutting action. They controls can be as simple as providing fixed speeds for the housing 124 rotation and the cutter 136 extension so that the radial force on the cutter 136 will not stall the motor 120 . Knowing the thickness of the tubular 118 the control package 104 can trigger the motor 120 to reverse when the cutters 136 have radially extended enough to cut through the tubular wall 118 . Alternatively, the amount of axial movement of the housing 130 can be measured or the number of turns of the ball screw 128 can be measured by the control package 104 to detect when the tubular 118 should be cut all the way through. Other options can involve a sensor on the cutter 136 that can optically determine that the tubular 118 has been cut clean through. Reversing rotation on motors 108 and 120 will allow the cutters 136 to retract and the anchors 116 to retract for a fast trip out of the well using the slickline 102 . [0030] FIG. 6 illustrates a scraper tool 200 run on slickline 202 connected to a control package 204 that can in the same way as the package 104 discussed with regard to the FIG. 5 embodiment, selectively turn on the scraper 200 when the proper depth is reached. A battery pack 206 selectively powers the motor 208 . Motor shaft 210 is linked to drum 212 for tandem rotation. A gear assembly 214 drives drum 216 in the opposite direction as drum 212 . Each of the drums 212 and 216 have an array of flexible connectors 218 that each preferably have a ball 220 made of a hardened material such as carbide. There is a clearance around the extended balls 220 to the inner wall of the tubular 222 so that rotation can take place with side to side motion of the scraper 200 resulting in wall impacts on tubular 222 for the scraping action. There will be a minimal net torque force on the tool and it will not need to be anchored because the drums 212 and 216 rotate in opposite directions. In the alternative, there can be but a single drum 212 as shown in FIG. 7 . In that case the tool 200 needs to be stabilized against the torque from the scraping action. One way to anchor the tool is to use selectively extendable bow springs that are preferably retracted for run in with slickline 202 so that the tool can progress rapidly to the location that needs to be scraped. Other types of driven extendable anchors could also be used and powered to extend and retract with the battery pack 206 . The scraper devices 220 can be made in a variety of shapes and include diamonds or other materials for the scraping action. [0031] FIG. 8 shows a slickline 300 supporting a jar assembly 302 that is commonly employed with slicklines to use to release a tool that may get stuck in a wellbore and to indicate to the surface operator that the tool is in fact not stuck in its present location. The Jar assembly can also be used to shift a sleeve 310 when the shifting keys 322 are engaged to a profile 332 . If an anchor is provided, the jar assembly 302 can be omitted and the motor 314 will actuate the sleeve 310 . A sensor package 304 selectively completes a circuit powered by the batteries 306 to actuate the tool, which in this case is a sleeve shifting tool 308 . The sensor package 304 can respond to locating collars or other signal transmitting devices 305 that indicate the approximate position of the sleeve 310 to be shifted to open or close the port 312 . Alternatively the sensor package 304 can respond to a predetermined movement of the slickline 300 or the surrounding wellbore conditions or an electromagnetic or pressure wave, to name a few examples. The main purpose of the sensor package 304 is to preserve power in the batteries 306 by keeping electrical load off the battery when it is not needed. A motor 314 is powered by the batteries 306 and in turn rotates a ball screw 316 , which, depending on the direction of motor rotation, makes the nut 318 move down against the bias of spring 320 or up with an assist from the spring 320 if the motor direction is reversed or the power to it is simply cut off. Fully open and fully closed and positions in between are possible for the sleeve 310 using the motor 314 . The shifting keys 322 are supported by linkages 324 and 326 on opposed ends. As hub 328 moves toward hub 330 the shifting keys 322 move out radially and latch into a conforming pattern 322 in the shifting sleeve 310 . There can be more than one sleeve 310 in the string 334 and it is preferred that the shifting pattern in each sleeve 310 be identical so that in one pass with the slickline 300 multiple sleeves can be opened or closed as needed regardless of their inside diameter. While a ball screw mechanism is illustrated in FIG. 8 other techniques for motor drivers such as a linear motor can be used to function equally. [0032] FIG. 9 shows using a slickline conveyed motor to set a mechanical packer 403 . The tool 400 includes a disconnect 30 , a battery 34 , a control unit 401 and a motor unit 402 . The motor unit can be a linear motor, a motor with a power screw or any other similar arrangements. When motor is actuated, the center piston or power screw 408 which is connected to the packer mandrel 410 moves respectively to the housing 409 against which it is braced to set the packer 403 . [0033] In another arrangement, as illustrated in FIG. 10 , a tool such as a packer or a bridge plug is set by a slickline conveyed setting tool 430 . The tool 430 also includes a disconnect 30 , a battery 34 , a control unit 401 and a motor unit 402 . The motor unit 402 also can be a linear motor, a motor with a power screw or other similar arrangements. The center piston or power screw 411 is connected to a piston 404 which seals off a series of ports 412 at run in position. When the motor is actuated, the center piston or power screw 411 moves and allow the ports 412 to be connected to chamber 413 . Hydrostatic pressure enters the chamber 413 , working against atmosphere chamber 414 , pushing down the setting piston 413 . A tool 407 thus is set. [0034] FIG. 11 illustrates a deviated wellbore 500 and a slickline 502 supporting a bottom hole assembly that can include logging tools or other tools 504 . When the assembly 504 hits the deviation 506 , forward progress stops and the cable goes slack as a signal on the surface that there is a problem downhole. When this happens, different steps have been taken to reduce friction such as adding external rollers or other bearings or adding viscosity reducers into the well. These systems have had limited success especially when the deviation is severe limiting the usefulness of the weight of the bottom hole assembly to further advance downhole. [0035] FIG. 12 schematically illustrates the slickline 502 and the bottom hole assembly 504 but this time there is a tractor 508 that is connected to the bottom hole assembly (BHA) by a hinge or swivel joint or another connection 510 . The tractor assembly 508 has onboard power that can drive wheels or tracks 512 selectively when the slickline 502 has a detected slack condition. Although the preferred location of the tractor assembly is ahead or downhole from the BHA 504 and on an end opposite from the slickline 502 placement of the tractor assembly 508 can also be on the uphole side of the BHA 504 . At that time the drive system schematically represented by the tracks 512 starts up and drives the BHA 504 to the desired destination or until the deviation becomes slight enough to allow the slack to leave the slickline 502 . If that happens the drive system 512 will shut down to conserve the power supply, which in the preferred embodiment will be onboard batteries. The connection 510 is articulated and is short enough to avoid binding in sharp turns but at the same time is flexible enough to allow the BHA 504 and the tractor 508 to go into different planes and to go over internal irregularities in the wellbore. It can be a plurality of ball and socket joints that can exhibit column strength in compression, which can occur when driving the BHA out of the wellbore as an assist to tension in the slickline. When coming out of the hole in the deviated section, the assembly 508 can be triggered to start so as to reduce the stress in the slickline 502 but to maintain a predetermined stress level to avoid overrunning the surface equipment and creating slack in the cable that can cause the cable 502 to ball up around the BHA 504 . Ideally, a slight tension in the slickline 502 is desired when coming out of the hole. The mechanism that actually does the driving can be retractable to give the assembly 508 a smooth exterior profile where the well is not substantially deviated so that maximum advantage of the available gravitational force can be taken when tripping in the hole and to minimize the chances to getting stuck when tripping out. Apart from wheels 512 or a track system other driving alternatives are envisioned such a spiral on the exterior of a drum whose center axis is aligned with the assembly 508 . Alternatively the tractor assembly can have a surrounding seal with an onboard pump that can pump fluid from one side of the seal to the opposite side of the seal and in so doing propel the assembly 508 in the desired direction. The drum can be solid or it can have articulated components to allow it to have a smaller diameter than the outer housing of the BHA 504 for when the driving is not required and a larger diameter to extend beyond the BHA 504 housing when it is required to drive the assembly 508 . The drum can be driven in opposed direction depending on whether the BHA 504 is being tripped into and out of the well. The assembly 510 could have some column strength so that when tripping out of the well it can be in compression to provide a push force to the BHA 504 uphole such as to try to break it free if it gets stuck on the trip out of the hole. This objective can be addressed with a series of articulated links with limited degree of freedom to allow for some column strength and yet enough flexibility to flex to allow the assembly 508 to be in a different plane than the BHA 504 . Such planes can intersect at up to 90 degrees. Different devices can be a part of the BHA 504 as discussed above. It should also be noted that relative rotation can be permitted between the assembly 508 and the BHA 504 which is permitted by the connector 510 . This feature allows the assembly to negotiate a change of plane with a change in the deviation in the wellbore more easily in a deviated portion where the assembly 508 is operational. [0036] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below:
A downhole tubular scraper is run in on slickline with an on board power supply. It features counter-rotating scrapers without an anchor in one embodiment or an anchor with single rotating scrapers. The scraper is selectively operated to conserve power in the power supply. A drive system uses a single driver to obtain counter-rotating motion in the scrapers.
4
FIELD OF THE INVENTION [0001] The invention relates to a process for the preparation of polymeric sulfur compounds with polythiocyclopentanediyl structural units which are used as vulcanizing agents for diene rubbers. BACKGROUND OF THE INVENTION [0002] EP-A 258 168 discloses the reaction of olefins with sulfur in water, it being possible for bases to be present as catalysts. Cyclopentadiene and dicyclopentadiene, inter alia, are mentioned as preferred olefins (page 4, lines 14-15). Cyclopentadiene de facto does not occur in the examples according to the present invention. Regarding industrial applicability, it is disclosed on page 7, lines 57-58 and page 8, lines 1-3 that the vulcanizing agents according to the invention lead to vulcanizates which are comparable in their physical properties to the properties obtained with a conventional sulfur vulcanization system. An improved reversion stability of the vulcanizates according to the present invention is not described. In example 1 of the German patent application with the application number DE 100002878.0, it is shown that the products cited therein from dicyclopentadiene and sulfur do not give vulcanizates with improved reversion stability. [0003] U.S. Pat. No. 3,523,926 discloses vulcanizing agents from diolefins, such as e.g. cyclopentadiene and dicyclopentadiene, and sulfur with amines as the catalyst. The additional use of hydrogen sulfide is neither described nor suggested in this reference. [0004] U.S. Pat. No. 2,989,513 discloses polymers of sulfur and an olefin for vulcanization of rubber. In column 3, line 21, cyclopentadiene, inter alia, is mentioned as a useful olefin. The reaction according to this reference is preferably carried out at between 145° and 160° C. The embodiment examples include only copolymers of sulfur and styrene or sulfur and ethylene or isobutylene. At no point in this reference is the additional use of hydrogen sulfide described or suggested. [0005] The German patent application with the application number DE 100002878.0 already describes polymeric sulfur compounds with polythiocyclopentanediyl structural elements which can be employed as crosslinking agents for diene rubbers. According to DE 100002878.0, the polymeric sulfur compounds are obtained by reaction of di-cyclopentenylpolysulfanes, which are known per se, with sulfur and hydrogen sulfide in the presence of amines at temperatures in the range from approx. 100° to 180° C. The di-cyclopentenylpolysulfanes employed can be prepared by (a) addition of sulfanes on to cyclopentadiene and/or methylcyclopentadiene or by (b) reaction of the cyclopentadienes according to the invention with liquid hydrogen sulfide to give (methyl)cyclopent-2-ene-1-thiol and subsequent reaction with elemental sulfur in the presence of amines as a catalyst. In the process according to (a), the preparation and handling of the sulfanes is very complex and expensive from the safety point of view, since sulfanes can decompose spontaneously into hydrogen sulfide and sulfur in contact with rough surfaces. In the process according to (b) the handling of a large amount of liquid hydrogen sulfide is necessary, which requires a gas liquefaction plant. Furthermore, the processes according to (a) and (b) are multi-stage processes. SUMMARY OF THE INVENTION [0006] The object of the present invention was to provide a one-stage process for the preparation of polymeric sulfur compounds with polythiocyclopentanediyl structural units which is industrially simple and easy to realize. [0007] The object has been achieved by direct reaction of (methyl)cyclopentadiene with sulfur and hydrogen sulfide in the presence of a catalyst. [0008] Therefore, the invention provides a process for the preparation of polymeric sulfur compounds of the formula [0009] wherein the substituents [0010] R 1 and R 2 are identical or different and represent hydrogen or methyl, [0011] n and m denote integers in the range from 2 to 12, and [0012] x denotes an integer in the range from 2 to 500, [0013] wherein (methyl)cyclopentadiene is reacted with sulfur and hydrogen sulfide at 100° to 180° C., in the presence of a catalyst, the molar ratio of sulfur to hydrogen sulfide being 1:0.1 to 1:5, and the molar ratio of (methyl)cyclopentadiene to sulfur being 1:1 to 1:9. DETAILED DESCRIPTION OF THE INVENTION [0014] Therefore, the present invention provides a process for the preparation of polymeric sulfur compounds of the formula [0015] wherein the substituents [0016] R 1 and R 2 are identical or different and represent hydrogen or methyl, [0017] n and m denote integers in the range from 2 to 12, preferably 2 to 7, and [0018] x denotes an integer in the range from 2 to 500, preferably 2 to 300, in particular 2 to 100, [0019] wherein (methyl)cyclopentadiene is reacted with sulfur and hydrogen sulfide at 100° to 180° C., preferably at 130° to 150° C., in the presence of a catalyst, the molar ratio of sulfur to hydrogen sulfide being 1:0.1 to 1:5, preferably 1:0.5 to 1:2, and the molar ratio of (methyl)cyclopentadiene to sulfur being 1:1 to 1:9, preferably 1:2 to 1:5. [0020] The numbers of the sulfur atoms n and m in the polymer chain are of course, in each case integers. Fractions can also result for the sulfur chain length averaged over all the polymer molecules, due to the formation of a mean value. [0021] The number x for the recurring unit in a specific polymer molecule is an integer. Fractions can also result for the average recurring unit of the total number of polymers, due to the formation of a mean value. [0022] Brönsted acids, Lewis acids or amines are possible as the catalyst for the process according to the present invention. Phosphoric acid, perchloric acid or trifluoromethanesulfonic acid or also mixtures thereof are preferably employed as Brönsted acids. Anhydrous aluminum chloride and in particular, boron trifluoride-etherate are preferably employed as Lewis acids. Possible amines are primary, secondary or tertiary, aliphatic, cycloaliphatic or aromatic or heterocyclic amines or mixtures thereof. Secondary or tertiary aliphatic amines with C 1 - to C 4 -alkyl radicals, such as e.g. dimethylamine, diethylamine, di-n-propylamine, di-i-propylamine, di-n-butylamine, trimethylamine, triethylamine, tri-n-propylamine, tri-i-propylamine or tri-n-butylamine are preferably employed. Triethylamine is more preferred. The catalyst is, in general, employed in an amount of 0.001 to 10 parts by wt., preferably 0.1 to 5 parts by wt., based on 100 parts by wt. of sulfur. [0023] The reaction according to the present invention takes place under pressure, this usually establishing itself in a range from approx. 1 to 500 bar, preferably approx. 1 to 250 bar, depending on the nature of the starting substances and the amount thereof and depending on the temperature used. [0024] The process according to the present invention can be carried out e.g. by a discontinuous or continuous process. In the discontinuous process (methyl)cyclopentadiene is initially introduced into a pressure reactor together with sulfur, hydrogen sulfide and the catalyst and the mixture is then heated up to a temperature of 100° to 180° C., while stirring, and reacted, or (methyl)cyclopentadiene is pumped into the stirred mixture which has been heated up to the temperature according to the invention. (feed process). In the continuous process the educts can be added to the reactor individually or also as a mixture and reacted at the reaction temperatures according to the invention. [0025] In an embodiment of the present invention, sulfur, hydrogen sulfide and the catalyst are initially introduced into an autoclave and the (methyl)cyclopentadiene is then added at the reaction temperature according to the present invention (feed process). [0026] The reaction according to the present invention can also be carried out in solvent. Possible suitable solvents are aliphatic C 5 - to C 12 -hydrocarbons, such as e.g. pentane, hexane, heptane or octane, or corresponding hydrocarbon mixtures, such as e.g. petroleum ether with a boiling point of 40° to 70° C., light petroleum with a boiling point of 70° to 90° C. or middle petroleum with a boiling point of 90° to 180° C., C 5 - to C 10 -cycloalkanes, such as e.g. cyclopentane, methylcyclopentane, cyclohexane, methylcyclohexane, cycloheptane or decalin, or corresponding mixtures thereof, C 1 - to C 5 -halogenoalkanes, such as e.g. chloromethanes, fluorochloromethanes, fluorochloroethanes or tetrachloroethylene, or corresponding mixtures thereof, C 1 - to C 5 -alcohols, such as e.g. methanol, ethanol, n- and i-propanol and n-, i- and tert-butanol, or corresponding mixtures thereof, ethers, such as e.g. diethyl ether, methyl tert-butyl ether or tetrahydrofuran, or corresponding ether mixtures thereof, and (chloro)aromatics, such as e.g. benzene, toluene xylene or chlorobenzene, and mixtures thereof. The solvents mentioned can, of course, also be employed in any desired mixtures with one another. Preferred solvents are toluene, methanol, hexane, petroleum ether or light petroleum. The amount of solvent is approx. 1 to 300 parts by wt., preferably approx. 1 to 150 parts by wt., based on 100 parts by wt. of (methyl)cyclopentadiene. [0027] In an embodiment of the present invention, the reaction is carried out without a solvent. [0028] The reaction time is about 0.5 to 10 h, preferably about 3 to 6 h. Excess hydrogen sulfide is removed from the reaction mixture and any solvent employed is distilled off. EXAMPLES Example Feed process [0029] A 1.3 l stirred autoclave which had been rendered inert with nitrogen was charged with 139.7 g (4.36 mol) sulfur, 2.4 g triethylamine and 180.0 g (5.28 mol) hydrogen sulfide. The autoclave was heated to 140° C., while stirring. At this temperature, the autoclave had an internal pressure of approx. 70 bar. 96.0 g (1.45 mol) of freshly distilled cyclopentadiene were pumped into this mixture in the course of approx. 9 minutes. After a reaction time of 4 h, calculated from the end of the feeding-in, the internal pressure in the reactor had fallen to approx. 35 bar. The autoclave was cooled, let down and flushed with nitrogen. A yellow, plastic solid which was completely soluble in carbon disulfide was obtained as the reaction product. The reaction proceeded virtually quantitatively. [0030] The following analytical data were obtained: [0031] (C 10 H 16 S 7.5 ) x (MW: [376.69] x ) [0032] C calc.: 31.89% H calc.: 4.28% S calc.: 63.83% [0033] C found: 31.7% H found: 4.3% S found: 63.8% [0034] IR (KBr): ν=1437 1/cm (s) [0035] ν=1313 1/cm (m) [0036] ν=1240 1/cm (s) [0037] DSC: Glass transition temperature T g =−14.3° C. mid point (rate of heating up: 5° C./min) [0038] GPC: A mixture of chloroform and carbon disulfide (volume ratio 10:1) was employed as the solvent for the reaction product. [0039]  The insoluble content of approx. 50 parts by wt., based on 100 parts by wt. of reaction product to be dissolved, was separated off. [0040] x=2 to 85 (Column: Jordi Gel DVB, 500 Å, 500×10 mm, eluent: chloroform with 0.5 part by wt. ethanol, UV detection: 260 nm, retention time: 9.7 to 23 min) [0041] NMR: 1 H- and 13 C-NMR (CDCl 3 /CS 2 =10:1; volume ratio) [0042] The typical ranges of the chemical shift (ppm) for 1 ,2-substitution are: 1,2-substituted Atom no. δ ( 1 H) δ ( 13 C) 1, 2 3.5-4.1 54.1-58.5 3, 5 1.9-2.4 30.7-34.1 4  1.5-1.9 21.8-24.6 [0043] The typical ranges of the chemical shift (ppm) for 1,3-substitution are: 1,3-substituted Atom no. δ ( 1 H) δ ( 13 C) 1, 3 3.2-3.9 48.1-51.7 2  2.2-2.4 37.9-41.7 4, 5 1.8-2.4 30.7-34.1 [0044] Content of the 1,3-substituted structure in the polymer: approx. 50%. [0045] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
The invention relates to a simple process for the preparation of polymeric sulfur compounds with polythiocyclopentanediyl structural elements which are used as vulcanizing agents for diene rubbers.
2
FIELD OF THE INVENTION [0001] The present invention relates to a film forming method and a film forming apparatus for forming a nonmetal film on a surface of a target substrate using an organic silane gas after performing a precoating process for attaching a thin film to surfaces of components in a processing chamber, including a surface of a mounting table, in advance. BACKGROUND OF THE INVENTION [0002] A film forming process is one of semiconductor manufacturing processes. The film forming process typically involves activating a processing gas in a vacuum atmosphere by, for example, converting it into plasma or thermally decomposing it; and depositing active species or reaction products on a substrate surface. A film forming apparatus for performing such a film forming process includes a mounting table disposed in a processing chamber which is configured as a vacuum chamber. As the mounting table, there can be used a ceramic plate which incorporates therein a temperature control unit for performing a temperature control of a substrate, the ceramic plate also serving as an electrostatic chuck by having a chuck electrode in a surface portion thereof. [0003] FIG. 6A illustrates an example of such a mounting table 9 . The mounting table 9 of FIG. 6A is formed of a ceramic plate disposed on a support 91 made of, e.g., aluminum. Installed inside the support 91 to penetrate it are, e.g., three elevating pins 92 for performing a transfer of a substrate 10 from/to a transfer mechanism (not shown). Further, a foil-shaped electrode 93 for attracting and holding the target substrate is embedded in the mounting table 9 formed of the ceramic plate. [0004] Meanwhile, the film forming apparatus performs a so-called pre-coating process before the substrate 10 is mounted on the mounting table 9 . The pre-coating process is a process for forming a film 100 , which is identical with a film 100 to be formed on the surface of the substrate 10 , on the surface of the mounting table 9 and the inner wall of a processing chamber (not shown). The reason why this pre-coating process is performed is as follows. If the inner wall of the processing chamber or the surface of the mounting table 9 is exposed, a rate of a thin film being attached to the inner wall and the like is high at an initial stage immediately after starting the film forming process. The attachment rate (a film forming rate), however, becomes stabilized after the attachment of the thin film to the inner wall and the like is made to some extent. Due to this discrepancy in processing environment, there is likelihood that several substrates 10 processed at the initial stage of the film forming process would not satisfy expected specifications. The pre-coating process is effective to avoid the possible problems as described above (see, for example, Japanese Patent Laid-open Application No. 2004-096060). [0005] Further, during the film forming process, it might happen that components of the pre-coated films attached to the inner wall and so forth are dispersed to the surface of the substrate 10 . Thus, it is required that the components of the pre-coated films are identical or similar to those of films to be processed (so that no affection is made on the films on the surface of the substrate 10 even if the pre-coated films attached to the inner wall are dispersed and mixed into the films on the surface of the substrate 10 ). [0006] There is still another reason why the pre-coating process is performed on the surface of the mounting table 9 . Aluminum nitride is widely used for the ceramic plate forming the mounting table 9 . When the substrate 10 is lowered and placed on the mounting table 9 after being received by the elevating pins 92 , the substrate 10 and the ceramic plate would be slightly scratched against each other due to slight horizontal misalignment between the substrate 10 and the mounting table 9 . In such a case, the aluminum nitride is attached to the rear surface of the substrate 10 . According to an analysis result of the present inventors, the quantity of aluminum attached to the rear surface of the substrate 10 was about 5×10 10 atoms/cm 2 . Though this is an infinitesimal quantity, it might cause a metal contamination in a manufacturing line. Therefore, it is effective to perform the pre-coating process on the surface of the mounting table 9 . [0007] There is a case of performing a film formation using an organic silane gas, e.g., trimethylsilane (SiH(CH 3 ) 3 ) gas as a processing gas. For example, a formation of a SiCN film (carbon and nitrogen containing silicon film) is performed by adding nitrogen (N 2 ) gas to the trimethylsilane gas. Here, the ceramic plate made of the aluminum nitride is obtained through the steps of adding and mixing powders of titanium oxide (TiO) to and with powders of aluminum nitride as a binder, as shown in FIG. 6B ; pressing and molding the mixture and sintering them. Thus, problems as follows can occur. If a pre-coating is performed on the SiCN film by using the organic silane gas, TiO contained in the aluminum nitride reacts with H of the trimetyhlsilane (SiH(CH 3 ) 3 ), generating Ti, as indicated by a reaction formula (I) as bellows. [0000] TiO+2H→Ti+H 2 O  (1) [0008] The amount of Ti generated while forming the pre-coat film is at a level that causes no problem. However, since the number of hydrogen atoms contained in a single molecule of the organic silane gas is great, the amount of hydrogen contained (trapped) in the pre-coated film will be also great. Due to the presence of this hydrogen, the Ti is generated with a lapse of time after the completion of the pre-coating. Ti thus generated is transferred to a rear surface of the substrate when the substrate is mounted on the mounting table. For example, as for a mounting table pre-coated with a SiCN film using trimethylsilane, the quantity of Ti transferred to the rear surface of a substrate immediately after the pre-coating process was about 5×10 10 atoms/cm 2 . However, the quantity reached up to about 5×10 13 atoms/cm 2 in 2 or 3 days. SUMMARY OF THE INVENTION [0009] It is, therefore, an object of the present invention to provide a technique capable of preventing metal contamination in performing, by using an organic silane gas, a film forming process on a target substrate mounted on a mounting table which is made of a ceramic plate containing a metal oxide. [0010] In accordance with a first aspect of the present invention, there is provided a film forming method including: pre-coating an inner wall of a processing chamber including a surface of a mounting table made of ceramic containing a metal oxide and disposed in the processing chamber with a silicon-containing nonmetal thin film, by introducing a processing gas containing an inorganic silane gas into the processing chamber; mounting a target substrate on the mounting table pre-coated with the nonmetal thin film; and forming a silicon-containing nonmetal thin film on a surface of the target substrate mounted on the mounting table, by introducing a processing gas containing an organic silane gas into the processing chamber. [0011] In accordance with the present invention, since the processing gas containing the inorganic silane gas (which has a small number of hydrogen atoms per a single molecule) is used in the pre-coating process; therefore, even if a metal oxide (e.g., TiO), which is contained in the ceramic plate forming the mounting table as, e.g., a binder, reacts with the hydrogen and a metal (in this case, Ti) generated as a result of such reaction infiltrates into the pre-coated film (the film formed by the pre-coating process), the amount infiltrated is very small. Accordingly, it is possible to greatly reduce the probability of metal contamination of the target substrate due to the transfer of the metal to the target substrate from the pre-coated film on the mounting table. [0012] For example, when pre-coating the inner wall of the processing chamber (including the surfaces of the mounting table and other parts therein) by using the inorganic silane gas, the pre-coated film and the film formed on the target substrate have same or similar properties because the inorganic silane gas belongs to a silane gas, like the organic silane gas used as the processing gas in performing the film forming process on the target substrate. Thus, even if components of the pre-coated film are dispersed, an adverse effect on the film on the substrate can be reduced. [0013] In accordance with a second aspect of the present invention, there is also provided a film forming method including: pre-coating an inner wall of a processing chamber including a surface of a mounting table made of ceramic containing a metal oxide and disposed in the processing chamber with a first silicon-containing nonmetal thin film, by introducing a processing gas containing an inorganic silane gas into the processing chamber; mounting a dummy substrate on the mounting table pre-coated with the first nonmetal thin film; removing the first nonmetal thin film formed on other regions of the mounting table than that covered with the dummy substrate, by introducing a cleaning gas for removing the first nonmetal thin film into the processing chamber; pre-coating the inner wall of the processing chamber and the surface of the mounting table on which the dummy substrate is mounted with a second silicon-containing nonmetal thin film, by introducing a processing gas containing an organic silane gas; unloading the dummy substrate from the processing chamber; mounting a target substrate on the mounting table after the dummy substrate is unloaded; and forming a silicon-containing nonmetal thin film on a surface of the target substrate mounted on the mounting table, by introducing a processing gas containing an organic silane gas. [0014] Also with the method of the second aspect, the processing gas containing the inorganic silane gas (which has a small number of hydrogen atoms per a single molecule) is used in the pre-coating process; therefore, even if a metal oxide (e.g., TiO), which is contained in the ceramic plate forming the mounting table as, e.g., a binder, reacts with the hydrogen and a metal (in this case, Ti) generated as a result of such reaction infiltrates into the pre-coated film (the film formed by the pre-coating process), the amount infiltrated is very small. Accordingly, it is possible to greatly reduce the probability of metal contamination of the target substrate due to the transfer of the metal to the target substrate from the pre-coated film on the mounting table. [0015] In particular, among the surface of the mounting table made of ceramic plate, by means of using the dummy substrate, a pre-coated film is formed only on the mounting table's surface area on which the target substrate is placed by using the inorganic silane gas (which can contain other gases as well). On the other regions including the inner wall of the processing chamber, a pre-coat film is formed by using the organic silane gas (which can contain other gases as well). Thus, the latter pre-coated film and the film formed on the target substrate are made of a same material. Accordingly, even if the components of the pre-coated film are dispersed, an adverse effect on the film on the target substrate can be completely avoided. In this regard, the method of the second aspect is more advantageous than that of the first aspect. Thus, if an operator determines that an adverse effect can be caused on the film formed on the target surface in the method in accordance with the first aspect, it is possible to employ the method of the second aspect instead. [0016] Further, the inner wall of the processing chamber including the surface of the mounting table may include surfaces of parts of the gas supply units exposed to the processing atmosphere. Further, the “pre-coating” refers to a process for forming a thin film in the processing chamber in advance prior to forming a thin film on the target substrate. [0017] It is preferred that the inorganic silane gas is a monosilane gas, a disilane gas or a dichlorosilane gas. [0018] Further, it is preferred that the silicon-containing nonmetal thin film formed by using the processing gas containing the organic silane gas is a carbon and nitrogen containing silicon film (SiCN film), a carbon-containing silicon oxide film (SiCO film) or a carbon and hydrogen containing silicon film (SiCH film). [0019] Also, it is preferred that a titanium oxide, which is a metal oxide, is contained in the mounting table as a binder. [0020] In accordance with a third aspect of the present invention, there is provided a film forming apparatus including: a processing chamber in which a mounting table for mounting a substrate thereon is disposed; a first processing gas supply unit for introducing a processing gas containing an inorganic silane gas into the processing chamber; a second processing gas supply unit for introducing a processing gas containing an organic silane gas into the processing chamber; a substrate transfer mechanism for transferring the substrate to/from the mounting table; and a control unit for controlling the first processing gas supply unit, the second processing gas supply unit and the substrate transfer mechanism to perform the film forming method described above. [0021] In accordance with a fourth aspect of the present invention, there is provided a computer executable program, executed by a computer for controlling a film forming apparatus including: a processing chamber in which a mounting table for mounting a substrate thereon is disposed; a first processing gas supply unit for introducing a processing gas containing an inorganic silane gas into the processing chamber; a second processing gas supply unit for introducing a processing gas containing an organic silane gas into the processing chamber; and a substrate transfer mechanism for transferring the substrate to/from the mounting table, wherein the computer executable program realizes the film forming method described above. [0022] Preferably, in an example, the computer executable program is made to execute pre-coating an inner wall of a processing chamber including a surface of a mounting table made of ceramic containing a metal oxide and disposed in the processing chamber with a silicon-containing nonmetal thin film, by introducing a processing gas containing an inorganic silane gas into the processing chamber; mounting a target substrate on the mounting table pre-coated with the nonmetal thin film; and forming a silicon-containing nonmetal thin film on a surface of the target substrate mounted on the mounting table, by introducing a processing gas containing an organic silane gas into the processing chamber. [0023] In another example, the computer executable program is made to execute pre-coating an inner wall of a processing chamber including a surface of a mounting table made of ceramic containing a metal oxide and disposed in the processing chamber with a first silicon-containing nonmetal thin film, by introducing a processing gas containing an inorganic silane gas into the processing chamber; mounting a dummy substrate on the mounting table pre-coated with the first nonmetal thin film; removing the first nonmetal thin film formed on other regions of the mounting table than that covered with the dummy substrate, by introducing a cleaning gas for removing the first nonmetal thin film into the processing chamber; pre-coating the inner wall of the processing chamber and the surface of the mounting table on which the dummy substrate is mounted with a second silicon-containing nonmetal thin film, by introducing a processing gas containing an organic silane gas; unloading the dummy substrate from the processing chamber; mounting a target substrate on the mounting table after the dummy substrate is unloaded; and forming a silicon-containing nonmetal thin film on a surface of the target substrate mounted on the mounting table, by introducing a processing gas containing an organic silane gas. BRIEF DESCRIPTION OF THE DRAWINGS [0024] FIG. 1 is a schematic cross sectional view illustrating an embodiment of a film forming apparatus (plasma processing apparatus) for performing a film forming method in accordance with the present invention; [0025] FIG. 2 sets forth a plan view showing a part of a first gas supply unit provided in the film forming apparatus of FIG. 1 ; [0026] FIGS. 3A to 3C are schematic diagrams illustrating a process flow of a first embodiment of the film forming method in accordance with the present invention; [0027] FIGS. 4A to 4C are schematic diagrams illustrating a process flow of a second embodiment of the film forming method in accordance with the present invention; [0028] FIGS. 5A to 5C are schematic diagrams illustrating a process flow of a third embodiment of the film forming method in accordance with the present invention; and [0029] FIG. 6A is a vertical cross sectional view showing a mounting table of a conventional film forming apparatus and FIG. 6B provides a diagram describing a generation of Ti from titanium oxide (TiO) which is a binder of the mounting table. DETAILED DESCRIPTION OF THE EMBODIMENTS [0030] An exemplary plasma processing apparatus employed in a film forming method in accordance with the present invention will be described with reference to FIGS. 1 and 2 . In FIG. 1 , a processing chamber (vacuum chamber) 1 is made of, e.g., aluminum, and a mounting member 2 having, e.g., a cylindrical shape is disposed in the processing chamber 1 . The mounting member 2 includes a support 21 made of, e.g., aluminum and a mounting table 22 disposed on the support 21 . The mounting table 22 is made of a ceramic plate having a thickness of, e.g., about 10 mm. Further, a foil-shaped electrode 22 a is buried in the mounting table 22 . The electrode 22 a is connected to a DC power supply 24 via a switch 23 . [0031] In this embodiment, the mounting table 22 is fabricated by mixing powders of aluminum nitride (AlN) with powders of titanium oxide (TiO) as a binder. The aluminum nitride powders contain about 0.1% of titanium oxide powders. [0032] Installed inside the mounting table 2 to penetrate it are, e.g., three elevating pins 25 which serve to receive and transfer a wafer W from and to a transfer mechanism 102 . The elevating pins 25 are movable up and down by an elevation mechanism 27 provided outside the processing chamber 1 via a support member 26 , whereby leading ends of the elevating pins 25 are moved between a transfer position protruded above the mounting table 22 and a standby position retracted in the mounting table 22 . [0033] Further, formed inside the support 21 is a path 28 for a temperature control medium which is used as a temperature control means. A coolant serving as the temperature control medium is introduced into the path 28 via an inlet line 29 and is discharged via an outlet line 30 after circulating through the path 28 . By means of this temperature control medium and a heater (not shown), the temperature of a to-be-processed semiconductor wafer W mounted on the mounting table 22 is maintained at a specific temperature level. Moreover, a high frequency bias power supply 31 of, e.g., about 13.56 MHz is connected to the support 21 . [0034] Besides, disposed above the mounting table 2 is a first gas supply unit 4 which is made of a conductor such as aluminum and is configured as, e.g., a substantially disk-shaped gas shower head. The first gas supply unit 4 is provided with a number of gas injection openings 41 at its surface facing the mounting table 22 . Formed inside the first gas supply unit 4 are grid-patterned gas channels 42 which communicate with the gas injection openings 41 . The gas channels 42 are connected with a gas supply line 43 . [0035] As shown in FIG. 1 , an upstream side of the gas supply line 43 divided into branch lines 5 a and 5 b . Connected to the branch line 5 a via a gas supply kit 52 is a gas supply source 51 for a vapor obtained by vaporizing an organic silane gas such as trimethysilane (SiH(CH 3 ) 3 ) which is used as a processing gas. Further, connected to the other branch line 5 b via a gas supply kit 54 is a gas supply source 53 for an inorganic silane gas such as SiH 4 gas which is used as a processing gas. Each of the gas supply kits 52 and 54 includes a valve, a mass flow controller serving as a flow rate control unit, and so forth, and they serve to control the supply of gas. [0036] Moreover, referring to FIG. 2 , the first gas supply unit 4 is provided with a multiplicity of openings 44 that are provided to vertically penetrate the first gas supply unit 4 . As shown in FIG. 2 , for example, the openings 44 are formed between neighboring gas channels 42 to allow plasma generated in a space above the first gas supply unit 4 to flow into a space below the first gas supply unit 4 . [0037] Furthermore, disposed above the first gas supply unit 4 is a gas supply line 6 which serves as a second gas supply unit. An upstream side of the gas supply line 6 divided into branch lines 6 a to 6 c . Connected to the branch lines 6 a to 6 c via gas supply kits 62 , 65 , 67 are gas supply source 61 , 64 , 66 for supplying N 2 gas as a processing gas, a cleaning gas, and Ar gas as a plasma gas, respectively. Each of the gas supply kits 62 , 65 and 67 includes a valve, a mass flow controller serving as a flow rate control unit, and so forth, and they serve to control the supply of gas. [0038] Disposed above the second gas supply unit 6 is a dielectric plate (microwave transmitting window) 7 , and an antenna section 8 is disposed on the dielectric plate 7 to be in close contact with the dielectric plate 7 . The antenna section 8 includes a circular flat antenna main body 80 ; and a disk-shaped planar antenna member 81 (slot plate) which is installed at a bottom surface of the antenna main body 80 via a retardation plate 83 and provided with a number of slot pairs. Each of the antenna main body 80 and the planar antenna member 81 is made of a conductor, and they are connected to a coaxial waveguide 11 , while forming a circular flat and hollow wave guide together. The antenna main body 80 , the planar antennal member 81 and the retardation plate 83 constitute a radial line slot antenna (RLSA). [0039] The antenna section 8 is connected to an external microwave generator 12 via the coaxial waveguide 11 . An outer waveguide 11 A of the coaxial waveguide 11 is connected to the antenna main body 80 , while a central conductor 11 B of the coaxial waveguide 11 is connected to the planar waveguide member 81 via an opening provided in the retardation plate 83 . [0040] Further, a gas exhaust line 13 is coupled to a bottom portion of the processing chamber 1 . A vacuum pump 15 serving as a vacuum exhaust unit is connected to a basal end side of the gas exhaust line 13 via a pressure control unit including, e.g., a butterfly valve or the like. In addition, a fence member (wall portion) having therein a heater 16 serving as a heating unit is disposed inside the inner wall of the processing chamber 1 . Further, a loading/unloading port 19 for a wafer W is provided in a lower space of the processing chamber 1 , wherein the port 19 is opened or closed by a gate valve 18 . [0041] Furthermore, the plasma processing apparatus includes a control unit 100 made up of, e.g., a computer. The control unit 101 controls the gas supply kits 52 , 54 and 62 , the pressure control unit 14 , the heater 16 , the microwave generator 12 , the electrostatic chuck switch 23 of the mounting table 22 , the gate valve 18 , the elevation mechanism 27 , and so forth. Further, though its specific structure is not shown, a transfer arm 102 serving as a transfer mechanism for transferring a wafer W to and from the mounting table 22 is provided outside the processing chamber 1 . As indicated by a block diagram in a lower side of FIG. 1 , the control unit 101 also controls the transfer arm 102 . [0042] Furthermore, the control unit 101 also includes a memory for storing sequence programs for executing a series of processes to be described later in the processing chamber 1 , an output unit for reading commands of each program and outputting control signals to each component, and so forth. First Embodiment [0043] Now, a series of processes performed in accordance with a first embodiment of the present invention will be described with reference to FIGS. 3A to 3C . [0044] First, a pre-coating process is performed before a target substrate is loaded into the processing chamber 1 . That is, while vacuum-evacuating the processing chamber 1 to a specific pressure level, N 2 gas is supplied into the processing chamber 1 via the gas supply line 6 which is the second gas supply unit, and an inorganic silane gas, e.g., monosilane (SiH 4 ) gas is supplied as a processing gas from the first gas supply unit 4 via the gas supply line 43 . The internal pressure of the processing chamber 1 is maintained at a specific process pressure level, and the surface temperature of the mounting table 22 is regulated at a certain temperature level, e.g., about 380° C. [0045] Meanwhile, a high frequency wave (microwave) of, e.g., about 2.45 GHz and 2000 W is supplied from the microwave generator 12 . The microwave propagates through the coaxial waveguide 11 in a TM mode, a TE mode or a TEM mode and reaches the planar antennal member 81 of the antenna section 8 . While being radially transmitted from the center of the planar antenna member 81 to its periphery, the microwave is emitted through the slot pairs and the dielectric plate 7 toward a processing space thereunder. [0046] At this time, along the array of the slot pairs, a circularly polarized wave is uniformly emitted to the entire planar surface of the planar antenna member 81 , whereby an electric field density in the processing space is made uniform. Further, the N 2 gas is activated by the energy of the microwave, so that high-density plasma is uniformly excited in the space above the first gas supply unit 4 . The plasma (active species) of nitrogen flows into the processing space below the first gas supply unit 4 through the openings 44 of the first gas supply unit 4 . Meanwhile, the SiH 4 gas supplied into the processing space from the first gas supply unit 4 is activated by the active species of nitrogen flown into the processing space, whereby a Si 3 N 4 (silicon nitride) film 200 is formed on the surface of the mounting table 22 , the inner wall of the processing chamber 1 , the surface of the first gas supply unit 4 , and so forth as a pre-coat film in a thickness of, e.g., about 5 nm, as illustrated in FIG. 3A . Then, the pre-coating process is completed. Though the Si 3 N 4 film is formed by using the SiH 4 gas and the N 2 gas in this embodiment, the Si 3 N 4 film may be formed by using Si 2 H 6 gas instead of the SiH 4 gas. [0047] Then, as shown in FIG. 3B , by the transfer arm 102 (see FIG. 1 ), a substrate to be processed, i.e., a wafer W having an interlayer dielectric already formed thereon is mounted on the mounting table 22 , which is coated with the Si 3 N 4 film 200 through the pre-coating process described above. The wafer W mounted on the mounting table 22 is adsorptively held on the mounting table 22 by a Coulomb force generated by a DC voltage applied to the electrode 22 a from the DC power supply 24 . [0048] Subsequently, as illustrated in FIG. 3C , a SiCN film (carbon-containing silicon nitride film) 201 is formed on the surface of the wafer W as a hard mask, for example. Here, N 2 gas is supplied through the gas supply line 6 which serves as the second gas supply unit and, also, an organic silane gas, e.g., trimethylsilane (SiH(CH 3 ) 3 ) gas is supplied as a processing gas from the first gas supply unit 4 through the gas supply line 43 . Then, as described above, the N 2 and the SiH(CH 3 ) 3 are converted into plasmas by the energy of microwaves from the microwave generator 12 , and a SiCN film 201 is formed on the surface of the wafer in a thickness of, e.g., about 5 nm. [0049] After the film formation on the wafer W is completed, the wafer W is unloaded. Then, next wafers W to be processed are loaded sequentially, and the same film forming process as described above is performed on them. After the film forming process has been performed on a preset number of wafers W, the inside of the processing chamber 1 is cleaned to remove the film attached to each component. Thereafter, the pre-coating process, that is the initial step, is performed again, and the series of processes as described above are performed repeatedly. Further, the gas for obtaining active species of nitrogen in forming the Si 3 N 4 and SiCN films is not limited to the nitrogen gas but ammonia gas can be employed instead. [0050] In accordance with the first embodiment, in forming the hard mask of SiCN film by using the organic trimethylsilane gas as a processing gas, the monosilane gas, which is an inorganic silane gas, is used as processing gas in the pre-coating process. Since the number of hydrogen atoms contained in a single molecule of the monosilane gas is small (four), the quantity of hydrogen contained in the pre-coated film is also small. Thus, the quantity of Ti generated with the lapse of time is kept at a negligible level, so that the probability of metal contamination due to a transfer of Ti to a backside of the wafer can be reduced greatly. In practice, a Ti contamination amount at the wafer backside was measured by using the mounting table on which the pre-coated film is formed in accordance with the first embodiment of the present invention. As a result, measured values were below a detection limit (1×10 10 atoms/cm 2 ) both when measured immediately after the pre-coating process and when measured after 2 or 3 days. [0051] Further, in this embodiment, the pre-coating is performed on the inside (inner wall, mounting table 22 and other components) of the processing chamber 1 is performed by using the monosilane gas. This monosilane gas belongs to a silane gas, like the trimethylsilane gas which is used as the processing gas for the film forming process, and the pre-coated Si 3 N 4 film 200 and the SiCN film 201 formed on the wafer W can be said to have similar properties. As described above, for first several wafers W processed right after the pre-coating process, there is a probability that components dispersed from the pre-coated film (Si 3 N 4 film) due to its contact with the plasma may enter the thin film (SiCN film) because the plasma exists in the processing atmosphere when performing the film forming process on the wafer W. However, the dispersed amount is very small and the two films have similar properties, so that an adverse influence thereof is negligible. [0052] The possible adverse influence should be estimated by an operator by considering types of films formed, thicknesses of the films, locations of the films on the device, and so forth. The method in accordance with the above-described embodiment is valid when the adverse influence is determined negligible. Second Embodiment [0053] Now, a series of processes performed in accordance with a second embodiment of the present invention will be explained with reference to FIGS. 4A to 5C . [0054] First, a pre-coating process is performed before a target substrate is loaded into the processing chamber 1 . As in the first embodiment, by using SiH 4 gas and N 2 gas, a Si 3 N 4 film 200 is formed on the surface of the mounting table 22 , the inner wall of the processing chamber 1 , the surface of the first gas supply unit 4 and so forth as a first pre-coat film in a thickness of, e.g., about 5 nm, as illustrated in FIG. 4A . [0055] Subsequently, as illustrated in FIG. 4B , by means of the transfer arm 102 (see FIG. 1 ), a dummy substrate D having the same size as a wafer W is mounted on the mounting table 22 which is coated with the Si 3 N 4 film 200 through the pre-coating process described above. The dummy substrate D mounted on the mounting table 22 is electrostatically attracted to and held on the mounting table 22 by a Coulomb force generated by a DC voltage applied to the electrode 22 a from the DC power supply 24 . [0056] Next, a cleaning gas, e.g., a CF-based gas and/or a CHF-based gas is introduced into the processing chamber 1 from the cleaning gas supply source 64 , whereby the inside of the processing chamber 1 is cleaned. As a result, among the Si 3 N 4 film 200 formed on the surface of the mounting table 22 , the film deposited on portions of the mounting table 22 other than the area below the dummy substrate D (i.e., the area covered with the dummy substrate D) are removed. Further, the Si 3 N 4 film 200 formed on the inner wall of the processing chamber 1 and the like is also removed. [0057] Subsequently, as shown in FIG. 5A , trimethysilane gas and N 2 gas are introduced into the processing chamber 1 as a processing gas, and according to the same principle as that of the SiCN film forming process in the first embodiment, a SiCN film 201 is formed on the surface of the mounting table 22 , the inner wall of the processing chamber 1 , the surface of the first gas supply unit 4 , and so forth as a second pre-coat film in a thickness of, e.g., about 5 nm. [0058] In this case, since the dummy substrate D is placed on the mounting table 22 , the mounting table 22 's area below the dummy substrate D remains uncoated with the SiCN film which is the second pre-coat film. [0059] Subsequently, as illustrated in FIG. 5B , the dummy substrate placed on the mounting table 22 is unloaded from the processing chamber 1 , and a wafer W having an interlayer dielectric formed in advance is loaded into the processing chamber as a target substrate to be processed and is mounted on the mounting table 22 to be electrostatically held thereon. [0060] Thereafter, by using the trimethylsilane gas and the N 2 gas, a SiCN film 201 is formed on the surface of the wafer W, which is mounted on the mounting table 22 , as a hard mask in a thickness of, e.g., about 5 nm, as illustrated in FIG. 5C . Afterward, the wafer W is unloaded from the processing chamber 1 and next wafers W are loaded thereinto sequentially to be subjected to the same film forming process. [0061] In accordance with the second embodiment, by means of using the dummy substrate D, the Si 3 N 4 film 200 , which is the first pre-coat film, is formed only on the surface area of the mounting table 22 on which the wafer W is placed, by using the monosilane gas which is an inorganic silane gas. On the other regions including the inner wall of the processing chamber 1 , the SiCN film 201 which is the second pre-coat film is formed by using the trimethysilane gas, which is an organic silane gas. Accordingly, since the pre-coat film formed based on the inorganic silane gas is present on the region of the mounting table 22 on which the wafer W is placed, a reduction amount of TiO in the aluminum nitride forming the mounting table 22 is small, so that the amount of Ti contained in that pre-coated film is small and the amount of Ti transferred to the wafer W can be reduced. Further, since the second pre-coat film formed in the processing chamber 1 and the film formed on the wafer W are same kinds (SiCN film 201 in this embodiment), no adverse effect is caused on the film on the wafer W due to the dispersion of the components of the second pre-coat film. In this regard, the second embodiment is more advantageous than the first embodiment. [0062] Here, it is to be noted that, in the second embodiment, forming the second pre-coat film by using an inorganic silane gas is included in the scope of the present invention, at least at the time of filing of this application. [0063] Further, in the present invention, the pre-coat film is not limited to the Si 3 N 4 film. For example, when forming SiO 2 film on a target substrate by using an organic silane gas, e.g., TEOS gas and O 2 (oxygen) gas, it is preferable to form the SiO 2 film as a pre-coat film by using, e.g., SiH 4 gas, Si 2 H 6 gas, SiCl 2 H 2 gas, or the like together with O 2 gas in a pre-coating process using an inorganic silane gas. [0064] Moreover, in the pre-coating process using the inorganic silane gas, a polysilicon film may be formed by using, e.g., SiH 4 gas at a processing temperature equal to or higher than about 600° C. [0065] That is, substantially, there is no limit in the kind of the first pre-coat film in the second embodiment. Meanwhile, it is preferable to appropriately set the kind of the second pre-coat film formed on, e.g., the inner wall of the processing chamber 1 by considering the kind of the film formed on the target substrate. [0066] Further, though the SiCN film is formed on the surface of the wafer W as a hard mask in the above-described embodiments of the present invention, it is also preferable that a SiCO film (carbon containing silicon oxide film) is formed as the hard mask by using trimethylsilane gas as a source gas and O 2 gas as a plasma gas. In addition, it is also preferable that a SiCH film (carbon and hydrogen containing silicon film) is formed as the hard mask by using trimethysilane gas as a source gas and Ar gas as a plasma gas. [0067] Moreover, the film forming apparatus for performing the present invention is not limited to the above-mentioned plasma processing apparatus, but a parallel plate electrode plasma processing apparatus, a thermal CVD apparatus, and the like can be employed instead. [0068] Further, the organic silane gas used to form the SiCN, the SiCO or the SiCH film is not limited to the trimethylsilane gas, but it can be CH 3 SiH 3 , (CH 3 ) 2 SiH 2 , (CH 3 ) 3 SiH, (CH 3 ) 4 Si, (CH 3 ) 2 Si(OC 2 H 5 ) 2 , (CH 3 ) 2 Si(OCH 3 ) 2 , CH 3 Si(OC 2 H 5 ) 3 , CH 3 Si (OCH 3 ) 3 , (HCH 3 SiO) 4 (cyclic structure), ((CH 3 ) 3 Si) 2 O, (H(CH 3 ) 2 Si) 2 O, (H 2 CH 3 Si) 20 , ((CH 3 ) 2 SiO) 3 , (CH 3 ASiO) 3 , ((CH 3 ) 2 SiO) 4 , (CH 3 ASiO) 4 , or the like. Here, the last three compounds have cyclic structures, and “A” is a vinyl group (CH—CH 3 ).
A film forming method is characterized in that the method is provided with a step of introducing a processing gas including inorganic silane gas into a processing chamber, in which a mounting table composed of ceramics including a metal oxide is arranged, and precoating an inner wall of the processing chamber including a surface of the mounting table with a silicon-containing nonmetal thin film; a step of mounting a substrate to be processed on the mounting table precoated with the nonmetal thin film; and a step of introducing a processing gas including organic silane gas into the processing chamber, and forming a silicon-containing nonmetal thin film on a surface of the substrate mounted on the mounting table.
7
This is a continuation of application Ser. No. 08/353,082, filed on Dec. 9, 1994, abandoned, which is a continuation-in-part application of U.S. Ser. No. 08/205,609, filed on Mar. 3, 1993, and issued as U.S. Pat. No. 5,398,350 on Mar. 21, 1995. BACKGROUND OF THE INVENTION 1. Field of the Invention The subject invention relates to spas, whirlpools, and the like and, more particularly, to improved cover apparatus for use with portable spas. 2. Description of Related Art Portable spas are generally known in the prior art and have become increasingly popular as a source of relaxation and physical therapy. Their structure generally includes a spa shell or "tub" fabricated of various materials such as fiberglass/acrylic or various thermoplastics, a layer of thermal insulation placed against the shell, and a wooden support structure, often employing a 2×4 frame. In many cases, the exterior of the spa is a continuation of the shell. In some cases, decorative redwood patterns have been applied to serve as the exterior sidewalls or "skirts" of free-standing units. Decorative tile work has also been variously used in the interior and exterior design of portable spas. In order to retain heat and reduce evaporation, portable spas have been fitted with insulating covers. The most commonly used cover is made of cut styrofoam halves surrounded by a sewn vinyl covering and permanently hinged together. This structure provides a flat cover, which is simply slid over the top of the spa when the spa is not in use. Another known spa cover for use with a so-called "soft core" spa is formed of one-piece polyethylene foam with a hand-sewn cover and fits into the spa like a cork. Other covers have employed foam cores with more resilient rigid covering materials and have employed various spring-biased hinged mechanisms for raising and lowering because of their considerable weight. To meet industry safety standards such as ASTM F1346-91, spa covers must meet static load, deflection, and surface drainage standards. Under ASTM F1346-91, a spa cover must support a weight of 485 pounds. A deflection test must be met to ensure that if a child under five falls on the cover, he cannot slip through any openings. The surface drainage standard ensures that the cover will not retain enough water to risk drowning of a small child. Spa covers of the prior art in general suffer from a number of drawbacks. The conventional spa covers are labor intensive to manufacture, cumbersome to use, and have a notoriously short life span in the face of hot chlorinated water, sunlight, and the wear and tear of use. Many of the designs, such as the soft core "cork," cannot meet industry safety standards. OBJECTS AND SUMMARY OF THE INVENTION It is therefore an object of the invention to improve covers used in connection with portable spas and similar pool structures; It is another object to increase the life of covers used in conjunction with spas; It is another object to improve the ease of use of spa covers; and It is another object to provide a spa cover design which is relatively lightweight and easy to use and which can meet industry safety standards; According to the invention, an improved portable spa cover integrating several novel aspects into the overall design is provided. These aspects include rigidly molded, interlocking cover sections, adapted to rest on the upper rim of the spa. The cover sections each preferably include an outer surface and an inner surface with a plurality of support ribs being provided to add strength and rigidity. Hinge means are provided which prevents disengagement when the cover sections are lying horizontal and which enable the cover sections to be engaged and disengaged when one of them is horizontally disposed and the other is at an acute angle to the horizontal. According to another aspect of the invention, the hinge means includes finger means which bias the cover halves together and further bolster and secure their horizontal relation. The inventive aspects just discussed are particularly disclosed in a three-piece cover embodiment wherein first and second end pieces are removably hinged to a center piece. BRIEF DESCRIPTION OF THE DRAWINGS The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which: FIG. 1 is a side elevational view of a spa wherein the preferred embodiment may find application; FIG. 2 is a perspective view of a spa according to FIG. 1 with the cover removed; FIG. 3 is a partial side sectional view of the spa of FIG. 1; FIG. 4 is a top view of a two-piece spa cover embodiment; FIG. 5 is a sectional view taken at 5--5 of FIG. 4; FIG. 6 is a sectional view taken at 6--6 of FIG. 4; FIG. 7 is a sectional view taken at 7--7 of FIG. 4; FIG. 8 is a detail illustrating the hinge structure of the two-piece cover embodiment; FIG. 9 is a detail further illustrating the hinge structure of the two-piece embodiment; FIG. 10 is a partial, cutaway perspective view of a first cover half according to the two-piece embodiment; FIG. 11 is a partial, cutaway perspective view of a second cover half; FIG. 12 is a top view of a three-piece, generally rectangular spa cover embodiment; FIG. 13 is a bottom view of the cover of FIG. 12; FIG. 14 is an end view depicting the inner end of an end cover piece of the cover of FIG. 12; FIG. 15 is a partial sectional view taken at 15--15 of FIG. 13; FIG. 16 is a sectional view of an end cover piece taken generally at 16--16 of FIG. 12; FIG. 17 is a sectional view taken at 17--17 of FIG. 12; FIG. 18 is a sectional view taken at 18--18 of FIG. 13; FIG. 19 is an end view of the center piece of the cover of FIG. 12; FIG. 20 is a sectional view of the cover center piece taken at 20--20 of FIG. 12; FIG. 21 is a sectional view of the cover center piece taken at 21--21 of FIG. 12; and FIG. 22 is a perspective view illustrating the center cover piece of the cover of FIG. 12 mounted on a cooperating spa rim. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide readily manufacturable and particularly useful portable spa improvements. FIG. 1 illustrates a spa 11 whereupon is mounted a cover 13 according to the preferred embodiment. The spa 11 further includes a decorative, interchangeable side skirt 15 and a bottom pan 17. The skirt 15 includes a zipper 132 and is removable and replaceable by skirts of, for example, different colors. FIG. 2 shows a typical interior configuration of the spa 11, including jet openings 25 and seating areas. The particular interior detail is, of course, variable, as will be appreciated by those skilled in the art. As shown in FIG. 3, the spa interior is provided by a molded shell 19, which may be molded from fiberglass, acrylic, polypropylene, or other materials. The shell 19 includes a crowned upper rim 20 having a depending vertical edge or lip 106. Adjacent the shell 19 is a layer of rigid foam insulation 21 which defines the exterior contour of the spa 11, providing a bottom surface 18 and a side surface 22. The foam insulation 21 is preferably a rigid, two-pound density, closed cell, polyurethane foam. The bottom surface 18 is contoured to conform to the interior surface shape of the bottom pan 17. The bottom pan 17 itself is waterproof and is glued to the rigid foam insulation 21 in order to provide a sealed, water impervious surface. The interchangeable skirt 15 is positioned adjacent the side surface 22 and includes interior foam padding or batting 23 and a backing layer of cloth material 24. The upper edge of the interchangeable skirt 15 inserts within the lower edge of an extrusion 16, which attaches to the depending vertical edge 106 of the spa rim 20. The top cover 13 is shown in more detail in FIGS. 4-11. The top cover 13 shown in FIG. 4 is generally circular and includes a female half 41 and a male half 43. These halves 41, 43 are adapted to abut one another along corresponding edges 26, 28. Each half 41, 43 further includes three identically-formed ribs 57, which separate or define four pie-shaped sections 60. Each cover half 41, 43 is a unitary part, preferably rotationally molded plastic, although injection molding might be used. As shown in FIG. 5, each rib 57 is formed by molding the bottom lower surface 66 of the particular cover half 41, 43 to conform to a bell-shaped cross-section, thereby forming a bell-shaped channel or impression 61. At regular intervals, the bell-shaped channel 61 is further provided with domes 63, which extend to meet a recess 68 in the upper surface 64 of a respective cover half 41, 43. Five such domes 63, equally spaced from one another, may be provided in each rib 57. This overall structure provides strength and rigidity to the respective cover halves 41, 43. Additional intermediate channel areas 62 are also preferably provided to add additional strength to the structure. These channel areas may be substantially identical in cross-section to that of the ribs 57 shown in FIG 5. Two domes 63 are preferably provided in the intermediate channels 62. As further illustrated in FIG. 5, openings 74 are provided in the lower surface 66 of each cover half 41, 43. These openings 74 are filled with foam beads such as polystyrene beads, and then plugs 67 are inserted. The beads provide insulation to the cover 13. Such beads could also provide additional structural support if they were molded into a core at the end of the rotational mold cycle. In the foregoing manner, the cover 13 is provided with an inner skin 66 and outer skin 64 spaced apart from one another, for example, by a mean spacing of 70-80 millimeters, except at a number of selected areas where the two surfaces are brought adjacent to one another by the dome structures 63, thereby facilitating a rotational molding process. A sealed interior providing desirable insulation characteristics is additionally achieved. As shown in FIG. 6, the top surface of each cover section 41, 43 angles gently downward to an outer rim 70, which includes an outer vertical wall 69 and an inner vertical wall 71. The inner vertical wall 71 curves through a 90-degree radius to a slightly recessed channel 73 molded to meet and rest on the rim 20 of the spa 11 in order to provide an adequate and effective seal therewith. If desired, this recessed area 73 may be provided with a strip of insulating material to provide a seal between the rim 20 and the cover 13. The rim 70 thus provides a depending skirt which surrounds the outer circumference of the spa 11 and retains the cover 13 in place on the spa 11. The cover halves 41, 43 feature an integrally molded interlocking hinge mechanism provided by an elongated, tapered female hinge projection 51, an elongated, tapered male hinge projection 50, a central finger extension 47, and first and second side finger extensions 45. Molded indentations 53, 55 (FIG. 4) of rectangular cross-section may be provided to strengthen the area behind the side finger extensions 45. FIG. 7 generally illustrates the cross-sectional mating structure of the elongated, tapered projections 51, 50 at the center of the two halves 41, 43, while omitting the finger detail. FIGS. 8 and 9 illustrate in detail the hinge cross-section at the location of the central finger extension 47 and the side finger extensions 45, respectively. As shown, the male projection 50 generally includes a bulbous portion 40 undercut to form a recessed receptacle portion 42, which curves into a descending angled floor portion 44. As illustrated in FIGS. 8-11, this cross-section continuously and symmetrically narrows from the center 46 of hinge projection 50 toward each end 48 thereof, resulting in a profile which generally recedes away from a relatively prominent bulbous crown 46 at the center 46 toward the ends 48. The female projection 51 is correspondingly contoured to conform to the varying cross-section of the receptacle 42 and the descending floor portion 44 presented by the male projection 51. The resulting interlocking structure cannot be pulled apart when both cover halves 41, 43 are horizontally disposed, but can be pulled apart when one half is elevated to an acute angle with the horizontal, the angle being determined by the geometry of the interlocking structure, particularly the upsweep of receptacle 42 and the clamping action between bulbous portion 40 and the finger extensions 45, 47. Thus, the two cover halves 41, 43, when lying on a flat plane, e.g., when their inner surfaces 73 are supported by the spa rim 20, are restrained from being pulled apart in a horizontal direction by the interaction of the hinge projections 50, 51 and the fingers 45, 47. Engagement and release of these mated, hinged parts is achieved by raising one of the cover halves 41, 43 to approximately 40 degrees above horizontal. At that point, the hinged halves 41, 43 release and allow separation for easier removal, handling, and storage. The fingers 45, 47 exhibit resilience and are further preferably disposed to provide an interference fit or bias; that is, the fingers 45, 47 are depressed slightly downward against their biased position as the cover halves 41, 43 interlock, and therefore tend to hold the cover halves 41, 43 in interlocking relationship to create a tight fit. This action is particularly desirable in the face of molding tolerances. The fingers 45, 47 also prevent the engaged cover halves 41, 43 from tending to bow in or out, and thus serve to preserve the horizontal interlocking relationship of the cover halves 41, 43. The natural locking tendency of the two cover shapes 41, 43 prevents horizontal separation and helps maintain a weathertight seal for the spa. The natural locking tendency of the two shapes 41, 43 further discourages unwanted or unauthorized entry of persons into the spa water, when used in conjunction with external lockdown mechanisms (not shown), which secure the cover halves 41, 43 to the spa proper. Thermal efficiency of the complete package is promoted by reducing loss of heat from the spa water that might occur with a nonjoined assembly of cover halves. Such efficiency may be further promoted in some configurations by placement of spongy insulation and sealing material along the portions of the surfaces of the abutting edges 26, 28 which lie adjacent the elongated hinge projections 50, 51. The molded, two-piece cover 13 is also relatively lightweight, lasts twice as long as conventional foam-based lids, can be fabricated to meet ASTM safety standards, and provides other advantages noted above. It may be noted that the structural advantages of the cover 13 can be adapted to various other cover shapes, for example square or rectangular. In such case, support ribs may run in directions other than radially and the same or similar hinge mechanism may be used. One such other cover shape is the three-part rectangular spa cover embodiment 201 shown in more detail in FIGS. 12-21. The spa cover 201 shown in FIG. 12 includes generally rectangular right and left end pieces 203, 205 and a generally rectangular middle piece 207. The right and left end pieces 203, 205 are adapted to abut the middle piece 207 along corresponding edges 212, 214. In the preferred embodiment illustrated, the right end piece 203 and left end piece 205 each have a generally straight, flat end 200, 202 which is radiused or arced through respective corners 204, 206 into slightly obtusely angled respective sides 208, 210. The sides 208, 210 symmetrically and gently expand apart from one another and terminate at the inner edge 212, 214 of each respective side piece 203, 205. In the preferred embodiment, the end pieces 203, 205 are mirror images of one another and, thus, essentially identical in various structural aspects. As noted, the middle piece 207 is generally rectangular in appearance with sides arced slightly to meet the sides 208, 210 of the respective end pieces 203, 205. Each cover piece or section 203, 205, 207 is a unitary part, preferably rotationally molded plastic, although injection molding might be used. The cover top shown in FIG. 12 is shown with detail areas, e.g. 216, raised slightly above channel areas, e.g. 218 by, e.g., 125-inch, for decorative purposes. Each cover piece 203, 205, 207 further includes generally radially distributed support ribs 215, 217, 219 (FIG. 13). The middle piece 205 also includes a cross-shaped center support rib 221. Each rib 215, 217, 219, 221 is formed by molding the respective bottom lower surface 266, 267, 268 of the respective cover piece 205, 207, 203 to conform to a bell-shaped cross-section, thereby forming a plurality of bell-shaped channels or impressions 261, as shown in FIG. 15. Such channels 261 may have a bottom width W 1 of two inches symmetrically narrowing to a width W 2 of, e.g., 1.1 inches. At selected intervals, each bell-shaped channel 261 is further provided with one or more domes 263, which extend to meet the upper surface 264 of a respective cover piece 203, 205, 207. The domes 263 are preferably spaced apart by approximately five inches, the number thus varying with the length of the rib. This overall structure provides strength and rigidity to the respective cover pieces 203, 205, 207. In the foregoing manner, the cover pieces 203, 205, 207 are each provided with an inner skin 266 and an outer skin 264 spaced apart from one another, for example, by a mean spacing of 70-80 millimeters, except at a number of selected areas where the two surfaces are brought adjacent to one another by the dome structures 263, thereby facilitating a rotational molding process. As with the cover structure illustrated in FIGS. 4-11, openings may be provided in the lower surface 266 of each cover piece 203, 205, 207 and filled with foam beads such as polystyrene beads, and then plugged. A sealed interior providing desirable insulation characteristics is additionally achieved. As shown in FIG. 17, the top surface of each cover end piece 203, 205 angles gently downward to an outer rim 270, which includes an outer wall 269 and an inner wall 271, each at a slight angle to the vertical. The inner wall 271 transitions through a first horizontal surface 272 to a slightly recessed channel 273 molded to meet and rest on the rim 220 of a cooperating spa structure in order to provide an adequate and effective seal therewith. The inner wall 271 is thus displaced, e.g., by about 0.75-inch from the side of the spa to accommodate tolerances and operation of a built-in gutter as hereafter described. If desired, this recessed area 273 may be provided with a strip of insulating material to provide a seal between the spa rim 20 and the cover 201. The rim 270 thus provides a depending skirt which surrounds the outer circumference of the spa and retains the cover 201 in place on the spa. As particularly shown in FIGS. 16, 18, and 21, the cover pieces 203, 205, 207 feature an integrally molded interlocking hinge mechanism provided by first elongated male hinge projections, e.g. 250, on the respective inner edge 214, 212 of each end piece 203, 205 and respective mating elongated female hinge projections 251, 351 on respective edges 254, 354 of the middle cover piece 207. As part of the hinge mechanism, each respective inner edge 214, 212 further includes a central finger extension 247, 347 and first and second side finger extensions 245 (FIG. 13), 345. As shown in FIG. 16, each end piece preferably includes an integrally formed handle opening 278. FIGS. 16, 18, and 21 generally illustrate the cross-sectional mating structure of the male and female hinge projections 251, 351, 250. As shown, the male projection 250 generally includes a bulbous portion 240 undercut to form a recessed receptacle portion 242, which curves into a descending angled floor portion 244. This cross-section is continuously maintained from the center of the male hinge projection 250 to each end thereof. Each end 246, 248 of the female hinge projection 351 is further located to extend beyond or overhang the midpoint of the spa rim 220, as particularly shown in FIG. 22. Through such positioning, the troughs 252, 352 provided by the female hinge projections 251, 351 are arranged to serve as gutters to conduct water incident on the top of the lid outside of the spa pool. The female projection 251 is correspondingly contoured to conform to the cross-section of the receptacle 242 and the descending floor portion 244 presented by the male projection 250. The resulting interlocking structure operates like the embodiment shown in FIGS. 4-11. Thus, the interlocked cover pieces 203, 205, 207 cannot be pulled apart when the mated pieces 203, 205, 207 are horizontally disposed, but can be pulled apart when either end cover piece 203, 205 has its outer end 200, 202 elevated to an acute angle with the horizontal, the angle being determined by the geometry of the interlocking structure, particularly the upsweep of receptacle 242 and the clamping action between bulbous portion 240 and the finger extensions, e.g., 245, 247. As with the embodiment of FIGS. 4-11, the fingers 245, 247; 345, 347 exhibit resilience and are further preferably disposed to provide an interference fit or bias; that is, the fingers 245, 247; 345, 347 are depressed slightly downward against their biased position as the mating cover sections interlock, and therefore tend to hold the cover sections 203, 205, 207 in interlocking relationship to create a tight fit and prevent the engaged cover sections 203, 205, 207 from tending to bow in or out, thus serving to preserve the horizontal interlocking relationship of the cover sections. In general, the three-piece cover of FIGS. 12-21 enjoys all the advantages of the two-piece embodiment of FIGS. 4-11. Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
A portable spa cover having three rigidly molded, interlocking pieces including two mirror image end pieces and a center piece and designed to conform with the contour of the rim of a spa. Each cover piece has an undersurface and outer surface with a plurality of radial support ribs being formed in the undersurface to provide strength and rigidity. Elongated, tapered male and female hinge members are integrally molded as part of the respective end pieces and center piece and permit the cover pieces to be engaged and disengaged from one another when at an angle with respect to one another, while remaining firmly locked together when the pieces all lie horizontally. The horizontal engagement is further facilitated by resilient fingers which extend out from the male projection at intervals along the cover edge and provide a resiliently biased interlocking mechanism.
4
This invention relates to catalysts. It relates in particular to a process for preparing a Fischer-Tropsch catalyst, and to a Fischer-Tropsch catalyst prepared by the process. SUMMARY OF THE INVENTION According to the invention, there is provided a process for preparing a Fischer-Tropsch catalyst, which process comprises subjecting a slurry comprising a particulate alumina carrier, water and an active component selected from the group consisting in cobalt (Co), iron (Fe) and mixtures thereof, to a sub-atmospheric pressure environment, thereby to impregnate the alumina carrier with the active component; drying the impregnated carrier under a sub-atmospheric pressure environment; and calcining the dried impregnated carrier, thereby to obtain the Fischer-Tropsch catalyst. The sub-atmospheric pressure environment during the impregnation may be at a pressure less than 20 kPa(a), and preferably at a pressure less than 10 kPa(a). Likewise, the sub-atmospheric pressure environment during the drying may be at a pressure less than 20 kPa(a), and preferably at a pressure less than 10 kPa(a). The drying temperature is limited by the lower limit of the decomposition temperature of the active component, which is typically a nitrate salt so that the drying temperature is typically 70° C.-90° C. The sub-atmospheric pressure environments can thus be obtained by placing the slurry in a suitable enclosed vessel, and drawing the required sub-atmospheric pressure or vacuum on the vessel. While the impregnation and drying in the sub-atmospheric pressure or vacuum environments or conditions can be effected in two separate or distinct steps, they can, if desired, be effected in a single step, so that the impregnation is effected while the drying takes place. The drying in the sub-atmospheric pressure environment may be continued until the moisture content of the impregnated carrier is below 20% by mass. Thereafter, the impregnated carrier may be dried further under non-sub-atmospheric pressure conditions to remove more water, particularly water of crystallization. The further drying may be effected by passing a drying medium, eg air, in co-current or counter-current fashion over the impregnated carrier. The drying temperature may then be between 100° C. and 180° C. Thus, for example, the further drying may be effected by means of hot air used to fluidize and dry the particulate carrier, eg in a tubular reactor, in which case the air flow is co-current. Instead, however, the further drying may be effected in a counter-current air drier, which may be a catalyst spray drier. The calcination of the dried impregnated carrier thus converts or decomposes the active component to its oxide form. Thus, for example, the active component can be used in the form of a salt, eg Co(NO 3 ) 2 , with the salt then being decomposed to the oxide of the active component, eg Co 3 O 4 . The calcining is thus effected in a calciner. For example, the calciner can be mounted to the lower end of a spray drier used for further drying of the carrier as hereinbefore described, with the dried carrier then falling directly into the calciner. If desired, the calcined catalyst may be re-slurried with water together with at least one of the following: the active component, another active component, or a dopant as hereinafter described, with the resultant impregnated carrier then again being subjected to drying and calcination, as hereinbefore-described. The process may include forming the slurry. In particular, the active component may initially be in the form of a water soluble compound of the component, and may then be dissolved in at least some of the water, prior to forming the slurry with the alumina carrier, so that formation of the slurry will then involve intimate admixing of the alumina carrier and a solution of the active component compound. Supersaturation during impregnation, which results in active component precursor crystallization, should be avoided during impregnation/drying. The supersaturation aspect is addressed through the slurry impregnation, while the vacuum drying at ˜75° C. of the aqueous solution addresses the precursor crystallization aspect. Thus, the purpose is to inhibit or prevent the diffusion of the catalyst precursor to the outer rim of the carrier body during drying (which would result in an egg-shell distribution) and which is enhanced by slow drying rates. Vacuum drying of an aqueous impregnation solution at ˜75° C. overcomes this problem, thereby also eliminating the option of using more volatile solvents, eg acetone, alcohol, etc, the use of which is also complicated by aspects such as: poorer solubilities of nitrates, for example ˜35% less Co(NO 3 ) 2 is soluble in acetone as compared to water at room temperature; and the presence of high quantities of crystal waters, eg Co (NO 3 ) 2 .6H 2 O. While the alumina carrier will typically not be structurally promoted, it is, however, envisaged that it can contain a structural promoter such as magnesium (Mg) or cerium (Ce) if desired, eg if it is desired to enhance the attrition resistance of the resultant catalyst which is obtained from the process of the invention. Irrespective of whether or not the alumina carrier is structurally promoted, the process of the invention may, however, be categorized thereby that no promoter to enhance the activity of the resultant catalyst or to modify its selectivity, such as potassium (K), chromium (Cr), magnesium (Mg), zirconium (Zr), ruthenium (Ru), thorium (Th), hafnium (Hf), cerium (Ce), rhenium (Re), uranium (U), vanadium (V), titanium (Ti), manganese (Mn), nickel (Ni), molybdenum (Mo), wolfram (W), lanthanum (La), palladium (Pd), uranium (U), praseodymium (Pr), neodymium (Nd) or other elements from groups IA or IIA of the periodic table of the elements, is added to the slurry or to the impregnated carrier. Thus, the resultant catalyst will then contain no such synthesis enhancing promoter(s). As a result, the calcination of the dried impregnated carrier may be effected at a relatively low temperature, eg at a temperature below 350° C., and even below 300° C. When the catalyst is to be used in a slurry bed reactor, it may be washed with a suitable washing medium, eg water, after the calcination, to remove unwanted contaminants, such as cobalt, which may have formed on the external surface of the catalyst in the form of a shell of cobalt, ie without alumina being present in the shell. This washing is preferably effected with agitation, which may be achieved through boiling of the water in which the catalyst is washed. Changing the water from time to time speeds up the procedure. The process may include reducing the calcined catalyst, eg by subjecting it to heat treatment under the influence of a reducing gas such as hydrogen. It is usually desired that the resultant catalyst must comply geometrically with certain requirements in order to obtain a desired activity and/or selectivity, without the use of synthesis enhancing promotors, as hereinbefore described. Thus, for example, the catalyst may have a specified minimum pore size, typically a pore size of at least 12 nm. If the alumina carrier geometry is such that these geometric requirements in respect of the resultant catalyst will not be met, then the process may include pretreating the alumina carrier appropriately. Thus, the process may include pretreating the particulate alumina carrier or substrate prior to forming the slurry thereof with the water and the active component, to modify the average diameter of its pores, ie its pore size, and/or to modify its chemical phase. This pretreatment may comprise chemically pretreating the carrier and/or precalcining it prior to the slurry formation. When the carrier is chemically pretreated, this may involve treating it with ammonia. In particular, the ammonia treatment may comprise forming a paste by admixing the alumina carrier with water; spraying ammonia onto the paste; optionally, spraying more water onto the ammoniated paste, with simultaneous mixing, eg kneading, of the paste; extruding the paste; drying it; and then calcining it. This calcination may be effected at a temperature between 200° C. and 1000° C., preferably between 500° C. and 900° C. An acid, such as acetic acid, may be added to the paste, if desired. When the carrier is precalcined without chemical pretreatment thereof, as hereinbefore described, this calcination may also be effected at a temperature between 200° C. and 1000° C., preferably between 500° C. and 900° C. More particularly, the pretreatment may then comprise admixing the alumina carrier with water and an acid such as acetic acid; spraying additional water onto the mixture while mixing, eg kneading, it further; extruding the resultant paste; drying the extruded paste; and then effecting the calcination thereof. The water and acid initially mixed with the carrier may be in the form of dilute acid solution. Naturally, the extrusion of the paste can be dispensed with if desired, eg if the resultant catalyst is to be used in a slurry bed reactor. The alumina carrier or support may be that prepared by a spray-drying technique, provided that it has been subjected to the calcination temperature hereinbefore referred to, either during manufacture thereof, or subsequently during pretreatment thereof as hereinbefore described. Thus, a commercially available alumina support, such as the spray dried alumina support available from CONDEA Chemie GmbH of uberseering 40, 22297 Hamburg, Germany. The alumina carrier is thus characterized thereby that it is used in a relatively pure form, containing at most only minor proportions of impurities or undesired substances such as titania and/or, silica, and/or a minor proportion of a structural promotor as hereinbefore described. Furthermore, the process may be characterized thereby that the alumina carrier is the only carrier, ie that the alumina is not used in conjunction with other carriers or supports such as titania or silica. The mass proportion of active component to alumina carrier in the slurry may be between 5:100 and 60:100, typically between 10:100 and 45:100. The process may include adding to the slurry or to the impregnated uncalcined carrier or to the calcined catalyst, as a dopant, a minor proportion of an agent capable of enhancing the reducibility of the active component. The dopant may instead, or additionally, be added to the slurry which is formed when the calcined catalyst is reslurried as hereinbefore described. The dopant may comprise copper (Cu) and/or platinum (Pt). The mass proportion of the dopant, when present, to active component may be between 0,005:100 and 10:100, typically between 0,1:100 and 5,0:100 for copper, and between 0,01:100 and 0,3:100 for platinum. The invention extends also to a Fischer-Tropsch catalyst, when produced by the process according to the invention. The catalyst has high specific activity, and is suitable for the selective conversion of synthesis gas, utilizing Fischer-Tropsch reaction conditions in fixed or slurry catalyst beds, to high molecular weight saturated hydrocarbons, ie waxes. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described in more detail with reference to the following non-limiting examples, and with reference to the accompanying drawings, in which FIG. 1 shows a plot of wax selectivity vs activity in respect of the catalysts of Examples 1 to 8; FIG. 2 shows a plot of wax selectivity vs pore size in respect of the catalysts of Examples 5, 7, 9, 10 and 11; FIG. 3 shows a plot of wax selectivity vs pore size in respect of the catalysts of Examples 36 to 59; and FIG. 4 shows a plot of percentage CO conversion vs selectivity in respect of the catalysts of Example 60. DESCRIPTION OF THE PREFERRED EMBODIMENTS In the examples hereunder, a series of cobalt supported catalysts on alumina were prepared and tested for their activity in the conversion of synthesis gas into hydrocarbons. Fixed Bed Tests These tests were performed using 40 ml of catalyst. The catalyst was either crushed and sieved extrudates to particle sizes ranging from 1 mm to 1,7 mm, or spray dried to particle sizes ranging between 0,05 mm and 0,15 mm. A tubular reactor was used, and had an internal diameter of 1 cm and a length of 100 cm. The top part of the reactor was filled with an inert material to act as a pre-heater for the gas feed. The feed gas consisted of hydrogen and carbon monoxide in an H 2 /CO molar ratio of 2/1. The hydrogen and carbon monoxide accounted for about 84% (molar basis) of the feed. The other 16% was composed of inert gases, mainly methane (14,5%) and nitrogen (about 1%). The reactor was surrounded by an aluminium jacket which was electrically heated. The feed flow was controlled by means of Brooks mass flowmeters, and the Gas Hourly Space Velocity (GHSV) used in all the experiments was 4200 h -1 , based on total feed flow. The waxy products were collected in a condenser at about 18 bar and 130° C. This was followed by a condenser at about 18 bar and 20° C. for the liquid products. Slurry Phase Tests Between 10 and 30 g of catalyst, spray-dried to particle sizes ranging between 38 μm to 150 μm, was suspended in 300 ml molten wax and loaded in a CSTR with an internal volume of 500 ml. The feed gas consisted of hydrogen and carbon monoxide in a H 2 /CO molar ratio of 2/1. This reactor was electrically heated and sufficiently high stirrer speeds were employed so as to eliminate any gas-liquid mass transfer limitations. The feed flow was controlled by means of Brooks mass flow meters, and space velocities ranging between 1 and 3 m 3 n /h/kg catalyst were used. GC analyses of the permanent gases as well as the volatile overhead hydrocarbons were used in order to characterize the product spectra. All catalysts were reduced, prior to synthesis, in a fixed bed reactor at a pure hydrogen space velocity of 2 500 h -1 and pressures ranging between 1 and 10 bar. The temperature was increased from room temperature to 350° C. to 400° C. at a rate of 1° C./min, after which isothermal conditions were maintained for 6 to 16 hours. The catalysts were prepared according to the following examples: EXAMPLE 1 50 g Alumina powder was added to 70 ml distilled water. To this 50 g Co(NO 3 ) 2 .6H 2 O was added. The mixture was kneaded thoroughly and extruded. The extrudates were dried in an oven for 2 to 3 hours at 100° C. and thereafter calcined at 350° C. for 16 hours. The alumina powder was that obtained from Degussa AG under the designation "Degussa Aluminium Oxide C". EXAMPLE 2 In a similar manner to Example 1, a catalyst was prepared by impregnation, drying and calcining, except that 42.5 g, instead of 50 g, Co(NO 3 ) 2 .6H 2 O was added to the alumina and water mixture. EXAMPLE 3 In a similar manner to Example 1, a catalyst was prepared but 37.5 g, rather than 50 g, Co(NO 3 ) 2 .6H 2 O was added to the alumina. EXAMPLE 4 In a similar manner to Example 1, a catalyst was prepared, but 20 g Cr(NO 3 ) 3 .9H 2 O was added as a promoter. EXAMPLE 5 50 g of the same alumina powder as used in Example 1, was added to 70 ml distilled water. To this mixture 25 g Co(NO 3 ) 2 .6H 2 O and 6.1 g Mg(NO 3 ) 2 .6H 2 O were added. The mixture was kneaded and extruded similarly to Example 1. EXAMPLE 6 A catalyst was prepared in a similar manner to Example 1, but 0.35 g KNO 3 was added as a promoter. EXAMPLE 7 A catalyst was prepared in a similar manner to Example 5, but 0.4 g KNO 3 was added in place of the Mg(NO 3 ) 2 .6H 2 O. EXAMPLE 8 A catalyst was prepared in a similar manner to Example 1, but 4.9 g Th(NO 3 ) 4 .5H 2 O was added as a promoter. The characteristics of the catalysts of Examples 1 to 8, as well as their performance in fixed bed Fischer-Tropsch synthesis, are presented in Table 1. TABLE 1__________________________________________________________________________ Fischer-Tropsch fixed bed synthesis performance at 18Catalyst Examples. bar and a GHSV of 4 200 h.sup.-1(Particle sizes varied Active metal Promoter Fischer-Tropschbetween 1.0 and 1.7 content Promotion level Reaction activity expressed as Mass % reactormm with a pore size (g Co per (expressed per temperature m mol H.sub.2 O formed wax selectivityof 24 nm) 100 g Al.sub.2 O.sub.3) Element 100 g Al.sub.2 O.sub.3) (°C.) per ml catalyst per h (˜C.sub.19+)__________________________________________________________________________1 20 -- -- 225 11.1 322 17 -- -- 220 7.5 373 15 -- -- 220 5.6 444 20 Cr 5.2 g 220 3.0 495 10 Mg 1.2 g 220 2.6 465 10 Mg 1.2 g 215 1.6 536 20 K 0.3 g 220 5.0 447 10 K 0.3 g 220 2.1 577 10 K 0.3 g 215 1.3 638 20 Th 4.0 g 218 4.4 42__________________________________________________________________________ It can thus be seen that there is a strong correlation between the wax selectivity (defined here as the fraction of hydrocarbons condensed at 130° C. at 18 bar) and the activity of the catalyst. This correlation is independent of the nature of the promoter and also independent of the addition of a promoter. This is more clearly indicated in FIG. 1 which graphically shows the data of Table 1. Additional supported cobalt catalysts were prepared according to the following procedure in order to cover a range of pore sizes. EXAMPLE 9 A catalyst was prepared in a similar manner to Example 1 but 12.5 g Mg(NO 3 ) 2 .6H 2 O was added as a promoter. EXAMPLE 10 A catalyst was prepared in a similar manner to Example 5 except that 4.0 g Zr(IV)acetylacetonate was added in the place of the Mg(NO 3 ) 2 .6H 2 O. EXAMPLE 11 A catalyst was prepared in a similar manner to Example 1, but 0.85 g KNO 3 was added as a promoter. These catalysts were dried, calcined and tested for their fixed bed synthesis behaviour in a similar fashion to the catalysts of Examples 1 to 8. The physical characteristics and the catalytic activity of the catalysts are presented in table 2. TABLE 2__________________________________________________________________________ Fischer-Tropsch fixed bed synthesis performance at 18 bar, 220° C., andCatalyst a GHSV of 4 200 h.sup.-1Examples Promoter Fischer-Tropsch Mass % Particle sizes Promotion level Pore activity expressed as reactor waxvaried between Active metal content (expressed per size m mol H.sub.2 O formed selectivity1.0 and 1.7 mm! (g Co per 100 g Al.sub.2 O.sub.3) Element 100 g Al.sub.2 O.sub.3) (nm) per ml catalyst per h (˜C.sub.19+)__________________________________________________________________________9 20 Mg 2.4 g 21.5 2.5 2410 10 Zr 1.5 g 22.5 2.1 305 10 Mg 1.2 g 24.0 2.6 467 10 K 0.3 g 24.3 2.1 5711 20 K 0.7 g 25.9 2.3 61__________________________________________________________________________ From Table 2 it can thus be seen that for a given activity (ie ˜2 m mol H 2 O/ml cat/h), reactor wax selectivity is a strong function of average catalyst pore size. This relationship is independent of the type of promoter added. This is more clearly illustrated in FIG. 2, which graphically illustrates the results shown in Table 2. In Examples 1 to 11, use was made of fumed Al 2 O 3 which was co-extruded with the catalytically active components. An alternative approach is to extrude (or spray dry) and calcine the Al 2 O 3 support separately as a first preparation step, prior to impregnation with the active component(s). This procedure allows for more freedom with respect to tailoring of the support geometry. For this application, precipitated Al 2 O 3 , supplied by Condea Chemie GmbH, under their designations `Pural SB alumina`, `Puralox SCCa 5/150, or Puralox HP 5/180` was used. The average pore size of the support was increased by the following pretreatment techniques: by calcination and/or by chemical treatment with an alkaline compound such as ammonia. Examples 12 to 35 thus are directed to pretreated supports. EXAMPLE 12 125 ml acetic acid diluted with 1.7 l distilled water was added to 2 kg Pural SB alumina powder obtained from Condea. Another 1.2 l water was sprayed on while kneading the mixture. The alumina was extruded, dried at 120° C. for 12 hours, and calcined at 600° C. for 16 hours, to produce a pretreated support. EXAMPLE 13 A support was prepared in a similar manner to the support of Example 12, but using a calcination temperature of 700° C., instead of 600° C. EXAMPLE 14 A support was prepared in a similar manner to the support of Example 12, but using a calcination temperature of 800° C., instead of 600° C. EXAMPLE 15 125 ml acetic acid diluted with 1.4 l distilled water was added to 2 kg Pural SB alumina in a mixer. 250 ml Ammonia (12.5 vol %) was sprayed onto this alumina paste. A further 1.2 l water was sprayed onto the alumina while kneading the paste. The alumina was then extruded, dried at 120° C. for 12 hours, and calcined at 600° C. for 16 hours. EXAMPLE 16 A support was prepared in a similar manner to the support of Example 15, but using a calcination temperature of 700° C., instead of 600° C. EXAMPLE 17 A support was prepared in a similar manner to the support of Example 15, but using a calcination temperature of 800° C., instead of 600° C. EXAMPLE 18 19 ml C 3 COOH was diluted to 210 ml with distilled water. 20 g of Zr(NO 3 ) 4 .5H 2 O was dissolved into this solution. This solution was then sprayed onto 300 g Pural SB alumina while mixing in a mixer. 180 ml of a 1.8 vol % ammonia solution was then sprayed onto the alumina while kneading the paste. The paste was then extruded, dried at 120° C. for 2 hours and calcined at 750° C. for 16 hours. EXAMPLE 19 A solution of 100 g 4 Mg(CO 3 ).Mg(OH 2 ).4 H 2 O, 160 ml CH 3 COOH and 150 ml distilled water was sprayed onto 300 g Pural SB alumina while mixing it in a mixer. This was then followed by spraying 220 ml of 12.5 vol % ammonia onto the kneading mixture. After extruding the paste, the extrudates were dried at 120° C. for 2 hours, and calcined at 750° C. for 16 hours. EXAMPLE 20 A solution of 30 g Zr(NO 3 ) 4 .5H 2 O in 210 ml distilled water was sprayed onto 300 g of Pural SB alumina while mixing in a mixer. While kneading this mixture, 180 ml of a 3.5 vol % ammonia solution was sprayed onto it. The paste was then extruded, dried at 120° C. for 2 hours, and calcined at 750° C. for 16 hours. EXAMPLE 21 A support was prepared in a similar manner to the support of Example 18, but instead of 20 g Zr(NO 3 ) 4 .5H 2 O, 30 g Mg(NO 3 ) 2 .6H 2 O was used. EXAMPLE 22 A support was prepared in a similar manner to the support of Example 18, but instead of 20 g Zr(NO 3 ) 4 .5H 2 O, 9 g KNO 3 was used. EXAMPLE 23 A support was prepared in a similar manner to the support of Example 18, but instead of 20 g Zr(NO 3 ) 4 .5H 2 O, 20 g Mn(NO 3 ) 2 .4H 2 O was used. EXAMPLE 24 Puralox SCCa 5/150 support was calcined at 750° C. for 16 hours. EXAMPLE 25 Puralox SCCa 5/150 support was calcined at 800° C. for 16 hours. EXAMPLE 26 Puralox SCCa 5/150 support was calcined at 900° C. for 16 hours. EXAMPLE 27 Puralox SCCa 5/150 support was calcined at 1 000° C. for 16 hours. EXAMPLE 28 Puralox HP 5/180 support was calcined at 600° C. for 16 hours. EXAMPLE 29 Puralox HP 5/180 support was calcined at 70020 C. for 16 hours. EXAMPLE 30 Puralox HP 5/180 support was calcined at 750° C. for 16 hours. EXAMPLE 31 Puralox HP 5/180 support was calcined at 800° C. for 16 hours. EXAMPLE 32 Puralox HP 5/180 support was calcined at 900° C. for 16 hours. EXAMPLE 33 Puralox HP 5/180 support was calcined at 1 000° C. for 16 hours. EXAMPLE 34 Puralox HP 5/180 support was calcined at 1 100° C. for 16 hours. EXAMPLE 35 A support was prepared in a similar manner to the support of Example 15, but using a calcination temperature of 750° C., instead of 600° C. The physical properties of the pretreated supports of Examples 12 to 35 are given in Table 3. TABLE 3______________________________________ Calcination Average pore Temperature BET area Pore Volume sizeExample °C. m.sup.2 /g ml/g nm______________________________________12 600 213 0.46 8.613 700 193 0.46 9.514 800 165 0.44 10.615 600 211 0.54 10.216 700 192 0.54 11.217 800 161 0.52 12.918 750 201 0.48 9.619 750 157 0.46 11.220 750 143 0.44 12.321 750 185 0.51 10.922 750 189 0.50 10.523 750 198 0.49 9.924 750 155 0.48 12.525 800 143 0.50 12.926 900 134 0.48 15.027 1 000 100 0.35 16.128 600 180 0.65 14.429 700 169 0.65 15.530 750 172 0.65 12.531 800 133 0.64 19.232 900 116 0.61 21.133 1 000 92 0.52 21.934 1 100 60 0.25 16.035 750 130 0.55 16.0______________________________________ Increasing calcination temperature thus decreased the surface area of the supports. This effect was very similar for both types of support, ie with and without ammonia treatment. The average pore size increased with an increase in the calcination temperature. The catalysts prepared with ammonia show a higher average pore size than the catalysts prepared in the absence of ammonia. The supports of Examples 12 to 35 were impregnated with cobalt to determine the effect of their average pore size on wax selectivity. The following procedure was used: 50 g of support was added to a solution of 50 g Co(N 3 ) 2 .6H 2 O and 0.05 g Pt(NH 3 ) 4 (NO 3 ) 2 in 50 to 70 ml distilled water. The water was evaporated at 70° C. under vacuum in a rotary evaporator. The catalyst was calcined at 350° C. in a counter-current airflow for 6 hours. The average pore sizes as well as reactor wax selectivities, as obtained in the tubular fixed bed reactor used in Examples 1 to 11, are shown in Table 4. TABLE 4__________________________________________________________________________ Mass % liquid hydrocarbons, drained as was and oil (ie - C.sub.5 +) as measured during20 Co/100 Al.sub.2 O.sub.3 catalysts fixed bed reactor tests(Particle sizes varied Reaction Conditions:between 0.1 and 1.7 mm Promoter Temperature 200-208° C.with pore volumes between Promotion level Average Pressure 18 bar0.32 and 0.44 ml/g) Support (expressed per pore size GHSV 2500-3500 h.sup.-1Example Example Element 100 g Al.sub.2 O.sub.3 (nm) Vol % CO conversion 10-20__________________________________________________________________________36 12 -- -- 7.5 4437 13 -- -- 8.0 5238 14 -- -- 8.9 5239 15 -- -- 8.6 5740 16 -- -- 9.7 6041 17 -- -- 10.7 6342 18 Zr 1.4 g 9.0 4643 19 Mg 8.6 g 10.1 6344 20 Zr 2.1 g 10.4 5445 21 Zr 0.9 g 9.5 5346 22 K 1.2 g 9.0 4447 23 Mn 1.5 g 9.4 4048 24 -- -- 11.0 7549 25 -- -- 11.3 7450 26 -- -- 13.1 8051 27 -- -- 13.7 6852 28 -- -- 13.6 7953 29 -- -- 14.1 8154 30 -- -- 15.9 8155 31 -- -- 17.0 7956 32 -- -- 17.7 7657 33 -- -- 18.7 7758 34 -- -- 17.3 8159 35 -- -- 10.7 58__________________________________________________________________________ From Table 4 it can be seen that for a given activity, the reactor wax selectivity is a function of average catalyst pore size, independent of the type of promoter used (ie Zr, Mg, Mn, or K). This is more clearly illustrated in FIG. 3, which summarizes the results shown in Table 4. These tubular fixed bed synthesis Examples thus show that the main variables affecting wax selectivity from a cobalt based Fischer-Tropsch catalyst are the average pore size diameter of the support or carrier and the intrinsic catalyst activity. In Examples 60 to 65 hereunder, commercially available spraydried and calcined Al 2 O 3 Puralox SCCa 5/150 was used. This material was calcined at a temperature between 600° C. and 700° C. during manufacture thereof. This Al 2 O 3 support material had a pore size of 12.5 nm which, as seen in FIG. 3, is optimal from a wax selectivity and catalyst activity point of view. All the physical properties of this support material are listed in Table 5. TABLE 5______________________________________ Al.sub.2 O.sub.3, Puralox SCCa 5/150 (used as selected support for the preparation of slurryPhysical phase Fischer-Tropschproperty catalysts)______________________________________Pore size 12.5 nmSurface area 150 m.sup.2 /gPore volume 0.5 ml/gParticle size 45-150 μmdistributionCrystalline Gammaphase______________________________________ Six catalyst samples were prepared with this support. EXAMPLE 60 40 g Co(NO 3 ) 2 .6H 2 O was dissolved in 50 ml distilled water, and 50 g Al 2 O 3 Puralox SCCa 5/150 was suspended in this solution. This slurry was treated for ˜2.5 hours at 75° C. and 2 to 5 kPa in a rotary evaporator to impregnate the alumina carrier and to dry the impregnated carrier. The dried impregnated carrier was dried further and calcined at 230° C. for 2 hours in an air flow of 1.5 l n /min. The resultant calcined sample was re-slurried in a solution that was made up by having dissolved 35 g Co(NO 3 ) 2 .6H 2 O and 50 mg Pt(NH 3 ) 4 (NO 3 ) 2 in 50 ml of distilled water. This slurry was again vacuum treated for ˜2.5 hours at 75° C. and 2 to 5 kPa until free flowing in a rotary evaporator. The dried impregnated carrier was calcined at 230° C. for 2 hours in an air flow of 1.5 l n /min. EXAMPLE 61 40 g Co(NO 3 ) 2 .6H 2 O was dissolved in 50 ml distilled water, and 50 g Al 2 O 3 Puralox SCCa 5/150 was suspended in this solution. This slurry was treated for ˜2.5 hours at 75° C. and 2 to 5 kPa in a rotary evaporator to impregnate the alumina carrier and to dry the impregnated carrier. The dried impregnated carrier was calcined at 380° C. for 5 hours in an air flow of 1.5 l n /min. The calcined sample was re-slurried in a solution that was made up by having dissolved 35 g Co(NO 3 ) 2 .6H 2 O in 50 ml distilled water. This slurry was again vacuum treated for ˜2.5 hours at 75° C. and 2 to 5 kPa in a rotary evaporator, followed by calcination at 380° C. for 5 hours in an air flow of 1.5 l n /min. The calcined sample was re-slurried in a solution that was made up by having dissolved 0.8 g Ru (III) acetylacetonate in 50 ml acetone. This slurry was again vacuum treated, ie dried, until free flowing at 75° C. and 2 to 5 kPa in a rotary evaporator, followed by a final calcination step at 330° C. for 4 hours in an air flow of 1.5 l n /min. EXAMPLE 62 40 g Co(NO 3 ) 2 .6H 2 O and 1.2 g perrhenic acid (HReO 4 ) was dissolved in 50 ml distilled water, and 50 g Al 2 O 3 Puralox SCCa 5/150 was suspended in this solution. This slurry was vacuum treated for ˜2.5 hours at 75° C. in a rotary evaporator to impregnate the alumina carrier and to dry the impregnated carrier, followed by calcination at 350° C. for 5 hours in an air flow of 1.5 l n /min. This calcined sample was re-slurried in a solution that was made up by having dissolved 35 g Co(NO 3 ).6H 2 O and 0.8 g perrhenic acid in 50 ml distilled water. This slurry was again vacuum dried for ˜2.5 hours at 75° C. until free flowing in a rotary evaporator, followed by calcination at 350° C. for 5 hours in an air flow of 1.5 l n /min. EXAMPLE 63 29.6 g Co(NO 3 ) 2 .6H 2 O and 30 mg Pt(NH 3 ) 4 (NO 3 ) 2 was dissolved in 50 ml distilled water, and 50 g Puralox SCCa 5/150 was suspended in this solution. The slurry was vacuum treated for ˜2.5 hours at 75° C. and 2 to 5 kPa in a rotary evaporator to impregnate the alumina carrier and to dry the impregnated carrier. The dried impregnated carrier was calcined at 230° C. for 2 hours in an air flow of 1.5 l n /min. The calcined sample was re-slurried in a solution that was made up by having dissolved 19.8 g Co(NO 3 ) 2 .6H 2 O and 20 mg Pt(NH 3 ) 4 (NO 3 ) 2 in 50 ml of distilled water. This slurry was again vacuum dried for ˜2.5 hours at 75° C. and 2 to 5 kPa until free flowing in a rotary evaporator. The dried impregnated sample was calcined at 230° C. for 2 hours in an air flow of 1.5 l n /min. EXAMPLE 64 This Example was similar to Example 61 with the following differences: 1st impregnation: 30 g Co(NO 3 ) 2 .6H 2 O was used instead of 40 g Co(NO 3 ) 2 .6H 2 O 2nd impregnation: 20 g Co(NO 3 ) 2 .6H 2 O was used instead of 35 g. Co(NO 3 ) 2 .6H 2 O 3rd impregnation: 0.55 g Ru (III) acetylacetonate was used instead of 0.8 g Ru (III) acetylacetonate Thus, Examples 60 to 64 were prepared by means of slurry impregnation, ie impregnation solution in excess of the total available alumina carrier pore volume. EXAMPLE 65 26 kg Al 2 O 3 Puralox SCCa 5/150 was incipient impregnated with a 12.5 l aqueous solution containing 13.9 kg Co(NO 3 ) 2 .6H 2 O and 8.6 g Pt(NH 3 ) 4 (NO 3 ) 2 . This impregnated sample was dried at 80° C. for 10 hours in an air flow of 40 l n /min, followed by calcination at 240° C. for 4 hours in an air flow of 250 l n /min. In incipient impregnation, the volume of the impregnation solution used, ie the aqueous solution referred to above, is equal to the pore volume of the alumina carrier. A second incipient impregnation step followed during which this sample was impregnated with 11.3 l of an aqueous solution containing 12.1 kg Co(NO 3 ) 2 .6H 2 O and 8.6 g Pt(NH 3 ) 4 (NO 3 ) 2 . Drying and calcination was performed similarly to the first step. A third and final incipient impregnation step followed during which this sample was impregnated with 13.2 l of an aqueous solution containing 14.2 kg Co(NO 3 ) 2 .6H 2 O and 8.6 g Pt(NH 3 ) 4 (NO 3 ) 2 , followed by the same drying and calcination steps as described above. The preparation method of Example 60 was successfully scaled up to pilot plant scale, more or less on the same scale as that of Example 65. Proper vacuum drying proved to be an important parameter in the case of the scaled up version of the slurry impregnation option. The final moisture content of this dried impregnated catalyst should be less than ˜20 mass %. This permits calcination where the dried impregnated catalyst is first passed through a counter current air drier (residence time of ˜1 min) set at 180° C., falling directly into a tubular calciner unit set at 250° C. The air flow through the calciner was set at ˜8 dm n 3 /kg cat/min at a superficial velocity of ˜5 cm/s. Proper calcination required calcination periods in excess of 3 hours, preferably ˜6 hours. Examples 60, 63 and 65 were "unpromoted". Small quantities of Pt were added to assist with catalyst reduction. These quantities could vary between 0.03 g Pt and 0.08 g Pt per 100 g Al 2 O 3 , and could be co-impregnated throughout all the impregnation steps (eg Example 65) or concentrated in the final impregnation step (eg Example 60). The slurry phase Fischer-Tropsch activities of catalyst Examples 60 to 65 are listed in Table 6. TABLE 6__________________________________________________________________________ Fischer-Tropsch slurry phase synthesis performance at 220° C., 20 bar, and at a space velocity of 2.0 m.sub.n.sup.3 /h/kg catalyst. Promoter (feed gas: 33.3 vol % CO and 66.7 vol % H.sub.2) Promotion After 100 hours on After 400 hours onActive metal level line line Content (expressed Vol % Productivity Vol % ProductivityCatalyst (g Co per per 100 g CO kg HC/kg CO kg HC/kgSample 100 g Al.sub.2 O.sub.3) Element Al.sub.2 O.sub.3) conversion Cat/h conversion Cat/h__________________________________________________________________________60 30 Pt 0.05 g 87 0.349 84 0.33661 30 Ru 0.41 g 77 0.307 70 0.28162 30 Re 3.0 g 70 0.281 NA NA63 20 Pt 0.05 g 73 0.291 63 0.25064 20 Ru 0.28 g 73 0.288 63 0.25265 31 Pt 0.05 g 77 0.310 NA NA__________________________________________________________________________ The following conclusions are evident from Table 6: Ru or Re promotion, which can be expensive at the required levels, does not result in enhanced specific Fischer-Tropsch activities at a cobalt content of ˜20 mass % (ie 30 g Co/100 g Al 2 O 3 ). Applying a reported cobalt based Fischer-Tropsch kinetic equation, such as: r.sub.FT =(k.sub.FT P.sub.h.sbsb.2 P.sub.CO)/(1+β.P.sub.CO).sup.2, shows that intrinsic activity is linearly proportional to the cobalt content of a m Co/0.05 Pt/100 Al 2 O 3 catalyst (Al 2 O 3 Puralox SCCa 5/150) up to a level of m=30 (ie constant cobalt utilization). At higher cobalt loadings (ie m>30) cobalt utilization is diminished. In the preparation of the m Co/0.05 Pt/100 Al 2 O 3 catalyst, the method of slurry impregnation (eg Example 60) is preferred with respect to incipient wetness impregnation (eg Example 65). The former impregnation method resulting in a catalyst with an intrinsic Fischer-Tropsch activity level ˜1.35 times higher than the latter. A selectivity investigation on this preferred cobalt slurry phase catalyst (ie Example 60) was performed and modelled. Table 7 provides an example of best fitted Schulz-Flury modelled selectivities of this catalyst, at representative synthesis conditions. TABLE 7______________________________________% CO conversion at Mass % selectivities of the catalyst220° C. and 20 bar with sample 36a feed composed of after 400 hours on line67 vol % H.sub.2 Fuelgas LPG Gasoline Diesel Waxand 33 vol % CO C.sub.1 -C.sub.2 C.sub.3 -C.sub.4 C.sub.5 -C.sub.11 C.sub.12 -C.sub.18 C.sub.19+______________________________________94 28 18 34 14 684 13 12 32 21 2268 8 9 26 21 3654 6 7 24 21 4244 6 7 22 20 4537 5 6 22 20 4732 5 6 21 20 4828 5 6 21 19 4923 5 6 20 19 5018 4 6 20 19 5115 4 6 20 19 51______________________________________ A graphical illustration of table 7 is presented in FIG. 4, which underlines the dependence between activity and selectivity, as also deduced from FIG. 1 for the fixed bed application. With respect to wax quality, slurry impregnation method (eg is described in the preparation of Example 60) is superior to the incipient wetness impregnation option (eg as described in the preparation of Example 65). The reaction wax produced by catalyst Example 65, contained suspended sub-micron Co 3 O 4 particles, at cobalt concentration level of ˜100 ppm, which could not be removed by means of filtration through a Whatmans 42 filter paper. This also impacted negatively on the wax colour, and an undesirable saybolt colour of -16 (ie darkest indicator) was determined for the filtered reactor wax. The origin of these sub-micron Co 3 O 4 contaminant, was traced back to the presence of a clearly defined shell containing Co and no Al (˜1 μm thick as observed through a SEM investigation), uniformly encapsulating the spray-dried γ Al 2 O 3 spheres. A thorough washing of the calcined catalyst Example 65, successfully removed this unwanted cobalt enriched material, without exerting any influence on the specific Fischer-Tropsch activity. This is despite of the fact that up to ˜8% of the original cobalt content could be washed out. Details of water washing procedure: Experience gained during the washing of ˜5 kg of catalyst Example 65 (ie after the final calcination step and before reduction), has shown that at least 25 l of water is required per kg of catalyst. Procedures that must be adhered to during the washing are: The water must be agitated to a limited degree, and this can be achieved through boiling. Changing water from time to time speeds up the procedure, eventually becoming clear, thus the recommended 25 l per kg of catalyst. The unwanted situation of wax contamination has been proved to be almost absent in the case of slurry phase impregnated catalysts (eg sample 60), viz: catalysts with more homogeneous cobalt distribution throughout the particles, encapsulated by a far less pronounced cobalt oxide shell, is produced. A water washing step is, however, still to be recommended in order to ensure a high quality wax. Wax produced by a washed slurry impregnated 30 Co/0.05 Pt/100 Al 2 O 3 catalyst contained only 1 to 3 ppm cobalt resulting in a saybolt colour of 10, after filtration through a Whatmans 42 filter paper. Thus, very active cobalt based (fixed bed and slurry phase) Fischer-Tropsch catalysts can be prepared in a relatively inexpensive and easy manner, eg no expensive wax selectivity promoters are required in accordance with the invention.
To prepare a Fischer-Tropsch catalyst, a slurry comprising a particular alumina carrier, water and an active component selected from the group consisting in cobalt (Co), iron (Fe) and mixtures thereof, is subjected to a sub-atmospheric pressure environment. The alumina carrier is thereby impregnated by the active component. The impregnated carrier is dried under a sub-atmospheric pressure environment. The dried impregnated carrier is calcined, thereby to obtain the Fischer-Tropsch catalyst.
2
PRIORITY [0001] Applicants claim priority under 35 U.S.C. 119(e) for the benefit of prior filed provisional application 61/874,465, filed Sep. 6, 2013. BACKGROUND OF THE INVENTION [0002] This disclosure concerns low voltage cable entry boxes with or without high voltage outlets for mounting electrically powered products to walls in building structures such as homes and apartments. The boxes are used for connection of communication cables and low voltage components in dry wall structures to flat screen televisions, flat panel displays and the like, with or without a high voltage electrical outlet. [0003] In recent years, TVs have been produced that have display screens that are much wider and higher than the previous TVs, and the sets usually are thin so that they can be mounted on a vertical wall. [0004] In new and in retrofit building construction where hollow wall structures are being formed, low voltage cable entry boxes may be mounted in the drywall of the building structure where TVs and other flat panel displays and the like are to be positioned. The cable entry boxes are used to provide a space to connect low voltage cable to a TV, etc. After the wall has been built out, a flat screen TV or other flat panel display can be mounted to the wall in front of the cable entry box. The cables extending through the hollow drywall structure to the cable entry box are then connected to the TV. It is desirable to make the wall opening of the cable entry box relatively small so that the cable entry box may be used to mount small flat screens to the wall without visually exposing the presence of the box or the cables and wires extending from the box to the TV. [0005] Also, when the cable and wires are pulled into the cable entry box, some lengths of the cable and wire must be available to the installer to handle and make the proper connections to the flat panel display, and the extra length of the cable and wire might not properly fit in the space available in the small entry box. In some situations, it is desirable to mount other low voltage items in the entry box, such as network media player/streamers, wire extending devices, HDMI extenders, and electronic transmitter or receiving devices. The cable entry boxes may be too small to accommodate the extra cable and the above listed devices. This may require a larger cable entry box that is too large for hiding behind the flat panel display screen. [0006] Accordingly, it would be desirable to provide an expandable cable entry box for mounting in a hollow wall structure with the box having a small entry opening but also having a means for expanding the internal dimensions of the box inside the hollow wall structure to form a pocket inside the drywall structure for additional cable and wiring and other low voltage devices such as listed above or that are used to power the flat panel display. It is desirable that the internal dimensions of the cable entry box be larger than the opening extending from the box through the drywall to the display. [0007] Further, it would be desirable that the cable entry box be expandable so that it can be used in either a small or a large internal configuration to accommodate the cable, electrical wiring, and other low voltage devices. [0008] Further, it would be desirable that the cable entry box assembly be provided that is optionally expandable at the job site, which can be packaged in a small container for delivery to the job site and placement through the opening in the hollow dry wall structure, and that would provide the option to the installer to use in a small or a large configuration inside the wall structure, as the need exists. SUMMARY OF THE INVENTION [0009] This invention concerns a cable entry box assembly primarily for mounting in a hollow drywall structure or the like for receiving low voltage electrical cable and other wiring and devices from within the drywall structure for connection to a TV or other electronic device mounted to the outer surface of the wall structure. [0010] The cable entry box assembly includes a support box for inserting through an opening of the drywall panel of a building structure between internal supports of the drywall that form the internal wall space. The support box has walls that define an internal cable space and its walls may include at least a top and/or bottom and/or side openings for passing cable into the internal cable space. The support box also includes a front opening for alignment with an opening in the drywall. One or more of the walls of the support box may include a side opening sized and shaped to register with an electrical power plug receptacle. [0011] An expansion opening is formed in a wall of the support box with the opening sized and shaped to pass an expansion pocket from within the internal cable space beyond the limits of the front opening of the support box, to a position protruding beyond the support box and into an adjacent space in the drywall structure. [0012] The expansion pocket is to move through the expansion opening behind the drywall panel so that expansion pocket is not viewable from outside the drywall when the display is mounted on the wall structure in front of the support box. The expansion pocket may be sized and shaped to be moved through the front opening of the support box into the internal cable space of the support box and then moved laterally through the expansion opening of the support box and extended farther into the wall space adjacent the support box behind the drywall for receiving electrical wiring and other components of the device to be supported interiorly of the wall structure. [0013] This arrangement accommodates the additional cable and/or electronic components so as to retain the small opening extending through the drywall and utilizing the additional space in the drywall adjacent the cable entry box without exposing the extra space or its contents through the drywall. [0014] Also, the invention may be summarized as an expandable cable entry box assembly mounted through a wall opening in a panel of a hollow drywall structure for supporting low voltage cable in the hollow drywall structure, with the assembly including a cable support box defining a front opening in registration with the wall opening, an internal cable space, and a side opening, an expansion pocket extending from the internal cable space through the side opening of the cable support box and away from the cable support box into the drywall structure beyond the cable support box behind the dry wall panel and not visible through the dry wall panel and enlarging the interior size of the cable entry box assembly, and low voltage cable extending into the internal cable space of the cable support box and from the internal cable space into the expansion pocket and back from the expansion pocket through the internal cable space. [0015] Other objects, features and advantages of the present invention will become apparent upon reading the following specification, taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0016] FIG. 1 is a perspective view of a portion of a drywall structure with the expandable cable entry box assembly mounted therein. [0017] FIG. 2 is a perspective view of the cable support box of FIG. 1 that is to be mounted through an opening in the drywall of a building structure, extending into the hollow internal portion of the drywall. [0018] FIG. 3 is a perspective expanded view of the expandable cable entry support box assembly, showing it adjacent the drywall structure. [0019] FIG. 4 is a top cross sectional view of a segment of a drywall structure with the opening formed in one of the wall panels, showing the support frame and plug receptacle mounted to the support frame and positioned internally of the drywall. [0020] FIG. 5 is a top cross sectional view of the drywall segment, taken along lines 5 - 5 of FIG. 1 , showing the cable entry support box positioned internally of the drywall, and with the external frame that surrounds the opening of the drywall mounted thereto. [0021] FIG. 6 is a top cross sectional view of the drywall segment along lines 5 - 5 of FIG. 1 and similar to FIG. 5 , but with the expansion pocket positioned in the internal space of the support box for convenience in shipping, storing, removing and mounting in the cable entry box assembly. [0022] FIG. 7 is a top cross sectional view of the drywall structure, similar to FIG. 6 , but showing how the expansion pocket is moved from the internal space of the support box, laterally into the adjacent space of the drywall structure, behind the drywall panel. [0023] FIG. 8A is a top cross sectional view and FIGS. 8B and 8C are perspective views of the expandable cable entry box assembly, showing openings in the top and bottom walls of the support box when the expansion pocket has been moved through the opening in a side wall of the support box. [0024] FIG. 9 is a perspective view of another embodiment of the assembled expandable cable entry box, showing the upper and lower walls defining openings therethrough, with panels closing the openings when they are not in use. [0025] FIGS. 10A and 10B are illustrations of the assembled expandable cable entry box, similar to FIG. 9 , but showing in FIGS. 10A and 10B a six port keystone cover plate in the top wall, and showing in FIG. 10B “star shaped” openings in the bottom wall of a flexible panel for the passage of cable, similar to that shown in U.S. Pat. No. 7,495,171. DETAILED DESCRIPTION [0026] Referring now in more detail to the drawings, in which like numerals indicate like parts throughout the several views, FIG. 1 illustrates an expandable cable entry box assembly 8 mounted in a drywall structure 10 . The dry wall structure is formed with front and rear parallel drywall panels 12 and 13 , with the panels mounted to vertically oriented studs 14 and 15 . This leaves a series of internal spaces in the drywall structure 10 . The cable entry box 8 is mounted in one of the internal spaces 16 between the studs 14 and 15 . [0027] While this disclosure specifically refers to and illustrates a conventional drywall structure as structurally described, the invention may be used in other types of hollow wall structures. [0028] The assembled cable entry box assembly 8 as shown in FIG. 1 includes a cable support box 20 that is mounted through an opening 22 ( FIG. 3 ) in the front drywall panel 12 . The cable support box includes perimeter walls, including parallel top wall 23 and bottom wall 24 , and parallel side walls 25 and 26 , that extend between the front and rear dry wall panels 12 and 13 . The support box 20 is inserted through the opening 22 of the first drywall panel 12 between the internal supports 14 and 15 that form the internal wall space 16 . The support box 20 includes an internal cable space 33 defined by the perimeter walls 23 - 26 . Top wall opening 30 is formed in the top wall 23 and the bottom wall opening 31 is formed in the bottom wall 24 . The top and bottom wall openings may be used to introduce electrical cable 32 and other items that extend from the drywall structure into the internal cable space 33 . [0029] First side wall 25 of the cable support box 20 defines a plug receptacle opening 34 that is to be aligned with and to surround the plug receptacle 35 , as shown in FIG. 1 . In new construction the plug receptacle 35 may be mounted on a conventional support frame 37 that is well known in the prior art, to be mounted at this position prior to the insertion of the cable entry box in the drywall structure. [0030] When it is not practical to use a support frame 37 behind the wall panel, such as in a retrofit in an existing wall structure, the perimeter frame 38 of the support box 20 illustrated in FIG. 2 may be mounted against the outer surface of the edge of the dry wall opening 22 in the dry wall panel 12 of the dry wall structure 10 , and conventional lock tabs 39 may be pivoted out from the perimeter frame behind the wall panel to secure the support box in its internal position behind the wall panel. The perimeter frame 38 functions as retaining means for retaining the support box at the opening in the wall panel. Other retainers may be used for the function of retaining the support box in position at the opening in the wall. [0031] As shown in FIG. 3 , a large front opening 36 of the support box 20 is positioned at the face of the support box 20 and is bordered by the perimeter frame 38 . The perimeter frame extends outwardly from the perimeter walls 23 - 26 of the support box 20 and, as described above, is used to engage the facing exterior perimeter surface about the drywall opening 22 to securely suspend the support box 20 in the internal wall space between the studs 14 and 15 of the drywall structure 10 . [0032] The second side wall 26 that opposes the first side wall 25 of the support box defines an expansion opening 40 of a shape that permits passage of an expansion pocket 45 or an electrical component through the side of the support box. For example, the expansion opening 40 may be formed in a rectangular shape as shown but may be of other shapes compatible with the function and shape of the cable entry box and the items to pass through the expansion opening. The expansion opening 40 is to be positioned interiorally of the drywall space 16 when the support box 20 is inserted through the opening 22 in the drywall panel 12 . [0033] As shown in FIGS. 3 and 6 , expansion pocket 45 has side walls 47 and bottom wall 50 that may be sized and shaped to conform to the shape of the expansion opening 40 of the side wall 26 and opening 54 . The expansion pocket is of a breadth and shape to be moved through the large front opening 36 of the support box 20 as indicted by arrow 43 of FIGS. 3 and 6 and to fit within the internal cable space 33 formed by the support box. This allows the expansion pocket 45 to be stored in the internal cable space 33 of the support box 20 with the size of the overall package being small for purposes of shipment and for convenience of access and in removing from or using with the support box 20 . [0034] FIG. 6 shows the expansion pocket 45 in its stored position when, for example, the entry box assembly 18 is being shipped or stored but not yet in use. If the expansion pocket is not needed for the job site, it may be simply removed from the internal cable space 33 of the support box 20 , by withdrawing it through the large front opening 36 . However, if additional storage space or space for other purposes is desirable in the support box assembly, once the support box 20 has been placed in the internal space 16 of the dry wall structure as shown in FIG. 6 , the expansion pocket 45 may be moved laterally through the expansion opening 36 as indicated by the arrow 43 of FIGS. 3 and 7 . A lateral protrusion, such as perimeter rim 48 , extends outwardly from the pocket entrance opening 49 ( FIG. 6 ) of the expansion pocket to a distance to engage the internally facing edge 41 of the expansion opening 40 of the support box 20 upon moving a predetermined distance through the expansion opening. This limits the distance that the expansion pocket 45 can move through the expansion opening 40 of the support box 20 . [0035] From the previous description, it will be understood that the installer of the cable entry box assembly has the option to retrieve the expansion pocket 45 from the support box 20 as shown in FIG. 3 or to move the expansion pocket 45 through the expansion opening 40 of the support box 20 , as shown in FIG. 7 . [0036] When the expansion pocket is moved on through the expansion opening 40 , this substantially increases the internal space that is defined by the support box assembly, providing additional space beyond the limits of side wall 26 in which to place additional electronic components to be connected to the flat panel display and associated equipment, such as, but not limited to, slack in the cable, electronic transmitting devices, network media player/streamer, and other components desired for mounting at the site of the flat panel display unit that is mounted in the wall opening. Low voltage cable 32 may extend from the interior of the hollow wall structure 10 , through bottom wall opening 31 of the cable support box 20 and into the internal cable space 33 , and from the internal cable space of the cable entry box into the expansion pocket 45 , and back from said expansion pocket into the internal cable space of the cable entry box, and through the large front opening 36 for connection to the back of a flat screen TV or other flat screen device. [0037] This also retains the small size of the opening 22 formed through the drywall of the drywall panel 12 , reducing the likelihood that the support box assembly will be exposed from behind the small flat screen TV. [0038] The support box is reversible in the sense that the expansion pocket may be oriented to extend inside the drywall beyond the wall opening either left or right or up or down, providing the installer a choice where the TV set is to be mounted. For example, if the cable entry box is to be placed adjacent an internal wall stud, the cable entry box may be oriented to have the expansion pocket protrude from the side of the support box that faces away from the adjacent stud. [0039] FIGS. 8A , 8 B and 8 C show other embodiments of the support box 20 in which openings 51 are formed in the bottom walls of the support box 20 . Other sized and shaped openings may be formed in the support box, as may be desired or necessary. [0040] FIG. 9 shows a perimeter rim 55 that may be mounted about the edge of a top wall opening so that other items may be mounted thereto. [0041] FIGS. 10A and 10B illustrate a six-port keystone plate 60 that may be mounted to the top wall of the support box, and FIG. 10B shows a flexible sheet 62 with a star cut opening 63 formed therethrough for the passage of cable. This type of opening is shown in more detail in U.S. Pat. No. 7,495,171. [0042] While the expandable cable entry box has been disclosed as accommodating low voltage electrical components and cables in a hollow wall structure, the expandable entry box may be used for other purposes. The expansion pocket 45 may be made in other shapes and materials, such as, but not limited to, transparent materials. [0043] Although a preferred embodiment of the invention has been disclosed in detail herein, variations and modifications of the disclosed embodiment can be made without departing from the spirit and scope of the invention as set forth in the following claims.
A cable entry box for mounting in a drywall panel, including a front opening for alignment with an opening in the drywall panel and a side opening to receive an expansion pocket that protrudes beyond the cable entry box, internally of the drywall panel for receiving electrical wiring and other components that are to be supported interiorly of the drywall structure.
7
This nonprovisional application claims the benefit of the U.S. provisional application No. 60/177,025 entitled “Micromachined Polarization-State Controller” filed on Jan. 19, 2000. The Applicants of the provisional application are Nicholas J. Frigo, Evan L. Goldstein, Lih-Yuan Lin, Chuan Pu, and Robert W. Tkach. The above provisional application is hereby incorporated by reference including all references cited therein. BACKGROUND OF THE INVENTION 1. Field of Invention The invention relates to methods and systems that tunably delay an optical signal. 2. Description of Related Art As optical fibers are becoming more and more ubiquitous in the optical communications community, the effects of polarization mode dispersion (PMD) caused by subtle defects of these optical fibers become increasingly important. Generally, PMD occurs when an optical signal propagates through a birefringent optical fiber causing various components of the optical signal to travel at varying velocities, thus causing a dispersion of an optical signal into multiple “images”. It is well known that PMD can be compensated for by splitting the multiple images and re-aligning the images into a single coherent optical signal. Generally, such compensation devices are formed by combining a polarization controller with an appropriately designed delay line. Unfortunately, both polarization controllers and delay lines are often unwieldly in size, difficult to tune and may be very expensive to manufacture or maintain. Therefore, there is a need to provide new methods and systems to compensate for PMD. SUMMARY OF THE INVENTION The invention provides methods and systems for tunable delay lines suitable for larger PMD compensation devices. Particularly, the invention provides compact and inexpensive micro-machined tunable delay lines using adjustable micro-mirrors to tunably alter a path length traversed by an optical signal. The combination of a polarization-state controller and the tunable delay line enables the components of a PMD-affected optical signal to be appropriately manipulated to compensate for PMD effects. For example, a dispersed optical signal, after having its polarization-state suitably altered, can be split into its fast and slow components. The fast component can then be delayed relative to the slow component, by controllably manipulating its path length via one or more adjustable micro-machined micro-mirrors. After appropriately delaying the fast component, the delayed fast component is combined with the slow component to provide an optical signal whose slow and fast components are substantially re-aligned with each other. Thus, the dispersing effects of PMD can be significantly compensated for. Other features and advantages of the present invention are described below and are apparent from the accompanying drawings and from the detailed description which follows. BRIEF DESCRIPTION OF THE DRAWINGS The invention is described with regard to the following figures, wherein like numbers reference like elements, and wherein: FIG. 1 is a block diagram of an exemplary optical transmission system containing a polarization mode dispersion compensator; FIG. 2 is a block diagram of the polarization mode dispersion compensator of FIG. 1; FIG. 3 is a block diagram of the controllable delay system of FIG. 2; FIG. 4 is a diagram depicting an exemplary micro-machined, step-wise tunable delay line according to an embodiment of FIG. 2; FIG. 5 is a diagram depicting an exemplary micro-machined continuously tunable delay line according to an embodiment of FIG. 2; and FIG. 6 is a flow chart outlining an exemplary technique for providing a tunable delay of an optical signal according to various exemplary embodiments of the present invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Optical fibers are ideally designed and manufactured to have cylindrically uniform properties throughout the length of the fibers. However, inconsistencies in manufacturing, laying, and environmental conditions can mechanically perturb the structure of an optical fiber to result in a non-uniform, non-cylindrical contour, such as a corkscrew or elliptic shape. As a result of these imperfections, an optical signal traversing such optical fibers can undergo a polarization sensitive dispersing phenomenon commonly referred to as polarization mode dispersion (PMD). It is well understood in the optical transmission arts that some of the deleterious effects of PMD can be compensated for by combining a polarization-state controller with a delay line such that the “fast” components of an optical signal are delayed relative to the “slow” components and by merging the two components to form a single compensated optical signal. Unfortunately, conventional polarization controllers and delay line devices can be unwieldy in size, operation, complexity and cost. Further, most delay line devices provide only fixed delay times. However, by applying micro-machine technology to either or both the various polarization controllers and delay line devices, compact and powerful PMD compensators can be produced. FIG. 1 illustrates a block diagram of an exemplary optical transmission system 100 . The system 100 includes an optical source 110 , a polarization mode dispersion compensator 120 and an optical receiver 130 . In operation, the polarization mode dispersion compensator 120 can receive optical signals from the optical source 110 via the optical conduit 112 , compensate for PMD in the optical signals, and then provide the compensated optical signals to the optical receiver 130 via the optical conduit 122 . The optical receiver 130 can also send commands, error conditions or other information to the PMD compensator 120 , via the optical conduit 122 or by other means such as a separate conduit to provide controllable adjustment of the effects of the PMD compensator 120 on the optical signals. Similarly, the PMD compensator 120 itself may include one or more sensors and feedback controls to provide controllable adjustment. The optical source 110 can be any of a number of different types of optical sources such as a computer with optical transceivers, or any other known or later developed combination of software and hardware capable of generating, relaying or recalling from storage any information capable of being transmitted in an optical signal. The optical receiver 130 can likewise be any one of a number of different types of optical receiving devices such as computers with optical transceivers, or any other known or later developed combination of software and hardware capable of receiving, relaying or otherwise sensing any information capable of being received in an optical signal. The optical conduits 112 and 122 can be any of a number of known or later developed optical transmission media, such as optical fibers, lenses, collimators, filters, free space, etc., such that an optical signal can propagate through without departing from the spirit and scope of the present invention. FIG. 2 is a block diagram of the polarization mode dispersion (PMD) compensator 120 of FIG. 1 . The PMD compensator 120 contains a polarization-state controller 210 and a tunable (or controllable) delay system 220 . In operation, one or more optical signals are received by the polarization-state controller 210 via conduit 112 . The polarization-state controller 210 then adjusts the state of polarization of the received optical signals and provides the adjusted optical signal to the tunable delay system 220 . The tunable delay system 220 receives the adjusted optical signal, splits the adjusted optical signal into its fast and slow components, delays the fast components relative to the slow components such that the fast and slow components are substantially aligned, recombines the fast and slow components to produce a compensated optical signal and provides the compensated optical signal to optical conduit 122 . The exemplary polarization-state controller 210 is a micro-machined device affixed to one or more substrates. While the exemplary polarization-state controller 210 is a micro-machined device, it should be appreciated that the polarization-state controller 210 can be any other known or later developed device capable of receiving an optical signal, appreciably adjusting the state of polarization of the optical signal and providing the adjusted optical signal to the tunable delay system without departing from the spirit and scope of the present invention. The tunable delay system 220 is also a micro-machined device affixed to a single substrate and, in various exemplary embodiments, is affixed to the same substrate as the polarization-state controller 210 . However, the tunable delay system 220 can be any other known or later developed device or system capable of receiving an optical signal, and substantially aligning the fast and slow components of the optical signal to produce a compensated optical signal without departing from the spirit and scope of the present invention. FIG. 3 is a block diagram of the tunable delay system 220 of FIG. 2 . The exemplary tunable delay system 220 includes a pair of polarization-beam-splitters (PBSs) 330 and 360 and a tunable delay 340 . In operation, the controllable delay system 220 can receive an optical signal corrupted by PMD—i.e., an optical signal dispersed into various images (represented, illustratively, as fast and slow components)—and substantially realign the fast and slow components of the optical signal to provide a compensated optical signal. To accommodate the re-alignment process, the exemplary received optical signal can have a state of polarization adjusted such that the first polarization-beam-splitter 330 can appropriately split the dispersed optical signal 320 into its fast and slow components. The first polarization-beam-splitter 330 , situated in the path of the polarizationstate-adjusted optical signal 320 , receives the adjusted optical signal and splits the received optical signal into two beams, a fast component 332 - 1 and a slow component 332 - 2 . The tunable delay 340 receives the first component, effectuates a variable temporal delay on the fast component 332 - 1 by variably controlling the path length of the fast component 332 - 1 and provides the delayed fast component 350 to the second polarization-beam-splitter 360 . The second polarization-beam-splitter 360 , situated in the paths of both the slow component 332 - 2 and the delayed fast component 350 , receives and combines the two optical components 332 - 2 and 350 to result in a compensated optical signal 370 such that the fast component is substantially adjusted to coincide with the slow component. The exemplary PBSs 330 and 360 , along with the tunable delay 340 , are micro-machined devices affixed to a single substrate. The exemplary PBSs 330 and 360 are silicon plates oriented such that a received optical beam will fall incident at the Brewster angle, which is 74° for silicon. While the exemplary PBSs 330 and 360 are composed of silicon, it should be appreciated that the materials can vary as a design choice or as otherwise required. It should be further appreciated that the materials and design of the tunable delay 340 can similarly vary as a design choice or as otherwise required. Finally, while the exemplary PBSs 330 and 360 and tunable delay 340 are manufactured using CHRONOS INTEGRATED MICROSYSTEMS® MUMPs® process with precision side latches, any micro-machining technology capable of producing the general configuration of the tunable delay system 220 can be used without departing from the spirit and scope of the present invention. Although FIG. 3 illustrates unimpeded paths from the PBSs 330 and 360 to and from the tunable delay 340 , and between the PBSs 330 and 360 , it should be appreciated that various devices such as fixed or adjustable micro-mirrors can be placed in between the PBSs 330 and 360 and the tunable delay 340 to provide fixed delays or otherwise affect the various optical signals 320 , 332 - 1 , 332 - 2 , 350 and 370 without departing from the spirit and scope of the invention. For example, a first micro-mirror could be placed in the path of the slow component to provide a fixed-delay while one or more second fixed micro-mirrors can be placed in the path of the delayed fast component to adjust the angle at which the second PBS 360 receives the delayed fast component. FIG. 4 is a first exemplary tunable delay 400 according to the controllable delay system 220 of FIG. 3 . The tunable delay 400 contains a first and second adjustable mirror 420 and 430 , affixed to a substrate 405 and a number of fixed paired-mirrors 440 - 470 . In operation, the first adjustable mirror 420 receives an optical signal 410 , such as a fast component of an optical signal corrupted by PMD, reflects the optical signal 410 to one of a number of left-half mirrors 440 a - 470 a of the paired-mirrors 440 to 470 , which reflects the optical beam to a respective right-half mirror 440 b - 470 b, which reflects the optical beam to the second adjustable mirror 430 to produce a delayed optical beam 490 . From FIG. 4, it is easily seen that as the angle and/or position of the adjustable micro-mirrors 420 and 430 is altered, the path of the optical signal 410 can be directed to any of the paired-mirrors 440 , 450 , 460 , and 470 , therefore enabling discretely adjustable path lengths. Accordingly, if the exemplary optical signal 410 is a fast component of an optical signal corrupted by PMD, the “time-of-arrival” of the fast component 410 can be temporally shifted such that the fast component can be adjustably aligned with a corresponding slow component. As discussed above, upon exiting the tunable delay 400 , a temporally aligned fast component can be combined with its respective slow component to form a compensated optical signal. To control the path length of the received optical signal 410 , the exemplary tunable delay 400 can adjust the positions and/or angles of the adjustable mirrors 420 and 430 . For example, in various embodiments the adjustable mirrors 420 and 430 can be micro-machined micro-mirrors each secured to an electrode plate (not shown) by a mirror frame and torsion beams (also not shown). In a first exemplary embodiment, torsion beams are affixed to one end of each of the adjustable micro-mirrors 420 and 430 such that the adjustable micro-mirrors move as hinged levers move when a voltage bias is applied to a respective electrode-plate. That is, the first adjustable micro-mirror 420 can controllably deflect the received optical signal 410 to any of the paired-mirrors 440 - 470 as it rotates through some first range θ 1 to θ 2 . Accordingly, the second adjustable micro-mirror 430 can be similarly adjusted such that an optical signal reflected from one of the paired-mirrors 440 - 470 can be suitably deflected to another device such, as a polarization beam splitter, as it rotates through a second range. In other exemplary embodiments, the torsion beams securing the adjustable micro-mirrors 420 and 430 can be configured such that a voltage bias on a respective electrode plate will not substantially change the angle of the adjustable micro-mirror 420 or 430 , but instead laterally move each micro-mirror 420 and 430 . For example, the first adjustable micro-mirror 420 can be adjustably positioned towards a center axis of the substrate 405 such that the received optical signal 410 is deflected to left-hand mirror 450 a, as opposed to any of the other left-hand mirrors 440 a, 460 a or 470 a. Accordingly, the second adjustable micro-mirror 430 can be similarly repositioned to receive the optical signal from right-hand mirror 450 b, as opposed to any of the other right-hand mirrors 440 b, 460 b or 470 b and deflect the optical signal to an external device. In still other exemplary embodiments, it should be appreciated that the adjustable micro-mirrors 420 and 430 can be configured such that both their positions and angles can be simultaneously adjusted to form other delay paths. For example, the position and angle of the first adjustable micro-mirror 420 can be controlled to deflect the optical signal to left-hand mirror 460 a. However, because the incident angle of the optical signal 410 can be controlled relative to left-hand mirror 460 a, the optical signal can be controllably directed to reflect from left-hand mirror 460 a to any of the right-hand mirrors 440 b - 470 b, as opposed to only right-hand mirror 460 b. The second adjustable micro-mirror 430 can be similarly configured to receive the optical signal 410 from any of the right-hand mirrors 440 b - 470 b and direct it to an external device. The exemplary adjustable micro-mirrors 420 and 430 and paired-mirrors 440 - 470 , like the PBSs of FIG. 3, are silicon devices manufactured using CHRONOS INTEGRATED MICROSYSTEMS MICROSYSTEMS® MUMPs® process with precision side latches. However, any micro-machining technology capable of producing the general configuration of the tunable delay 400 can be used without departing from the spirit and scope of the present invention. Furthermore, while the exemplary tunable delay 400 has four paired-mirrors 440 - 470 , it should be appreciated that any number of pairedmirrors can be used as desired or otherwise required by design. Furthermore, in various embodiments the various paired-mirrors 440 - 470 can be replaced with a single mirror having a complex shape such as a curved and/or polygon shaped surface such that various paths can be implemented. Still further, each pair of mirrors of the paired-mirrors 440 - 470 can be replaced with any number of mirrors, e.g., three or more micro-mirrors may be used in each set of mirrors, if desired. In still other exemplary embodiments, it should be appreciated that each set of paired-mirrors 440 - 470 can be adjustable micro-mirrors similar to adjustable micro-mirrors 420 and 430 to add further degrees of freedom in controlling the path length of an optical beam. FIG. 5 is a second exemplary tunable delay 500 according to the present invention having a first and second fixed mirror 520 and 530 and an adjustable paired-mirror 540 . As similarly described in FIG. 4, the second tunable delay 500 can adjust the path length of an optical signal 505 , such as a fast component of a dispersed optical signal, to provide a delayed optical signal 515 . However, while the exemplary paired-mirrors 440 - 470 of FIG. 4 are discretely positioned to provide a number of discrete delays, the second tunable delay 500 can provide a continuously tunable path length delay. That is, as the adjustable paired-mirror 540 is controllably positioned along its range δ, the path length of the received optical signal is continuously varied by as much as 2δ. Similarly to the fixed mirrors of FIG. 4, it should be appreciated that mirrors 520 and 530 can also be adjustable devices that can be adjustably rotated and/or translated to provide further degrees of freedom. Furthermore, it should be appreciated that in various embodiments, that mirrors 520 and 530 and/or the mirrors of the adjustable paired-mirrors 540 can be adjustably rotated, together or separately, to provide still further degrees of control. Still further, it should be appreciated that the surfaces of the adjustable paired-mirrors 540 and/or fixed mirrors 520 and 530 can have complex shapes as desired or otherwise advantageous by design. While FIG. 5 illustrates a single mirror pair 540 that is adjustably translatable to any point in the range bounded by 2δ, it should be appreciated that the embodiment of FIG. 5 can be modified with additional mirror pairs placed within the range bounded by 2δ, and actuated to provide variable step-wise delays. That is, mirrors 540 and mirror sets (not shown) can be situated in the substrate 510 at points corresponding to predetermined path lengths within the path of an optical beam, and the mirrors 540 and mirror sets (not shown) may be controllably raised out of the substrate into the path of the optical beam or controllably lowered into the substrate out of the path of the optical beam, to provide variable step-wise path delay. Various micro-machined systems and devices for raising and lowering micro-machined mirrors in and out of a substrate are described in Lin et al., “Free-Space Micromachined Optical Switches with Submillisecond Switching Time for Large-Scale Optical Crossconnects”, IEEE Photonics Techology Letters, Vol. 10, No. 4, April 1998, pp. 525-527, herein incorporated by reference in its entirety. FIG. 6 is a flow chart outlining an exemplary technique for adjusting the path length of an optical beam according to various exemplary embodiments of the present invention. Beginning in step 610 , a dispersed optical signal is received. Next, in step 620 , the state of polarization of the received optical signal is adjusted such that a subsequent beam-splitter receiving the adjusted optical signal can suitably split the adjusted optical signal into its fast and slow components. Then, in step 630 , the adjusted optical signal is split into its fast and slow components. While the exemplary technique uses a micro-machined polarization-beam-splitter made of silicon affixed to a single substrate, it should be appreciated that any known or later discovered device, system or technique useful to split an optical signal into its fast and slow components can be used without departing from the spirit and scope of the present invention. The process continues to step 640 . In step 640 , the path length of the fast component is controllably lengthened or shortened according to a desired or estimated delay such that the fast component, suitably delayed, can be combined with its respective slow component to substantially produce a single image, i.e., compensate for PMD. While the exemplary technique controllably alters the fast component, it should be appreciated that, in various exemplary embodiments, the fast component can be delayed by a fixed amount and the slow component can be controllably lengthened or shortened to align the fast and slow components. Furthermore, while the exemplary technique uses one or more adjustable micro-machined micro-mirrors affixed to a single substrate controlled using electrode plates and torsion beams to control path length, it should be appreciated that any known or later developed technique useful to vary the path length of an optical signal relative to another optical signal can be used without departing from the spirit and scope of the present invention. The process continues to step 650 . In step 650 , the delayed fast component is combined with the slow component to produce a single optical signal. While the exemplary technique uses a polarization beam splitter similar to that used in step 630 , it should be appreciated that any known or later developed technique useful to combine optical signals can be used without departing from the spirit and scope of the present invention. The process continues to step 660 . In step 660 , a determination is made as to whether the fast and slow components are suitably aligned such that the combined optical signal is appreciably a single image of the original signal. If the fast and the slow components are suitably aligned, control continues to step 680 where the process stops; otherwise, control jumps back to step 640 where the path length of the fast component is further adjusted. The process continues through steps 640 - 660 until the fast and slow components are suitably aligned and the process stops in step 680 . It should be understood that each of the components shown in the various FIGS. 1-5 can be implemented as portions of a larger suitably structured device. Alternatively, each of the components shown in the various figures can be implemented as physically distinct components or discrete elements. Furthermore, various components of the various devices can be rearranged and combined with various other devices without departing from the spirit and scope of the present invention. It should be understood that any combination of hardware or software capable of implementing the systems of FIGS. 1-5 or the flowchart of FIG. 6 can be used without departing from the spirit and scope of the present invention. For example, it should be appreciated that the components of the polarization mode dispersion compensator can be achieved by monolithic-integration on a substrate, or by packaging discrete chips together. Also, the actuation of the micro-mirrors is not restricted to the examples mentioned, as other micro-actuated-mirror technology can achieve optical switching or manipulation to effectuate time delaying of optical signals, i.e., the position and orientation of the various paired-mirrors can be controlled via translational substrates connected to the paired-mirrors such that the paired-mirrors are fixed to the substrate and the substrates are translated and/or rotated. Further, micro-mirror pairs can be hierarchically situated (i.e., 3-D) to provide more than two-dimensional path length adjustment. Finally, while this invention is disclosed in the context of providing a tunable delay line for use in PMD compensation, this invention is not intended to be limited to only aiding in PMD compensation and can be used in any environment where control of a signal or beam of energy is required to be tunably delayed. While this invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, preferred embodiments of the invention as set forth herein are intended to be illustrative and not limiting. Thus, there are changes that may be made without departing from the spirit and scope of the invention.
The invention provides methods and systems for micro-machined tunable delay lines. Particularly, the micro-machined tunable delay lines of the present invention utilize adjustable micro-machined micro-mirrors to alter the path length traversed by an optical signal.
6
TECHNICAL FIELD This invention relates to the field of utility vehicles, generally. The methods and apparatus are particularly related to the field of self-propelled light and medium-duty personnel and cargo-carrying vehicles, including such vehicles as estate vehicles, industrial vehicles, airport personnel transporters, turf maintenance vehicles, and vehicles useful in performing similar tasks, industrial maintenance vehicles, parts transporters, warehouse picking vehicles, among others. More specifically, this is an improved multiple-purpose utility vehicle that has a body that can be converted from a configuration for carrying people to a configuration for carrying cargo, including granular bulk cargo, very quickly and easily, without tools. BACKGROUND A variety of utility and specialty vehicles have been, and continue to be, used to accommodate the specific needs of various endeavors. Golf courses, airports, and factories are examples of enterprises that use special purpose vehicles to move goods and transport passengers from one place to another. The market for any particular model of this type of off-road vehicle is relatively small compared to the size of the market for vehicles used for highway transportation, agriculture, construction, and the like. Specialty vehicles may be expensive to purchase. For example, the economies of scale available to the manufacturer of a popular family sedan are unavailable to the producer of a special-purpose motorized parts carrier used in an automobile assembly plant. Innovations that facilitate reconfiguration of a generalized utility vehicle from one purpose to another can provide competitive and operational advantages to both the manufacturer and end users. Large industrial facilities such as grain mills, electrical generating power plants, manufacturing enterprises, golf courses, and college campuses all routinely dispatch maintenance, management, or production support personnel to geographically separated locations. Those personnel may also utilize helpers, supplies, production parts, repair parts, tools, and other items. Sometimes it is advantageous for a repair technician to travel to the site to evaluate what materials, assistance, and equipment will be needed to carry out the assigned tasks. Additional trips may be needed to assemble the needed crew and materials. Golf course maintenance requires the delivery of landscaping materials, turf care products, tools, personnel, etc. to various locations. It can be a particular difficulty to quickly transport more than a single individual with the conventionally available course maintenance vehicles. Among the undesirable results of this situation are that: a single individual may be assigned to tasks that require much more time to accomplish than would be needed if carried out by a team; extra vehicles may be required to transport additional personnel to and from a work site; extra trips and disruption of scheduled activities may be required to convey personnel to and from a work site. The following example illustrates the problem: Suppose that a golf course manager needs to amend a bunker, replace some sod and prune several trees and shrubs at a remote location. A landscape supervisor might, in this example, prefer to take the necessary personnel, supplies, and equipment to the site, see that the tasks are properly underway, and proceed to another location. Doing so is unlikely to be convenient because few load-carrying or traction vehicles carry passengers. For this reason, it is often necessary to provide each work crew of two individuals with an expensive utility vehicle which will (or should) remain idle while the work is underway. If the supervisor determines that the tasks might be most efficiently accomplished by a crew of three persons, the supervisor might travel to the site in a vehicle with one crew member while the other two individuals proceed in a separate vehicle that will remain with the crew. But when it is time to return, the ordinary utility vehicle cannot carry the whole crew of three, so it will be necessary to make two trips. In view of this, two crews of two, each with a vehicle, might be assigned to the tasks. Providing two vehicles, neither of which is really needed, to carry out the work, may be so expensive that a facility operator may find it impractical. One or both work crews may need to walk to many work sites which reduces productivity and increases the likelihood that personnel may ride vehicles that are not designed for passengers. It would be advantageous to have a utility vehicle that could carry some tools and materials together with several additional passengers in this and similar instances. A supervisor could then take three workers, their tools, and necessary materials to the site. Once work was underway, the supervisor could go on to other things. At the proper time, a vehicle could be dispatched to return with the crew. Substantial cost savings result from reducing the number of specialty vehicles needed from three to one. Earlier workers in the fields of passenger vehicle and cargo vehicle design have attempted to expand the range of purposes for which particular models may be used. Availability of optional configurations or features that allow a vehicle to fulfill additional needs beyond a primary one can greatly increase the functionality of a vehicle and enhance the value of the vehicle to the owner. Some vehicles have features that allow passenger-carrying spaces to convert to a cargo-carrying mode. For example, it is an established practice to provide automobile seat backs that fold down to accommodate cargo that is too large to fit into the trunk. In a variation on that practice, Minka discloses” a Convertible Seat of a Vehicle that extends the trunk enclosure of a coupe or sedan into the passenger space by hinging the rear seat back at the top and rotating the bottom of the seat back forward to a horizontal orientation. The seat bottom is hinged at the front and the bottom of the seat rotated upwardly to a vertical orientation. Station wagons may also be equipped with a rear seat that folds flat to make a load-carrying surface coplanar with the interior side of an open, horizontally-hinged, tailgate. A Fold-away Auxiliary Seat Unit for a Vehicle is disclosed in U.S. Pat. No. 5,482,346 for just such an apparatus. Ferrara shows a Vehicle Seat in U.S. Pat. No. 4,191,417 which is suitable for fitting into sport-utility vehicles. It is adapted to have the seat back fold forward over the seat bottom so that the cushion portions of the back and bottom come into facing contact to bring the uncushioned side of the seat back coplanar with the load-contacting bed surface. Evenrude shows a Convertible Golf Car in U.S. Pat. No. 3,471,071 that includes a seat with a complex linkage that allows the,car to transport golf bags, passengers, or cargo. The seat cushion is exposed at all times making it unsuited for hauling bulk materials, sod, tools, or machinery. In U.S. Pat. No. 4,125,284 Hicks et al. show a Vehicle with Convertible Step and Foot Rest. Unfortunately, their design precludes cushions for either the seat or the back. Passengers desiring to travel in the Hicks et al. vehicle would be seated directly onto the cargo-carrying surface which may make it difficult for passengers to keep their clothing clean. Green's Retrofittable Passenger or Cargo Carrier for a Golf Cart is described in U.S. Pat. No. 5,429,290. It is a conceptually different approach which places the additional passengers face-to-face on opposite sides of the vehicle. Many people find it uncomfortable to be seated in a position facing perpendicular to the direction of vehicle travel. None of the utility vehicles known in the art satisfactorily provide both passenger-carrying and load-carrying capacity. Similarly, none of the vehicles provide a system that allows the conversion of passenger-carrying space to cargo-carrying space and back with sufficient quickness and ease to make it practical to do so several times during each day. None of the previously known convertible seat systems for utility vehicles shows a system that provides seat and back cushions that are protected from grime, dust, moisture, and loaded materials when the bed is in cargo-carrying mode and the seats are not in use. What is needed, then, is a utility vehicle body convertible for carrying cargo or passengers that can carry cargo, including bulk material cargo, and be convertible for comfortably carrying passengers on seats that are uncontaminated by the materials previously hauled. Another need is for a utility vehicle that can be converted from cargo-carrying to passenger-carrying and back easily and quickly many times during a single day. Another long-felt need is for a utility vehicle that comfortably accommodates a driver and at least three additional passengers plus some tools, equipment, or materials. SUMMARY OF THE INVENTION In contrast to the devices mentioned above and the developments of other skilled individuals, this vehicle and body convertible for carrying cargo or passengers is unmatched in its simplicity and functionality. While it is likely to be embodied as original equipment in newly manufactured vehicles, the convertible body can readily be retrofitted to many existing utility vehicles. A typical utility vehicle bed has a horizontal planar rectangular upper surface, is supportingly affixed to the vehicle frame, and is situated behind the operator seat, above the rear wheels. There may also be vertical sides and ends that are either fixed or removable. A stake bed is quite common because the vertical sides and ends are easily removable by withdrawing vertical members from openings at the perimeter of the bed making it possible to load from either side or the rear. However, it may be preferred to have the sides and front of the bed permanently affixed to reduce initial cost and to discourage overloading. Whether the sideboards and front panel are fixed or removable, the tailgate is usually hinged transversely at the bottom so that the top of it may be rotated downwardly and rearwardly to form a rearward extension of the bed. The tailgate may also be hinged at the top so that the bottom of the tailgate may be rotated rearwardly and upwardly away from the back end of the bed. Being able to open the tailgate at the bottom is often desirable when bulk materials are being off-loaded or spread using an optional tilt, or dump mechanism comprising a hydraulic pump, ram and control valves. It will be appreciated that a tailgate hinged both at the bottom and at the top is inherently removable. Removing the tailgate makes it possible for an operator to grasp a cover, shaped in cross-section like an inverted letter “L,” that houses the seat cushions, draw the lowest edge of the cover, first upward and rearward, so the cover pivots about a transverse hinge that is situated at the end of the shorter portion of the letter “L” and then continuing the pivot so that the movement continues upward and forward until the rotation has been continued approximately 180 degrees. That rotation brings the portion of the cover that was part of the upper surface of the of the bed into face-to-face contact with the immediately adjacent upper surface portion of the bed. The tailgate may be stowed on either side of the vehicle, at a shop or garage, or elsewhere when desired. The seat and seat-back cushions are revealed by opening the seat cover the seat back maybe rotated upwardly and forwardly on a transverse hinge provided at the lower edge of the seat back when the seat back is in the full, upright position. The vehicle is ready for transporting passengers when these three steps are completed. To convert the utility vehicle from the passenger-carrying configuration to the cargo-carrying configuration, simply reverse the three steps—pivot the seat back down into contact with the seat bottom cushion, close the seat cover, and, if desired, replace the tailgate. The vehicle is ready for transporting cargo when these three steps are completed. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view looking down toward the left rear portion of the convertible utility vehicle body is configured for transporting passengers. FIG. 2 shows the embodiment of FIG. 1 configured for transporting cargo. FIG. 3 shows the embodiment of FIG. 1 configured of transporting passengers looking up toward the left front portion of the convertible utility vehicle body. FIG. 4 is a side elevation of the convertible utility vehicle body of FIG. 1 configured for transporting cargo. FIG. 5 is a side elevation of the convertible utility vehicle body of FIG. 1 configured for transporting passengers. FIG. 6 is a side elevation of a utility vehicle on which is mounted the utility vehicle body of FIG. 5 . DETAILED DESCRIPTION Referring now to the various figures of the accompanying drawings, FIG. 1 depicts a convertible utility vehicle body 20 with a generally rectangular fixed bed portion 22 that has a front edge 24 , back edge 26 , left edge 28 , and a right edge 30 . The upper surface 32 of the fixed bed portion 22 has at the perimeter a front panel 34 , a left side 36 , a right side 38 , and a hinged bed portion 40 located opposite the front panel 34 . FIG. 2 shows the hinged bed portion 40 that swings on a transverse hinge swing axis 42 which is generally parallel to the back edge 26 of the fixed bed portion 22 . The configuration depicted in FIG. 2 shows the upper hinged surface 44 generally co-planar with the upper surface 32 of the fixed bed portion 22 . A seat back upper surface 46 is formed generally downwardly perpendicular to the upper hinged surface 44 at the rear end of the hinged bed portion 40 . FIG. 1, viewed again, shows a seat cushion 48 affixed to the opposite side of the upper hinged surface 44 . A back 50 has a back cushion surface 52 on the side opposite from the back upper surface 46 . The back cushion surface 52 has a back cushion 54 affixed to it and is oriented generally perpendicular to the seat cushion 48 . A leg rest 56 extends generally downwardly from the back edge 26 of the fixed bed portion 22 and may be formed from the same piece of sheet material. A generally horizontal foot rest 58 extending from the leg rest may also be formed from the same sheet of material. However, it is equally possible to fabricate the convertible utility vehicle body 20 using separate pieces for these features. There may be a left gusset 60 and a right gusset 62 or other reinforcement of the back 50 . Compared to other reinforcement structures, the gussets 60 62 reduce the amount of dust that can penetrate to the cushions 48 54 , especially if the gusset angles are set to correspond to the angle of the leg rest 56 . It is to be understood that reinforcement may not be needed. If provided, the reinforcement material may be strap, bar, rod, or other shape, and need not be triangular plate. The transverse bed hinge 64 may be pivoted on pins through the left and right sides, although it is possible to use other known hinge shapes. An advantage of locating the hinge swing axis 42 displaced from the hinged edge 66 is that space for a resilient seal 68 may be provided. The resilient seal 68 may run transversely on either the back edge 26 , the hinged edge 66 , or both, from the left hinged bed portion edge 70 to the right hinged bed portion edge 72 . The seal 68 is optional, and although a resilient seal may be easier to use, it would also be possible to use a seal made of sheet or strip material, or no seal at all. FIG. 3 shows that the convertible utility vehicle body 20 may be configured as a dump body 74 by arranging an attachment point to serve as a dump body pivot 76 and by providing attachment points 78 for one or more optional hydraulic rams. In FIG. 4, there is shown an installed optional removable tailgate 86 . In order to remove the tailgate 86 , sliding tailgate bottom hinge pins 88 maybe disconnected from the tailgate hinge bracket 90 and the top retaining pins 92 removed to allow the top tailgate swing pin 94 to be withdrawn from the u-bracket 96 located at the upper rear of the left side 36 and right side 38 . The back cushion 54 may be fitted at its lower edge with a back cushion hinge 80 having a pivot axis 82 transverse to the convertible utility vehicle body 20 and generally parallel to the hinge swing axis 42 , as shown in FIG. 2 . The back cushion hinge 80 allows the back cushion surface 52 to pivot forward to contact the seat cushion 48 . There may optionally be provided a means for securing 84 the back cushion parallel to and proximate the seat cushion. Such a securing means includes any means now known or later developed, including, without limitation, tie straps, cords, clamps, clips, latches, hook and loop fasteners, spring catches, hook and eye fasteners, or slide fasteners. Some means for securing 84 the back cushion 54 will require a mating element 85 affixed proximate the seat cushion 48 . In FIG. 4, the convertible utility vehicle body 20 is configured in the cargo-carrying mode 98 . In FIG. 5, the convertible utility vehicle body 20 is in the passenger-carrying mode 100 . If the convertible utility vehicle body 20 is not to be configured as a dump body 74 , the attachment points 76 78 , or their equivalents, may be fixedly attached to the frame 102 of a typical utility vehicle 104 such as that depicted in FIG. 6 . Most suitable utility vehicles 104 have flotation-type ground-contacting wheels 106 for traversing soft or carefully maintained terrain, but may be equipped with other wheel/tire combinations suited for operation over other generally horizontally support surfaces 108 . A housing for the prime mover 110 is normally provided to protect the internal combustion engine or electric motor within. Means for controlling 112 the various operational functions of the vehicle are normally positioned within the reach of an operator seated in the operator seat 114 . Thus, this invention encompasses a self-propelled, on-board operator controlled, terrain and other generally horizontal surfaces-traversing utility vehicle having a body convertible from a cargo carrying mode to a passenger carrying mode, comprising: a utility vehicle portion comprising at least three ground-contacting rotatable wheels, at least one wheel being steerable by an operator and at least one wheel being a driving wheel, a prime mover mounted on the frame, the prime mover being drivingly linked to the driving wheel, operative means for controlling vehicle speed and vehicle direction, the controlling means being accessible by an operator positioned at an operator seat attached to the frame, a utility vehicle body convertible for carrying cargo or for carrying passengers being affixed to the frame, the convertible body further comprising: a generally horizontally planar fixed bed portion having; a front edge, a back edge, a left edge, a right edge, an upper surface, a generally planar front panel located at the front edge of the fixed bed portion; the front panel extending generally perpendicularly upwardly from the upper surface of the fixed bed portion, and also extending transversely between the left edge of the fixed bed portion and the right edge of the fixed bed portion; a generally planar left side extending generally perpendicularly upwardly from the left edge of the fixed bed portion and generally rearwardly from the front panel, a generally planar right side extending generally perpendicularly upwardly from the right edge of the fixed bed portion and generally rearwardly from the front panel, a generally planar hinged bed portion situate between the left side and the right side, the hinged bed portion having; a hinge swing axis proximate the back edge of the fixed bed portion, an upper hinged surface generally coplanar with the upper surface of the fixed bed portion, a seat cushion surface opposite the upper hinged surface, a generally planar back upper surface situated opposite the hinge and angled downwardly between 60 degrees and 120 degrees with respect to the upper hinged surface, and a back cushion surface opposite the back upper surface. The utility vehicle body convertible for carrying cargo or passengers may also include a generally planar leg rest portion extending generally downwardly from the back edge upper surface of the fixed bed portion, and/or a generally planar foot rest portion extending generally perpendicularly rearwardly from the leg rest portion; sides that extend downwardly proximate a foot rest and/or a leg rest that may extend transversely between the left side and the right side. The fixed bed portion, the leg rest, and the foot rest may easily be formed of a single sheet of metal or other planar material such as polymer, plastic, composite materials, wood, plywood, laminates, oriented strand board, fiberboard, particle board, fiberglass, vinyl, any and all of which are deemed equivalent to metal sheet for the purposes of the present disclosure, it being known that sheet steel has many advantages for the purposes of the present disclosure, among them durability, strength, easily worked with commercially available tools, and general acceptance among purchasers of outdoor power equipment. Applications in which the convertible utility vehicle body may preferably be made of aluminum sheet, extrusion, and structural shapes may arise. Likewise, it may be preferable in some instances to make the convertible utility vehicle body from polymer or composites, whether laid-up, vacuum formed, roto-cast, injection molded, or manufactured using other techniques. A reinforcing gusset member oriented generally parallel to and spaced apart slightly from the left side may be fitted between the back cushion surface and the seat cushion surface; a corresponding right gusset member oriented generally parallel to and spaced apart slightly from the right side may be fitted between the back cushion surface and the seat cushion surface. A utility vehicle body convertible for carrying cargo or passengers is comprised of a generally horizontally planar fixed bed portion having a front edge, a back edge, a left edge, a right edge, an upper surface, a generally planar front panel located at the front edge of the fixed bed portion; the front panel extending generally perpendicularly upwardly from the upper surface of the fixed bed portion, and extending transversely between the left edge of the fixed bed portion and the right edge of the fixed bed portion, a generally planar left side extending generally perpendicularly upwardly from the left edge of the fixed bed portion and generally rearwardly from the front panel, a generally planar right side extending generally perpendicularly upwardly from the right edge of the fixed bed portion and generally rearwardly from the front panel, a generally planar hinged bed portion connected to the fixed bed portion by a transverse bed hinge having a hinge swing axis proximate the back edge of the fixed bed portion, the hinged bed portion having a hinged edge extending transversely between a left hinged bed portion edge and a right hinged bed portion edge, a hinged bed portion upper surface positionable generally coplanar with the upper surface of the fixed bed portion, a generally planar transverse back portion located at the portion of the hinged bed portion opposite the bed hinge, the back portion being angled between 60 degrees and 120 degrees downwardly from the hinged bed portion upper surface when the hinged bed portion upper surface is generally coplanar with the fixed bed portion upper surface, a seat cushion surface opposite the hinged bed portion upper surface, a back cushion surface opposite the back upper surface, a generally planar leg rest portion extending generally downwardly from the back edge upper surface of the fixed bed portion, and a generally planar foot rest portion extending generally perpendicularly rearwardly from the leg rest portion. The utility vehicle body convertible for carrying cargo or passengers may be a hydraulically, electrically, or manually actuated dump body. The side's may extend downwardly proximate the foot rest. A resilient seal may also be interposed between the hinge edge of the hinged bed portion and the back edge of the fixed bed portion. The back cushion may be hinged with a hinge swing axis generally parallel to the bed hinge axis and proximate the seat cushion whereby the back cushion may be swung generally adjacent and parallel to the seat cushion for storage. A means for securing the back cushion parallel to and proximate the seat cushion for storage may be provided for convenience to make operating the convertible seat more convenient and to minimize the accumulation of dust on the seat and back cushions. Suitable means for securing the back cushion proximate the seat cushion for storage include, without limitation, resilient cord, straps, ties, hook-and-loop fasteners, shock cord, snaps, springs, tape, ribbon, mechanical fasteners of all types, latches, catches, seat belts, and other equivalent means. The utility vehicle body convertible for carrying cargo or passengers may optionally include a removable tail gate that can be installed transversely between the left and right sides, and generally parallel to the front panel. More generally, a utility vehicle body convertible for carrying cargo or passengers is shown; this body may easily be retrofitted to many types and models of utility vehicle. From the foregoing, it may be readily understood by those skilled in the art that the embodiments disclosed are applicable to industry and outdoor power equipment generally, and to machinery and vehicles that are operated in off-road circumstances, particularly. Changes and modifications in the specifically described embodiments can be carried out without departing from the scope of the invention which is intended to be limited only by the scope of the appended claims.
A utility vehicle body is shown that may be easily and quickly converted, without tools from a flat-bed cargo hauling configuration to a configuration having seating for one to three passengers and a reduced cargo-carrying area. The body may be retrofitted to existing utility vehicles or installed as original equipment. This convertible utility vehicle body is particularly adapted for use by personnel involved in landscaping, golf course maintenance, and maintenance of manufacturing and energy conversion facilities. It is also useful to persons who need access to remote areas for vocational, recreational, or residential activities.
1
TECHNICAL FIELD [0001] This disclosure is generally directed to compositions and methods for the preparation of a high density (HD) piezo printhead for inkjet printing. More specifically, this disclosure is directed to solvent systems and methods for using these solvent systems for enabling thin film deposition of epoxy adhesives for HD piezo printhead interstitial bonding during their fabrication. BACKGROUND [0002] HD piezo printheads are typically composed of multiple layers or stacks of plates, each plate performing an ascribed function within the printhead. FIG. 1 provides a schematic view of a HD piezo printhead assembly 100 representative of a 150 dpi color or 600 dpi mono printhead. The assembly 100 includes an inlet manifold or port 105 which passes through layers of stackup to a finger 110 , a filter 115 , an inlet 120 , a body 125 , an outlet 130 , an exit nozzle aperture plate 135 , and a nozzle 140 . Ink comes in at one of four ports (one for each color of cyan, magenta, yellow, and black) and may be channeled to any of the 7,040 exit nozzles (A3, 4 colors, 150 CNPI, 12″ head), for which only one path is illustrated. To bond any combination of plates (e.g., stainless steel, aluminum, or polyimide layers) requires a thin film adhesive. [0003] An ideal adhesive for bonding polymer layers in printheads should include features such as: ink compatibility with solid inks, aqueous inks, UV gels and other commercially available UV inks, oil based inks and solvent based inks; minimum squeeze out of the adhesive to prevent blocking of printhead nozzles; minimum air trapped bubbles to prevent non uniformity in inkjet printhead geometry and occurrence of leaks; good bonding strength, e.g. >200 psi; appropriate storage modulus for compliance and ink jetting requirements; and thermal oxidative stability. [0004] For the HD piezo printhead design, R1500, a thermoset modified acrylic adhesive, has been used for this purpose. This adhesive, when used at a 0.002″ thickness, has the ability to take up surface flatness non-uniformities—a requirement at the manifold and heater interfaces of the printhead. However, when printheads fabricated with R1500 adhesive are used with the Xerox UV curable inks or external UV inks (e.g., from Sun Chemicals), the acrylate monomers in these inks adversely interact with R1500 acrylic adhesive. This causes swelling of the adhesive, which as used in the printhead, reduces the inlet diameter and flow rate. Furthermore, increased thickness at the material interfaces affects jetting performance. The R1500 acrylic adhesive film also shows a 160% weight gain in UV inks in six weeks. [0005] By contrast, epoxy adhesives, such as I2300L epoxy adhesive (available from Resin Designs, LLC) described in U.S. Patent Application Publication No. 2013/0135391, the disclosure of which is hereby incorporated by reference in its entirety, have good ink compatibilities with acrylate-based inks as well as with other ink chemistries, for example, wax-based/water-less inks and UV gel inks. Epoxy adhesives, however, may require the addition of solvents for depositing a thin film of the adhesive onto a base material of interest, for example, a stainless steel or polyimide-based materials commonly used in HD piezo printhead fabrication. [0006] There remains a need for solvent systems and methods for enabling thin film deposition of an adhesive for HD piezo printhead interstitial bonding. SUMMARY [0007] The following detailed description is of the best currently contemplated mode of carrying out exemplary embodiments herein. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the exemplary embodiments herein, since the scope of the disclosure is best defined by the appended claims. [0008] Various inventive features are described below that may each be used independently of one another or in combination with other features. [0009] Broadly, embodiments of the disclosure herein generally provide an epoxy adhesive solution which includes an epoxy adhesive; a dialkyl ether solvent selected from the group consisting of dimethoxymethane and dimethoxyethane; and an alkyl alcohol solvent selected from the group consisting of methanol, ethanol, and isopropanol. [0010] In an embodiment, an epoxy adhesive solution includes an epoxy cresol polymer adhesive, a dialkyl ether solvent, and an alkyl alcohol solvent. [0011] In another embodiment, a high density (HD) printhead includes a plurality of layers; and an epoxy adhesive composition between two of the layers, wherein the composition includes an epoxy cresol polymer adhesive. [0012] In yet another embodiment, an epoxy adhesive solution for a high density (HD) printhead comprises an epoxy cresol polymer adhesive, a dialkyl ether solvent, and an alkyl alcohol solvent. BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 illustrates a HD piezo printhead design prepared with R1500 acrylic adhesive for interstitial bonding of the stackup layers. [0014] FIG. 2 illustrates the chemical components of an I2300L epoxy adhesive composition. [0015] FIG. 3 illustrates a thin film of an I2300L epoxy adhesive composition prepared using two solvents on a baseline material. [0016] FIG. 4 illustrates a thin film of an I2300L epoxy adhesive composition prepared using a single solvent on a baseline material. [0017] FIG. 5 illustrates a schematic view of an I2300L epoxy adhesive composition bonding together a bottom stainless steel body plate and a top polyimide plate. DETAILED DESCRIPTION [0018] According to embodiments herein, an epoxy adhesive may include an epoxy cresol polymer(s); a latent curing agent(s); and optionally one or more co-polymers. These compositions provide epoxy adhesives having a high chemical resistance and thermal stability performance. Epoxy Adhesive(s) [0019] Novolacs are a class of phenol-formaldehyde polymers linked by a methylene group (—CH 2 —), with a formaldehyde to phenol molar ratio of less than one. Cresol may be substituted for phenol resulting in a class of ortho-, meta-, and/or para-methyl substituted phenol-formaldehyde polymers linked by a methylene group (cresol-formaldehyde polymers). Reaction of a cresol-formaldehyde polymer with epichlorohydrin produces a propylene oxide substituted cresol-formaldehyde polymer (i.e., epoxy cresol polymer). [0020] As used herein, “epoxy cresol polymer” includes the propylene oxide substituted cresol-formaldehyde polymer and other epoxy substituted cresol-formaldehyde polymers. Epoxy cresol polymers are highly viscous to solid materials. [0021] The high epoxide content in these polymers forms a highly cross-linked network, which provides the resulting polymer with a high temperature and chemical resistance, particularly chemical resistance to acrylate monomers found in many printing inks and gels. [0022] In an embodiment, the epoxy cresol polymer(s) may be present in an amount of from about 1 weight % to about 10 weight %, or from about 2 weight % to about 8 weight %, or from about 2 weight % to about 5 weight %, or about 4 weight of the epoxy adhesive composition. [0023] In an embodiment, the epoxy cresol polymer is an ortho-epoxy cresol polymer, which is present in I2300L epoxy adhesive shown below in Table 1. [0000] TABLE 1 Chemical Description CAS # Weight, % Bisphenol A Epoxy Polymer 25036-25-3 11-17 Bisphenol A Epoxy Polymer 25068-38-6 5-7 Latent Curing Agent 461-58-5 2-3 ortho-Epoxy Cresol Polymer 29690-82-2 68-72 [0024] As shown in Table 1, commercially available I2300L epoxy adhesive (without CAB-O-SIL®) includes an ortho-epoxy cresol polymer, along with two bisphenol A epoxy polymers, and a latent curing agent such as dicyandiamide. CAB-O-SIL® is fumed silica made from flame pyrolysis of silicon tetrachloride or from quartz sand vaporized in a 3000° C. electric arc and is sold by Cabot Corporation. [0025] FIG. 2 illustrates the chemical structures for the ortho-epoxy cresol polymer, the latent curing agent (dicyandiamide), and bisphenol A epoxy polymers present in the I2300L epoxy adhesive. [0026] In an embodiment, I2300L epoxy adhesive is present in an amount of from about 1 weight % to about 10 weight %, or from about 2 weight % to about 8 weight %, or from about 4 weight % to about 6 weight %, or about 5 weight % of the epoxy adhesive solution. Curing Agent(s) [0027] In an embodiment, the curing agent is dicyandiamide which may be present in an amount of from about 1 weight % to about 5 weight %, or from about 1.5 weight % to about 4 weight %, or from about 2 weight % to about 3 weight % of the epoxy adhesive composition. [0028] Dicyandiamide is a latent curing agent that forms crystals having a high melting point of about 207° C. to 210° C. Dicyandiamide has a pot life of 24 hours when it is dissolved in an epoxy polymer using a solvent or the like, but it is normally used in the form of a fine powder dispersed in an epoxy polymer, which has a very long pot life of 6 to 12 months. Dicyandiamide cures at high temperatures of 160° C. to 180° C. in 20 to 60 minutes. The cured polymers have good adhesiveness and are less prone to staining. Optionally, an accelerator may be used with dicyandiamide, for example, basic compounds including but not limited to tertiary amines, imidazole, aromatic amines, and the like. [0029] Other suitable curing agents herein include but are not limited to primary, secondary and tertiary amines. Amines may further be classified into aliphatic, alicyclic, and aromatic amines. In general, these types of curing agents have more than three active hydrogen atoms and two amino groups in a molecule so that the cured polymer becomes cross-linked. The curing speed of a curing agent depends on the type and loading of the amine and the type of epoxy resin. [0030] Aliphatic polyamine curing agents include but are not limited to diethylenetriamine (DTA), triethylenetetramine (TTA), tetraethylenepentamine (TEPA), diproprenediamine (DPDA), diethylaminopropylamine (DEAPA), 1,6-hexamethylenediamine (NMDA), and the like. [0031] Alicyclic polyamine curing agents include but are not limited to N-aminoethylpiperazine (N-AEP), 4-[(4-amino-3-methylcyclohexyl)methyl]-2-methyl-cyclo-hexan-1-amine (Lamiron C-260), menthane diamine (MDA), isophorone-diamine (IPDA), 4,4′-diaminodicyclohexyl methane (Wandamin HM), 1,3-bis(amino-methyl)-cyclohexane (1,3-BAC), and the like. [0032] Aliphatic aromatic amines include but are not limited to meta-xylenediamine (m-XDA), Sho-amine X (xylylenediamine), Amine black (xylylenediamine trimer), Sho-amine black (xylylenediamine trimer), Sho-amine N (xylylenediamine derivative), Sho-amine 1001 (xylylenediamine derivative), Sho-amine 1010 (xylylenediamine derivative), and the like. [0033] Aromatic amines include but are not limited to meta-phenylene diamine (MPDA), diaminodiphenylmethane (DDM), diaminodiphenylsulfone (DDS) and the like. Solvent(s) [0034] According to embodiments, the epoxy adhesive can be dissolved in a solvent(s) that is present in an amount of from about 1 weight % to about 10 weight %, or from about 2 weight % to about 8 weight %, or from about 4 weight % to about 6 weight %, or about 5 weight % of the epoxy adhesive solution. [0035] Embodiments of the solvents can comprise one or more dialkyl ethers and/or one or more alkyl alcohols. [0036] In embodiments, dialkyl ethers can include compounds having formula: (C 1 -C 12 )alkyl-O—(C 1 -C 12 )alkyl-O—(C 1 -C 12 )alkyl, or formula (C 1 -C 12 )alkyl-O—(C 1 -C 6 )alkyl-O—(C 1 -C 12 )alkyl, or formula (C 1 -C 6 )alkyl-O—(C 1 -C 6 )alkyl-O—(C 1 -C 6 )alkyl, wherein each alkyl group may independently be a straight-chain, a branched chain and/or contain cyclic groups. [0037] Exemplary dialkyl ethers herein can include: dimethoxymethane (methylal, CH 3 OCH 2 OCH 3 ), diethoxymethane (CH 3 CH 2 OCH 2 OCH 2 CH 3 ), dipropoxymethane (CH 3 CH 2 CH 2 OCH 2 OCH 2 CH 2 CH 3 ), dibutoxymethane (CH 3 CH 2 CH 2 CH 2 OCH 2 O—CH 2 CH 2 CH 2 CH 3 ), dimethoxyethane (DME, ethylene glycol dimethyl ether, glyme, monoglyme, dimethyl glycol, dimethyl cellosolve, (CH 3 OCH 2 CH 2 OCH 3 )), diethoxyethane (ethylene glycol diethyl ether (CH 3 CH 2 OCH 2 CH 2 OCH 2 CH 3 ); dipropoxyethane (ethylene glycol dipropyl ether, CH 3 CH 2 CH 2 OCH 2 CH 2 O—CH 2 CH 2 CH 3 ), dibutoxyethane (ethylene glycol dibutyl ether, CH 3 CH 2 CH 2 CH 2 O—CH 2 CH 2 OCH 2 CH 2 CH 2 CH 3 ), and the like. These compounds are clear, colorless, aprotic, and high boiling liquid ether solvents in comparison to diethyl ether and tetrahydrofuran (THF) solvents. [0038] In embodiments, alkyl alcohols can include compounds having formula: (C 1 -C 12 )alkyl-OH or formula (C 1 -C 6 )alkyl-OH, wherein each alkyl group may independently be a straight-chain, a branched chain, and/or contain cyclic groups. [0039] Exemplary alkyl alcohols herein can include: methanol (CH 3 OH), ethanol (CH 3 CH 2 OH), n-propanol (CH 3 CH 2 CH 2 OH), isopropanol ((CH 3 ) 3 COH), n-butanol (CH 3 CH 2 CH 2 CH 2 OH), sec-butanol (CH 3 CH(CH 2 OH)CH 3 ), and the like, are light, volatile, colorless, flammable liquids with distinctive odors, which are used as polar, protic liquid solvents. [0040] In embodiments herein, the dialkyl ether(s) can be present in an amount of from about 65 weight % to about 75 weight %, or from about 60 weight % to about 75 weight %, or from about 50 weight % to about 80 weight % of the epoxy adhesive solution. [0041] In embodiments herein, the alkyl alcohol(s) can be present in an amount of from about 25 weight % to about 35 weight %, or from about 30 weight % to about 40 weight %, or from about 20 weight % to about 50 weight % of the epoxy adhesive solution. [0042] In an embodiment, the dialkyl ether solvent is dimethoxyethane and the alkyl alcohol solvent is methanol, in which dimethoxyethane and methanol are present in the epoxy adhesive composition of about 60 weight % dimethoxyethane and about 35 weight % methanol, or of about 65 weight % dimethoxyethane and about 30 weight % methanol, or of about 70 weight % dimethoxyethane and about 25 weight % methanol of the epoxy adhesive solution. [0043] Organic solvents for diluting the epoxy adhesive may also include the addition of a small amount of water in order to solubilize the curing agent, e.g., the dicyandiamide component. However, water has a much lower vapor pressure at room temperature than most organic solvents and, consequently, a thin film coating or deposit of an epoxy cresol polymer adhesive, such as I2300L epoxy adhesive, may not be uniform on drying due to the water residue, which cannot dry out of the film concurrently with the organic solvents. [0044] As shown in Table 2, dialkyl ether organic solvents; and polar, protic, alkyl alcohol solvents such as methanol; have a higher vapor pressure than water. Consequently, a thin film coating or deposit of an epoxy cresol polymer adhesive, such as I2300L epoxy adhesive, when dissolved in a co-solvent mixture of dimethoxyethane and methanol, can provide a uniform film upon drying without any residual water. [0000] TABLE 2 DME Water (Dimethoxyethane) Methanol CAS Number 7732-18-5 110-71-4 67-56-1 Molecular Formula H 2 O C 4 H 10 O 2 CH 4 O Molecular Mass 18.01528 g/mol 90.12 g/mol 32.04 g/mol Boiling Point 99.98° C. 85° C. 64.7° C. Vapor Pressure 17.5 mmHg 48 mmHg 97 mmHg (20° C.) [0045] In embodiments, the bonding strength of the epoxy adhesive may be from about 200 psi to about 3,000 psi, or from about 300 psi to about 2,000 psi, or from about 500 psi to about 1,500 psi, as measured from lap shear testing. Epoxy Adhesive Coating or Deposit [0046] In embodiments, when an epoxy adhesive solution herein is applied to the surface of a polyimide baseline material and allowed to dry, the resulting thin film epoxy adhesive coating or deposit may have a film thickness from about 1 micron to about 25 microns, or from about 2 micron to about 10 microns, or from about 2 micron to about 5 microns. [0047] After application of the epoxy adhesive solution to a baseline material (e.g. stainless steel, aluminum, or polyimide layer), the thin film epoxy adhesive coating or deposit may have a smooth surface with a reduction in air bubbles from about 80% to about 99%, or from about 85% to about 98%, or from about 90% to about 95%, when compared to an epoxy adhesive coating or deposit prepared with methylene chloride. [0048] In embodiments, the surface roughness of the thin film epoxy adhesive coating or deposit may be from about 0.1 micron to about 2 microns peak to valley, or from about 0.1 microns to about 1 micron peak to valley, or from about 0.3 microns to about 0.8 microns peak to valley, or about 0.6 microns peak to valley, where the surface topography measurements are performed on the films using Tencor Surfscan. [0049] In embodiments, the thin film epoxy adhesive coating or deposit may have minimal weight gain over time, for example from about 0.1% to about 10%, or from about 0.5% to about 5%, or from about 1% to about 3% over 32 weeks. Examples [0050] The following examples illustrate embodiments of the instant disclosure. The Examples are intended to be illustrative only and are not intended to limit the scope of the disclosure. Example I Preparation of I2300L Epoxy Adhesive Composition [0051] The preparation of a solution of I2300L epoxy adhesive composition involved two steps: [0052] STEP 1: Mix the I2300L epoxy adhesive with a dialkyl ether, such as dimethoxyethane (DME), to make about a 5 weight % solution of the I2300L epoxy adhesive; and [0053] STEP 2: Slowly add an alkyl alcohol, such as methanol into the mixture prepared in STEP 1, until the solution becomes clear. The final concentration of I2300L epoxy adhesive is about 3.5 weight %. [0054] In one embodiment of Example 1, the addition of about 95 grams of dimethoxyethane to about 5 grams of I2300L epoxy adhesive (STEP 1), followed by the addition of about 43 grams of methanol (STEP 2), provided a final I2300L epoxy adhesive concentration of about 3.5 weight %. Example 11 I2300L Coated Polyimide Film Preparation [0055] I2300L epoxy adhesive coated polyimide film was prepared for bonding performance evaluation. The procedure of I2300L epoxy adhesive coated polyimide film preparation included: [0056] Step 1: I2300L epoxy adhesive was dissolved in dimethoxyethane and methanol as described in Example 1, to form about a 3.5 weight % I2300L epoxy adhesive that may be coatable. [0057] Step 2: The above about 3.5 weight % I2300L epoxy adhesive composition was draw bar coated to form a thin uniform film on the polyimide surface. The polyimide surface was oxygen plasma treated before coating. [0058] Step 3: The I2300L epoxy adhesive film coating was allowed to air dry for about 30 minutes to about an hour, to allow the solvents to evaporate to provide a thin film of the epoxy adhesive coating or deposit. [0059] FIG. 3 illustrates a schematic view of an I2300L epoxy adhesive composition coated as a film on top of a polyimide base or support as prepared according to Example II. Example III I2300L Coated Polyimide Film Preparation [0060] A solution of I2300L epoxy adhesive was prepared using methylene chloride as the solvent. As shown in FIG. 4 , when methylene chloride was used to dilute I2300L epoxy adhesive before dispensing, air voids or air bubbles were formed after drying on the surface of the base material due to the non-dissolvable solid contents present in the epoxy adhesive formulation, e.g. the polar latent curing agent dicyandiamide. In addition to this non-uniformity, which may affect the geometry and integrity of the printhead, bonding strength between the layers was reduced. Other organic solvents, for example, methyl ethyl ketone, toluene, ethylene glycol, tetrahydrofuran, and the like, cannot dissolve I2300L epoxy adhesive as well as methylene chloride, and air voids or air bubbles results at the bonding interface upon drying when the solvents were used. [0061] As shown in FIG. 5 , two thin film I2300L epoxy adhesive bonding structures were prepared for comparison and evaluation of their bonding performance. A first film was prepared from I2300L epoxy adhesive dissolved in methylene chloride according to Example III to provide a 50 weight % solution of I2300L epoxy adhesive, which was then spray coated onto a stainless steel body plate. After drying, 1 mil polyimide was bonded on top at 190° C./70 min/200 psi. A second film was prepared from about a 3.5% I2300L epoxy adhesive composition using dimethoxyethane-methanol as described in Example 1. A thin layer of the I2300L epoxy adhesive composition was deposited onto 1 mil polyimide using a draw bar. After drying, the epoxy coated polyimide was bonded with a stainless steel body plate at 190° C./70 min/200 psi. [0062] Surface topography measurements were performed on these films using Tencor Surfscan. Surface roughness of the first film was ˜8 micron peak to valley. By contrast, the surface roughness of the second film was ˜0.6 micron peak to valley. Thus, the surface roughness of the film was significantly reduced using co-solvents dimethoxyethane/methanol in the I2300L epoxy adhesive composition. [0063] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various, presently unforeseen or unanticipated, alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
The disclosure provides a solvent system for dissolving an epoxy adhesive such as I2300L epoxy adhesive. The solvent system includes a dialkyl ether solvent and an alkyl alcohol solvent. The disclosure also provides methods for preparing a uniform thin film deposit of an epoxy adhesive for printhead interstitial bonding during their fabrication.
2
BACKGROUND OF THE INVENTION This invention is a continuation in part of our earlier application, Ser. No. 134,878, filed Mar. 28, 1980, now U.S. Pat. No. 4,314,890. This invention relates to a system and method for the distillation of ethanol from ethanol-water mixtures through the use of solar, electrical, or other energy sources. More particularly, this invention relates to a system and method for the separation of ethanol from ethanol-water mixtures wherein the feed to the distillation device is automatically controlled so as to feed water-ethanol mixtures to the distillation chamber only when the chamber is sufficiently hot to allow distillation to take place. The distillation of ethanol from ethanol-water mixtures is well known for the recovery of ethanol for alcoholic beverages and for industrial purposes. However, with the recently spiraling costs of fossil-based fuels, the utilization of ethanol in internal combustion engines has become increasingly important. Ethanol may be prepared naturally by fermentation and may also be prepared by industrial processes such as the hydration of ethylene. In both methods of manufacture, a dilute aqueous solution of ethanol is formed requiring the ethanol to be removed from the greater portion of the water in order for it to function effectively as a fuel in an internal-combustion engine. In our earlier patent application, Ser. No. 083,281, an apparatus and method for removing ethanol from ethanol-water mixtures was disclosed wherein the ethanol-water mixtures were preheated by solar means and were then passed to a solar vaporization chamber wherein the ethanol was distilled or vaporized from the water utilizing solar energy as the sole source of heat. While the above-mentioned invention provides an extremely improved method for the utilization of solar energy, there are many times when such energy is not readily available. Moreover, there are times when the combined utilization of solar and other forms of energy might operate more economically when other factors are taken into consideration. OBJECTS AND SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide an efficient distillation still for the separation of water-ethanol mixtures by solar, electrical, or other forms of energy, or a combination of such forms of energy. It is also an object of the present invention to provide a still for the separation of water-ethanol mixtures wherein the feed to the vaporization apparatus is controlled by the temperature of the water-ethanol mixture and rate of distillation within the vaporization chamber. It is further an object of the present invention to provide a distillation still for the separation of water-ethanol mixtures wherein the mixture to be separated is preheated in a chamber immediately adjacent to the vaporization chamber wherein the same source or sources of energy are used to both preheat and vaporize the mixture and is also used to control the rate at which water-ethanol mixture is fed through the preheating chamber. These and other objects are accomplished by means of an inclined still, heated by solar, electrical, or other forms of energy, or a combination of such forms of energy. The inclined still comprises a lower preheating chamber and an upper vaporization chamber having a vaporization floor. The vaporization floor thus serves as the dividing barrier between the lower preheating chamber and the upper vaporization chamber. Water-ethanol mixtures entering the preheating chamber are heated by an appropriate energy source, such as by solar energy striking the vaporization floor, or by electrical resistance heaters that are adjacent the vaporization chamber. As the water-ethanol mixture is heated in the preheating chamber, the specific gravity of the mixture becomes less dense allowing the mixture to expand and eventually boil causing the mixture to rise to the top of the preheating section and spill over onto the vaporization floor. In the vaporization chamber, the ethanol is separated from the aqueous solution and may be passed into a fractionation column, or equivalent device. The residual liquid at the bottom of the vaporization chamber is removed and disposed of or recycled back to the preheating chamber depending upon the ethanol content of such residual liquid. The feed of water-ethanol to the still is controlled by the temperature of the water-ethanol mixture in the apparatus and the rate of ethanol distillation. The water-ethanol feed is controlled by a float valve such that when the still is not working the liquid level within the feed container housing the float valve and the liquid level within the still are the same. As the still is heated and the water-ethanol mixture within the preheating action expands and begins to vaporize or be distilled, the level of the water-ethanol mixture in the feed chamber is lowered and the float valve opens permitting additional feed to enter into the feed chamber. However, the feed entering into the feed chamber through the float valve is controlled by the rate at which the ethanol is removed from the ethanol-water mixture within the still. DRAWINGS OF THE INVENTION The above and other objects, features, and advantages of the present invention will be more apparent from the following more particular description, presented in connection with the following drawings, in which: FIG. 1 is a front perspective view of the preferred embodiment of the invention partially broken away in order to illustrate the vaporization section of the apparatus; FIG. 2 is a rear elevational view of the apparatus shown in FIG. 1 partially broken away to show the preheating chamber of the apparatus and the float valve of the feed chamber; FIG. 3 is a side cross-sectional view of the apparatus shown in FIG. 1 taken along line 3--3 thereof and also contains a schematic flow diagram showing the operation of the apparatus; FIG. 4 is a transverse cross-sectional view of the apparatus shown in FIG. 1 taken along line 4--4 thereof; FIG. 5 is a cross-sectional view of the feed chamber showing one type of level control float and valve arrangement taken along lines 5--5 of FIG. 3. DETAILED DESCRIPTION OF THE INVENTION There is shown in FIGS. 1 through 5 a complete and preferred embodiment of the invention. While the invention herein disclosed is concerned only with a distillation still 10 and related support structure, a fractionation column 13 is also shown in the drawings to give an indication of how the still could be used in a complete distillation and fractionation system. Further, while water-ethanol mixtures from various sources may be utilized in this invention, the apparatus will be described in terms of the separation of the water-ethanol mixture containing about 9 to 13% ethanol. This is representative of water-ethanol mixtures obtained by the natural fermentation of carbohydrate sources. The apparatus as shown consists of an inclined still 10 supported by stand 11. A feed chamber 12 is connected to the rear of the still 10. A fractionation column 13 and condenser 14 may be connected to and located above the apparatus as shown. The still 10 is generally rectangular in shape, having a generally flat insulated floor 15 surrounded on each side by insulated upwardly extending walls 16a, b, c and d. Dividing the still into a preheating chamber 17 and a vaporization chamber 18 is a vaporization floor 19. Floor 19 may be any suitable material. Preferably it is realized from materials that readily absorb heat from external sources; and, in turn, transfer at least a portion of this absorbed heat to the solution in the preheating chamber. For example, if solar rays are allowed to strike the upper surface of the floor 19 (e.g., through a translucent top or lid 22), the floor 19 may advantageously be a metal having a solar absorbent surface. Small heat absorbing projections 20, which inhibit the downward flow of water-ethanol solution, thereby allowing sufficient time for ethanol distillation from such solutions, are selectively placed on the upper surface of the floor 19. These projections 20 may consist of expanded metal sheets having a honeycomb or similar configuration placed over the vaporization floor 19. Such expanded metal sheets are commonly used in the construction industry as a base for plaster. This type of floor is a considerable improvement over the fabric type of material disclosed in Ser. No. 083,281 in that the floor does not become plugged by foreign matter but remains free of foreign matter since liquid flowing over the surface of the floor 19 washes these materials from this surface. Floor 19 is contiguous with lower end wall 16d and sidewalls 16b and 16c, but terminates short of upper end wall 16a to enable the water-ethanol from the preheating chamber 17 to spill over the upper end of vaporization floor 19 onto the upper projections 20. It follows that the upper end of floor 19 must be horizontally level so that the water-ethanol mixture will be uniformly distributed onto the surface of floor 19. The actual distance between the upper end of floor 19 and end wall 16a is not critical as long as there is sufficient room for removal of distilled vapors from both chambers 17 and 18 of the still 10 into a fractionation column 13, or similar collection and/or purification device. In one embodiment, the still 10 may contain one or more transparent or translucent covers which are capable of transmitting solar energy. Depending upon the climatic conditions, two or more such layers could be used. The primary cover 21 is preferably sealed into walls 16 by appropriate means such as gaskets, caulking and the like. A lid 22 containing one or more layers of glass or plastic 23 may be placed about the upper edges of walls 16 and over cover 21. Each layer of covering, i.e., layers 21 and 23, is separated from each other by a dead-air space. When constructed in this manner the transmission of light through the cover is not inhibited but the outward loss of heat within the vaporization chamber is effectively prevented. Moreover, cover 21 remains heated thereby helping prevent the collection of condensed vapors thereon as is done in conventional solar stills. Alternatively, the cover 21, especially the underneath side thereof, could be realized using an opaque, or nearly opaque, solar absorbing material. The heat thus absorbed, would not only prevent the collection of condensed vapors on the underside of the cover 21, but would also serve to further heat the vaporization chamber 18. Floor 15, the lower end wall 16d and sidewalls 16b and 16c are insulated to retain heat. Any form of insulation conventionally used which will provide an R-15 to R-30 rating is adequate. Typical of such insulating materials are urethane and polystyrene foams. The upper wall 16a is also preferably insulated but need not be. Attached to the underside of vaporization floor 19 and running essentially the length thereof may be one or more electrical resistance heaters 24 which are positioned so as to heat liquid contained in preheating chamber 18 and also heat the surface of vaporization floor 19. Sources of energy other than solar energy may be used, of course, to heat the preheating chamber 17 and the vaporization chamber 18. As indicated in the preceding paragraph, electrical heating coils could be imbedded into or attached to the floor 19 and surrounding walls. Steam derived from either a geothermal source or from natural gas, coal, or similar fuels, could also be selectively distributed throughout the floor 19 and/or surrounding walls in appropriate tubing. Such tubing could even be selectively positioned on the upper surface of the floor 19 so as to serve as the portions 20 that are used to inhibit the downward flow of the water-ethanol solution. Other forms of energy, both known and yet to be discovered, could also be used to perform the necessary heating function by those skilled in the art. A line 25 closeable by valve 26 interconnects feed chamber 12 with the lower portion of preheating chamber 17. A drain or recycle line 27, whose flow direction is controlled by drain valve 28 or recycle valve 29 and pump 30, completes the plumbing of the still 10. As mentioned, a fractionation column 13 may be interconnected with still 10 via an aperture in upper end wall 16a. Any suitable type of fractionation column may be used. Glass beads, glass wool or any other conventional packing material 31 is commonly used in fractionation columns. A retaining screen 32 or glass wool plug prevents the packing material from entering the still 10 while allowing vapors from the still to enter the column. The walls of column 13 are insulated in essentially the same manner as the walls of the still. Preferably, a coiled water line 33 is placed in the upper end of fractionation column 13 adjacent outlet line 34. Line 34 passes through condenser 14 which is essentially a water-cooled jacket having an inlet 35 and outlet 36. The water-ethanol feed system formed by the still and fractionation column may have an optional water-ethanol storage tank 37 connected to feed chamber 12 via line 38 which may be closed by valve 39. Line 34 (from the fractionation column and passing through condenser 14) either interconnects line 38 when valve 40 is closed or ethanol product withdrawal line 41 when valve 42 is closed and valve 40 is open. The flow of water-ethanol through the still is controlled by means of a float control valve located in feed chamber 12. Various valves can be used and thus the invention is not to be limited to the specific embodiment disclosed herein. Basically, the valve control consists of a float 43 attached to an arm 44 which is connected to a wall of feed chamber 12 via a swivel 45. A valve stem 46 interconnects the arm 44 a short distance away from swivel 45. A hydraulic valve head 47 adapted to seat in fluid tight relationship into valve chamber 48 completes the feed system. The feed chamber 12 is positioned relative to still 10 such that the level of liquid in the preheating chamber 17 of the still will be just below the upper end of vaporization floor 19 when the level of liquid in the feed chamber raises the float 43 high enough to seat valve head 47 into the valve body 48, thereby closing off line 38. With the distillation still and system described above, the specific mode of operation will now be disclosed. A water-ethanol mixture prepared synthetically or by fermentation is stored in tank 37. When valves 39 and 26 are opened, feed chamber 12 and preheating chamber 17 are filled by means of fluid flow via lines 38 and 25. As the water-ethanol mixture approaches the top of vaporization floor 19 in chamber 17, feed chamber 12 also fills causing float 43 to rise, which rising thrusts valve head 47 into the valve body 48 and shuts off the fluid flow by hydraulic pressure. As previously taught, still 10 may be heated by solar heat, electrically supplied heat, or a wide variety of other sources of heat, or a combination of such sources of heat. If solar heat is used, the positioning of the still relative to the sun, as taught in Ser. No. 083,281, may be applied to the present invention. Electrical energy, when used, is supplied to resistance heaters 24 via electrical line 49. A thermostat 50 may be used to control the flow of current to the heaters to provide the desired temperature within the still and allow for optimum usage of solar energy. If other sources of energy are used, suitable controls would likewise be employed to achieve the desired temperature. As the temperature within the still rises, the water-ethanol mixture in preheating chamber expands and eventually boils, causing the solution to overflow onto the upper surface of vaporization floor 19. The barriers 20 delay the downward flow of the water-ethanol mixture along this floor 19. The distillation process begins in the preheating chamber 17 and is intensified in vaporization chamber 18. The liquid passing downward along floor 19 becomes progressively more ethanol depleted as it approaches the lower end of chamber 18. Therefore, the liquid reaching the end of chamber 18 consists primarily of water with only minor amounts of ethanol. This ethanol depleted water is withdrawn via line 27 through valve 28 and is discarded. However, if the ethanol content is sufficiently high, valve 28 may be closed and valve 29 opened allowing the liquid to be recycled by pump 30 back to line 25. If desired, a hydrometric valve or equivalent may be used to determine the ethanol content of solution in line 27 and automatically effect a recycle if the ethanol content is sufficiently high. On the other hand, periodic analysis may be made of this residual solution by a hydrometer or a gas chromatograph or other conventional means in order to determine whether to recycle or discard the residual solution. As the solution within chamber 17 spills over onto the floor of chamber 18, the water-ethanol within feed chamber 12 feeds by gravity flow into chamber 17. This causes the float 43 to lower, thereby unseating valve head 47 and allowing fresh feed from tank 37 to enter the feed chamber. As long as the temperature in still 10 remains sufficient to sustain distillation, the feed will be continuous. However, once the temperature in the still drops, the liquid level within chamber 17 automatically lowers, causing the valve head to seal off the flow of feed to feed chamber 12. Thus, water-ethanol mixture cannot flow through the still in the absence of adequate distillation temperatures. Moreover, the still operates automatically with few moving parts, thereby lessening the need of having an operator constantly monitoring the still. As the temperatures within the vaporization chamber 18 become operational, the insulated cover 21 becomes sufficiently warm that ethanol vapors do not condense on the underside thereof. Therefore, essentially all of the vapors within both chambers of the still rise upwardly and may be withdrawn into a suitable container or further purifying element, such as the fractionation column 13. These vapors, depending upon the temperature within the still, consist primarily of ethanol with varying amounts of water. The Column 13 functions to separate the lower boiling ethanol from the higher boiling water through a series of redistillations as commonly occurs in any fractionation column with the higher purity ethanol vapors passing to the upper portion of column 13 and through line 34 into condenser 14. Surprisingly, it has been found that the vapors entering the column can be fractionated to produce a high quality ethanol with a column which is shorter and less densely packed than is required with a conventional reflux fractional distillation system. A coiled water line 33 is preferably placed in the top of the fractionation column 13 to regulate the purity or concentration of ethanol vapors exiting line 34 and being condensed in condenser 14. The temperature of water flowing through line 33 is carefully regulated by means, now shown, to liquify vapors having too high a water concentration and prevent them from passing out of the column via line 34. In this manner the concentration of ethanol leaving the fractionation column can be controlled. For example, at 78.2° C. vapors exiting column 13 would contain 92% w ethanol whereas the condensed liquid would have 91% w or less ethanol. At 81.2° C. vapors exiting column 13 would contain 80% w ethanol whereas the condensed liquid would contain equal weights of water and ethanol. Through published tables, such as is contained on page 2117 of the Handbook of Chemistry and Physics, 39th Edition published by the Chemical Rubber Publishing Company, the optimum temperatures in coiled line 33 for a given ethanol concentration may be determined. The vapors condensed in column 13 are either redistilled in the column or pass downwardly into the still for redistillation. The vapors passing through condenser 14 are liquified by heat exchange with cold water passing through the condenser via lines 35 and 36 and pass through valve 40 into line 41 for collection as fuel grade ethanol. If the temperature at the top of the fractionation column is not carefully controlled or if, for any other reason, the concentration of water in the ethanol is too high, valve 40 may be closed and valve 42 opened in order to recycle the condensate back to feed chamber 12. In the alternative, this product could be recycled directly to line 25 and bypass the feed chamber 12. If desired valves 40 and 42 could be replaced by a single hydrometric valve as disclosed in our earlier application, Ser. No. 083,231. When operating the invention as described above, the temperatures within the still may vary somewhat. Preferably the temperatures will be between 80° and 95° C. in order to produce a fuel grade ethanol which is 160 proof or better. However, higher temperatures may be used for ethanol of lesser concentrations, or vice versa. It is also possible to utilize the system described herein to separate other liquids having different boiling points such as solvent-resin mixtures. The following examples were carried out utilizing the system described above and are illustrative of the invention but are not to be considered as limitations thereof. For example, in certain examples a lower quality ethanol is produced due to the lack of temperature control in the fractionation column. Thus, a two-stage distillation is required to provide a higher grade of ethanol. It is apparent from the following examples that the invention may be utilized to produce various grades of ethanol and that a plurality of stills arranged in parallel or in series may be interconnected to obtain the grade of ethanol desired. EXAMPLE I The apparatus set up for this example included an inclined still 18×46 inches in size having a 3.5 gallon preheating chamber capacity. A tank containing an automatic float control valve was fed by gravity from a 50 gallon barrel, and the still was fed from the tank. A fractionation column 3 inches in diameter and 48 inches long was utilized which did not contain a temperature control coil at the top. A 17.5 gallon sample of 24 proof alcohol from a mash fermentation process was placed in the barrel and fed to the tank and still. As the preheating chamber of the still filled to near capacity, the float control valve in the tank closed preventing the dilute alcohol from overflowing into the vaporization chamber of the still. The still and contents were at an ambient temperature of about 18.5° C. This example was conducted indoors without the use of solar energy. The still was equipped with electrical heating means. The still was plugged into a 220 volt electrical outlet and a meter reading was taken. After 22 minutes, the temperature within the still had risen to 88.3°, and the water-ethanol solution in the preheating chamber began to boil. Six minutes later, the first drop of distilled ethanol was collected resulting in a start-up time of 28 minutes requiring an electrical consumption of 1.4 kilowatt hours. After start up, the distillation continued to produce one gallon of approximately 110 proof ethanol every 113.5 minutes requiring an energy consumption of 5.68 kilowatts per gallon. The waste water drained from the bottom of the vaporization chamber was analyzed periodically and averaged approximately 2% volume ethanol. EXAMPLE II The procedure followed in Example I was utilized except that the water-ethanol mixture was 10% ethanol, and the still operated to produce one gallon of 105 proof ethanol every 90 minutes with an energy consumption of 4.5 kilowatt hours per gallon. The wast water had an average ethanol content of 2.3% by volume. EXAMPLE III The 105 proof ethanol obtained from Example II was passed through the still a second time in order to provide a higher purity product. Following is a summation of the results obtained. ______________________________________Start up time 27 minutesEnergy consumed in start up 1.35 kw hr.Gallons per hour of ethanol 1.25 gal/hrproductionTotal volume of ethanol 15,900 ml or 4.2 gal.producedAverage proof of ethanol 150-155 proofproducedTotal volume of waste water 9,300 ml or 2.46 gal.Average proof of waste water 40 proof - 20% v ethanolKilowatt consumption per 2.66 kwh/gal. to 2.22 kwh/gal.gallon of ethanol producedafter start up______________________________________ EXAMPLE IV A larger inclined still having a vaporization floor surface area of approximately two square meters was used in this example. The still was operated solely by electrical energy. The still was warm from a previous test and, therefore, required only an eight-minute warm up before condensate started collecting from the fractionation column. The still operated at an internal temperature of 94° C. The aqueous feed was controlled by a float valve and had an ethanol content of about 10% v. After start up, the still operated to produce about one gallon of 110 proof ethanol every 45.4 minutes utilizing 4.54 kilowatt hours of electricity per gallon. At the end of the run, the electricity was turned off and the float valve closed shutting off the flow of feed to the still. EXAMPLE V The still utilized in Example I is used in this example by modifying the upper portion of the fractionation column to include a constant temperature coil maintained by the circulation of water at a constant temperature of about 80.5° C. The still is operated at 89.5° C. and is fed with 12% v dilute ethanol. After an initial start up of about 29 minutes, the still is automatically fed by use of a float control valve and produces about one gallon of 164 proof ethanol every three hours of operation leaving a waste product containing about 3% v ethanol. The average energy consumption is about 9 kilowatt hours per gallon.
Heated distillation still for separating ethanol-water mixtures divided into an upper solar absorbent vaporization section and a lower pre-heating section by a vaporization floor, float means to automatically control the ethanol-water feed to the lower portion of the preheating section when distillation is taking place, means to evenly distribute the ethanol-water mixture on the vaporization floor, means to heat the ethanol-water mixture in the distillation chamber, and means to remove or recycle residual aqueous liquid from the lower end of the vaporization section.
8
CROSS REFERENCE TO RELATED APPLICATIONS [0001] The present application claims priority from Japanese Patent Application No. 2008-202188 filed on Aug. 5, 2008, which is hereby incorporated by reference in its entirety. BACKGROUND [0002] 1. Technical Field [0003] The present invention relates to a technology of cooling a coil. [0004] 2. Related Art [0005] A switching power supply such as DC-converter uses a choke coil for smoothing current and boosting voltage. This choke coil is generally constituted by a toroidal coil which has windings wound around a doughnut-shaped toroidal core. The windings of the toroidal coil are exposed on the outer periphery of the coil. Therefore, when the toroidal coil is directly attached to a substrate, wiring pattern cannot be provided on a surface where the toroidal coil is mounted in the vicinity of the toroidal coil for securing sufficient insulation. For increasing the degree of freedom of the wiring pattern, the toroidal coil is attached to an insulating plate member (pedestal), and the coil attached to the pedestal (coil assembly) is mounted on the substrate (for example, see JP-A-6-44123, JP-A-2007-235054, JP-A-2007-234752, JP-A-2005-286066, JP-A-2001-326126, and JP-A-2000-228320). [0006] Since the choke coil included in the switching power supply is disposed on the source current path, a relatively high current flows in the choke coil. Thus, Joule heat is generated on the windings of the choke coil due to winding resistance, and the temperature of the choke coil rises. According to the known coil assembly which has the coil attached to the plate-like pedestal, however, efficiency of cooling the coil is not sufficiently high. This problem arises not only from the coil assembly containing the toroidal coil but also from various types of coil assembly included in the switching power supply and the like. SUMMARY [0007] It is an advantage of some aspects of the invention to provide a technology of increasing efficiency of cooling a coil. [0008] A coil assembly according to an aspect of the invention includes a coil, and a pedestal fixed to the coil. The pedestal includes a supporting member configured to support the coil in such a manner as to form a space through which air flows on a surface of the coil attached to the pedestal. [0009] According to this structure, a space through which air can flow on the surface of the coil attached to the pedestal is produced by the supporting member provided on the pedestal. Thus, the surface of the coil attached to the pedestal is cooled as well, and efficiency of cooling the coil improves. [0010] It is preferable that the coil is a toroidal coil, and that the pedestal configured to support the coil such that the toroidal direction of the coil being substantially parallel with a substrate on which the coil assembly is provided. [0011] In this structure, the area of the coil surface facing the space increases by disposing the toroidal surface of the toroidal coil substantially parallel with the substrate. Thus, cooling of the coil can be further promoted by air passing through the space. [0012] It is preferable that the pedestal includes a plate-like portion contacting the substrate, and that the supporting member extends in the direction opposite to the substrate from the plate-like portion. [0013] According to this structure, the coil assembly can be more easily attached to the substrate by providing the plate-like portion on the pedestal. [0014] It is preferable that a through hole penetrated through the coil side and the substrate side is provided on each of the plate-like portion and the substrate in an area containing a position corresponding to a hole of the coil. [0015] According to this structure, a through hole penetrated through the coil side and the substrate side is provided on each of the plate-like portion and the substrate in an area containing a position corresponding to a hole of the coil Thus, air flowing through the through hole of the plate-like portion and the hole of the toroidal coil can be easily generated. Accordingly, efficiency of cooling the coil can increase. [0016] In this case, it is more preferable that a through hole is similarly formed on the substrate as well as on the plate-like portion. By providing the through hole on the substrate, air passing through the through hole of the substrate and the hole of the toroidal coil can be generated. Thus, efficiency of cooling the coil can further improves. [0017] It is preferable that the supporting member is made of heat conductive resin. [0018] According to this structure, the supporting member is formed by resin having high heat conductivity. Thus, heat generated by the coil can be released from the supporting member. Accordingly, efficiency of cooling the coil can further increases. [0019] The invention can be practiced in various forms such as a coil assembly and a method of mounting a coil, a power supply using the coil assembly and the method of mounting the coil, a discharge lamp driving device and a light source device including the power supply, and an image display apparatus including the light source device. BRIEF DESCRIPTION OF THE DRAWINGS [0020] The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements. [0021] FIG. 1 shows a general structure of a projector including a ballast unit according to a first embodiment of the invention. [0022] FIG. 2 is a circuit diagram showing an example of the ballast unit. [0023] FIGS. 3A through 3D show a condition of a mounted choke coil according to the first embodiment. [0024] FIGS. 4A through 4D show a pedestal in related art and a pedestal according to the first embodiment disposed between the choke coil and a substrate. [0025] FIGS. 5A through 5D show a condition of a mounted choke coil according to a second embodiment. [0026] FIGS. 6A through 6D illustrate a pedestal according to a first modified example. [0027] FIGS. 7A and 7B illustrate a pedestal according to a second modified example. [0028] FIGS. 8A through 8D illustrate a pedestal according to a third modified example. [0029] FIGS. 9A and 9B illustrate a pedestal according to a fourth modified example. [0030] FIG. 10 illustrates a choke coil mounted on a substrate according to a modified example. DESCRIPTION OF EXEMPLARY EMBODIMENTS A. First Embodiment A1. Structure of Projector [0031] FIG. 1 illustrates a general structure of a projector 1000 including a ballast unit according to a first embodiment of the invention. The projector 1000 includes a power supply unit 100 , a ballast unit 200 , a control unit 300 , a light source lamp 400 , a liquid crystal panel 500 , and a projection lens 600 . [0032] The power supply unit 100 generates DC power to be supplied to the respective components of the projector 1000 from commercial power supply such as AC 100V. The power supply unit 100 has a not-shown boosting type converter (boost converter) to generate high tension DC power to be supplied to the ballast unit 200 . The boost converter has a not-shown power factor improvement circuit (PFC) so as not to send high-frequency noise generated by switching (chopper process) to the commercial power supply. However, the PFC circuit may be eliminated depending on the characteristics of noise filter or the like provided on the commercial power supply side of the power supply unit 100 . The boost converter which boosts voltage by chopper process is referred to as boost chopper as well. [0033] The ballast unit 200 generates light source driving power for driving the light source lamp 400 from the high tension DC power supplied from the power supply unit 100 in response to a switch control signal transmitted from the control unit 300 . The light source driving power thus generated is supplied to the light source lamp 400 from the ballast unit 200 . Generation of the light source driving power using the ballast unit 200 will be described later. [0034] The control unit 300 includes a CPU 310 , an image processing unit 320 , and a memory 330 . The CPU 310 performs various processes and controls under a computer program stored in the memory 330 . The image processing unit 320 applies image processing to image data received from an external device such as PC, DVD player, and external memory connected with an external connector (not shown), for example, and supplies the processed image data to the liquid crystal panel 500 . The control unit 300 operates by control unit driving power generated by the power supply unit 100 . [0035] The light source lamp 400 is a discharge lamp for supplying light to the liquid crystal panel 500 . The liquid crystal panel 500 is a transmission type liquid crystal panel which modulates light emitted from the light source lamp 400 according to image data given from the image processing unit 320 . The projection lens 600 projects the light modulated by the liquid crystal panel 500 onto a screen (not shown). By projecting the light modulated by the liquid crystal panel 500 to the screen, an image can be displayed on the screen. A2. Structure of Ballast Unit [0036] FIG. 2 is a circuit diagram showing an example of the ballast unit 200 which supplies light source driving current to the light source lamp 400 . The ballast unit 200 in the first embodiment includes a down type converter (back converter) 210 , and an inverter 220 . [0037] The back converter 210 has a switching element Q 1 , a choke coil L 1 , a diode D 1 , and a capacitor C 1 . The switching element Q 1 switches between ON and OFF in response to a switch control signal transmitted from the control unit 300 . The high-tension DC power supplied from the power supply unit 100 ( FIG. 1 ) is decreased to voltage appropriate for the light source driving power according to chopper process by controlling the duty ratio of the ON condition of the switching element Q 1 . The power thus decreased is supplied to the inverter 220 . The back converter which decreases voltage by chopper process is referred to as back chopper as well. [0038] The inverter 220 is a full-bridge inverter having four full-bridge-connected switching elements Q 21 through Q 24 . The switching elements Q 21 through Q 24 also switch between ON and OFF in response to the switch control signal transmitted from the control unit 300 . The pair of the switching elements Q 21 and Q 24 and the pair of the switching elements Q 22 and Q 23 are alternately turned on to supply AC power having rectangular waves as the power supply driving power to the light source lamp 400 connected with two bridge intermediate points MP 1 and MP 2 . [0039] The light source lamp 400 is a reflection type light source lamp including a high-pressure discharge lamp such as high-pressure mercury lamp and metal halide lamp. The light source lamp 400 has an arc tube 410 fixed to the central portion of a reflection mirror 420 by heat resistance cement. As described above, electrodes 412 and 414 of the arc tube 410 are connected with the two bridge intermediate points MP 1 and MP 2 included in the inverter 220 . A3. Mounting Choke Coil [0040] FIGS. 3A through 3D illustrate mounting conditions of a choke coil L 1 included in the ballast unit 200 in the first embodiment. FIGS. 3A and 3B show a pedestal 700 on which the choke coil L 1 is mounted. FIGS. 3C and 3D illustrate the choke coil L 1 disposed on a substrate 900 . According to the first embodiment, the choke coil L 1 is constituted by a toroidal coil which has windings 820 around a doughnut-shaped toroidal core 810 as shown in FIGS. 3C and 3D . FIGS. 3A and 3C illustrate the pedestal 700 and the choke coil L 1 as viewed from the surface (upper surface) on which the choke coil L 1 is mounted. FIGS. 3B and 3D illustrate the pedestal 700 and the choke coil L 1 as viewed from the side. [0041] As shown in FIGS. 3A and 3B , the pedestal 700 has a disk 710 having approximately the same outside diameter as that of the toroidal core 810 , cylindrical pins 720 extended toward the upper surface from the disk 710 , and lead holding portions 730 extended in the direction of the outer circumference of the disk 710 from the disk 710 . Each of the lead holding portions 730 has a notch 732 extending from the outer circumference toward the center. The pedestal 700 can be integrally formed by injection molding using thermoplastic resin, for example. However, the pedestal 700 is not required to be integrally formed but may be produced by inserting the pins 720 formed separately from the disk 710 and the lead holding portions 730 into the disk 710 . Each diameter, length, shape, number, position, and the like of the pins 720 may be varied, and the shape of the plate-shaped disk 710 may be changed to an arbitrary shape such as rectangular shape. [0042] As illustrated in FIGS. 3C and 3D , the choke coil L 1 is placed on the pedestal 700 such that the toroidal direction of the toroidal core (i.e., direction of magnetic flux) being parallel with the substrate 900 in the first embodiment. Leads 822 at both ends of the windings 820 are attached to the lead holding portions 730 under the condition of contact between the choke coil L 1 and the pins 720 . By this arrangement, the choke coil L 1 is fixed to the pedestal 700 such that position shift caused by vibration can be prevented. Moreover, the choke coil L 1 and the pedestal 700 (collectively referred to as “coil assembly” as well) can be handled more easily by fixing the choke coil L 1 to the pedestal 700 . [0043] The leads 822 extended from the lead holding portions 730 toward the lower surface project toward the lower surface of the substrate 900 via through holes (not shown) formed on the substrate 900 . The leads 822 projecting toward the lower surface are connected with a wiring pattern (not shown) provided on the substrate 900 by soldering or by other methods. According to the first embodiment, the distance between the choke coil L 1 and the substrate 900 can be increased by providing the pins 720 on the pedestal 700 . Thus, transmission of noise to the wiring pattern disposed close to the choke coil L 1 can be prevented. [0044] FIGS. 4A through 4D illustrate a pedestal 700 x in related art and the pedestal 700 in the first embodiment disposed between the choke coil L 1 and the substrate 900 . FIGS. 4A and 4B show the related-art pedestal 700 x for insulating the choke coil L 1 from the wiring pattern on the upper surface of the substrate 900 as a comparison example. FIGS. 4C and 4D show the condition of the pedestal 700 in the first embodiment. FIGS. 4A and 4C show the pedestals 700 x and 700 and the choke coil L 1 as viewed from the mounting surface (upper surface) of the choke coil L 1 . FIGS. 4B and 4D show the pedestals 700 x and 700 and the choke coil L 1 as viewed from the side. [0045] As illustrated in FIG. 4B , the choke coil L 1 contacts the flat upper surface of the pedestal 700 x in the related art. Thus, air passing through the center of the choke coil L 1 is not generated, achieving substantially no cooling of the choke coil L 1 by natural convection. When airflow for cooling the choke coil L 1 is supplied from the side, only the upper surface of the choke coil L 1 is cooled. Thus, cooling efficiency cannot be easily raised. [0046] According to the first embodiment, however, a space is produced between the choke coil L 1 and the disk 710 by the presence of the pins 720 on the pedestal 700 . By providing this space, air flowing from the outer circumference toward the center on the lower surface side of the choke coil L 1 and flowing upward at the center is generated as indicated by arrows in FIGS. 4C and 4D . Thus, the choke coil L 1 in the first embodiment can be sufficiently cooled by natural convection. When airflow for cooling the choke coil L 1 is supplied from the side, the air passes along both of the upper surface and the lower surface of the choke coil L 1 . Thus, both the upper surface and the lower surface of the choke coil L 1 are cooled, and cooling efficiency becomes higher than that in case of the comparison example. [0047] According to the first embodiment, therefore, the choke coil L 1 can be sufficiently cooled by natural convection. Thus, the degree of freedom for positioning the choke coil L 1 within the housing can be increased. Even in case of forced air cooling, efficiency of cooling the choke coil L 1 can be similarly raised. Thus, the degree of freedom for disposing the choke coil L 1 within the housing can be further improved, and the air flow amount from a cooling fan required for supplying airflow decreases. Accordingly, the entire size of the ballast unit 200 can be reduced by miniaturization of the cooling fan, and power consumption can be decreased by reduction of the power for driving the cooling fan. [0048] The heat generated from the choke coil L 1 provided with the toroidal core 810 is chiefly constituted by Joule heat from the windings 820 . Thus, rated current of the choke coil L 1 is determined by the diameter of the windings 820 . Since the cooling of the choke coil L 1 is promoted in the first embodiment, the diameter of the windings 820 of the choke coil L 1 for the same rated current can be reduced. By reducing the diameter of the windings 820 , inductance of the choke coil L 1 can be raised with an increased number of windings, and the size of the choke coil L 1 can be reduced with miniaturization of the toroidal core 810 . B. Second Embodiment [0049] FIGS. 5A through 5D illustrate conditions of the mounted choke coil L 1 according to a second embodiment. FIGS. 5A and 5B show a pedestal 700 a on which the choke coil L 1 is placed in the second embodiment. FIGS. 5C and 5D show the condition of the choke coil L 1 disposed on a substrate 900 a. [0050] As shown in FIGS. 5A and 5B , the pedestal 700 a in the second embodiment is different from the pedestal 700 in the first embodiment shown in FIGS. 3A and 3B in that a through hole 740 is formed at the center of the pedestal 700 a at a position corresponding to the hole of the choke coil L 1 . Moreover, as shown in FIGS. 5C and 5D , a through hole 940 corresponding to the through hole 740 formed on the pedestal 700 a is formed on the substrate 900 a . Other parts are similar to those in the first embodiment. [0051] According to the second embodiment, air flowing from the lower surface toward the upper surface of the substrate 900 a is generated as indicated by arrows by providing the through holes 740 and 940 on the pedestal 700 a and the substrate 900 a . Thus, efficiency of cooling the choke coil L 1 by natural convection further improves. Moreover, by providing projection or the like at a position corresponding to the through hole 940 on the lower part of the substrate 900 a , airflow for forced air cooling can be guided from the lower surface toward the upper surface of the substrate 900 a through the through hole 940 . In this case, efficiency of cooling the choke coil L 1 by forced air cooling further improves. [0052] In the second embodiment, the through holes 740 and 940 having substantially the same diameters as that of the hole of the choke coil L 1 are formed. However, the diameters of the through holes 740 and 940 may be larger. Generally, each of the through holes 740 and 940 is only required to penetrate through the upper surface and the lower surface in an area containing the position corresponding to the hole of the choke coil L 1 . C. Modified Example of Pedestal [0053] The pedestal on which the choke coil L 1 is mounted is not limited to those in the respective embodiments, but may be various types. For example, the supporting members for supporting the choke coil L 1 such as the pedestal 700 and the pins 720 may be made of heat conductive resin to conduct heat generated by the choke coil L 1 to the pedestal 700 or the pins 720 and thereby improve cooling efficiency. Moreover, the shape of the pedestal may be various shapes as long as a space through which air can pass toward the surface of the choke coil L 1 facing the substrates 900 and 900 a , that is, the surface on the pedestal side can be produced. The shapes of the pedestal are shown in FIGS. 6A through 9B as modified examples. C1. Pedestal in First Modified Example [0054] FIGS. 6A through 6D illustrate a pedestal according to a first modified example. A pedestal 700 b shown in FIGS. 6A and 6B according to the first modified example is different from the pedestal 700 in the first embodiment in that plate-like fins 720 b are provided on the disk 710 in place of the cylindrical pins 720 . Other parts are similar to those of the pedestal 700 in the first embodiment shown in FIGS. 3A and 3B . Airflow in the direction along the fins 720 b can be generated by using the plate-like fins 720 b shown in FIGS. 6A and 6B . In forced air cooling, airflow can be produced on the lower surface side of the choke coil L 1 by adjusting the direction of the fins 720 b to the cooling airflow direction, and thus efficiency of cooling the choke coil L 1 can be sufficiently increased. While the pedestal 700 b in the first modified example shown in FIGS. 6A through 6D does not have a through hole, a through hole may be formed at the center of the pedestal 700 b similarly to the second embodiment. C2. Pedestal in Second Modified Example [0055] FIGS. 7A and 7B show a pedestal in a second modified example. According to this example shown in FIGS. 7A and 7B , a choke coil L 1 c having substantially circular cross section is used. FIGS. 7A and 7B do not show a toroidal core and windings of the choke coil L 1 c . As shown in FIG. 7A , the shapes of pins 720 c are varied according to the shape of the choke coil L 1 c depending on the positions of the pins 720 c . By changing the shapes of the pins 720 C according to the shape of the choke coil L 1 c , the choke coil L 1 c can be fixed to a more accurate position on a pedestal 700 c , and position shift of the choke coil L 1 c can be more securely prevented. It is possible to form a through hole at the center of the pedestal 700 c in the second modified example shown in FIGS. 7A and 7B similarly to the second embodiment. C3. Pedestal in Third Modified Example [0056] FIGS. 8A through 8D show a pedestal in a third modified example. A pedestal 700 d in the third modified example shown in FIGS. 8A and 8B is different from the pedestal 700 in the first embodiment shown in FIGS. 3A and 3B in that lead holding portions 730 d extend toward the upper surface and that pins 720 are removed. According to the third modified example, the choke coil L 1 is supported by the lead holding portions 730 d extended toward the upper surface as shown in FIGS. 8C and 8D . In the third modified example, a space through which air can pass is produced on the lower surface of the choke coil L 1 similarly to the first embodiment. Thus, cooling the choke coil L 1 can be promoted similarly to the first embodiment. It is possible to form a through hole at the center of the pedestal 700 d in the third modified example shown in FIGS. 8A through 8D similarly to the second embodiment. [0057] According to the third modified example, the choke coil L 1 is supported by the lead holding portions 730 d extended toward the upper surface. However, the choke coil L 1 may be supported by members similar to the lead holding portions 730 in the first embodiment and members similar to the lead holding members 730 d in the third modified example. For example, the choke coil L 1 can be supported by supporting members 750 similar to the lead holding portions 730 d indicated by alternate long and two short dashes lines in FIG. 8A . It is preferable that the choke coil L 1 is supported in a direction different from the direction of extracting leads 822 as in this case in view of avoiding bending stress applied to the leads 822 . In this structure, the choke coil L 1 is fixed to the supporting members 750 by adhesive or the like. It is possible to use both the lead supporting portions 730 d in the third modified example and the supporting members 750 at the same time. C4. Pedestal in Fourth Modified Example [0058] FIGS. 9A and 9B show a pedestal in a fourth modified example. As shown in FIG. 9A , a pedestal 700 e in the fourth modified example includes pins 722 and 724 having different heights at positions close to the two lead holding portions 730 . Thus, the choke coil L 1 attached to the upper side of the pedestal 700 e is fixed with inclination to the disk 710 and the substrate 900 as shown in FIG. 9B . The description “the toroidal direction of the choke coil L 1 is substantially parallel with the substrate” includes the condition in which the choke coil L 1 is obliquely attached as shown in FIGS. 9A and 9B . [0059] According to the fourth modified example, the choke coil L 1 is fixed with inclination to the disk 710 . In this case, air from the right in the figure passes the center of the toroidal core 810 and flows from the lower surface toward the upper surface as indicated by an arrow in FIG. 9B . Thus, cooling efficiency in forced air cooling can be sufficiently increased. [0060] In the example shown in FIGS. 9A and 9B , the pins 722 and 724 are provided at positions close to the lead holding portions 730 , and the leads 822 are extracted in the arrangement direction of the pins 722 and 724 . It is more preferable, however, that the extracting direction of the leads 822 is different from the arrangement direction of the pins 722 and 724 in view of prevention of bending stress applied to the leads 822 . D. Mounting in Modified Example [0061] FIG. 10 shows a condition of the choke coil L 1 mounted on the substrate 900 according to a modified example. The choke coil L 1 and the pedestal 700 (coil assembly) according to the mounting in this modified example shown in FIG. 10 are similar to those in the first embodiment. In the example shown in FIG. 10 , however, a heat conductive sheet 980 and a heat sink 990 fixed to the substrate 900 are attached to the upper surface of the choke coil L 1 . The heat sink 990 is fixed to the substrate 900 by screw (not shown) or the like. [0062] In the example shown in FIG. 10 , a space is similarly produced on the lower surface side of the choke coil L 1 . Thus, the choke coil L 1 is cooled by air flowing on the lower surface of the choke coil L 1 as well as heat conduction by the heat conductive sheet 980 and the heat sink 990 . Accordingly, cooling of the choke coil L 1 can be further promoted. In the example shown in FIG. 10 , it is similarly preferable that the pedestal 700 and the pins 720 are formed by heat conductive resin in view of achieving higher cooling efficiency. [0063] Moreover, the distance between the choke coil L 1 and the substrate 900 (mounting height) can be more easily changed by adequately adjusting the length of the pins 720 on the pedestal 700 . For adjusting the mounting height, a spacer may be additionally provided between the pedestal 700 and the substrate 900 . According to the example shown in FIG. 10 , the choke coil L 1 can be sufficiently cooled by the heat conduction from the heat conductive sheet 980 and the heat sink 990 and the air passing the lower surface of the choke coil L 1 even when the spacer is added between the pedestal 700 and the substrate 900 . E. Other Modified Examples [0064] The invention is not limited to the embodiments and examples described herein, but may be practiced otherwise without departing from the scope and spirit of the invention. For example, the following modifications may be made. E1. Modified Example 1 [0065] While the invention has been applied to a toroidal coil in the embodiments, the invention is applicable to various types of coil other than the toroidal coil. For example, the invention can be applied to a coil having windings wound around a bar-shaped or E-shaped core. Generally, heat generated on the coil is chiefly constituted by Joule heat on the windings. Thus, by mounting the coil on the pedestal, the windings producing a large volume of heat can be efficiently cooled, and efficiency of cooling the coil can be further increased. E2. Modified Example 2 [0066] While the invention is applied to the choke coil L 1 of the back converter ( FIG. 2 ), the invention is applicable to coils included in various switching power supplies. More specifically, the invention is applicable to a choke coil included in a boost converter, a choke coil included in a back-boost converter, a flyback transformer included in a flyback type converter, an insulation transformer included in an insulation type converter, or other coils included in various switching power supplies. In these switching power supplies, the choke coil and transformer are disposed on the flow path of source current, and relatively high current flows in these transformer units. By disposing these coils on the pedestal to promote cooling of the coils, miniaturization of coils, increase in inductance, higher degree of freedom for disposition, and reduction of power for cooling can be achieved. Also, the invention is applicable to various types of coil generating a large volume of heat such as common mode transformer and choke coil included in noise filter or the like. E3. Modified Example 3 [0067] While the projector 1000 ( FIG. 1 ) includes the liquid crystal panel 500 as the light modulation unit in the respective embodiments, the light modulation unit may be other modulation units such as DMD (digital micromirror device: trademark of Texas Instruments Co.).
A switching power supply includes: a coil; and a pedestal fixed to the coil, the pedestal includes a supporting member configured to support the coil in such a manner as to form a space through which air flows on a surface of the coil attached to the pedestal.
7
This application is a continuation, of application Ser. No. 08/138,643, filed Oct. 15, 1993, now U.S. Pat. No. 5,461,065. BACKGROUND OF THE INVENTION Endometriosis is a condition of severe dysmenorrhea, which is accompanied by severe pain, bleeding into the endometrial masses or peritoneal cavity and often leads to infertility. The cause of the symptoms of this condition appear to be ectopic endometrial growths which respond inappropriately to normal hormonal control and are located in inappropriate tissues. Because of the inappropriate locations for endometrial growth, the tissue seems to initiate local inflammatory-like responses causing macrophage infiltration and a cascade of events leading to initiation of the painful response. The exact etiology of this disease is not well understood and its treatment by hormonal therapy is diverse, poorly defined, and marked by numerous unwanted and perhaps dangerous side effects. One of the treatments for this disease is the use of low dose estrogen to suppress endometrial growth through a negative feedback effect on central gonadotropin release and subsequent ovarian production of estrogen; however, it is sometimes necessary to use continuous estrogen to control the symptons. This use of estrogen can often lead to undersirable side effects and even the risk of endometrial cancer. Another treatment consists of continuous administration of progestins which induces amenorrhea and by suppressing ovarian estrogen production can cause regressions of the endometrial growths. The use of chronic progestin therapy is often accompanied by the unpleasant CNS side effects of progestins and often leads to infertility due to suppression of ovarian function. A third treatment consists of the administration of weak androgens, which are effective in controlling the endometriosis; however, they induce severe masculinizing effects. Several of these treatments have also been implicated in causing a mild degree of bone loss with continued therapy. Therefore, new methods of treating endometriosis are desirable. SUMMARY OF THE INVENTION This invention provides methods for inhibiting endometriosis, comprising administering to a human in need of treatment an effective amount of a compound of formula I ##STR3## Wherein R 1 and R 3 are independently hydrogen, --CH 3 , ##STR4## wherein Ar is optionally substituted phenyl; R 2 is selected from the group consisting of pyrrolidino and piperidino; and pharmaceutically acceptable salts and solvates thereof. DETAILED DESCRIPTION OF THE INVENTION The current invention concerns the discovery that a select group of 2-phenyl-3-aroylbenzothiophenes (benzothiophenes), those of formula I, are useful for inhibiting endometriosis. The methods of treatment provided by this invention are practiced by administering to a human in need of inhibition of endometriosis, a dose of a compound of formula I or a pharmaceutically acceptable salt or solvate thereof, that is effective to inhibit endometriosis. The term inhibit is defined to include its generally accepted meaning which includes prophylactically treating a human subject to incurring endometriosis, and holding in check and/or treating existing endometriosis. As such, the present method includes both medical therapeutic and/or prophylactic treatment, as appropriate. Generally, the compound is formulated with common excipients, diluents or carriers, and compressed into tablets, or formulated as elixirs or solutions for convenient oral administration, or administered by the intramuscular or intravenous routes. The compounds can be administered transdermally, and may be formulated as sustained release dosage forms and the like. The compounds used in the methods of the current invention can be made according to established procedures, such as those detailed in U.S. Pat. Nos. 4,133,814, 4,418,068, and 4,380,635 all of which are incorporated by reference herein. In general, the process starts with a benzo b!thiophene having a 6-hydroxyl group and a 2-(4-hydroxyphenyl) group. The starting compound is protected, alkylated, and deprotected to form the formula I compounds. Examples of the preparation of such compounds are provided in the U.S. patents discussed above. Substituted phenyl includes phenyl substituted once or twice with C 1 -C 6 alkyl, C 1 -C 4 alkoxy, hydroxy, nitro, chloro, fluoro, or tri(chloro or fluoro)methyl. The compounds used in the methods of this invention form pharmaceutically acceptable acid and base addition salts with a wide variety of organic and inorganic acids and bases and include the physiologically acceptable salts which are often used in pharmaceutical chemistry. Such salts are also part of this invention. Typical inorganic acids used to form such salts include hydrochloric, hydrobromic, hydroiodic, nitric, sulfuric, phosphoric, hypophosphoric and the like. Salts derived from organic acids, such as aliphatic mono and dicarboxylic acids, phenyl substituted alkanoic acids, hydroxyalkanoic and hydroxyalkandioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, may also be used. Such pharmaceutically acceptable salts thus include acetate, phenylacetate, trifluoroacetate, acrylate, ascorbate, benzoate, chlorobenzoate, dinitrobenzoate, hydroxybenzoate, methoxybenzoate, methylbenzoate, o-acetoxybenzoate, naphthalene-2-benzoate, bromide, isobutyrate, phenylbutyrate, β-hydroxybutyrate, butyne-1,4-dioate, hexyne-1,4-dioate, caprate, caprylate, chloride, cinnamate, citrate, formate, fumarate, glycollate, heptanoate, hippurate, lactate, malate, maleate, hydroxymaleate, malonate, mandelate, mesylate, nicotinate, isonicotinate, nitrate, oxalate, phthalate, teraphthalate, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, propiolate, propionate, phenylpropionate, salicylate, sebacate, succinate, suberate, sulfate, bisulfate, pyrosulfate, sulfite, bisulfite, sulfonate, benzene-sulfonate, p-bromophenylsulfonate, chlorobenzenesulfonate, ethanesulfonate, 2-hydroxyethanesulfonate, methanesulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate, p-toluenesulfonate, xylenesulfonate, tartarate, and the like. A preferred salt is the hydrochloride salt. The pharmaceutically acceptable acid addition salts are typically formed by reacting a compound of formula I with an equimolar or excess amount of acid. The reactants are generally combined in a mutual solvent such as diethyl ether or benzene. The salt normally precipitates out of solution within about one hour to 10 days and can be isolated by filtration or the solvent can be stripped off by conventional means. Bases commonly used for formation of salts include ammonium hydroxide and alkali and alkaline earth metal hydroxides, carbonates and bicarbonates, as well as aliphatic and primary, secondary and tertiary amines, aliphatic diamines and hydroxy alkylamines. Bases especially useful in the preparation of addition salts include ammonium hydroxide, potassium carbonate, sodium bicarbonate, calcium hydroxide, methylamine, diethylamine, ethylene diamine, cyclohexylamine and ethanolamine. The pharmaceutically acceptable salts generally have enhanced solubility characteristics compared to the compound from which they are derived, and thus are often more amenable to formulation as liquids or emulsions. Pharmaceutical formulations can be prepared by procedures known in the art. For example, the compounds can be formulated with common excipients, diluents, or carriers, and formed into tablets, capsules, suspensions, powders, and the like. Examples of excipients, diluents, and carriers that are suitable for such formulations include the following: fillers and extenders such as starch, sugars, mannitol, and silicic derivatives; binding agents such as carboxymethyl cellulose and other cellulose derivatives, alginates, gelatin, and polyvinyl pyrrolidone; moisturizing agents such as glycerol; disintegrating agents such as calcium carbonate and sodium bicarbonate; agents for retarding dissolution such as paraffin; resorption accelerators such as quaternary ammonium compounds; surface active agents such as cetyl alcohol, glycerol monostearate; adsorptive carriers such as kaolin and bentonite; and lubricants such as talc, calcium and magnesium stearate, and solid polyethyl glycols. The compounds can also be formulated as elixirs or solutions for convenient oral administration or as solutions appropriate for parenteral administration, for instance by intramuscular, subcutaneous or intravenous routes. Additionally, the compounds are well suited to formulation as sustained release dosage forms and the like. The formulations can be so constituted that they release the active ingredient only or preferably in a particular part of the intestinal tract, possibly over a period of time. The coatings, envelopes, and protective matrices may be made, for example, from polymeric substances or waxes. The particular dosage of a compound of formula I required to inhibit endometriosis, according to this invention will depend upon the severity of the condition, the route of administration, and related factors that will be decided by the attending physician. Generally, accepted and effective daily doses will be from about 0.1 to about 1000 mg/day, and more typically from about 50 to about 200 mg/day. Such dosages will be administered to a subject in need of treatment from once to about three times each day, or more often as needed to effectively inhibit endometriosis. It is usually preferred to administer a compound of formula I in the form of an acid addition salt, as is customary in the administration of pharmaceuticals bearing a basic group, such as the piperidino ring. It is also advantageous to administer such a compound by the oral route to an aging human (e.g. a post-menopausal female). For such purposes the following oral dosage forms are available. FORMULATIONS In the formulations which follow, "Active ingredient" means a compound of formula I, Formulation 1: Gelatin Capsules Hard gelatin capsules are prepared using the following: ______________________________________Ingredient Quantity (mg/capsule)______________________________________Active ingredient 0.1-1000Starch, NF 0-650Starch flowable powder 0-650Silicone fluid 350 centistokes 0-15______________________________________ The ingredients are blended, passed through a No. 45 mesh U.S. sieve, and filled into hard gelatin capsules. Examples of specific capsule formulations of the compound of formula 1 wherein R 2 is piperidino, (raloxifene), that have been made include those shown below: Formulation 2: Raloxifene capsule ______________________________________Ingredient Quantity (mg/capsule)______________________________________Raloxifene 1Starch, NF 112Starch flowable powder 225.3Silicone fluid 350 centistokes 1.7______________________________________ Formulation 3: Raloxifene capsule ______________________________________Ingredient Quantity (mg/capsule)______________________________________Raloxifene 5Starch, NF 108Starch flowable powder 225.3Silicone fluid 350 centistokes 1.7______________________________________ Formulation 4: Raloxifene capsule ______________________________________Ingredient Quantity (mg/capsule)______________________________________Raloxifene 10Starch, NF 103Starch flowable powder 225.3Silicone fluid 350 centistokes 1.7______________________________________ Formulation 5: Raloxifene capsule ______________________________________Ingredient Quantity (mg/capsule)______________________________________Raloxifene 50Starch, NF 150Starch flowable powder 397Silicone fluid 350 centistokes 3.0______________________________________ The specific formulations above may be changed in compliance with the reasonable variations provided. A tablet formulation is prepared using the ingredients below: Formulation 6: Tablets ______________________________________Ingredient Quantity (mg/tablet)______________________________________Active ingredient 0.1-1000Cellulose, microcrystalline 0-650Silicon dioxide, fumed 0-650Stearate acid 0-15______________________________________ The components are blended and compressed to form tablets. Alternatively, tablets each containing 0.1-1000 mg of active ingredient are made up as follows: Formulation 7: Tablets ______________________________________Ingredient Quantity (mg/tablet)______________________________________Active ingredient 0.1-1000Starch 45Cellulose, microcrystalline 35Polyvinylpyrrolidone 4(as 10% solution in water)Sodium carboxymethyl cellulose 4.5Magnesium stearate 0.5Talc 1______________________________________ The active ingredient, starch, and cellulose are passed through a No. 45 mesh U.S. sieve and mixed thoroughly. The solution of polyvinylpyrrolidone is mixed with the resultant powders which are then passed through a No. 14 mesh U.S. sieve. The granules so produced are dried at 50°-60° C. and passed through a No. 18 mesh U.S. sieve. The sodium carboxymethyl starch, magnesium stearate, and talc, previously passed through a No. 60 U.S. sieve, are then added to the granules which, after mixing, are compressed on a tablet machine to yield tablets. Suspensions each containing 0.1-1000 mg of medicament per 5 mL dose are made as follows: Formulation 8: Suspensions ______________________________________Ingredient Quantity (mg/5 ml)______________________________________Active ingredient 0.1-1000 mgSodium carboxymethyl cellulose 50 mgSyrup 1.25 mgBenzoic acid solution 0.10 mLFlavor q.v.Color q.v.Purified water to 5 mL______________________________________ The medicament is passed through a No. 45 mesh U.S. sieve and mixed with the sodium carboxymethyl cellulose and syrup to form a smooth paste. The benzoic acid solution, flavor, and color are diluted with some of the water and added, with stirring. Sufficient water is then added to produce the required volume. TEST PROCEDURE In Tests 1 and 2, effects of 14-day and 21-day administration of compounds of the invention on the growth of explanted endometrial tissue can be examined. Test 1 Twelve to thirty adult CD strain female rats are used as test animals. They are divided into three groups of equal numbers. The estrous cycle of all animals is monitored. On the day of proestrus surgery is performed on each female. Females in each group have the left uterine horn removed, sectioned into small squares, and the squares are loosely sutured at various sites adjacent to the mesenteric blood flow. In addition, females in Group 2 have the ovaries removed. On the day following surgery, animals in Groups 1 and 2 receive intraperitoneal injections of water for 14 days whereas animals in Group 3 receive intraperitoneal injections of 1.0 mg of a compound of the invention per kilogram of body weight for the same duration. Following 14 days of treatment each female is killed and the endometrial explants, adrenals, remaining uterus, and ovaries, where applicable, are removed and prepared for histological examination. The ovaries and adrenals are weighed. Test 2 Twelve to thirty adult CD strain female rats are used as test animals. They are divided into two equal groups. The estrous cycle of all animals is monitored. On the day of proestrus surgery is performed on each female. Females in each group have the left uterine horn removed, sectioned into small squares, and the squares are loosely sutured at various sites adjacent to the mesenteric blood flow. Approximately 50 days following surgery, animals assigned to Group 1 receive intraperitoneal injections of water for 21 days whereas animals in Group 2 receive intraperitoneal injections of 1.0 mg of a compound of the invention per kilogram of body weight for the same duration. Following 21 days of treatment each female is killed and the endometrial explants and adrenals are removed and weighed. The explants are measured as an indication of growth. Estrous cycles are monitored. Test 3 A. Surgical induction of endometriosis Autographs of endometrial tissue are used to induce endometriosis in rats and/or rabbits. Female animals at reproductive maturity undergo bilateral oophorectomy and estrogen is supplied exogenously thus providing a specific and constant level of hormone. Autologous endometrial tissue is implanted in the peritoneum of 5-150 animals and estrogen supplied to induce growth of the explanted tissue. Treatment consisting of a compound of the invention is supplied by gastric lavage on a daily basis for 3-16 weeks and implants are removed and measured for growth or regression. At the time of sacrifice, the intact horn of the uterus is harvested to assess status of endometrium. B. Implantation of human endometrial tissue in nude mice. Tissue from human endometrial lesions is implanted into the peritoneum of sexually mature, castrated female nude mice. Exogenous estrogen is supplied to induce growth of the explanted tissue. In some cases the harvested endometrial cells are cultured in vitro prior to implantation. Treatment consisting of a compound of the invention is supplied by gastric lavage on a daily basis for 3-16 weeks and implants are removed and measured for growth or regression. At the time of sacrifice, the uteri is harvested to assess the status of the intact endometrium. Test 4 A. Tissue from human endometrial lesions is harvested, and maintained in vitro as primary nontransformed cultures. Surgical specimens are pushed through a sterile mesh or sieve or alternately teased apart from surrounding tissue to produce a single cell suspension. Cells are maintained in media containing 10% serum and antibiotics. Rates of growth in the presence and absence of estrogen are determined. Cells are assayed for their ability to produce complement component C3 and their response to growth factors and growth hormone. In vitro cultures are assessed for their proliferative response following treatment with progestins, GnRH, a compound of the invention and vehicle. Levels of steroid hormone receptors are assessed weekly to determine whether important cell characteristics are maintained in vitro. Tissue from 5-25 patients is utilized. Activity in any of the above assays indicates that the compounds of the invention are useful in the treatment of endometriosis.
A method of inhibiting endometriosis comprising administering to a human in need of treatment an effective amount of a compound having the formula ##STR1## Wherein R 1 and R 3 are independently hydrogen, --CH 3 , ##STR2## wherein Ar is optionally substituted phenyl; R 2 is selected from the group consisting of pyrrolidine and piperidino; or a pharmaceutically acceptable salt of solvate thereof.
0
This is a continuation of application Ser. No. 494,014, filed Aug. 1, 1974, now abandoned, which application was a divisional of application Ser. No. 411,577 filed on Oct. 31, 1973. BACKGROUND OF THE INVENTION Fluorenone and 2-vinylfluorene are known compounds. However, the oxidation of 2-vinylfluorene to 2-vinylfluorenone is problematical due to the reaction of the vinyl group during oxidation. In order to convert 2-vinylfluorene to 2-vinylfluorenone it is necessary to employ an oxidant which is sufficiently strong to cause the desired oxidation without causing prepolymerization or other undesirable side reactions. Preparation of 2-vinylfluorenone would be desirable since it can be polymerized to provide poly-2-vinylfluorenone. This polymer is of interest since it has been found to be an excellent insulator which can be applied to conductive substrates from solution. The monomers themselves possess this insulating property; however, it is preferred to polymerize the monomer before its application to the substrate or to cause polymerization in situ after such application due to the enhanced mechanical properties of the polymer film as compared to a film of the monomer. However, the inability of the prior art to come up with a method to prepare 2-vinylfluorenone has hindered attempts to prepare the polymer. An alternate route for preparation of the polymer, i.e. preparation of poly-2-vinylfluorene with subsequent oxidation of the fluorene units to fluorenone, has not been entirely successful. For example, it is reported in Polymer Letters, Vol. 9, pp. 671-676 (1971) that a 50/50 copolymer of 2-vinylfluorene/2-vinylfluorenone can be prepared by the oxidation of poly-2-vinylfluorene with chromium trioxide in glacial acetic acid. This reference illustrates the difficulty of obtaining complete oxidation by pointing out that a residue having an oxygen analysis indicating almost complete conversion to poly-2-vinylfluorenone was insoluble in organic solvents and strong acids. This insolubility, which is probably due to extensive crosslinking during the oxidation, is undesirable since the polymers cannot be applied to substrates from their solutions in organic solvents. It appears, from the state of the art, that the only way to prepare poly-2-vinylfluorenone containing no fluorene units in a form which is soluble in common organic solvents is to prepare 2-vinylfluorenone and cause its polymerization. Accordingly, it would be desirable and it is an object of the present invention to provide a method for the preparation of 2-vinylfluorenone. An additional object is to provide, as a composition of matter, 2-vinylfluorenone, α-methyl-2-vinylfluorenone and substituted derivatives thereof. An additional object is to provide polymers of 2-vinylfluorenone and α-methyl-2-vinylfluorenone. A further object is to provide copolymers of 2-vinylfluorenone with other vinyl monomers. SUMMARY OF THE INVENTION The present invention is a composition of matter characterized by the structural formula: ##STR2## In the above formula R 1 is hydrogen or methyl and R 2 , R 3 and R 4 are hydrogen, halogen or aliphatic groups containing 1 to 4 carbon atoms. The above-described composition is prepared by reacting a composition of the formula: ##STR3## wherein R 1 , R 2 , R 3 and R 4 are as defined above with benzyltrimethyl ammonium hydroxide and oxygen in a suitable solvent to oxidize the fluorene to fluorenone. DETAILED DESCRIPTION The novel compounds of the present invention are characterized by the formula: ##STR4## In the above formula, R 1 is H or methyl. The remaining constituents, i.e. R 2 , R 3 and R 4 are either H, halogen or aliphatic groups having from 1 to 4 carbon atoms. Examples of R 2 , R 3 and R 4 include alkyl or substituted alkyl, e.g. methyl, ethyl, chloroethyl, cyanoethyl, propyl, butyl and isobutyl. In addition, the R 2 , R 3 and R 4 substituents can be halogen; e.g. bromo, chloro or fluoro; or alkoxy; e.g. methoxy, ethoxy, propoxy or butoxy. In general, the composition in which the R substituents are H, i.e. 2-vinyl fluorenone, is preferred. These compositions are prepared by the controlled oxidation of 2-vinylfluorene. Great care must be taken in selecting an oxidant that is neither too mild nor too strong. Too mild an oxidant will not convert the fluorene to fluorenone, whereas too strong an oxidant will cause premature polymerization or oxidative reactions of the vinyl substituent. It has been discovered that 2-vinylfluorenone can be prepared in good yields without appreciable polymerization by reacting, in a suitable solvent, 2-vinylfluorene with benzyltrimethyl ammonium hydroxide and oxygen. This process can also be used to prepare the derivatives of 2-vinylfluorenone and α-methyl-2-vinylfluorenone described above. After preparation, the 2-vinylfluorenone or derivative thereof can be polymerized either by bulk or solution polymerization or emulsion techniques to provide homopolymeric compositions consisting of repeating units of -2-vinylfluorenone or derivatives thereof characterized by the formula: ##STR5## where R 1 , R 2 , R 3 and R 4 are as defined above and n is a number representing the degree of polymerization. This polymerization, which can be initiated either by free radical or cationic initiators, can also be used to provide copolymers of 2-vinylfluorenone and other vinyl monomers. Examples of other vinyl monomers which may be copolymerized with 2-vinylfluorenone include styrene, vinyl chloride, methyl methacrylate, vinyl carbazole, vinyl naphthalene, methyl acrylate, isoprene, butadiene, substituted styrenes, acrylonitrile and vinyl acetate. The degree of polymerization which can be obtained will vary depending on the polymerization technique. Generally, a degree of polymerization of up to 1000 may readily be obtained and higher degrees of polymerization are possible. A degree of polymerization of from 10 to 5000 is typical. The invention is further illustrated by the following examples in which all percentages are by weight unless otherwise specified. EXAMPLE I Synthesis of 2-vinylfluorene is carried out as follows: Triphenylmethyl phosphonium bromide (36 gms/0.1 mole) in 500 milliliters of dry THF is treated under nitrogen with 90 milliliters of a 1.1 molar solution of n-butyl lithium in hexane and stirred for 2 hours. A solution of 19.4 gms. (0.1 mole) of fluorene-2-carboxaldehyde in 100 milliliters of THF is added dropwise and the final mixture refluxed for 1 1/2 hours. One liter of hexane is added to the cold solution and the precipitate filtered off. The filtrate is evaporated and the residue chromatographed on alumina (Woehlm neutral) using hexane to give 15 gms. (75% theory) of product. Recrystallization from hexane yields 2-vinylfluorene as colorless plates. The structure of the product is confirmed by nuclear magnetic resonance and elemental analysis. EXAMPLE II Synthesis of 2-vinylfluorenone is accomplished as follows: The 2-vinylfluorene prepared in Example I is dissolved in 800 milliliters of pyridine and cooled to 0° C. One-half milliliter of a 40% solution of benzyltrimethyl ammonium hydroxide in pyridine is slowly added with air being bubbled through the reaction solution. The initially formed red coloration fades over a period of 1 to 2 hours and the solution is poured into water and extracted with benzene to yield 9 grams (90% theory) of a yellow solid. The residue is chromatographed on alumina (Woehlm basic) and eluted with benzene. Recrystallization from hexane gives 2-vinylfluorenone as a pale yellow material (melting point 69°-70° C). The structure of the product is confirmed by nuclear magnetic resonance and elemental analysis. EXAMPLE III Synthesis of α-methyl-2-vinylfluorenone is accomplished by acetylation of fluorene as described in Organic Synthesis, Collective, Vol. 3, page 23. Conversion to the vinyl derivative is achieved in a 70% yield using the procedure described in Example I. Recrystallization of the product from hexane gives α-methyl-2-vinylfluorene as tan crystals (m.p. 155°-156° C). The product is oxidized to the corresponding fluorenone derivative by the procedure described in Example II. Recrystallization of the product from hexane yields α-methyl-2-vinylfluorenone as pale yellow crystals (m.p. 76°-77° C). The structure of the product is verified by nuclear magnetic resonance and elemental analysis. Polymerization of 2-vinylfluorenone is accomplished in following Examples IV - VII. EXAMPLE IV Emulsion In a 1 liter Morton flask is placed 200 milliliters of H 2 O together with 3 gms. of sodium oleate. The solution is blanketed with nitrogen and heated to 80°-85° C. At this point, 13.4 gm. (0.065 moles) of 2-vinylfluorenone are added to the flask. Subsequently, three portions of a solution of 0.01 gm. of K 2 S 2 O 8 in 10 milliliters of H 2 O are added over a period of 1 hour. The resulting solution is allowed to stir for 6 hours and coagulated with 50 milliliters of a saturated sodium acetate solution. The resulting precipitate is filtered and dried to yield 11.5 gm. of a polymer having a molecular weight of approximately 350,000. EXAMPLE V Cationic In a beverage bottle are placed 5 gm. (0.024 M) of 2-vinylfluorenone and 75 milliliters of methylene chloride to form a solution which is saturated with nitrogen. The bottle is capped and chilled to -30° C whereupon 0.10 milliliter of a BF 3 .Et 2 O solution is added as catalyst and the mixture stirred for 3 hours. The mixture is then quenched with methanol to yield 3 gm. of a polymer having a molecular weight of approximately 10,000. EXAMPLE VI Solution In a polymer tube are placed 0.5 gm. (0.0024 M) 2-vinylfluorenone; 0.007 gm. (4 × 10.sup. -5 M) of AIBN and 15 milliliters of toluene. The tube is degassed, sealed and heated to 85° C for 24 hours. The reaction product is dissolved in THF and precipitated with methanol to yield 0.35 gm. of a polymer having a molecular weight of approximately 50,000. EXAMPLE VII Bulk In a 100 milliliter round bottomed flask are placed 11.1 gm. (0.05 M) 2-vinylfluorenone and 0.005 gm. (3 × 10.sup. -5 M) of AIBN. The contents are blanketed with nitrogen and heated to 70°-75° C for 2 hours. The reaction product is dissolved in THF and precipitated in benzene to yield 8 gm. of a polymer having a molecular weight of approximately 200,000. EXAMPLE VIII Cationic polymerization of α-methyl-2-vinylfluorenone. In a 100 milliliter flask are placed 2 gm. of α-methyl-2-vinylfluorenone and 50 milliliters of chlorobenzene. The contents of the flask are blanketed with nitrogen and cooled to -40° C at which point a small amount of BF 3 gas is added. The reaction mass, which turned red upon the addition of the BF 3 , is kept below -30° C with stirring for 3 hours. The reaction is quenched with methanol and precipitated with methanol to yield 0.5 gm. of a polymer having a molecular weight of approximately 10,000. EXAMPLE IX A copolymer of 2-vinylfluorenone and N-vinylcarbazole is prepared as follows: In a polymer tube are placed 1.1 gm. (0.005 M) of 2-vinylfluorenone; 0.95 gm. (0.005 M) of N-vinylcarbazole; 5 milliliters of benzene and 0.048 gm. (2 × 10.sup. -4 M) benzoyl peroxide. The tube is degassed, sealed and heated to 65° C for 18 hours. The resulting product is precipitated into methanol to give an eighty percent yield of a copolymer containing approximately 80 mole % of 2-vinylfluorenone and 20 mole % of N-vinylcarbazole. The polymers of the instant invention possess excellent dielectric and insulating properties making them ideal materials for use in thin polymer film capacitors. Furthermore, the polymers exhibit good thermal stability at elevated temperatures up to 150° C. The polymers possess dielectric constants of approximately 4(100 Hz) over the temperature range of -200° C to 50° C with a dielectric loss factor of less than 0.1 at the same frequency. The polymers can be used to fabricate capacitors using either solvent coating or in situ polymerization techniques. EXAMPLE X A solution of poly-2-vinylfluorenone is prepared by dissolving the polymer in benzene. The solution is coated on a thin aluminum film using a doctor blade technique and the solvent evaporated to provide a polymer film approximately 2.5 μ thick. This metal/insulator sheet is cut into units of the desired dimensions two of which are positioned so as to allow contact leads to be attached, rolled into a compact cylinder and potted in an epoxy type resin to produce a functioning capacitor. EXAMPLE XI A standard paper/aluminum foil capacitor is impregnated with a solution of 2-vinylfluorenone and AIBN in benzene. The monomer is polymerized using heat as the stimulus and potted as previously described to provide the finished capacitor.
Disclosed is a composition of matter characterized by the structural formula: ##STR1## wherein R 1 is hydrogen or methyl and R 2 , R 3 and R 4 are hydrogen, halogen or aliphatic groups containing 1 to 4 carbon atoms. Also disclosed are vinyl polymers of the above compounds.
2
BACKGROUND OF THE INVENTION The present invention relates to an apparatus for and a method of assembling small numbers of a large variety of goods, such as goods with curved elongated members like curved pipes or curved control rods. Referring to FIG. 11(a), an automotive power steering gear assembly is described as a typical example of the items of the above kind. It comprises a gear housing 1 with an integral power cylinder 2, and curved pipes 3. Mounted within the gear housing 1 are a gear train of the rack and pinion type and a rotary valve. The curved pipes 3, which are formed by bending straight pipes, interconnect the gear housing 1 and the power cylinder 2 and serve as hydraulic fluid passages. In the automobile assembly plants, small numbers of a large variety of automobiles are manufactured, and thus a large variety of different power steering gear assemblies are needed. Therefore, it has been the conventional practice to prepare a variety of different curved elongated pipes by bending straight pipes, each having flared ends with nuts 3a as shown in FIG. 11(b), and store a considerably large quantity of them at a suitable storage location for adequate supply to the assembly line. Upon receipt of production instructions including a product specification, an appropriate gear housing is connected to the corresponding power cylinder in accordance with the product specification. Then, an appropriate one of the curved pipes is selected at the storage location, held at a right position relative to the gear housing integral with the power cylinder, and secured thereto by tightening nuts at a predetermined torque. Since small numbers of a large variety of different power steering gear assemblies are assembled and different curved pipes have to be prepared, a relatively large space is required at the storage location for the curved pipes. Besides, the appropriate one of the different curved pipes is manually selected so that there is the possibility of human error in making the selection. Accordingly, an object of the present invention is to provide an apparatus for and a method of assembling small number of a large variety of different products wherein the above-mentioned problems have been alleviated. SUMMARY OF THE INVENTION According to the present invention, there is provided an apparatus for assembling small numbers of a large variety of different products, comprising: means for delivering a work piece to a predetermined position; means for storing a variety of different straight elongated members; means for selecting a predetermined straight elongated member out of said variety of different straight elongated members in accordance with a production instruction; means for bending said predetermined straight elongated member in accordance with the production instruction to form a curved elongated member; means for receiving said curved elongated member and holding the same in a predetermined position relative to said work piece; and means for mounting said curved elongated member to said work piece. According to another aspect of the present invention, there is provided a method of assembling small numbers of a large variety of different products, comprising the steps of: delivering a work piece to a predetermined position; storing a variety of different straight elongated members; selecting a predetermined straight elongated member out of said variety of different straight elongated members in accordance with a production instruction; bending said predetermined straight elongated member in accordance with the production instruction to form a curved elongated member; receiving said curved elongated member and holding the same in a predetermined position relative to said work piece; and mounting said curved elongated member to said work piece. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an apparatus according to the present invention which performs a method according to the present invention; FIG. 2(a) is a top plan view of a pipe bender for bending an elongated pipe; FIG. 2(b) is a side elevation of the pipe bender; FIG. 3(a) is a fragmentary front elevation, partly sectioned, of a pipe set robot which receives a curved pipe and holds the same relative to a work, and shows a hand of the robot; FIG. 3(b) is a side elevation of the hand of the pipe set robot; FIG. 4(a) is a fragmentary front elevation, partly sectioned, of a nut tightening robot and shows a hand of the nut tightening robot; FIG. 4(b) is a side elevation of the hand of the nut tightening robot; FIG. 5(a) is a longitudinal section of an open end air wrench; FIG. 5(b) is a fragmentary view, partly sectioned, of the open end air wrench as viewed from the bottom in FIG. 5(a); FIG. 6 is a plan view, partly sectioned, of a torque wrench; FIG. 7 is an air pressure circuit for activation of the hand of the pipe set robot and the open end air wrench; FIG. 8 is a block diagram of a control unit for the nut tightening robot; FIG. 9 is a flow diagram of a control program for activating the apparatus shown in FIG. 1; FIG. 10 is a flow diagram of a control program for tightening nut with the open end air wrench and the torque wrench; FIG. 11(a) is a perspective view of a power steering gear assembly discussed before as a typical example of products; FIG. 11(b) is a section of a portion of the power steering gear assembly, showing connection between a flared end of the pipe and the power cylinder; and FIG. 12 is a perspective view of a master cylinder as another typical example of the products. DETAILED DESCRIPTION OF THE INVENTION Referring to the accompanying drawings, and particularly to FIG. 1, an apparatus according to the present invention comprises a numerically controlled (NC) pipe bender 11, a pipe set robot 31, and a nut tightening robot 51. Referring to FIGS. 2(a) and 2(b), the NC pipe bender 11 comprises a slide table 12 with a mobile carrier 14 thereon. The mobile carrier 14 rotatably supports a chuck 13, and has mounted thereon a torque motor 15 for rotating the chuck 13. The mobile carrier 14 is guided in such a manner that it can slide in the longitudinal direction of the table 12 in response to rotation of a feed motor 16 mounted on the table 12 on the righthand end, as viewed in FIGS. 2(a) and 2(b). Mounted on the lefthand end, as viewed in FIG. 2(a) and 2(b), of the table 12 are a bending roll 17 with an outer peripheral groove 17a having a semicircular cross sectional profile, and a clamp 18 with a semicircular groove opposed to the groove 17a of the bending roll 17. The bending roll 17 and the clamp 18 are rotatable by a drive mechanism, not shown, about an axis of rotation of the bending roll 17. Also mounted on the lefthand end, as viewed in FIG. 2(a), is a pressure die 19 with a semicircular groove opposed to the groove 17a of the bending roll 17. The pressure die 19 is guided to move in the longitudinal direction of the table 12 and it is activated to move toward or away the bending roll 17. Referring back to FIG. 1, this pipe bender 11 comprises a microcomputer based control unit 20, and a pipe loader 21. The control unit 20 controls actions of the above-mentioned mechanisms and the pipe loader 21 in accordance with instructions contained in control program stored in a memory of the microcomputer. The pipe loader 21 comprises a chute 22 including four trays storing four different groups of straight pipes 3, respectively. Each of the pipes 3 has flared ends with flare nuts 3a thereon, see FIG. 11(b). Straight pipes 3 of four different lengths are prepared and divided into four groups and stored in different trays of the chute 22. The pipe loader 21 also comprises a chain conveyer 23, and a hand 24. Among all, an appropriate straight pipe 3 is selected and supplied to the chain conveyer 23 by means of a stopper mechanism, not shown. The conveyer 23 lifts the straight pipe 3 supplied up to a predetermined position where the hand 24 grips the pipe 3. After having gripped the pipe 3, the hand 24 brings it to a predetermined position above the slide table 12. With the NC pipe bender 11, if the control unit 20 is instructed with the specification of a gear power steering gear assembly and the bending process of a pipe 3, the stopper mechanism of the pipe loader 21 supplies a straight pipe 3 having a length corresponding to the specification given to the chain conveyer 23 from the chute 22. The chain conveyer 23 delivers this pipe 3 to the hand 24. Then, the hand 24 holds this pipe 3 at the predetermined position above the slide table 24. Thereafter, the chuck 13 moves toward the bending roll 17 to hold the adjacent end of the pipe 3, and further moves in the same direction until that portion of the pipe 3 which is to be subjected to the bending is disposed between the bending roll 17 and clamp 18. Then, the clamp 18 moves toward the bending roll 17 until the pipe 3 is interposed between the groove of the clamp 18 and the outer peripheral groove 17a of the roll 17, while the pressure die 19 moves toward the bending roll 17 and it receives the pipe 3 in its groove to support the same. With this state being kept, the roll 17 and clamp 18 rotate, while the chuck 13 moves without any resistance in accordance with this rotation. In this process, the pressure die 19 holds the pipe 3 in the outer peripheral groove 17a of the bending roll 17 and thus the pipe 3 is bent to a predetermined curvature. The clamp 18 and pressure die 19 move back away from the bending roll 17, and the roll 17 and clamp 18 rotate back. Then, the chuck 13 moves towards the roll again until another portion of the pipe 3 which is to be subjected to the bending process is disposed between the bending roll 17 and clamp 18. During this movement, the chuck 13 may be turned through a predetermined angle if desired. Then, the above-mentioned bending process is repeated. The straight pipe 3 has predetermined portion or portions bent to make a predetermined curved pipe corresponding to the specification given. The pipe set robot 31 is disposed between a conveyer 42 and the NC pipe bender 11. A work piece, namely, an integral unit of a gear housing 1 integral with a power cylinder 2, is placed on a pallet 41. The pallet 41 is delivered by the conveyer 42 to a predetermined position relative to the pipe set robot 31. The pipe set robot 31 includes a hand 32 that is illustrated in FIGS. 3(a) and 3(b). Referring to FIG. 3(a), the hand 32 has a pair of claws 33 with fingers 34, respectively. The claws 33 are movable toward each other by an air cylinder, not shown. The hand 32 therefore can hold the pipe 3 between the fingers 34 when the claws 33 are moved toward each other. The pipe set robot 31 is controlled by a control unit, not shown. Upon completion of the bending process by the NC pipe bender 11, the above-mentioned hand 32 holds the curved pipe 3 and then the chuck 13 releases the pipe 3 and moves back to the waiting position. Then, the pipe set robot 21 moves the hand 32 with the curved pipe 3 interposed between the fingers 34 to a predetermined position relative to the gear housing 1 integral with the power cylinder 2, keeping it at this predetermined position. The nut tightening robot 51 is opposed to the pipe set robot 31 across the conveyer 42, and includes a generally C-shaped bracket 52, as a hand, as illustrated in FIGS. 4(a) and 4(b). Referring to FIGS. 4(a) and 4(b), the bracket 52 has a clamp 55 slidably mounted thereon by four guide shafts 53 and a ball type bushing 54. Springs 56 are arranged between one arm of the bracket 52 and the clamp 55 to bias the clamp 55 downwadly, as viewed in FIG. 4(a). The guide shafts 53, bushing 54 and springs 56 constitute an equalizer. As best seen in FIG. 4(b), the clamp 55 supports the open end air wrench 611 and the torque wrench 81 in such a manner that they extend in the opposite directions from the bracket 52. Referring to FIG. 5(a), the open end air wrench 61 includes an air operated motor 62 with a reduction gear box. The output shaft 62a of the air motor 62 is fixedly coupled with a bevel gear 63 which meshes with another bevel gear 64 integral with a pinion 65. As best seen in FIG. 5(b), the pinion 65 meshes with a gear 66 which in turn meshes with a gear 67. The gear 67 meshes with two pinions 68 and 69 which in turn meshes with an external gear 70a formed around the outer periphery of a socket 70. The arrangement is such that if the pinion 65 rotates counterclockwise, as viewed in FIG. 5(b), the socket 70 rotates counterclockwise; and if it rotates clockwise, the socket 70 rotates clockwise. The socket 70 includes a hexagonal portion 70b and a bottom wall 70c, and it is formed with a cutout or opening 70d. The open end air wrench 61 includes a ratchet 71 and a rotary encoder 72. The ratchet 71 is arranged such that when the socket 70 rotates in a direction opposite to a direction in which the nut is tightened, it engages with the gear 67 and stops this rotation of the socket 70 when socket 70 comes to a receptive position where the opening 70d faces to the left as viewed in FIG. 5(b). The rotary encoder 72 measures an angle of rotation of the bevel gear 64 and thus an angle of rotation of the socket 70. With the open end air wrench 61, when air pressure is supplied to one port, the output shaft 62a rotates clockwise as viewed from the left in FIG. 5(a). This clockwise rotation of the output shaft 62a is transmitted via the gears 63 to 69 to the socket 70, causing the socket 70 to rotate in the nut tightening direction, namely in counterclockwise direction as viewed in FIG. 5(b). Since the output shaft 62a rotates continuously, the socket 70 rotates continuously in the nut tightening direction. When air pressure is supplied to the other port of the air motor 62, the output shaft 62a rotates in the opposite direction and thus the socket 70 tends to rotate in the opposite direction. Since the gears 67 and 70a are substantially identical to each other, the reverse rotation of the socket 70 is stopped at the central receptive position as illustrated in FIG. 5(b) because the ratchet 70 engages with the gear 67 before the gear 67 make a full turn during its reverse rotation. Referring to FIG. 6, the torque wrench 81 includes a tube 82 with an open end, and a spanner-like head 83. The head 83 is formed with the opposed spaced parallel sides 83a and is pivotably mounted via a head pin 84 on the tube 82 at a portion adjacent the open end thereof. The spanner-like head 83 extends into the tube 82 has an inner end connected via an inclined link 85 to the adjacent end of a thruster 86 slidably disposed in the tube 82. The inclined link 85 is inclined relative to the axis of the tube 82. A spring 88 is operatively disposed between the thruster 86 and a thrust ring 87. The thrust ring 87 is threadedly engaged in the tube 82 and adjustable in axial direction relative to the tube 82. Mounted on the outer periphery of the tube 82 is a limit switch 89 which is so constructed and arranged as to detect rotation of the head 83 beyond a predetermined angle. With the nut interposed between the opposed two spaced parallel sides 83a, if the tube 82 is rotated about the central axis of the nut. a moment about the head pin 84 is imparted to the head 83, biasing the thruster 86 via the link 85. If the biasing force exceeds the preloaded pressure applied to the spring 88, the head 83 begins to rotate about the head pin 84, thus activating the limit switch 89. Therefore, with this torque wrench 81, the limit switch 89 is activated to produce an output signal when the torque applied to the nut exceeds the predetermined torque. This predetermined torque is adjustable by adjusting the position of the thrust ring 87 to modulate the preloaded pressure of the spring 88. The supply of air pressure to the air cylinder of the hand 32 and to the open end air wrench 61 is controlled by an air pressure circuit shown in FIG. 7. This air pressure circuit comprises a source of air pressure 91, and a pressure reduction valve 92. The air pressure generated by the pressure reduction valve 92 is supplied on one hand to a solenoid operated selector valve 95 via a pressure line 93, and on the other hand to a solenoid operated selector valve 96 via a pressure line 94. The solenoid operated selector valve 95 is connected to both chambers of the air cylinder of the double action type of the hand 32, respectively, and it has five ports and three positions. The other solenoid operated selector valve 96, which has a function to acivate or stop the action of the open end air wrench, has five ports and two positions and it is connected to a solenoid operated selector valve 97. The solenoid operated selector valve 97 has five ports and three positions, and it has an outlet port connected to a pressure line 98 and other outlet port connected to a another pressure line 99. The pressure line 98 is connected to a solenoid operated selector valve 100 having five ports and two positions. The solenoid operated selector valve 100 has a function to select low speed rotation of air motor 62 or high speed rotation thereof, and it has an outlet port connected to an air pressure line 101 and another outlet port connected to an air pressure line 102. The air pressure line 101 is connected via a one-way check valve 103 to a port inducing positive rotation of the air motor 62 of the air wrench 61, while the another pressure line 102 is connected via a pressure reduction valve 104 and a thorttle valve 105 to a port inducting reverse rotation of the air motor 62 of the air wrench 61. In this air pressure circuit, the pressure reduction valve 92 regulated air pressure discharged from the source of pressure 91 to generate a base pressure. This base pressure is delivered to the pressure lines 93 and 94. In response to the position taken by the solenoid operated selector valve 95, the base pressure is supplied selectively to one or the other chamber of the air cylinder of the hand 32, causing the fingers 34 to move toward each other or away from each other. If the solenoid operated selector valve 96 is activated, the supply of base pressure to the solenoid operated selector valve 97 is permitted or interrupted in response to the position taken by the solenoid operated selector valve 96. If the solenoid operated selector valve 97 is activated, the base pressure supplied thereto is supplied selectively to the pressure line 98 or the pressure line 99. The base pressure supplied to the pressure line 98 is further supplied selectively to the pressure line 101 or the pressure line 102 under the control of the solenoid operated selector valve 100. The base pressure admitted to the pressure line 101 is supplied via the one-way check valve 103 to the port inducing the forward rotation of the air motor 62, causing the air motor 62 and thus socket 70 to rotate in the forward direction at a high speed. On the other hand, the base pressure admitted to the pressure line 102 is supplied to the pressure reduction valve 104 where the pressure reduction is effected and the reduced air pressure is supplied via the throttle valve 105 to the port inducing the reverse rotation of the air motor 62, causing the air motor 62 and thus the socket 70 to rotate in the positive direction at a low speed. The base pressure admitted to the pressure line 99 is subjected to pressure reduction at the pressure reduction valve 106 and supplied via the throttle valve 107 to the port inducing the reverse rotation of the air motor 62, causing the air motor 62 and thus the socket 70 to rotate in the reverse rotation at a low speed. As previously described, the solenoid operated selector valve 95 controls action of the hand 32, while the solenoid operated selector valves 96, 97, and 100 control action of open end air wrench 61. The nut tightening robot 51 and open end air wrench 61 are controlled by the control unit 111 as shown in FIG. 8. The control unit 111 comprises a central processor unit (CPU) 112, an arithmetic logic circuit (ALC), and an output circuit 114 including a digital analog converter, a signal input interface 115, a signal output interface 116, a pulse counter 117, a differential circuit 118, and a driver 119. The CPU 112 operates based on a control program stored in a memory and supplies the ALC 113 with output signals indicative of a path of movement of the hand of the nut tightening robot 51 and a velocity of the movement. It generates an output signal which is supplied via the output interface 116 to the solenoid operated selector valves 96, 97 and 100 for activating the open-end air wrench 61. It receives an output signal of the limit switch 89 via the signal input interface 115. The ALC 113 calculates a target position of each of joints of the nut tightening robots 51 and a target velocity thereof in order for the hand of the nut tightening robot 51 to move along the path of movement given by the CPU 112 at the velocity given by the CPU 112. Via the digital analog conversion at the output circuit 114, the output signals of the ALC 113 indicative of the target position and velocity of each of the joints are supplied to the driver 119. The driver 119 activates motors for the joints of the nut tightening robot 51. An actual position indicative signal indicative of the actual position of each of the joints of the nut tightening robot 51 is fed via the differentiation circuit 118 to the ALC 113. In order to decrease a difference between the desired and actual position indicative signals, the ALC 113 modulates the target actual indicative signal supplied via the output circuit 114 to the driver 119.. The output signal of the encoder 72 mounted on the open-end air wrench 61 is supplied to the pulse counter 117 where the number of pulses is counted. The output signal of the pulse counter 117 is supplied to the ALC 113. Based on this output signal of the pulse counter 117, the ALC 113 calculates an angle of nut after the nut tightening operation has been completed. The result of this calculation is fed to the CPU 112. The differentiation circuit 118 calculates the first derivative of the actual position indicative signal supplied thereto to give an actual velocity of each of the joints of the nut tightening robot 51. The output of the differentiation circuit 118 indicative of the actual velocity is supplied to the driver 119. The apparatus according to the present embodiment operates in accordance with the control program as illustrated in FIG. 9 to assemble two curved pipes 3 in manufacturing the power steering gear assemblies as shown in FIG. 11. The execution of the control program shown in FIG. 9 is initiated upon receipt of production instruction of the power steering gear assembly. At a step 121, it is confirmed whether the preparation for assembling of the curved pipes has been completed or not. What are checked at this step 121 are whether the work, i.e., the gear housing 1 integral with the power cylinder 2, and whether the NC pipe bender 11 stays in the waiting state where the chuck 13 of the NC pipe bender 11 stays in the rest position. Then, the program proceeds to a step 122 if the preparation has been completed. At the step 122, in accordance with the specification of the power steering gear assembly to be produced following the production instruction, appropriate control programs for the NC pipe bender 11, pipe set robot 31 and nut tightening robot 51 are selected and loaded. Specifically, the selection of the appropriate control programs is made in accordance with the length of the straight pipes 3, the curvature to be given to the pipe during the bending process, and the appropriate positions of the pipes 3 relative to the gear housing 1 integral with the power cylinder 2. Then, the execution of the control programs is initiated. At a step 123, the NC pipe bender 11 has the pipe loader 21 to select the appropriate one out of four kinds of different, in length, straight pipes and operates to bend the straight pipe 3 supplied to the predetermined curved shape. In this bending process, the appropriate gear housing 1 is connected to the corresponding power cylinder 2, the pipe set robot 31 stays in its waiting position where it does not interfere with the bending process of the pipe 3, see step 124, and the nut tightening robot 51 stays in its waiting position where it does not interfere with the pipe set robot 31 operating to set the pipe 3, see step 125. Upon completion of the bending process, the pipe set robot 31 let its hand 32 move to hold the pipe 3 held by the chuck 13 of the NC pipe bender 11, see a step 126. Subsequently, at steps 127 and 128, the chuck 13 releases the pipe 3 and returns to the rest position. Then, the pipe set robot 31 moves the pipe 3 to a waiting position where it does not interfere with the gear housing 1 with the poser cylinder 2 disposed on the pallet 41. When the pallet 41 has reached a predetermined position, the program proceeds to a step 130 where the pipe set robot 31 set the pipe 3 at a predetermined position where the flare nuts 3a of the pipe 3 abut against the ports of the gear housing 1 and the power cylinder on the parallel 4 with the central axes of the flare nuts 3a arranged in alignment with the central axes of the ports of the gear housing 1 and power cylinder 2, respectively. Thereafter, at steps 131 and 132, the nut tightening robot 51 tighten the flare nut 3a on the power cylinder 2 side of the pipe 3 with the open-end air wrench 61, and tighten its firmly with the torque wrench 81 to the predetermined torque. The nut tightening and the subsequent torque check are performed by executing the control program as shown in FIG. 10. Referring to FIG. 10, at a step 141, with the socket 70 held in the central rest position where the opening 70d faces forwardly toward the pipe 3, the open end air wrench 61 moves toward a position about to receive the nut 3a where the socket 70 receives therein the pipe 3 adjacent the nut 3a disposed near the power cylinder 2. Then, at a step 142, the air wrench 61 is caused to rotate at a low speed. At the subsequent step 143, the open end air wrench 61 moves toward the power cylinder 2 until the socket 70 has the flare nut 3a to receive therein. Thereafter, at a step 144, the air wrench 61 starts rotating at a high speed. It keeps on rotating at the high speed for a predetermined period of time. This causes the flare nut 3a advance toward the power cylinder 2 until the flare nut 3a has a flared end portion of the pipe 3 interposed between it and the bottom wall of the port structure of the power cylinder 2, see FIG. 11(b). After this tightening operation, the open end air wrench 61 is caused to step back from the power cylinder to disengage the socket 70 from the flare nut 3a at a step 146. The, at a step 147, the air wrench 70 is rotates in the reverse direction until the socket 70 takes the central rest position where the opening 70a faces forwardly. During this reverse rotation, the number of pulses generated by the rotary encoder 72 is counted. Using this result, an angle of rotation in the reverse direction till the socket 70 takes the central rest position is determined, and thus the direction along which two spaced opposed sides of the flare nut 3a extend upon completion of the tightening process is determined. Then, the bracket 52 is rotated through 180 degrees and the torque wrench 81 is caused to advance toward the pipe 3 till a position about to receive the nut 3a where the head 83 of the torque wrench 81 receive the pipe 3 therein at a position adjacent the nut 3a. During this movement of the torque wrench toward the pipe 3, the angular position of the torque wrench 81 which is to take for the two opposed paralled sides 83a of the head 83 align with the two opposed sides of the flare nut 3a is calculated based on the result of counting the number of pulses generated by the encoder 72. Then, at a step 149, the position of the torque wrench 81 is revised to the position determined by the calculation. Thereafter, at a step 150, the torque wrench 81 is caused to move toward the power cylinder 2 until the head 83 receives the flare nut 3a therein. At a step 151, the torque wrench 81 is rotated about the pipe 3 in the nut tightening direction, and if, at a step 152, it is determined that the output signal of the limit switch 89 is received and thus the predetermined torque has been achieved, the program proceeds to a step 153. At the step 153, the torque wrench 81 is caused to step back away from the power cylinder 2 to disengage the head 83 from the flare nut 3a. After the tightening of and torque check of the flare nut 3a on the power cylinder 2 side have been completed, the program proceeds to a step 133 where the partial tightening of the flare nut 3a on the gear housing 5 side is carried out. The partial tightening of the nut 3a is carried out in substantially the same manner as illustrated by the steps 141 to 145 except that instead of high speed rotation of the air wrench 61 at steps 144 and 145, the air wrench 61 is turned at a low speed for a relatively short period of time. With this operation, the flare nut 3a is temporarily engaged with the port on the gear housing 1. This is an effective measure not to impart big stress on the pipe 3 that is held by the pipe set robot 31, thus preventing deformation of the pipe 3. The program then proceeds to a step 134, the pipe set robot 31 is caused to release the pipe 3. After it is confirmed that the pipe set robot 31 has release the pipe 3, the program proceeds to steps 135 and 136 where the tightening of the flare nut 3a on the gear housing 1 side and the torque check are carried out in the same manner as illustrated in the flow chart in FIG. 10. After releasing the pipe 3, the pipe set robot 31 returns to an intial rest position, see step 137. After the torque check at the step 136, the nut tightening robot 51 returns to its initial rest position, see step 138. While the pipe set robot 31 sets the pipe 3 and the nut tightening robot 51 operates to tighten the flare nuts 3a, the NC pipe bender 11 performs beinding of the second pipe 3 repeating the steps 123 to 128 unless it is decided that the second pipe 3 has been subjected to the bending process. If, at a step 140, it is decided that the second pipe 3 is not yet assembled, the pipe set robot 31 and the nut tightening robot 51 are caused to assemble the second pipe 3 to the gear housing 1 intergal with the power cylinder 2 by repeating the steps 126 to 138. The present invention may be applied to assembling of pipes 5 with a brake master cylinder 4 as shown in FIG. 12 or assembling of a control rod with a carburetor. From the preceding description, it will now be appreciated that according to the present invention a space for storing parts has been minimized since what are needed to store are elongate straight members like straight pipes or rods before being subjected to bending process. Besides, human error in selecting and assembling an inappropriate member has been eliminated.
An apparatus for and a method of assembling small numbers of a large variety of different products are disclosed. In order to eliminate stock of parts and prevent error in assembling inappropriate part, a straight pipe or rod is subjected to bending to a desired curved shape, and set to a predetermined position to assemble with the other parts, and then assembled.
1
This application is a Continuation of U.S. application Ser. No. 12/607,284 filed Oct. 28, 2009, which is a continuation of International Application No. PCT/US2007/074918 filed Aug. 1, 2007, which claims the benefit of U.S. Provisional Application Nos. 60/947,731 filed Jul. 3, 2007 and 60/915,761 filed May 3, 2007. FIELD OF THE INVENTION The present invention relates to granules and solid oral pharmaceutical dosage forms, suitably tablets, suitably capsules, comprising 3′-[(2Z)-[1-(3,4-dimethylphenyl)-1,5-dihydro-3-methyl-5-oxo-4H-pyrazol-4-ylidene]hydrazino]-2′-hydroxy-[1,1′-biphenyl]-3-carboxylic acid bis-(monoethanolamine) represented by the following formula (I) and hereinafter referred to as “eltrombopag olamine” or Compound B: BACKGROUND OF THE INVENTION 3′-{N′-[1-(3,4-dimethylphenyl)-3-methyl-5-oxo-1,5-dihydropyrazol-4-ylidene]hydrazino}-2′-hydroxybiphenyl-3-carboxylic acid (hereinafter Compound A) is a compound which is disclosed and claimed, along with pharmaceutically acceptable salts, hydrates, solvates and esters thereof, as being useful as an agonist of the TPO receptor, particularly in enhancing platelet production and particularly in the treatment of thrombocytopenia, in International Application No. PCT/US01/16863, having an International filing date of May 24, 2001; International Publication Number WO 01/89457 and an International Publication date of Nov. 29, 2001; which has United States Publication Number US2004/0019190 A1, having a United States Publication date of Jan. 29, 2004; now U.S. Pat. No. 7,160,870, issued Jan. 9, 2007, the disclosure of which is hereby incorporated by reference. The bis-(monoethanolamine) salt of this compound is disclosed (disclosed as 3′-[(2Z)-[1-(3,4-dimethylphenyl)-1,5-dihydro-3-methyl-5-oxo-4H-pyrazol-4-ylidene]hydrazino]-2′-hydroxy-[1,1′-biphenyl]-3-carboxylic acid, which also describes Compound A) in International Application No. PCT/US03/16255, having an International filing date of May 21, 2003; International Publication Number WO 03/098002 and an International Publication date of Dec. 4, 2003; which has United States Publication Number US2006/0178518 A1, having a United States Publication date of Aug. 10, 2006; the disclosure of which is hereby incorporated by reference. Compound A is disclosed for the treatment of degenerative diseases/injuries in International Application No. PCT/US04/013468, having an International filing date of Apr. 29, 2004; International Publication Number WO 04/096154 and an International Publication date of Nov. 11, 2004; which has United States Publication Number US2007/0105824 A1, having a United States Publication date of May 10, 2007; the disclosure of which is hereby incorporated by reference. Compositions that may contain Compound A and/or Compound B are disclosed in International Application No. PCT/US01/16863, International Application No. PCT/US03/16255 and International Application No. PCT/US04/013468. Solid oral pharmaceutical dosage forms are popular and useful forms of medications for dispensing pharmaceutically active compounds. A variety of such forms are known, including tablets, capsules, pellets, lozenges, and powders. However, the formulation of an acceptable solid oral pharmaceutical dosage form on a commercial scale is not always straightforward. The formula and process of manufacture must be such as to provide an integral solid dosage form that maintains its integrity until used. The solid dosage form must also possess acceptable dissolution and disintegration properties so as to provide the desired profile in use. Pharmaceutically active compounds with low solubility and/or that can react with commonly used excipients can present particular challenges in preparing high quality solid dosage forms, since the physical properties of the drug influence the properties of the solid dosage form. The formulator must balance the drug's unique properties with the properties of each excipient in order to prepare a safe, efficacious and easy to use solid dosage form. Eltrombopag olamine presents the formulator with unique concerns when attempting to formulate this compound into a suitable solid oral pharmaceutical dosage form, suitably a tablet, suitably a capsule, with a desirable pharmacokinetic profile, particularly on a commercial scale. Such concerns include, but are not limited to; the tendency of the compound to form insoluble metal complexes when contacted with excipients that contain a coordinating metal, slow dissolution of the compound from solid dosage forms and the tendency of the compound to under go a Maillard reaction when contacted with excipients that contain reducing sugars. Significant realization of these concerns will have an adverse effect on the in vivo administration of eltrombopag olamine. It would be desirable to provide eltrombopag olamine in a solid oral pharmaceutical dosage form on a commercial scale with a desirable pharmacokinetic profile. The present invention is directed to granules and solid oral pharmaceutical dosage forms that contain eltrombopag olamine, suitably the solid dosage form is a tablet, suitably the solid dosage form is a capsule, suitably these solid dosage forms are produced on a commercial scale. SUMMARY OF THE INVENTION The present invention relates to granules and solid oral pharmaceutical dosage forms comprising a therapeutically effective amount of eltrombopag olamine. The invention also relates to a process for making granules and solid oral pharmaceutical dosage forms comprising eltrombopag olamine. Another aspect of this invention relates to granules and solid oral pharmaceutical dosage forms, suitably tablets, suitably capsules, comprising eltrombopag olamine that are formulated using diluents that are substantially free of reducing sugars, which as used herein and in the claims includes diluents that are free of reducing sugars, and that are substantially free of coordinating metals, which as used herein and in the claims includes diluents that are free of coordinating metals. Such granules and solid oral pharmaceutical dosage forms exhibit improved properties. Such improved properties help to ensure safe and effective treatment. Another aspect of this invention relates to film coated pharmaceutical tablets comprising eltrombopag olamine, wherein the film coat contains no coordinating metals, or only an amount of coordinating metal approximately equal to or less than 0.025 parts of Compound B. Such tablets exhibit improved properties. Such improved properties help to ensure safe and effective treatment. Another aspect of this invention relates to granules and solid oral pharmaceutical dosage forms comprising eltrombopag olamine that are formulated with a defined drug particle size range where about 90% of drug particle size is in the range of 10 to 90 microns. Such tablets exhibit improved properties. Such improved properties help to ensure safe and effective treatment. Another aspect of this invention relates to granules and solid oral pharmaceutical dosage forms containing eltrombopag olamine comprising a high percentage of disintegrant, suitably an amount equal to or greater than 4%. Such tablets exhibit improved properties. Such improved properties help to ensure safe and effective treatment. Another aspect of this invention relates to a method of treating thrombocytopenia, which method comprises administering to a subject in need thereof a therapeutically effective amount of granules or a solid oral pharmaceutical dosage form of the present invention. Another aspect of this invention relates to a method of agonizing the TPO receptor, which method comprises administering to a subject in need thereof a therapeutically effective amount of granules or a solid oral pharmaceutical dosage form of the present invention. Also included in the present invention are methods of co-administering granules or a solid oral pharmaceutical dosage form of the present invention with further active ingredients. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 depicts the dissolution comparison of tablets containing eltrombopag and a metal containing diluent with tablets containing eltrombopag and a non-metal containing diluent. FIG. 2 depicts the effect of API particle size on the dissolution of eltrombopag from 75 mg tablets. DETAILED DESCRIPTION OF THE INVENTION By the term “coordinating metal” and “coordinating metals” and derivatives thereof, as used herein is meant a metal or a metal containing excipient, suitably a diluent, or metal containing tablet coating material, which forms a complex, such as a chelate complex, in the presence of eltrombopag olamine. Examples of such metals include: aluminum, calcium, copper, cobalt, gold, iron, magnesium, manganese and zinc. By the term “reducing sugar” as used herein is meant a sugar or sugar containing excipient, suitably a diluent, which reacts with eltrombopag olamine to form a Maillard product when admixed together. Examples of such reducing sugars include: lactose, maltose, glucose, arabinose and fructose. The term Maillard reaction is well known in the art and is utilized herein as to its standard meaning. Generally, the term Maillard reaction is used herein to mean the reaction of a reducing sugar, as defined herein, in a formulation, suitably granules or solid dosage forms, with eltrombopag olamine that produces a pigment or pigments, suitably a brown pigment. The pigments are referred to herein as Maillard products. The production of such Maillard products is an indication of chemical instability. As used herein, the term “improved properties” and derivatives thereof, contemplates several advantages to the pharmacokinetic profile of the in vivo release of Compound B from a formulation, suitably granules or a solid oral pharmaceutical dosage form, that utilizes an aspect of the present invention when compared to a formulation that does not utilize that aspect of the present invention, suitably the formulation is produced on a commercial scale, and will vary depending on the particular aspect of the invention being utilized. Examples of improved properties include: increased oral bioavailability, reduced formation of insoluble metal complexes, improved chemical stability, a consistent pharmacokinetic profile and a consistent dissolution rate. As used herein, the term “drug” or “active ingredient” and derivatives thereof, means Compound B or eltrombopag olamine. By the term “commercial scale” and derivatives thereof, as used herein is meant, preparation of a batch scale greater than about 20 kg of granulation mix, suitably greater than 50 kg, suitably greater than 75 kg or a batch size suitable to prepare at least about 50,000 tablets, suitably at least 75,000 tablets, suitably at least 100,000 tablets. When indicating that the diluents for use herein and in the claims are substantially free of coordinating metals and/or that are substantially free of reducing sugars, it is contemplated that minor amounts, for example: about 5% or less, of the diluent component could contain a coordinating metal or metals and/or a reducing sugar or reducing sugars. In this aspect of the invention, it is believed that very minor amounts of coordinating metals and/or reducing sugars can be incorporated into the diluent component without adversely effecting tablet performance. The term “effective amount” and derivatives thereof, means that amount of a drug or active ingredient that will elicit the biological or medical response of a tissue, system, animal or human that is being sought, for instance, by a researcher or clinician. Furthermore, the term “therapeutically effective amount” means any amount which, as compared to a corresponding subject who has not received such amount, results in improved treatment, healing, prevention, or amelioration of a disease, disorder, or side effect, or a decrease in the rate of advancement of a disease or disorder. The term also includes within its scope amounts effective to enhance normal physiological function. As used herein, the term “formulation” and derivatives thereof, unless otherwise defined refers to granules and/or solid oral pharmaceutical dosage forms of the invention that contain eltrombopag olamine. By the term “co-administering” and derivatives thereof as used herein is meant either simultaneous administration or any manner of separate sequential administration of granules and/or a solid oral pharmaceutical dosage form of the present invention and a further active ingredient or ingredients, known to treat thrombocytopenia, including chemotherapy-induced thrombocytopenia and bone marrow transplantation and other conditions with depressed platelet production. The term further active ingredient or ingredients, as used herein, includes any compound or therapeutic agent known to or that demonstrates advantageous properties when administered with TPO or a TPO mimetic. Preferably, if the administration is not simultaneous, the compounds are administered in a close time proximity to each other. Furthermore, it does not matter if the compounds are administered in the same dosage form, e.g. one compound may be administered topically and another compound may be administered orally. Examples of a further active ingredient or ingredients for use in combination with the presently invented formulations include but are not limited to: chemoprotective or myeloprotective agents such as G-CSF, BB10010 (Clemons et al., Breast Cancer Res. Treatment, 1999, 57, 127), amifostine (Ethyol) (Fetscher et al., Current Opinion in Hemat., 2000, 7, 255-60), SCF, IL-11, MCP-4, IL-1-beta, AcSDKP (Gaudron et al., Stem Cells, 1999, 17, 100-6), TNF-a, TGF-b, MIP-1a (Egger et al., Bone Marrow Transpl., 1998, 22 (Suppl. 2), 34-35), and other molecules identified as having anti-apoptotic, survival or proliferative properties. By the term “granules” and derivatives thereof, as used herein refers to formulated particles that comprise eltrombopag olamine, diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars, and suitably also binders and/or lubricants and/or disintegrants such that the particles are suitable for utilization in preparing solid oral pharmaceutical dosage forms. It is also possible to administer the granules directly to a subject in need thereof as a medicament. However, it is anticipated that the granules are most appropriately utilized in the preparation of solid oral pharmaceutical dosage forms as indicated above. By the term “solid oral pharmaceutical dosage form” and “solid dosage form” and derivatives thereof, as used herein refers to a final pharmaceutical preparation that comprises eltrombopag olamine, such tablets, capsules, pellets, lozenges and powders (including coated versions of any of such preparations) that are suitable for in vivo administration. Suitably, the granules and solid oral pharmaceutical dosage forms of the present invention comprise eltrombopag olamine, a diluent (also known as filler or bulking agent), and suitably also a binder and/or a lubricant and/or a disintegrant. Those skilled in the art will recognize that a given material may provide one or more functions in the tablet formulation, although the material is usually included for a primary function. The percentages of diluent, binder, lubricant and disintegrant provided herein and in the claims are by weight of the tablet. Diluents provide bulk, for example, in order to make the tablet a practical size for processing. Diluents may also aid processing, for example, by providing improved physical properties such as flow, compressibility, and tablet hardness. Because of the relatively high percentage of diluent and the amount of direct contact between the diluent and the active compound in the typical pharmaceutical formulation, the interaction of the diluent with the active compound is of particular concern to the formulator. Examples of diluents suitable for general use include: water-soluble fillers and water-insoluble fillers, such as calcium phosphate (e.g., di and tri basic, hydrated or anhydrous), calcium sulfate, calcium carbonate, magnesium carbonate, kaolin, spray dried or anhydrous lactose, cellulose (e.g., microcrystalline cellulose, powdered cellulose), pregelatinized starch, starch, lactitol, mannitol, sorbitol, maltodextrin, powdered sugar, compressible sugar, sucrose, dextrose, and inositol. The diluents that do not contain coordinating metals and diluents that are non-reducing sugars are suitable for tablets of the current invention. Suitable diluents for use in this invention include microcrystalline cellulose, powdered cellulose, pregelatinized starch, starch, lactitol, mannitol, sorbitol, and maltodextrin. Unsuitable diluents include calcium phosphate (e.g., di and tri basic, hydrated or anhydrous), calcium sulfate, calcium carbonate, magnesium carbonate, kaolin, and spray dried or anhydrous lactose. In one embodiment of the present invention, the diluent is composed of one or both of Mannitol and microcrystalline cellulose. The granules and solid oral pharmaceutical dosage forms of the present invention typically comprise from about 25% to about 89%, of one or more diluents. One aspect of the present invention comprises granules wherein the granules are formulated using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars. One aspect of the present invention comprises solid oral pharmaceutical dosage forms wherein the solid dosage forms are formulated using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars. One aspect of the present invention comprises pharmaceutical tablets, wherein the tablets are formulated using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars. One aspect of the present invention comprises pharmaceutical capsules, wherein the capsules are formulated using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars. Binders impart cohesive properties to the powdered material. Examples of binders suitable for use in the present invention include: starch (e.g., paste, pregelatinized, mucilage), gelatin, sugars (e.g., sucrose, glucose, dextrose, molasses, lactose, dextrin, xylitol, sorbitol), polymethacrylates, natural and synthetic gums (e.g., acacia, alginic acids and salts thereof such as sodium alginate, gum tragacanth, Irish moss extract, panwar gum, ghatti gum, guar gum, zein), cellulose derivatives [such as carboxymethyl cellulose and salts thereof, methyl cellulose (MC), hydroxypropyl methyl cellulose (HPMC), hydroxypropyl cellulose (HPC), hydroxyethyl cellulose (HEC) and ethyl cellulose (EC)], polyvinylpyrrolidone, Veegum, larch arabogalactan, polyethylene glycol, waxes, water, alcohol, magnesium aluminum silicate, and bentonites. In one embodiment of the present invention, the binder comprises polyvinylpyrrolidone (PVP). The granules and solid oral pharmaceutical dosage forms of the present invention typically comprise up to about 8% binder. The formulations suitably comprise up to about 5%, suitably up to about 2% binder. Lubricants are generally used to enhance processing, for example, to prevent adhesion of the formulation material to manufacturing equipment, reduce interparticle friction, improve rate of flow of the formulation, and/or assist ejection of the formulations from the manufacturing equipment. Examples of lubricants suitable for use in the present invention include: talc, stearates (e.g., magnesium stearate, calcium stearate, zinc stearate, palmitostearate), stearic acid, hydrogenated vegetable oils, glyceryl behanate, polyethylene glycol, ethylene oxide polymers (e.g., CARBOWAXes), liquid paraffin, sodium lauryl sulfate, magnesium lauryl sulfate, sodium oleate, sodium stearyl fumarate, DL-leucine, and silica derivatives (e.g., colloidal silicon dioxide, colloidal silica, pyrogenic silica, and hydrated sodium silicoaluminate). In one embodiment of the present invention, the lubricant comprises magnesium stearate. The granules and solid oral pharmaceutical dosage forms of the present invention typically comprise up to about 2% lubricant. The formulations suitably comprise up to about 1.5%, suitably up to about 1% lubricant. Disintegrants are employed to facilitate breakup or disintegration of the formulation after administration. Examples of disintegrants suitable for use in the present invention include: starches, celluloses, gums, crosslinked polymers, and effervescent agents, such as corn starch, potato starch, pregelatinized starch, modified corn starch, croscarmellose sodium, crospovidone, sodium starch glycolate, Veegum HV, methyl cellulose, microcrystalline cellulose, cellulose, modified cellulose gum (e.g., Ac-Di-Sol R), agar, bentonite, montmorillonite clay, natural sponge, cation exchange resins, ion exchange resins (e.g., polyacrin potassium), alginic acid and alginates, guar gum, citrus pulp, carboxymethylcellulose and salts thereof such as sodium lauryl sulfate, magnesium aluminum silicate, hydrous aluminum silicate, sodium bicarbonate in admixture with an acidulant such as tartaric acid or citric acid. In one embodiment of the present invention, the disintegrant is sodium starch glycolate. The granules and solid oral pharmaceutical dosage forms of the present invention typically comprise an amount from 4% to about 12% disintegrant. The formulations suitably comprise from about 6% to about 10%, suitably from about 7% to 9% disintegrant. The solid oral pharmaceutical dosage forms, suitably tablets, suitably capsules, of the present invention will typically be sized up to 1 gram, e.g., from about 0.01 gram to about 0.8 gram. These solid dosage forms typically comprise from about 5 mg to about 900 mg of eltrombopag olamine per dosage form. In suitable embodiments, the solid dosage forms comprise from about 5 to about 200 mg eltrombopag olamine (e.g., in an about 100-800 mg dosage form). Tablet formulations of the invention may have a variety of shapes, including diamond, modified capsule, modified oval, and hexagonal, and may optionally have a tilt. Tablets The choice of particular types and amounts of excipients, and tabletting technique employed depends on the further properties of eltrombopag olamine and the excipients, e.g., compressibility, flowability, particle size, compatibility, and density. The tablets may be prepared according to methods known in the art, including direct compression, dry granulation, fluid bed granulation, and wet granulation, and the type of excipients used will vary accordingly. It has been found that wet granulation is particularly suitable for providing high strength, low breakage tablets comprising relatively high concentrations of eltrombopag olamine (e.g., about 40% or more), on a scale suitable for commercial production. Suitable wet granulated tablets of the invention comprise granules comprising eltrombopag olamine and one or more of fillers, binders and disintegrants, wherein the granules are mixed with additional filler, binder, disintegrant and/or lubricant to form a compression mixture that is compressed to form tablets. Included in the present invention are pharmaceutical compositions in tablet form, suitably prepared on a commercial scale, that comprise eltrombopag olamine, wherein the tablet is made by a wet granulation process using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars. Also included in the present invention are such pharmaceutical compositions that contain a film coat, wherein the film coat contains no coordinating metals, or only an amount of coordinating metal approximately equal to or less than 0.025 parts of Compound B. Also included in the present invention are pharmaceutical compositions that comprise eltrombopag olamine, wherein the tablet is made by a wet granulation process, suitably on a commercial scale, using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars, and about 90% of the eltrombopag olamine particles have a particle size greater than 10 micron but less than 90 micron. Also included in the present invention are pharmaceutical compositions that comprise eltrombopag olamine, wherein the tablet is made by a wet granulation process, suitably on a commercial scale, using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars, and about 90% of the eltrombopag olamine particles have a particle size greater than 10 micron but less than 90 micron, suitably greater than 20 micron but less than 50 micron. Also included in the present invention are pharmaceutical compositions that comprise eltrombopag olamine, wherein the tablet is made by a wet granulation process, suitably on a commercial scale, using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars, and about 50% of the eltrombopag olamine particles have a particle size greater than 5 micron but less than 50 micron, suitably greater than 5 micron but less than 20 micron. In one embodiment of the present invention, the tablets of the present invention comprise: (i) from about 2% to about 65% eltrombopag olamine; (ii) from about 25% to about 89% of diluent; (iii) up to about 8% binder, suitably up to about 5%, suitably up to about 4%; (iv) up to about 2% lubricant, suitably up to about 1.5%, suitably up to about 1%; and (v) from 4% to about 12% disintegrant, suitably 6% to 10%, suitably from 7% to 9%. Suitable wet granulated tablets comprise, by weight of the tablet, from about 10% to about 95% of eltrombopag olamine active intragranules and from about 5% to about 90% of external excipients; wherein the eltrombopag olamine active intragranules comprise, by weight of the intragranules: (i) from about 2% to about 88% eltrombopag olamine; (ii) from about 10% to about 96% diluent; (iii) from about 2% to about 5% binder; and (iv) optionally from 0% to about 4% disintegrant; and wherein the external excipients comprise, by weight of the tablet: (i) from 0% to about 70% diluent; (ii) from about 0.25% to about 2%, suitably from about 0.25% to about 1.25% lubricant; and (iii) from 4% to about 10% disintegrant. In the foregoing embodiments, the diluent is suitably a combination of mannitol and microcrystalline cellulose, the non-reducing sugar is suitably mannitol, the binder is suitably polyvinylpyrolidone, the lubricant is suitably magnesium stearate, and the disintegrant is suitably sodium starch glycolate. Suitably, the intragranule filler is a mixture of mannitol and microcrystalline cellulose and the external filler is microcrystalline cellulose. In one embodiment of the current invention, tablets are coated with a film coat formed from an aqueous film coat composition. Aqueous film coat compositions suitable for use in the present invention comprise a film-forming polymer, water as a vehicle, and optionally one or more adjuvants such as are known in the film-coating art. When the film coat contains a coordinating metal, as used herein, the amount of coordinating metal is approximately equal to or less than 0.025 parts of Compound B. The film-forming polymer is selected to form coatings with mechanical properties (e.g., mechanical strength, flexibility) suitable to meet performance requirements, such as those required by the intended use environment (e.g., dissolution profile in gastrointestinal fluids), and/or use (e.g. solution viscosity). Examples of suitable film-forming polymers include cellulosic polymers (e.g., cellulose ethers such as HPMC, HPC, MC, EC, HEC, CAP, sodium ethyl cellulose sulfate, carboxymethyl cellulose and the like); polyvinylpyrolidone; zein; and acrylic polymers (e.g., methacrylic acid/methacrylic acid ester copolymers such as methacrylic acid/methylmethacrylate copolymers and the like). Cellulosic polymers are preferred in the present invention, especially cellulosic ethers and more especially HPMC and HPC. The polymers are typically provided in either aqueous or organic solvent based solutions or aqueous dispersions. However, the polymers may be provided in dry form, alone or in a powdery mixture with other components (e.g., a plasticizer and/or colorant), which is made into a solution or dispersion by the user by admixing with the aqueous vehicle. The aqueous film coat composition further comprises water as a vehicle for the other components, to facilitate their delivery to the tablet surface. The vehicle may optionally further comprise one or more water soluble solvents, e.g., alcohols (e.g., methanol, isopropanol, propanol) and ketones (e.g., acetone). The skilled artisan can select appropriate vehicle components to provide good interaction between the film-forming polymer and the vehicle to ensure good film properties. In general, polymer—vehicle interaction is designed to yield maximum polymer chain extension to produce films having the greatest cohesive strength and thus mechanical properties. The components are also selected to provide good deposition of the film-forming polymer onto the tablet surface, such that a coherent and adherent film is achieved. The aqueous film coating composition may optionally comprise one or more adjuvants known in the art, such as plasticizers, colorants, detackifiers, secondary film-forming polymers, flow aids, surfactants (e.g., to assist spreading), maltodextrin, and polydextrose. Plasticizers provide flexibility to the film, which may reduce film cracking and improve adhesion to the tablet. Suitable plasticizers will generally have a high degree of compatibility with the film-forming polymer and sufficient permanence such that the coating properties are generally stable. Examples of suitable plasticizers include glycerin, propylene glycol, polyethylene glycols (e.g., molecular weight from 200 to 20,000, including Union Carbide's PEG 400, 4000, 6000, 8000, and 20,000), glycerin triacetate (aka triacetin), acetylated monoglyceride, citrate esters (e.g., triethyl citrate, acetyl triethyl citrate, tributyl citrate, acetyl tributyl citrate), phthalate esters (e.g., diethyl phthalate), mineral oil and hydrogenated glucose syrup. In one embodiment of the present invention, the plasticizer is chosen from polyethylene glycols, triacetin, propylene glycol, glycerin, and mixtures thereof. The aqueous film coat composition suitably comprises one or more colorants. In addition to enhancing esthetic appeal, the colorant provides product identification. Suitable colorants include those approved and certified by the FDA, including FD&C and D&C approved dyes, lakes, and pigments, and titanium dioxide, provided that the film coat contains no coordinating metals, or only an amount of coordinating metal approximately equal to or less than 0.025 parts of Compound B. Suitably, the colorant comprises one or more coloring agents selected from the group consisting of red iron oxides, red dyes and lakes, yellow iron oxides, yellow dyes and lakes, titanium dioxide, and indigo carmine. For example, the colorant may be selected to provide a light beige shade, for example consisting essentially of a) red iron oxide, red dye, and/or red lake, b) yellow iron oxide, yellow dye, and/or yellow lake, and c) titanium dioxide. Alternatively, the colorant may be selected to provide a pink shade (e.g., consisting essentially of titanium dioxide and red iron oxide, red dye and/or red lake); a light green shade (e.g., consisting essentially of yellow iron oxide, yellow dye and/or yellow lake, indigo carmine, and titanium dioxide); a light blue shade (e.g., consisting essentially of titanium dioxide and indigo carmine); or an orange shade (e.g., consisting of essentially of titanium dioxide and sunset yellow). The above mentioned colorants that contain a coordinating metal are acceptable at a level approximately equal to or less than 0.025 parts of Compound B. In suitable alternative embodiments, the aqueous film coating composition for use in the current invention comprises: (i) a cellulosic film-forming polymer; and (ii) a plasticizer. Suitably, such compositions further comprise a colorant. Such compositions may optionally further comprise one or more additional adjuvants such as a detackifier, flow aid, surfactant, and secondary film-forming polymer. Examples of optional detackifiers include lecithin, stearic acid, mineral oil, modified derivatized starch, tapioca dextrin, and polyethylene glycol. Examples of optional secondary film-forming polymers include sodium alginate, propylene glycol alginate, and polyvinylpyrrolidone. Examples of optional surfactants include dioctyl sodium sulfosuccinate and polysorbate 80. Examples of optional flow aids include talc, fumed silica, bentonite, hydrogenated vegetable oils, stearines, and waxes. The aqueous film coat composition will typically comprise from about 5% to about 25%, suitably about 5% to about 20%, coating solids in the vehicle. In suitable embodiments, the solids typically comprise from about 25% to about 70%, suitably about 60% to about 70% film-forming polymer, about 5% to about 10%, suitably about 6% to about 8%, plasticizer, and about 20% to about 35% colorant, by weight. A number of suitable aqueous film coating compositions are commercially available. The aqueous film coat composition may be provided in the form of a solution or dispersion. Alternatively, the composition may be provided in a dry form that can be combined with the vehicle components according to supplier instructions prior to coating the tablet. Suitably, aqueous film coating compositions are those commercially available from Colorcon, Inc. of West Point, Pa., under the trade name OPADRY and OPADRY II (nonlimiting examples include Opadry YS-1-7706-G white, Opadry Yellow 03B92357, Opadry Blue 03B90842). These compositions are available as dry film coating compositions that can be diluted in water shortly before use. OPADRY and OPADRY II formulations comprise a cellulosic film forming polymer (e.g., HPMC and/or HPC), and may contain polydextrose, maltodextrin, a plasticizer (e.g., triacetin, polyethylene glycol), polysorbate 80, a colorant (e.g., titanium dioxide, one or more dyes or lakes), and/or other suitable film-forming polymers (e.g., acrylate-methacrylate copolymers). Suitable OPADRY or OPADRY II formulations may comprise a plasticizer and one or more of maltodextrin, and polydextrose (including but not limited to a) triacetin and polydextrose or maltodextrin or lactose, or b) polyethylene glycol and polydextrose or maltodextrin). The tablets are also suitably coated to provide a uniform coating without speckling. The tablets are typically coated to provide a dry tablet weight gain of from about 2 to about 5%, suitably about 3 to 4%. The uncoated tablet cores are coated with the aqueous film coating composition by methods well known in the art using commercially available equipment (e.g., Thomas Accela-Cota, Vector Hi-Coater, Compu-Lab 36). In general, the process usually involves rolling or tumbling the tablets in a pan, or suspending the tablets on a cushion of air (fluidized bed), and intermittently or continuously (preferably continuously) spraying a fine mist of atomized droplets of the coating composition onto the tablets, the droplets wetting, spreading and coalescing on the surface of the tablets to form an adherent and coherent film coating. The tablets are typically heated to about 40 to 50° C., suitably about 45 to 50° C., e.g., by air having a temperature of up to about 75° C., suitably about 65 to 70° C. Process of Making the Tablet Pharmaceutical tablets of the invention that are wet-granulated can be prepared by a process comprising the steps of: I) preparing the granules; which comprises the steps of: a) mixing together the dry materials comprising eltrombopag olamine, a diluent, a binder, and optionally a disintegrant for a time sufficient to homogenize the materials; b) adding a granulating fluid to the mixture of dry materials, preferably while mixing; c) mixing the granulating fluid with the mixture of dry materials for a granulating time sufficient to generally uniformly wet the dry materials, so as to form wet granules; d) wet-milling the wet granules; e) drying the wet-milled granules to form dry granules; and f) dry milling the dry granules to form granules of desired size; II) preparing the tablet; which comprises the steps of: a) mixing the granules prepared in step I) f) with external excipients comprising a filler, a lubricant and a disintegrant for a time sufficient to homogenize the granules and external excipients; and b) compressing the mixture comprising the granules and external excipients to form a tablet. Suitably, the tablets are further film-coated, especially aqueous film-coated. In preparing wet-granulated granules, the dry materials may be mixed with suitable equipment such as known in the art (e.g., Niro-Fielder Blender/Granulator, Bear Varimixer, Key High Shear Mixer/Granulator) for a time sufficient to homogenize the materials, e.g., for about 3 minutes. The granulating fluid is then added to the dry mixture, preferably while mixing. The granulating fluid is suitably water, although may alternatively be comprised of water in admixture with one or more of binders such as PVP and HPMC, from about 10 v/w % to about 30 v/w % of the granulating fluid, based on the total wet granulation mixture, is suitably used. The granulating fluid and dry materials may be mixed using suitable equipment such as known in the art (e.g., Niro-Fielder Blender/Granulator, Bear Varimixer, Key High Shear Mixer/Granulator) for a total time sufficient to generally uniformly wet the dry material so as to form wet granules, suitably for about 3 to about 15 minutes. Typically the fluid is added to the dry material with mixing over a period of about 1 to about 15 minutes, then the total batch is mixed for an additional time (post-granulating fluid-addition time), of about 0.5 minutes to about 6 minutes. In a suitable embodiment, about 10 v/w % to about 30 v/w % granulating fluid and a post-granulating fluid-addition granulating time of about 6 minutes or less is used. Suitably, about 24 v/w % granulating fluid and a post-granulating fluid-addition granulating time of less than 3 minutes is used, e.g., about 2.5 minutes. Suitably, about 16 v/w % granulating fluid and a post-granulating fluid-addition granulating time of more than 2.5 minutes is used, e.g., about 4 minutes. The wet granules are then wet-milled by methods such as are known in the art for providing a generally uniformly sized wet mass (such that the granules dry relatively evenly). Suitable wet-milling techniques may involve screening (e.g., manual screens), comminuting mills (such as a Co-mil, including but not limited to a 0.375″ screen), or extruders. The wet-milled granules are dried by methods such as are known in the art for providing generally uniform drying, to a low residual amount of granulating fluid (preferably about 0.5% to about 1.0%). Fluid bed dryers are suitable drying equipment. The dried granules are then dry-milled using known methods to provide generally uniformly sized granules (unimodal distribution), suitably having a mean particle diameter of less than 240 microns (found to provide improved content uniformity). Suitable dry-milling equipment includes Co-mils, including but not limited to having a 0.094″ screen. Suitably the granules and the dry materials of the compression mix are generally unimodal in size distribution, in order to facilitate formation of a homogeneous mix and to mitigate possible segregation of the mix after blending. If necessary, the dry materials may be pre-screened to provide the desired particle size distribution. Screening of the lubricant may be particularly useful to deagglomerate the lubricant. In preparing the compression mixture, the granules, filler, and disintegrant are mixed over a suitable period of time, about 5 to 15 minutes. Lubricant is then added and mixed for a suitable period of time, about 1 to 4 minutes. The mixture is then compressed into tablets using presses such as are known in the art (e.g., rotary tablet press). It has been found that the above granulating fluid levels, granulating times, and excipients provide improved processing. Capsules The choice of particular types and amounts of excipients, and capsulation technique employed depends on the further properties of eltrombopag olamine and the excipients, e.g., compressibility, flowability, particle size, compatibility, and density. The capsules may be prepared according to methods known in the art, suitably filling a standard two piece hard gelatin capsule with eltrombopag olamine admixed with excipients, suitably filling a standard two piece hard gelatin capsule with granules prepared according to this invention, suitably on a scale suitable for commercial production. Suitable capsules of the invention comprise granules comprising eltrombopag olamine and one or more of fillers, binders and disintegrants, wherein the granules are mixed with additional filler, binder, disintegrant and/or lubricant to form a granular mixture that is filled into capsules. Included in the present invention are pharmaceutical compositions in capsule form, suitably prepared on a commercial scale, that comprise eltrombopag olamine, wherein the capsule is made using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars. Also included in the present invention are pharmaceutical compositions that comprise eltrombopag olamine, wherein the capsule is made, suitably on a commercial scale, using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars, and about 90% of the eltrombopag olamine particles have a particle size greater than 10 micron but less than 90 micron. Also included in the present invention are pharmaceutical compositions that comprise eltrombopag olamine, wherein the capsule is made, suitably on a commercial scale, using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars, and about 90% of the eltrombopag olamine particles have a particle size greater than 10 micron but less than 90 micron, suitably greater than 20 micron but less than 50 micron. Also included in the present invention are pharmaceutical compositions that comprise eltrombopag olamine, wherein the capsule is made, suitably on a commercial scale, using a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars, and about 50% of the eltrombopag olamine particles have a particle size greater than 5 micron but less than 50 micron, suitably greater than 5 micron but less than 20 micron. The invented granules and solid oral pharmaceutical dosage forms may be administered in therapeutically effective amounts to treat or prevent a disease state, e.g., as described in the above referenced International Applications Nos. PCT/US01/16863, PCT/US03/16255 and PCT/US04/013468, the disclosures of which are herein incorporated by reference. It will be recognized by one of skill in the art that the optimal quantity and spacing of individual dosages of eltrombopag olamine formulations of the invention will be determined by the nature and extent of the condition being treated and the particular patient being treated, and that such optimums can be determined by conventional techniques. It will also be appreciated by one of skill in the art that the optimal course of treatment, i.e., the number of doses of eltrombopag olamine given per day for a defined number of days, can be ascertained by those skilled in the art using conventional course of treatment determination tests. A method of this invention of inducing TPO agonist activity in humans comprises administering to a subject in need of such activity a therapeutically effective amount of a solid oral pharmaceutical dosage form of the present invention. The invention also provides for the use of eltrombopag olamine in the manufacture of a solid oral pharmaceutical dosage form of the present invention. The invention also provides for the use of eltrombopag olamine in the manufacture of a solid oral pharmaceutical dosage form of the present invention for use in enhancing platelet production. The invention also provides for the use of eltrombopag olamine in the manufacture of a solid oral pharmaceutical dosage form of the present invention for use in treating thrombocytopenia. The invention also provides for a solid oral pharmaceutical dosage form for use as a TPO mimetic which comprises eltrombopag olamine and a pharmaceutically acceptable carrier of the present invention. The invention also provides for a solid oral pharmaceutical dosage form for use in the treatment of thrombocytopenia which comprises eltrombopag olamine and a pharmaceutically acceptable carrier of the present invention. The invention also provides for a solid oral pharmaceutical dosage form for use in enhancing platelet production which comprises eltrombopag olamine and a pharmaceutically acceptable carrier of the present invention. The invention also provides a process for preparing solid oral pharmaceutical dosage forms containing a diluent or diluents that are substantially free of coordinating metals and/or that are substantially free of reducing sugars and a therapeutically effective amount of eltrombopag olamine, which process comprises bringing eltrombopag olamine into association with the diluent or diluents. No unacceptable toxicological effects are expected when the compound of the invention is administered in accordance with the present invention. Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following Examples, therefore, are to be construed as merely illustrative and not a limitation of the scope of the present invention. All the excipients utilized herein are standard pharmaceutical grade excipients available from numerous manufacturers well known to those in the art. EXAMPLES Examples 1 to 7 Tablet Preparation Wet granulated, tablets comprising eltrombopag olamine and the ingredients in Table 1 were prepared. TABLE 1 Tablet Strength Component 12.5 mg 25 mg 25 mg 50 mg 50 mg 75 mg 100 mg Granules 40% Drug-loaded (39.9) (79.7) (79.7) (159.4) (159.4) (239.1) (318.8) eltrombopag olamine, milled 15.95 31.9 31.9 63.8 63.8 95.7 127.6 Microcrystalline cellulose 7.45 14.9 14.9 29.8 29.8 44.7 59.6 Mannitol 14.9 29.7 29.7 59.5 59.5 89.2 118.9 Povidone 1.6 3.2 3.2 6.4 6.4 9.6 12.8 Purified water — — — — Extra-granular components Microcrystalline cellulose 119.4 238.8 238.8 159.1 159.1 79.3 NA Sodium starch glycolate 14.0 28.0 28.0 28.0 28.0 28.0 27.6 Magnesium Stearate 1.75 3.5 3.5 3.5 3.5 3.5 3.5 Film-coating components Purified water — — — — Opadry ® white 8.9 14.0 14.0 14.0 Opadry Orange 14.0 Opadry Brown 14.0 Opadry Blue 14.0 Total tablet weight (mg/tablet) 183.9 364 364 364 364 364 364 Granules were prepared by separately weighing and screening mannitol, microcrystalline cellulose and povidone. As a general procedure, the ingredients were blended with the active ingredient and then wet-granulated (in a high-shear wet-granulator) with purified water. The wet-granule mass was wet-milled, then dried in a fluid-bed dryer and the dried granules were milled. Then extragranular ingredients (microcrystalline cellulose, if needed, and sodium starch glycolate) were separately weighed, screened and blended with the granules. Magnesium stearate was added and blended with the mixture. The blend was compressed and the tablet cores were then film coated. The tablets were film coated with an aqueous suspension of OPADRY film coating preparation. Example 8 Tablet Preparation Eltrombopag olamine tablets containing diluents with the coordinating metal calcium phosphate dibasic anhydrous were manufactured in a similar manner as described above. Tablet composition for the tablet coordinating metal diluent is provided in table 2. TABLE 2 Tablet Strength Component 50 mg Granules 40% Drug-loaded (159.4) eltrombopag olamine, milled 63.8 Calcium Phopshate dibasic anhydrous 89.3 Povidone 6.4 Purified water — Extra-granular components Microcrystalline cellulose 159.1 Sodium starch glycolate 28.0 Magnesium Stearate 3.5 Film-coating components Purified water — Opadry ® white 14.0 Total tablet weight (mg/tablet) 364 In FIG. 1 , the tablet prepared with no coordinating metal diluent (indicated as “with non-coordinating metal diluent”) is a eltrombopag 50 mg tablet generally prepared as described in Table 1 above and the tablet prepared with the coordinating metal diluent—Calcium Phopshate dibasic anhydrous—(indicated as “with coordinating metal diluent”) is a eltrombopag 50 mg tablet generally prepared as described in Table 2 above. Dissolution comparison was performed using USP Apparatus II, 50 rpm, in phosphate buffer pH 6.8 containing 0.5% Tween 80. Example 9 FIG. 2 depicts the effect of API particle size distribution on eltrombopag olamine dissolution. Eltrombopag olamine 75 mg tablets were generally prepared in the manner described in Example 5, using different particle sizes. The particle size refers to the particle size of the drug granules used in the formulation. Dissolution comparison was performed using USP Apparatus II, 50 rpm, in phosphate buffer pH 6.8 containing 0.5% Tween 80.
Disclosed are novel pharmaceutical compositions containing 3′-[(2Z)-[1-(3,4-dimethylphenyl)-1,5-dihydro-3-methyl-5-oxo-4H-pyrazol-4-ylidene]hydrazino]-2′-hydroxy-[1,1′-biphenyl]-3-carboxylic acid bis (monoethanolamine) (eltrombopag olamine) and processes for preparing the same.
0
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates generally to phosphorescent based materials and, more particularly, to a process and product by process for incorporating a long persistent phosphor within a settable material. [0003] 2. Description of the Prior Art [0004] Various types of phosphor materials are well known in the art and which provide varying degrees of persistent luminescence. A common objective of phosphor materials is to provide an application for a luminescent light source which takes advantage of intermittent light irradiation and/or the absence of irradiating light on a continuous basis. [0005] While the existence of phosphor materials such as above is fairly well known in the art, the recent trend has been to identify useful applications of persistent phosphor which will enable the production of production of sufficient light illumination following an iterative period of light irradiation. SUMMARY OF THE INVENTION [0006] A process for incorporating a long persistent phosphor within a settable material includes firing a doped phosphor to obtain a phosphor having a persistence that ranges from minutes to hours. The fired phosphor is then ground into a phosphor particulate having a mean domain size. The phosphor particulate is thereafter encapsulated within a water impervious coating material. The coated phosphor particulate is then mixed in a specified volume ratio within the settable material while the settable material is in a pre-set state. [0007] A phosphorescent settable formulation includes 0.1 to 30 volume percent of a long persistent doped sulfide phosphor particulate having a mean particle domain size of between 1 and 60 microns. The particulate has a water impervious silicon oxide or fluoride coating thereover A settable material carrier is provided for the particulate. [0008] A method of forming a phosphorescent solid is also provided based upon setting of an inventive formulation. BRIEF DESCRIPTION OF THE DRAWINGS [0009] Reference will now be made to the attached illustration, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which: [0010] [0010]FIG. 1 is a schematic of the production of a settable host material incorporating the long persistent phosphor according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0011] The present invention is a process, as well as a product produced by a process, for incorporating a long persistent phosphor within a settable host material. A significant number of different settable materials are capable of being utilized as carriers for the phosphorescent material and such settable materials are defined as constituted by a flowable liquid or semi-cured or semi-soft solid of some established viscosity. Without limitation, settable materials include gels, acrylic resins, epoxy resins, urethanes, polyalkylene resins polymeric monomers and oligomers, crosslinkable polymers, rubbers, and silicone resins. Other types of settable materials may include VOC polymer solutions, concrete, inks, paint formulations such as enamels, oil based, water based, latexes; water glass, caulk, putty, glues and adhesives, varnishes, plaster, nail polish, and lacquers. It is appreciated that the settable carrier materials of the present invention are amenable to the addition of optional additives illustratively including catalysts, fillers, plasticizers, solvent, thickeners, and pigments. [0012] The long persistent phosphorescent material is constituted by any of a number of various chemical compositions as are known in the art. As used herein “long persistence” is defined to mean a phosphorescence lifetime greater than 1 minute. The phosphor is typically provided as a powderized or granulate material and, in one instance, may include a lime green phosphor produced under the commercial name Nemoto Luminova and consisting of a strontium aluminate material. Additional Luminova colors include blue and which is constituted by a recipe of a Calcium Strontium Aluminate, and which is doped with Europium. [0013] Other phosphors may specifically include a strontium sulfide material which is fired in an inert crucible at a selected elevated temperature and for a determined time period. To achieve the desired level of long persistence as well as a given color, a dopant is added to the phosphor. While dopant precursors are typically slurried with phosphor precursors prior to firing, it is appreciated that dopants are also intercalated into a phosphor through exposing a fired phosphor to a dopant. Post firing dopant addition illustratively occurs through solution surface coating or ion implantation. Experimentation of different dopants has determined that a Europium dopant will achieve a persistent phosphor having an orange/red color. Dopants are typically present from 0.1 to 5 atomic percent. Often it is desirous to include a second dopant to enhance persistence lifetimes or modify phosphor color. As is also well known in the art, additional types of dopants may include alumina, lanthanide oxides, fluorides and chlorides and are capable of yielding persistent phosphors having pale yellow and purple shades. Further, the use of varying percentages of Calcium with Strontium Sulfide will achieve additional color shades leading to a purer red color. [0014] Following the crucible firing of the doped phosphor, the persistent phosphor composition is dried and is retrieved in a rock-like form. A subsequent crushing and grinding operation reduces the particle domain size to a preferred range of 1 to 60 microns. More preferably, the particle mean domain size is from 1 to 45 microns. Certain paint or solvent based applications require particular sizes to be reduced to, in some instances, down to 1 micron in size. Prior to introducing the phosphorescent particles into a host material, it is desirable to coat or encapsulate them so as to ensure its long term performance. It has been found that moisture, over time, tends to degrade the ability of the phosphor to maintain its long-term performance. [0015] Accordingly, one or more types of encapsulation techniques are employed to coat the individual phosphor granulates. A first type of encapsulation is provided by a silicon oxide applied during a firing temperature of 800° C. A fluoride material may be applied contemporaneously with or separately from the silicon oxide. Typically, a firing temperature of approximately 700° C. is best suited for application of fluoride. Other encapsulation techniques may employ organic chlorosilanes in hexane or heptane solvents. The process steps in which the encapsulation of the material is accomplished typically includes mixing the coating powder with the substrate powder in an appropriate ratio, firing the mixed powder at the prescribed temperature for a defined time, washing the fired powder to remove the uncoated portion of the core powder, and drying the washed powder. Additional encapsulation techniques are illustratively detailed in U.S. Pat. Nos. 4,710,674; 5,049,408; 5,196,229; 5,118,529; 5,113,118 and 5,220,341. [0016] With reference again to the list of settable materials previously recited, as well as to FIG. 1, the encapsulated phosphor particulate is illustrated at 10 . The encapsulated long persistent phosphor is mixed during the manufacture stage of the settable host material 20 at a desired ratio by weight. Although not clearly illustrated in FIG. 1, it is desirable to congregate the phosphorescent material towards the surface layers of some settable host materials. The effect of this is to reduce the volume of the fairly expensive to produce phosphor which is needed to provide the desired illuminating effect. Consistent with this goal, it is further desirable that the phosphor granulate possess isopycnic characteristics so that they are capable of being suspended within the host material. Accordingly, the phosphorescent particulate is incorporated into the host material during its fluidic or semi-fluidic states. Encapsulation of the phosphor particulates permits them to maintain their long persistent and rechargeable characteristics during the setting stage of the host material, as well as during subsequent use and exposure to the environment. The settable material 20 upon application of the encapsulated particulate 10 results in a solution or suspension 30 suitable for application to a variety of substrates. It is appreciated that a settable material suspension or solution 30 according to the present invention is operative with other settable materials, suspensions or solutions containing encapsulated particulate applied in a step-wise fashion. Thus, by way of example, a base coating applied to a substrate is devoid or deficient in encapsulated phosphor relative to a subsequently applied top coat, thereby enhancing the phosphorescence per unit area of substrate for a given quantity of encapsulated phosphor. [0017] In a first application the encapsulated phosphorescent powder is incorporated within a host material such as a nail polish formulation. As was previously described, it is desirous to vary the percentage by weight of the phosphor powder relative to that of the host material and, in the instance of a clear nail polish, 1 to 30% by volume phosphor in the formulation is operative, with a mixture of 15% by volume of phosphor within the vial of nail polish has been found to be optimal for forming a long persistent and rechargeable application. Tests on selected phosphors have yielded several uninterrupted hours of long persistent glow. [0018] A further application of a long persistent phosphor involves mixing within a wax candle so as to provide a soft long persistent glow. Recharging of the phosphor is continuously maintained by the effect of the lit flaming end. Phosphors are typically present from 0.1 to 20% by volume in a candle wax according to the present invention. [0019] A yet further application involves an encapsulated long persistent phosphor incorporated into a ceramic/silicate material such as a brick paver or specialty cement. In the preferred embodiment, the phosphor is added into the top one inch of the cementitious mixture during its semi-solid or slurry stage at typically between 0.1 and 20 volume percent. This permits the phosphor to intermix freely with the top surface layers of the paver blocks and, as previously discussed, thereby diminishing the need of incorporating a greater volume by weight of phosphor throughout the entire thicknesses of the pavers, including portions or surfaces which are never exposed in use. In an alternative variant, a settable paint material can be employed to sufficiently coat the surface of the paver bricks. [0020] Any patents mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These patents are herein incorporated by reference to the same extent as if each individual patent was specifically and individually incorporated by reference. [0021] Having described our invention, it will become apparent that it teaches a novel and useful process and product by process for incorporating a long persistent phosphor, such as in a particulate form, within a settable host material. Many and numerous additional embodiments will become apparent to those skilled in the art to which it pertains without deviating from the scope of the appended claims.
A process for incorporating a long persistent phosphor within a settable material includes firing a doped phosphor to obtain a phosphor having a persistence that ranges from minutes to hours. The fired phosphor is then ground into a phosphor particulate having a mean domain size. Typical particulate mean domain size ranges from 1 to 60 microns. The phosphor particulate is thereafter encapsulated within a water impervious coating material such as silicon oxide or fluoride. The coated phosphor particulate is then mixed in a specified volume ratio within the settable material while the settable material is in a pre-set state. Typical formulation ratios range from 0.1 to 30 volume percent of particulate. A method of forming a phosphorescent solid article is also disclosed.
2
BACKGROUND OF THE INVENTION This invention relates to rail changing machines and, more particularly to such machines incorporating means for lifting tie plates and means for positioning tie plates after the ties have been prepared. In rail changing techniques existing to date for lifting old rails from a track, after unspiking, preparing the old ties and laying new rails on the old ties various different operations with different machines have been necessary. One reason for this is that, before the old ties can be prepared it is necessary to remove the tie plates which may be recycled to a tie plate positioning means or it may even be necessary, in the case of laying larger rails, to replace the old tie plates with new tie plates. No satisfactory mechanism or device for handling adequately such tie plates from and including pick-up, conveying to dropping of the tie plates back on the prepared ties. SUMMARY OF THE INVENTION It is an object of the present invention to provide in a rail changing machine such tie plate handling means. According to one aspect of the invention there is provided a rail changing machine having means for removing rails from a track, means for lifting the tie plates from the old ties, means for preparing the old ties, means for relaying tie plates on the prepared ties and means for laying new rails in the relaid tie plates, wherein the means for lifting the tie plates comprises at each rail location a first magnetic wheel rotatably mounted on a lateral axis and also mounted for generally vertical movement, means for moving the first magnetic wheel vertically downward for its engagement by its periphery with a tie plate on a tie and vertically upwards for raising the subsequently adhered tie plate off the tie, means for rotating stepwise the first magnetic wheel in the raised position to index a vacant space on the wheel periphery to a downward facing location of the wheel, means for removing from the top of the magnetic wheel tie plates adhered thereto, and means for conveying the removed tie plates to a desired location. Preferably, the machine includes at each rail a second magnetic wheel aligned longitudinally with the first magnetic wheel and also rotatably mounted on a lateral axis, means for driving the second magnetic wheel at a predetermined speed in the opposite direction to rotation of the first wheel, a conveyor extending between the top of the first magnetic wheel and the bottom of the second magnetic wheel, means for driving the conveyor at a speed corresponding to the peripheral speed of the second wheel whereby tie plates removed from the first wheel upside down are conveyed to the second wheel to which they adhere, and means for removing tie plates from the top of the second wheel rightside up. According to another aspect of the invention there is provided a rail changing machine having means for removing rails from a track, means for lifting the tie plates from the old ties, means for preparing the old ties, means for relaying tie plates on the prepared ties and means for laying new rails in the relaid tie plates, wherein the means for relaying tie plates on the prepared ties comprises an electromagnetic holder adapted to receive tie plates from a conveyor in the correct orientation, the electromagnetic holder being movable from a raised position for reception of a tie plate to a lowered position for dropping the tie plate on a tie. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described in greater detail with reference to the accompanying drawings in which: FIGS. 1A and 1B together constitute a schematic view of a rail changing machine incorporating novel tie plate pick up means, adzers and tie plate drop means; FIG. 2 is a side view of a tie plate lifting device incorporated in the machine of FIGS. 1A and 1B; FIG. 2a is a fragmentary perspective view of the periphery of a magnetic wheel forming part of the tie plate lifting device; FIG. 2b is a plan view showing an arrangement for matching lateral movement of part of the lifting device with a conveyor which is fixed laterally; FIG. 3 is a side view of a tie plate dropping device incorporated in the machine of FIGS. 1A and 1B; FIG. 4 is a view similar to FIG. 3 but showing more detail of the tie plate dropping device; FIG. 5 is a plan view of a guide arrangement for orienting the tie plates properly for reception in the tie plate holder; FIG. 6 is a plan view of the tie plate dropping device of FIG. 3, portions being omitted for clarity; and FIG. 7 is a block diagram of a digital distance measuring device for dropping the tie plates at the proper location on the ties. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIGS. 1A and 1B, the center beam or main frame 10 of a rail changing machine R is shown connected to the beam 11 of a leading powered car 12 and to the beam 13 of a trailing car 14. The old rails 20 of the old track are shown being picked up by rollers 21 of the old conventional rail removing means and these rails are then spread by spreaders (not shown) and deposited on the shoulders of the track in known manner. New rails 24 have previously been deposited on the shoulders of the track adjacent the existing rails 20 and new rail rollers 25 of a new rail laying means controlled by an operator pick up and lay the new rail, as is known. Between the old rail moving means and the new rail moving means are positioned a series of track working instruments each mounted on a respective work frame. These instruments comprise, in turn, a magnetic pick-up means 36 for the tie plates left after lifting and spreading of the old rails, crib sweeping means 38 mounted in front of an adzer 40 and tie plate dropping means 42. A hole plugging station 46 is provided between the tie plate pick-up 36 and the crib sweeper 38 and a creosoting station 48 is preferably provided after adzer. A lining device 50, line spiker 52, gauger 54 and gauge spiker 56 complete the work stations. In operation, the tie plate pick-up means 36 picks up the old tie plates left after lifting and spreading of the old rails, it being understood that the spikes securing the old rails to the ties would have been removed as a preliminary step, as is known. As the machine advances, a human operator in the hole plugging station injects a polyurethane foam into the old spike holes. The cribber 38 then sweeps a path in front of the adzer 40 to remove ballast and other debris from the line of the adzer which proceeds to adze the ties at the tie plate locations at each rail to provide flat beds of increased size in the upper surface of the tie which are capable of receiving new or recycled tie plates of increased size. The creosoter 68 then supplies creosote to the adzed surfaces of the tie and the new or recycled tie plates are dropped onto the prepared ties by tie dropper 42 after which lining of the track, line spiking, gauging and gauge spiking are carried out. Each of the various track working instruments does, of course, have means for operating simultaneously at the right and left rail locations. For example, the adzer comprises two adzer devices both mounted on a single frame and the crib sweeper comprises two spaced brushes mounted on the frame. The pairs of devices at each work station are mounted on the respective frames at a distance apart corresponding to the track gauge and the frames are laterally movable conjointly in response to signals from a center line follower, which detects the track center line, so as to maintain the devices situated over the appropriate rail locations even on curved sections of track. Referring now to FIG. 2, the device 36 for picking up old tie plates 90 from the ties comprises a first magnetic wheel 92 arranged to engage at its periphery the tie plates and rotate them counterclockwise on to a conveyor 94 along which they are conveyed to a second magnetic wheel 96 which transfers the tie plates clockwise to a conveyor 98 which conveys the tie plates ultimately to a trailing gondola car (not shown) or to a tie plate dropping mechanism which will be described below in detail. It should be understood that the above arrangement is duplicated for left and right rails so that there is a pair of such wheels aligned over each rail or, more accurately, each rail location as the old rails 20 have been lifted and moved off the tie plates at the position of the tie plate pick-up device. Each wheel 92 or 96 is essentially non-magnetizable aluminum except for the periphery which is steel. As best seen in FIG. 2a, the periphery is formed with two equally radially extending continuous steel flanges 100 magnetically interconnected by a steel band 102 which extends around the entire periphery in the recess between the two flanges 100. Small permanent magnets (not shown) are mounted around the periphery of the wheel immediately under and magnetically engaged with the steel band 102. Wheels 92 and 96 are rotatably mounted on transverse axes, wheel 92 being located behind, in the direction of travel of the rail changing machine, the other wheel and being disposed lower than wheel 96. A pair of such wheels is located, respectively, over each rail. Both pairs of wheels are carried on a frame 104 which is mounted for lateral movement on the main frame 10 of the rail changing machine. To this end, the main frame 10 carries an I-beam 106 welded to the underside of main frame 10 and extending transversely thereof, and main frame 10 carries another I-beam 108 welded to a support member 110, in turn welded to the underside of the main frame. I-beam 106 is disposed with its web vertical and I-beam 108 with its web horizontal. Frame 104 includes two spaced longitudinally extending beams 112, one of which can be seen in the drawing, interconnected at their ends by transverse members 114 to form a rectangular subframe 105. Upstanding from the forward ends of beams 112 are vertical beams 116 the tops of which are interconnected by a flat transverse member 118. Two rows of rollers 120 are rotatably mounted in journal members 122 secured to the top of member 118 by bolts or other fastening means at both end portions of member 118. The rollers 120 are received on both sides of the web of I-beam 106 and run on flanges of the I-beam. Near the trailing end of sub-frame 105 are two spaced depending members 124 interconnected by a transverse member 126 carrying along the trailing side thereof a row of rollers 128 which run along the upper surface of the web of I-beam 108. A hydraulic cylinder 129 connected, for example, between members 110 and 124 is operable to move frame 104 laterally, the two sets of rollers running along the respective I-beams. The front wheel 96 of each pair is journalled between a respective one of the longitudinal beams 122 and a similar parallel beam (not shown) of the frame 104, the axes of rotation 130 being approximately mid-way along the beams 112. Frame 104 incorporates also two separate L-shaped sub-frames 132, one at each rail location, which carry, respectively, the second wheels 92 of the two pairs. Each sub-frame 132 comprises two laterally spaced approximately vertical beams 134 each pivotably connected near its upper end to a respective one of longitudinal beams 112 by means of a pivot pin 136 protruding laterally outwardly from beam 112 at the rotation axis 130 of wheel 96. The two laterally spaced approximately horizontal members 138 form the other arm of the L-shaped sub-frame, members 138 being secured at their one end by welding to the generally vertical members 134. Horizontal members 138 are secured to each other at the forward end by a transverse beam 137. A pneumatic cylinder 140 is connected between each sub-frame 132 and the corresponding sub-frame 105 near the trailing end of the latter for raising and lowering sub-frame 132 by pivoting it about pin 136. A centre-line follower 142 is supported intermediate the pair of wheels 92 and 96 on the right hand side of the machine and the pair on the left hand side by means of a sub-frame 144 which is mounted forward of wheels 96 to the forward transverse member 114 which joins longitudinal beams 112. Sub-frame 144 is equidistant from beams 112 and the centre-line follower 142 is pivotally connected to the bottom portion 146 of sub-frame 144. Specifically, two links 148 of the centre line follower are mounted at their upper ends to pivot pins 150, the lower ends of links 148 being pivotally mounted to the body 152 of centre-line follower 142 by means of pivot pins 154. The body 152 of the centre line follower is adapted to run along the track in engagement with the upper surfaces of the ties as shown and move to right or left as it engages a line of nails 156 which have previously been driven into the ties to mark the centre line of the track. For a more detailed description of the construction of the centre-line follower reference may be made to co-pending application Ser. No. 951,131 of Raymond Ralph Lund filed on even date and entitled Center Line Follower. The centre-line follower is so constructed to derive a signal to control the cylinder 129 via a solenoid valve (not shown) so that the frame 104 is moved to the right or left to follow the centre line of the track thus to accommodate curves on the track. By this means tie plate pick-up wheel 92 may be kept essentially at a constant distance from the track centre line. The reason that this is so important is that the wheel is designed to engage the central flat portion of the upper surface of the tie plates and if the wheel is greatly off the tie plate centre line it will not make good contact with the tie plates which may not adhere to the wheel. The lower wheel 92 is mounted between the trailing end portions of the laterally spaced approximately horizontal members 138. Specifically, the wheel 92 is journalled between two brackets 160 mounted, respectively, to the trailing end portions of members 138. A bracket 162 mounted on one of horizontal members 138 supports a constant torque hydraulic motor 164 driving a sprocket 166. A chain 168 drivingly connects sprocket 166 to a sprocket 170 which is rigidly connected to wheel 92. Sprocket 170 carries a centrally mounted dog plate 172 which is formed with a plurality of dogs 174 defined by peripheral recesses 176. A hydraulic cylinder 178 is also mounted on outer bracket 160 and this is arranged so that the piston (not shown) thereof extends through a hole (not shown) in bracket 160 and into registry with the recesses and pawls of plate 172. Engagement of a dog 174 with the piston prevents rotation of the wheel 92 but when the cylinder 178 is powered momentarily, the piston retracts permitting rotation of wheel 92 counter-clockwise, as seen in the drawings, under the driving action of the hydraulic motor 164. As energization of the cylinder 178 is only momentary, the piston is immediately received in the succeeding recess and engages the succeeding dog to stall motor 164 until the cylinder 178 is energized again. Thus, the wheel can be rotated in step-wise fashion, i.e. indexed, by energizing the cylinder. Energization of cylinder 178 is controlled by a limit switch 180 mounted on one of the longitudinal beams 112 of sub-frame 105 near the pivot 130 for actuation by the adjacent approximately vertical member 134 when member 134 has pivoted away from switch 180 by a predetermined distance. This distance corresponds to a predetermined height, e.g. 3 inches, by which the wheel 92 has been raised off the tie surface. Pneumatic cylinder 140 which, as briefly described above, is connected between each sub-frame 132 and corresponding sub-frame 105, will now be described in more detail. The interconnections between, the piston rod 182 and sub-frame 132 is made via a housing 184 rigidly secured to sub-frame 105 and having a hole 186 in its top wall 187 through which hole the piston rod free end portion is slidably received. The free end 188 of piston rod 182 is formed with an increased diameter which, because it is wider than hole 186, is prevented from rising clear of the housing 184. A limit switch 190 is secured inside housing 184 such that when piston end 188 is in abutment with top 187, piston end 188 is clear of switch 190 and when piston end 188 moves downwardly relative to top 187, piston end 188 actuates the limit switch 190. The cylinder 140 is normally in the retracted position but piston rod 182 may be extended under command from a manually operable "start" button and solenoid valve (not shown). Limit switch 190 controls via the solenoid valve retraction of piston rod 182 when the limit switch is activated. The design of the interconnection described above is such that when piston rod 182 is extended when desired by the operator, the weight of the sub-frame 132, wheel 92 and other components mounted on sub-frame 132 is sufficient to tend to permit housing 184 to drop faster than piston 182 is extending, thus keeping piston end 188 in abutment with housing top 187, i.e. clear of switch 190. The sub-frame 132 does, of course, pivot about axis 130 at a speed determined by the rate of extension of piston rod 182. When wheel 92 abuts against a tie plate 90 on one of the ties, further downward movement of housing 184 is prevented and piston rod 182 continues to extend until piston end 188 engages and actuates limit switch 190 causing retraction of piston rod 182 to pivot sub-frame 132 and wheel 92 upwardly. As indicated above, after a predetermined upward travel, say 3 inches, the limit switch 180 is actuated. This cuts off further fluid to the cylinder 140 to retain it in the up position. Limit switch 180 also controls through a solenoid valve (not shown) the operation of hydraulic cylinder 178 such that, when switch 180 is actuated after the 3 inch upward movement of wheel 10, the piston thereof is retracted momentarily allowing the wheel 92 to be indexed the angular distance between two consecutive dogs 174 under the action of hydraulic motor 164. The reason for raising wheel 92 is to permit the tie plate 90 which had become adhered to the periphery of wheel 92 to be rotated on wheel 92 without interference between the tie plate and the tie on which it was lying. The angular distance indexed is sufficiently great to ensure that each adhered tie plate is rotated away from the bottom position so that the successive tie plate may be adhered to the wheel 92 as the machine advances to the next tie plate. Conveyor 94 is supported on the sub-frame 132 and is simply an endless belt 200 mounted on sprockets 202 rotatably mounted between vertical side plates 204. A motor (not shown) also housed between plates 204 drives the belt through one of the sprockets 202 at a constant speed which is matched to the rotational speed of the wheel 96 so that there is essentially zero relative motion between the magnetized periphery of wheel 96 and belt 200 which assists in ensuring good transfer from belt 200 of the tie plates. The drive means for wheel 96 is similar to that for wheel 92 except that there is no indexing mechanism. Thus, motor 206 mounted on a longitudinal beam 112 drives continuously sprocket 208, chain 210 and sprocket 212 mounted on wheel 96. The means for removing the tie plates adhered to wheels 92 and 96 is essentially the same for both wheels and comprises, in the case of wheel 92, a sloping chute 214 recessed at its trailing edge 216 which is positioned at the top centre position of the wheel by means of support legs 218 mounted on beams 138 such that the magnetized wheel periphery passes through the recess as the wheel rotates. The slope and curvature of the chute is arranged such that when a tie plate adhered to the wheel passes just beyond top centre it is engaged by the chute which scrapes off the tie plate which then falls under gravity on to the corresponding conveyor. Chute 214' for wheel 96 is similarly arranged on support legs 218' mounted on beams 112. Because wheels 92 and 96 are movable with frame 105 laterally inwardly and outwardly in response to the action of the centre-line follower 142 as described above it should be apparent that the delivery end 220 of chute 214' will also move inwardly or outwardly by an amount dependent on the degree of curvature of the track. However, the conveyor 98 which conveys the tie plates back to the gondola car or to the tie plate dropping means is mounted to the main frame 10 of the machine by means of rigid connecting members, such as member 222 and this conveyor cannot be moved laterally. Accordingly, it is necessary to provide between delivery end 220 of chute 214' and the input end 224 of conveyor 98 (which is conveniently an endless belt or series of endless belts mounted and driven in a manner similar to that of conveyor 94 described above) means for matching laterally movable end 220 to fixed end 224. This matching means comprises two small conveyors 226 (See particularly FIG. 2b) disposed one on each side of a central conveyor 228, the upper surfaces of these conveyors being coplanar with that of lower portion of chute 214'. Central conveyor 228 is a low-friction non-driven roller conveyor, the rotational axes of the rollers being perpendicular to the slope direction of the chute 214'. Conveyors 226 are continuous belt conveyors, the belts of which are driven with their upper stretches moving towards conveyor 228 as indicated by the arrows in FIG. 2b. Completing the matching means is a short chute 230 disposed at the lower, i.e. output side of conveyor 228. The whole arrangement of conveyors 226 and 228 and chute 230 may be connected together as one assembly and mounted to the main frame 10 by means of a rigid member such as vertical beam 232 such that the output end 234 of chute 230 is aligned laterally with conveyor 98. It should be readily appreciated that as delivery end 220 of chute 214' moves laterally tie plates will be delivered to one side or other of roller conveyor 228 either completely or partly overlying one or other of conveyors 226. The action of conveyors 226 is to return off centre tie plates to the roller conveyor 228 where they will roll under gravity onto fixed chute 230 and subsequently onto fixed conveyor 98. The complete operating sequence of the tie-plate lifting device described above is summarized as follows: 1. The operator, who would normally be seated at a location just behind the tie-plate lifting device operates the "start" button when the wheel 92 is over a tie-plate 90. 2. This causes wheel 92 to drop into engagement with the upper surface of the tie-plate which becomes adhered to the wheel. 3. Actuation of limit switch 190 causes raising of wheel 92 to a position at which limit switch 180 is activated. 4. Activation of limit switch 180 stops upward travel of wheel 92 and indexing of wheel 92 to rotate the adhered tie plate out of the bottom centre position. 5. The wheel is retained in that position until the wheel is positioned over the next tie and tie plate at which the operator pushes the "start" button to repeat the cycle. Every time wheel 92 is indexed the leading tie plate on that wheel is scraped off by chute 214 and delivered upside down on to conveyor 94. The plates on conveyor 94 are consecutively engaged on their undersides by wheel 96 from which they are scraped off by chute 214 as they reach the top position. The plates then slide down chute 214' right side up and on to conveyor 98 via the conveyor matching means. While the above operations are taking place frame 105 is continuously tracking to right and left as necessary to follow the centre line to position wheel 92 at the correct location. Old tie plates picked up by the pick-up device described above are fed by conveyor 98 back along the rail changing machine as best seen in FIG. 1. The conveyor 98 continues all the way back to the gondola car where they may be stored or dumped off at the side of the track. However, the old tie plates can be recycled by means of a gate 240 which selectively connects conveyor 98 with a forwardly running conveyor 242 which feeds the tie plates down a chute 248 to the tie plate drop device 42. The conveyor 242 extends all the way back also to the gondola car where new tie plates, for example larger tie plates if larger rail is being laid, can be loaded on instead of recycling the old tie plates. For that case, gate 240 would be pivoted to the up position. This is a device for receiving tie-plates, either new or recycled from conveyor 242' and automatically positioning and guiding these tie plates so that each tie plate drops at the correct location on the newly adzed portion of the respective tie. There are three main aspects of positioning which are important. The first is that the tie plates must be correctly spaced laterally with respect to the track centre line and the second is that the tie plates must be dropped at the correct longitudinal location to ensure that the tie plates are placed centrally with respect to the tie width, i.e. so that tie plates do not overhand or miss altogether the ties. The third aspect of positioning is that the tie plates should not be skewed relative to the rail axis so that the rails will fit into the tie plates. Referring to FIG. 3, the tie plate drop device 42 comprises a chute 248 extending from the delivery end of conveyor 242 down into a tie plate holding device 250 which protrudes through the open bottom of housing or frame 252 which is integral with chute 248. Extending across the top of frame 252 is a beam 254 (see FIG. 4) which is connected to the main frame 10 of the rail changing machine by means of a pneumatic cylinder 256 mounted on pivot pins 258 and 260. The combined chute 248 and frame 252 assembly 246 is pivotally mounted to main frame 10 at the trailing end of chute 248 by means of a pivot pin 261. Thus, extension or retraction of cylinder 256 causes pivoting of frame 252 about pin 261. Associated with the tie plate holding device 250 is a referencing device 264 which is also mounted on frame 252 for lateral movement on rods 266 and also protrudes below the frame 252. Referencing device 264 ends on a skid 268 which runs on the adzed ties and is sufficiently long to bridge two consecutive ties. Extending inwardly of skid 268 is a rigid member 270 which carries a centre line follower (not shown) which is identical to the centre line follower 142 of the plate pick-up device. Referencing device 264 is movable laterally along its guide rods 266 by means of two parallel spaced double linkages 271 each comprising a first member 272 having, a through hole at its lower end which hole pivotally and slidably receives the upper guide rod 266 and a second member 274 pivotally joined to the first member at the upper end of the first member by means of a pivot pin 276. The lower end of member 274 is pivotally joined to a transverse slide member 278 by means of a pivot pin 280. Because of the parallel arrangement of the double linkages, the one pivot pin 276 is used for both linkages as is pivot pin 280. A strengthening sleeve 282 extends laterally and around pivot pin 276 between the two linkages and a similar sleeve 284 receiving pivot pin 280 extends between the two linkages. Slide member 278 is rectangular and is received slidably on a rectangular cross beam 286 which is supported on a vertical beam 288 welded to the main frame 10 of the rail changing machine. A pneumatic cylinder 290 is connected between vertical beam 288 and slide member 278 for moving slide member 278 and the double linkage laterally inwardly and outwardly. The centre line follower is arranged to control operation of cylinder 290 in the same way that the centre line follower 142 of the tie plate pick-up device controls operation of cylinder 129. The plate drop device will now be described in greater detail with reference to FIG. 4 and FIG. 5. Chute 248 has two side walls 292 and a slide surface 294. Extending parallel with the side walls 292 are two spaced guide members 296 which are supported above slide surface 294 by rods 298 extending between guide members 296. Any suitable fastening means may be used to fasten guide members 296 at any selected lateral position and spacing. For example nuts 300 with threaded portions on the rods 298 may be used. Also, rods 298 may be arranged in slots in side walls 292 to permit the spacing of guide members 296 with respect to the slide surface 294 to be varied. Guide members are bent towards each other at top and bottom portions 302 and 304. The purpose of chute 248 is to convey in approximately the correct orientation and lateral positioning tie plates 90 from conveyor 242 to tie plate holding device 250. As a tie plate slides from conveyor 242 right side up onto chute 248, the guide members 296 are received in the central recess 306 of the tie plate, portions 302 at the top of the guide members serving to guide the tie plate onto the guide members. It will be appreciated that the height and spacing of guide members 296 is previously chosen to match the type of tie plate. Referring now to FIG. 4, it can be seen that the slide surface 294 extends downwardly beyond the side walls 292 and guide members 296, the end of slide surface 294 being referenced 308. However, this slide surface is effectively extended to point 310 by means of a plate 312 slidably supported under the lower end of chute 248 and movable parallel to slide surface 294 by means of a pneumatic cylinder 314 connected between bracket 316 of plate 312 and bracket 318 connected under chute 248. Located between the lower ends of guide members 296 and tie plate holder 250 is a device 260 for indexing the tie plates to the holder 250. This device comprises a gate 322 pivotally mounted at its upper end by means of a pin 324 to brackets 326 mounted to a plate 328 extending across chute 248. At an end remote from pivot pin 324, gate 322 is formed with a finger 330 engageable with the slide surface 294 adjacent end 308. Gate 322 is formed of two identical spaced plates between which is disposed a pneumatic cylinder 340. Cylinder 340 is pivotally mounted at its one end at a pivot pin 342 extending between the spaced plates and is pivotally mounted at its other end to a foot member 344 having a surface 346 which is gently curved and positioned to engage tie plates 90 disposed on slide surface 294. Extension of cylinder 340 causes foot 344 to be urged hard against the tie plate 90 immediately following that retained by finger 330, and to pivot gate 322 clockwise (as seen in FIG. 4) about pivot pin 324, upward rotation being limited by abutment of gate 322 against a stop 348. Such pivoting frees finger 330 from the leading tie plate thus permitting the leading tie plate to slide further down surface 294 and plate 312 into the plate holder 250. Because of the force exerted by foot 344, the next tie plate is prevented from sliding. When cylinder 340 is retracted subsequently, finger 330 is rotated to assume its original position and, because the force exerted by foot 344 has now been removed, the next tie plate is free to slide down to be retained by finger 330 and another tie plate takes its place under foot 344. Extension and retraction of cylinder 340 are brought about by means of a manually operable "start" button (not shown). The plate holder 250 comprises a housing 350 supported for sliding movement on rods 262. Housing 350 has two spaced side walls between which is mounted a pivot pin 352 located at the bottom of housing 350 and pivotally supporting a lower end of an electromagnet 354. The electromagnet 354 is retained upwardly inclined at an approximately 45° angle with respect to the horizontal by means of a pneumatic cylinder 356 which is disposed generally vertically in housing 350. Cylinder 356 is pivotally mounted at its upper end to housing 350 and at its lower end to electromagnet 354. Thus, extension of cylinder 356 rotates electromagnet clockwise to a downwardly inclined position. Operation of cylinder 356 is under control of a proximity switch 358 on slide retraction cylinder 314 so that pivoting of electromagnet 354 to its down position can only occur after retraction of slide 312. Electromagnet 354 has an elongate recess 360 which extends from the upper end thereof and defines a space into which the leading tie plate will slide when released by gate 322. The lower end of the recess is formed as a stop surface 362. A limit switch 364 is mounted in stop surface 362 and this is operable to extend a gauge cylinder (not shown) which is mounted in recess 360 and extends laterally thereof. When the gauge cylinder is extended it engages the side of a tie plate in recess 360 and urges it laterally against a stop (not shown) which stop is accurately referenced to the means described below for moving electromagnet 354 laterally to the position at which the tie plate has to be dropped. Referring now to FIG. 6, tie plate holder 250 is shown supported on rods 262 for sliding movement relative to frame 252. A pneumatic cylinder 365 is connected between one vertical wall of frame 252 and housing 350 of plate holder 250 for moving tie plate holder 250 laterally outwardly. A stop 366 adjustably mounted on the inner wall of frame 252 determines the inner limit of travel of the plate holder 250. Referencing device 264 is also shown in FIG. 6. This can be seen to be sandwiched between the double linkages 271 which as indicated previously are laterally movable by cylinder 290 under control of a centre line follower. A stop 368 is adjustably mounted at a laterally outer location of referencing device 254, the stop 368 being disposed in the line of travel of the plate holder 250 and, accordingly, defining the lateral outward limit of travel of tie plate holder 250. Both stops 366 and 368 may conventionally be threaded members which can be adjusted in lateral position simply by turning. It should be understood that referencing device 264 is moved laterally as the centre line follower tracks laterally and that the stop 366 is used as the varying reference for determining the required lateral position of a tie plate. The magnetic tie-plate holder 250 is pushed laterally outwards by its cylinder 365 until it abuts stop 366 at which point the tie plate holder 250 will be at the correct lateral position. The complete operating sequence of the tie plate dropping device described thus far will now be summarized, it being understood that cylinder 256 has been extended so that skid 268 is in engagement with the ties of the track. 1. On operation by an operator of the "start" button, gate 322 is released and the leading tie plate is indexed into the electromagnet recess. 2. The tie plate actuates the limit switch 364 in the recess which causes extension of the gauge cylinder to push the tie plate laterally hard up against the reference stop in the recess. Activation of this limit switch also starts an electronic timer. 3. After timing out of the timer the electromagnet 354 is energized and the slide 312 is simultaneously withdrawn leaving the tie plate adhered to the electromagnet. 4. When slide 312 has been fully withdrawn, proximity switch 358 is activated and this causes extension of cylinder 356 and pivoting of electromagnet and tie plate down into engagement with the tie. 5. At the same time as electromagnet 354 is energized, cylinder 365 (FIG. 6) is extended due to timing out of the timer and this causes electromagnet 354 and the adhered tie plate to move laterally away from the chute 248 until housing 350 engages stop 368 of referencing device 254. 6. Referencing device has, independently of the above operations, been tracking right or left in response to the centre line follower. The tie plate is now in the correct orientation and correct lateral distance to be dropped onto the prepared tie. However, it still remains to ensure that the tie plate is dropped in the correct longitudinal location so that the tie plate does not miss or overhang the tie and the following description relates to means for ensuring just that. With reference again to FIG. 4, the skid 268 incorporates a limit switch 370 actuable by an arm 372 extending below the skid 268 and carrying at its lower end a wheel 374. Limit switch 370 is tripped or actuated by wheel 374 engaging the trailing edge of a tie and it is opened by wheel 374 leaving the forward edge of the tie. A distance encoder 376 is driven by a track engaging wheel 61 located near a front boggie of the rail changing machine R (see FIG. 1). Referring to FIG. 7, a block diagram is shown of a digital distance measuring system which is used to de-energize electromagnet 354 of tie plate holding device 250 when the tie plate is properly positioned over the tie, i.e., the tie plate 90 will be dropped at the longitudinal center of the tie regardless of the width of the particular tie under consideration. When the limit switch 370 is closed due to engagement with the trailing edge of a particular tie, pulses from the distance encoder are directed to divide by two circuit 378 and counted in tie width counter 380. When limit switch 370 is deactuated by the wheel 374 leaving the leading edge of the tie, the count in tie width represents 1/2 the width of the tie. This deactuation of limit switch 370 causes distance counter 382 to be reset to zero, the value in the tie width counter 380 to be put in memory 384 and made available to adder 386, the tie width counter to be reset to zero, and the pulses from the encoder 376 to be accumulated in distance counter 382. The value in memory 384 is summed with the value accumulating in distance counter 382 by adder 386. The sum out of adder 386 is compared in comparator 388 with a constant from store 390. The value of the constant represents the distance x from the limit switch 370 to the center of electromagnet 354 (see FIG. 4). When the value out of adder 384 equals the constant from store 390, the comparator 388 actuates relay 392 turning off the power to electromagnet 354 causing tie plate 90 to be dropped. The use of memory 384 allows the circuit to count on the next tie before it causes a tie plate to be dropped on a previous tie. This allows for different spacing of ties.
In a rail changing machine which removes old rails, prepares the surfaces of the old ties and lays down new rail, a tie plate pick-up device is arranged to pick up the old tie plates and convey them selectively to a trailing car or to a tie plate positioning and dropping device where they are re-laid on the prepared ties. In the event that the old tie plates are not recycled new tie plates are conveyed to the tie plate dropping device. Permanent magnetic pick-up wheels are used and an electromagnetic tie plate holder is used at the dropping station. Problems of lateral alignment at both the pick-up and drop stations and tie plate orientation and longitudinal alignment with the ties at the drop station are overcome using novel mechanisms.
4
BACKGROUND OF THE INVENTION The problem encountered in switch cabinets is that the components built into the cabinet must be connected with electrical lines outside of the cabinet; in other words, the “insides” must be connected to the “outside world.” A particular problem in this connection is the necessity of configuring housings, especially switch-cabinet housings, in accordance with the standard IEC 529, namely such that moisture and/or foreign objects cannot enter, in an effort to prevent damage to the components housed in the switch cabinet. In this connection, the degree of protection IP 54 included in the aforementioned standard establishes particularly high requirements. According to the state of the technology, screw terminals or series terminals, to which the electrical conductors led from the outside into the switch cabinet are connected, are provided in the cabinet for connecting the “insides” of the cabinet to the “outside world.” From the terminals, the individual lines lead to the different components housed in the switch cabinet. The electrical lines led into the switch cabinet from the outside are led through bores in one or more side walls of the cabinet and guided up to the screw or series terminal. For additional sealing, the bores are provided with rubber grommets or similar sealing elements. A disadvantage of this is that the switch cabinet must be opened for connecting the external lines. A further disadvantage is that the person tasked with connecting the lines must be very familiar with the internal layout of the switch cabinet to ensure that the correct conductor is always connected to the correct terminal input. This setup also requires a certain amount of manual dexterity—particularly under unfavorable circumstances, such as cramped conditions or the presence of moisture—for guiding the conductors into the terminal so as to assure a durable, reliable terminal connection. A further problem associated with the known switch cabinets according to the state of the technology is that connecting the external lines with the aid of plug couplings is hardly possible. While it is possible to substitute a multipoint connector or edge socket connector for the terminal strip disposed inside the switch cabinet, the problem that arises is that the leadthrough bores in the cabinet walls are kept as small as possible to make the passageway for the external lines subsequently as impenetrable as possible to moisture and dirt; these bores are therefore typically much too small for leading through ready-made lines equipped with plugs or bushings. This means that, in the use of plug couplings, the external lines must be guided through the cabinet wall in a first work cycle, and the plug or bushing elements are then mounted on the line ends in a second, on-site work cycle, so the corresponding coupling can then be inserted. Finally, for connecting external, ready-made lines that have plugs or bushings to switch cabinets, it is known from the state of the technology to arrange corresponding coupling parts directly in the housing bores so that lines can be led further from these couplings to the aforementioned screw terminals or terminal strips, or the desired components in the switch cabinet can be actuated directly. It is known from U.S. Pat. No. 5,002,502, for example for antenna connections to satellite receivers, to cut holes into a device wall and arrange a board having coupling elements in the corresponding wall opening. Plugs that are fixed to conductors can be inserted onto the coupling elements, both from the outside and inside of the wall. For additional sealing, the coupling elements are provided with outside threads, onto which the plugs can be tightly fixed with the aid of union nuts. A disadvantage of this is the extremely complex design of the coupling elements or plugs. A further drawback is the fact that the same number of coupling elements as wall openings is provided on both sides of the board having the coupling elements, so there is always a 1:1 plug connection, that is, a coupling-plug combination on the outside of the device and a respective associated coupling-counterplug combination inside the device. According to the state of the technology, the board having the coupling elements is only an opening for guiding the external lines into the device interior. It is therefore necessary to provide further electrical or electronic functional parts in the switch cabinet to connect the lines, both in terms of conduction and function, to the components disposed in the cabinet. DE-U 90 03 879 discloses a cable-plug distributing box having a plug bushing for a plug on the outside. To achieve a flat construction, the plug bushing is disposed on an intermediate board, which is in turn oriented perpendicular to a main board, so the insertion direction of the plug extends perpendicular to the main board. For the exit of the lines, individual contact sheets, to which the outgoing lines are connected individually, are disposed on the side opposite the plug bushing. EP 0 663 782 A1 discloses a distributing cabinet that is designed for the connection of an external network to an internal network. For this purpose, it has a so-called routing distributor, which is held to pivot inside the distributing cabinet. The lines of both the internal and external networks are guided to modules embodied with plug bushings on the rear side of the routing distributor, with the individual lines of the external network being appropriately connected to those of the internal network. SUMMARY OF THE INVENTION In view of the problems outlined at the outset, it is the object of the invention to embody a leadthrough adapter for a switch cabinet to permit the external lines to be connected easily, assure the impermeability to moisture and foreign objects according to the degree of protection IP 54 pursuant to IEC 529, and improve the function of the adapter. This object is accomplished in a simple, inventive manner with the present invention. The concept underlying the invention is to mount plugs onto the ends of the external lines provided for connecting to the switch cabinet; the plugs can be inserted simply into a bushing strip on the cabinet that has a complementary embodiment. To permit the use of ready-made plugs, the bushing strip is simply mounted to the outside of a housing wall of the switch-cabinet housing. The bushings into which the plugs can be inserted to produce a plug coupling are then mounted on the front side of the adapter mounted on the outside of the cabinet housing. Disposed on the rear side of the adapter, which faces the interior of the switch cabinet, are elements for connecting the components housed inside the cabinet to the adapter. These elements for connecting the components housed in the switch cabinet encompass electrical or electronic functional parts, in the form of connecting elements, for the components that are disposed inside the switch cabinet, the parts being positioned directly on the rear side of the adapter. The connecting elements have plug-and-socket connectors with varying embodiments for the components. The plug-and-socket connectors are embodied as system plug-and-socket connectors, such as keyed plug connectors, flat-line plug-and-socket connectors or latch-5 plug connectors. The plug-and-socket connectors are preferably compatible with the plug-and-socket connections on the components. Thus, the external lines and the “insides” of the switch cabinet can be connected easily via plug connections. In comparison to the state of the technology, however, there is no 1:1 plug connection; instead, an arbitrary number and type of input plug connections can be combined with a likewise arbitrary number and type of different output plug connections. It is also advantageously possible with the invention to provide different electrical or electronic structural elements directly on the adapter, such as signal converters, display devices or separating devices. It is particularly advantageous to be able to mount fuse elements, such as overcurrent switches or other safeguards, near the switch-cabinet housing, and thus near the plugs. The power pack for supplying voltage to the switch cabinet can just as easily be disposed on the rear side of the leadthrough adapter. If, for example, an overcurrent switch trips, or an error occurs at the power pack, removing the adapter from the housing wall can immediately remedy the damage without necessitating the opening of the switch cabinet. A further advantage is the elimination of a strict 1:1 plug connection according to the state of the technology. This strict 1:1 plug connection is replaced by an integral design of connecting elements and, simultaneously, structural elements. In the region of the adapter, therefore, the integration density is improved over that of the state of the technology. A further advantage is the ability to contact the switch cabinet externally with ready-made plugs and, at the same time, the ability to provide an individual, functional embodiment of the leadthrough adapter on the rear side of the leadthrough adapter. Hence, the same adapter base model can be used successfully, and in a technically simple and inexpensive manner, in numerous applications. A further advantage of the invention is that ready-made external lines can be mounted to a likewise ready-made switch cabinet without necessitating the opening of the cabinet. It is also not necessary for the technician to be familiar with the design and interaction of the “insides” of the cabinet, that is, the components housed within it, for connecting the external lines to the cabinet. A further advantage is the high speed permitted by the plug assembly of the external lines in accordance with the invention. The provision of a front plate on the outside of the switch-cabinet housing notably assures the tight closure of the adapter. The bushings can be mounted directly to the front plate. This embodiment also permits the use of commercially-available, ready-made bushings, and their arrangement in the front plate, behind the openings in the direction of insertion. The bushings and openings are then aligned, so the plugs are inserted into the bushings through the openings. The use of so-called “latch-5 bushings” and correspondingly-embodied “latch-5 plugs” is particularly advantageous. In this instance, the bushings mounted in the adapter on the side of the switch cabinet comprise a bushing housing and a plurality of contact tabs disposed adjacently according to the so-called “latch-5 plug pattern.” Contact shoes, whose embodiment complements that of the contact tabs, are disposed in the plug housing having an embodiment that complements that of the bushing housing, so when the plug is inserted, a respective contact shoe is inserted onto a contact tab, thereby producing a line-type connection between bushing contacts, on the one hand, and plug contacts, on the other hand. To prevent mismatches in the association of individual plugs with individual bushings, a non-interchangeable coding of the plugs and bushings is required. The use of commercially-available contact bushings and a front plate that is provided with holes and is separate from the contact bushings permits the edges of the openings in the front plate to be embodied to partially overlap the bushing inputs. In the regions that overlap the bushing inputs, groove-type recesses are left open; these can have arbitrary cross-section shapes. It is therefore possible to provide dovetail grooves, rounded-out grooves, polygonal grooves, etc. A coding that specifies an individual groove arrangement for each opening, i.e., an opening-specific recess pattern, is especially effective. To complete the coding, ribs or projections embodied to complement the recesses must be provided on the plug housings. It is evident that the embodiment of the projection or rib pattern must be complementary to the recess pattern of the recess associated with the plug. In this way, simple elements effectively prevent a plug from being inserted through a recess into a bushing contact to which it is not supposed to be connected. The mechanical coding can be enhanced by color-coding to facilitate assembly. This can be effected simply by the assignment of a separate color to each opening. The adapter then has a multicolored front plate with different-colored openings. To complete the color-coding, the corresponding connectors are painted in the same color. Finally, it is possible to embody the front plate such that text boxes are provided next to the openings. These text boxes can contain any type of information, for example symbols that also appear on the associated plugs, and therefore constitute a further, separate allocation option. Of course, mechanical coding, like the aforementioned color-coding and/or symbol coding, can also be provided separately. It is therefore not necessary to combine a plurality of coding types. Nevertheless, the mechanical coding discussed above represents a very simple, reliable, foolproof coding, because it precludes erroneous insertion. With the mechanical coding, it is impossible to insert a plug into a bushing contact (behind a recess) to which the plug is not actually supposed to be connected. It is advantageous to provide a circuit board on the rear side of the adapter. In another advantageous embodiment, a circuit is printed onto the circuit board. Thus, a wide range of circuits can be realized on the leadthrough adapter through a simple exchange of circuit boards with different printed circuits. It is also possible to equip the circuit board with different structural elements for adapting devices that are disposed inside the switch cabinet and standardized for the circuit board. It is further possible to mount actuators or sensors directly on the circuit board, or to provide electrical outputs for actuators or sensors. Of course, it is especially advantageous to equip the circuit board with connecting elements that are compatible with the plug connections typically provided at the respective actuator or sensor. The use of a circuit board as stated above thus allows the circuit board to be used as an electrical interface between the “outside world” and the “insides” of the switch cabinet. For this purpose, bushing contacts that are aligned with and preferably behind recesses are connected to the one side of the circuit board, while the opposite side of the circuit board supports connecting elements for the components housed in the switch cabinet. This is especially advantageous because the “plug philosophy” underlying the invention also involves embodying the connecting elements for the “insides” of the switch cabinet as plug connections, for example as keyed plug connectors, flat-line plug-and-socket connectors and also latch-5 plug connectors. Of course, it would also be possible to provide conventional screw terminals on the circuit board. Hence, arbitrary “connector worlds” can be combined with one another according to the invention. The embodiment of the adapter rear side as a receiving basket takes into account the concept of creating an integral structural element. The connecting elements and the structural elements, including the circuit board, can be held reliably and in a protected manner in the receiving basket. The leadthrough adapter can also be exchanged easily. Hence, different standard models of adapters embodied as an integral structural element can cover numerous applications. The provision of a sealing bead at the edge of an opening, which simultaneously creates a plug pot for the connector to be inserted, serves a dual function. During the insertion process, the plug pot acts as a guide for the plug. In the plug that is guided, the precise guidance of the plug effectively prevents jamming, which considerably reduces the risk of damage to the plug contacts disposed in the plug, or to the corresponding bushing contacts. When the plug is inserted, the circumferential sealing bead performs a sealing function, and additionally prevents the intrusion of moisture or foreign objects into the switch cabinet. In another embodiment, the locking elements, namely the spring hooks mounted at the plug ends, prevent an undesired withdrawal of the plugs from the switching cabinet during operation. The locking elements are disposed to likewise terminate in the plug pot, so they are inaccessible from the outside when the plug is inserted, thereby precluding an undesired unlocking from the outside or damage to the locking elements from the outside. The arrangement of further sealing ribs projecting laterally from the plug housing significantly improves the sealing properties of the plug coupling. Whereas, without the sealing ribs, only one sealing plane is present in the transition region between the plug and the coupling in the plug pot, the provision of a plurality of sealing ribs creates a number of sealing planes that corresponds to the number of sealing ribs. The creation of a plurality of sealing planes expands the sealing system of the plug coupling to a sealing labyrinth that particularly effectively prevents the intrusion of small dust particles, as well as moisture. The mounting of the auxiliary housing around the plug permits the external conductors to be crimped onto their connector contacts, on the one hand, and on the other hand, permits injection-molding around the sides and back of the crimped contacts, so the outside plug housing can be embodied as an injection-molded part. This is favorable from a manufacturing technology standpoint, and, in terms of function, has the advantage that plug housings injection-molded in this manner are particularly well-sealed. A further embodiment of the plugs that can be inserted into the adapter bushings will be discussed below. Here, the wires of the conductor are preferably connected with quick-connect receptacles. The quick-connect receptacles can be crimped onto the conductors. The conductor wires connected with the quick-connect receptacles are laid in an auxiliary housing. A sealing housing formed from two housing-half shells is then fixed to the end of the auxiliary housing. The actual plug housing is then injection-molded around the sealing housing and the auxiliary housing. An advantage of this setup is that the additional sealing housing that shields the auxiliary housing prevents injection-molding completely around the auxiliary housing. Because no injection-molding material of the outer housing jacket penetrates the auxiliary housing, the quick-connect receptacles are seated to float in the auxiliary housing, which compensates fluctuations in tolerance at the counterconnectors or counterbushings. The effective shielding of the plug housing prior to the injection-molding of the outer housing jacket minimizes the quantity of rejected pieces in production. Finally, fixing the conductors in the auxiliary housing in advance and subsequently mounting the sealing housing also eliminates the theoretical possibility that, with incorrect crimping or unintentional splicing of stranded wires, the stranded wires come so close beneath the surface of the injection-molded jacket that a contact with these voltage-conducting parts lying improperly close beneath the injection-molded jacket may occur during insertion. In this way, a high-voltage test of the individual plugs following the injection-molding around the housing can also be omitted. Another embodiment of the sealing housing divides the auxiliary housing into two housing-half shells. This is advantageous in terms of production technology. The housing-half shells can have a symmetrical embodiment, so both sides of the sealing housing can be produced with one half-shell model or a single mold. In another embodiment, the housing-half shells perform a dual function. In addition to their shielding function, they provide strain relief for the finished plug. In an assembly aid for the adapter according to the invention, pre-locking elements that cooperate with the housing wall are embodied on the adapter. Thus, the adapter can be inserted into its installation opening in the housing wall and pre-locked there. The assembling technician therefore has both hands free to screw the adapter to the housing wall of the switch cabinet. Of course, it is possible to arrange one or more seals between the adapter front side and the housing-wall regions overlapped by the adapter front side. A primary advantage of the invention is that it permits the adaptation of a switch cabinet having pre-defined “insides” to individual operator requirements merely through the adaptation of the leadthrough adapter to the customer-specific requirements. For example, the bushing contacts on the front plate of the adapter can be adapted to a customer-specific plug pattern. Moreover, functional elements for a customer-specific adaptation of the switch cabinet can be disposed in the receiving basket. BRIEF DESCRIPTION OF THE DRAWINGS The invention is described in detail by way of embodiments illustrated in the drawing figures in which: FIG. 1 is a photograph of the front plate of a leadthrough adapter according to the invention; FIG. 2 is a photograph of the rear side of a leadthrough adapter according to the invention; FIG. 3 is a photograph taken from the side into the receiving basket of the leadthrough adapter according to the invention; FIG. 4 is a photograph of a plug whose embodiment is compatible with that of the leadthrough adapter; FIG. 5A is a plan view of the front plate of a first embodiment of the adapter, having six openings with bushings that end flush with the openings, FIG. 5B is a perspective view of a switchgear cabinet with a leadthrough adapter, similar to that of FIG. 5A; FIG. 6 is a view of a further embodiment of the leadthrough adapter that includes only one closed opening, the view corresponding to FIG. 5A; FIG. 7 is a detailed view of an opening having a predefined coding pattern; FIG. 8 is a plan view of the adapter rear side; FIG. 9 is a side view, in a vertical section, of the adapter; FIG. 10 is two adjacent coupling regions having inserted plugs, in a horizontal section; and FIG. 11 is a vertical section of a plug having an auxiliary housing and a sealing housing. DETAILED DESCRIPTION OF THE INVENTION The front plate 1 of the leadthrough adapter shown in FIG. 1 has two rows of openings 3 , which are disposed adjacently in the horizontal direction 2 . The openings 3 of each vertical row are superposed in the vertical direction 4 . Finally, a text box 5 is disposed between the two rows of openings extending in the vertical direction 4 . Furthermore, the front plate 1 has a bore 6 in each corner region for the insertion of an illustrated fastening screw 16 . The fastening screws 16 fix the leadthrough adapter 1 to a switchgear cabinet 34 (see FIG. 5B) or a housing wall 35 of the switchgear cabinet 34 . In the final assembly stage, the receiving basket 7 projects from the adapter rear side into the switch cabinet (FIG. 2 ). The circuit board 8 is disposed in the receiving basket 7 . A keyed bushing 9 , a plug connector having contact pins 10 and three so-called latch-5 bushings of varying size are mounted to the circuit board 8 . A plug 13 is connected, ready-made, to a respective external line 12 . The plug 13 has an injection-molded plug housing 14 with sealing ribs 26 formed onto it. The Phillips-head screws 16 , with which the front plate 1 of the adapter is fixed to the switch cabinet 35 —shown in FIG. 5B of the drawings—are visible in the representation of FIG. 6 . The Phillips-head screws 16 are inserted through the bores 6 . The openings 3 have edges 17 , which project in the drawing plane defined by the horizontal direction 2 and the vertical direction 4 . Recesses 18 are left open in the edges 17 to form an individual coding pattern for each opening 3 . As can be seen clearly in FIGS. 5 and 6, the individual openings 3 have different coding patterns, namely recesses 18 at different locations. As can be seen clearly in FIG. 7, the individual recesses 18 can have different dimensions, and can vary in geometry. The invention permits an infinite number of different codings. The regions of the edges 17 that are not interrupted by recesses 18 serve simultaneously as the floor of the plug pots disposed upstream of the individual openings 3 . The collars 19 form the walls of the plug pots. The collars 19 respectively frame an opening 3 . Each collar 19 projects from the adapter front plate, and thus out of the drawing plane of FIGS. 5A, 6 and 7 , in the counter-insertion direction 20 , i.e., perpendicular to both the horizontal direction 2 and the vertical direction 4 . The plug bushings 22 are embodied, aligned with and behind the openings 3 , in the insertion direction 21 opposite the counter-insertion direction 20 , which also extends perpendicular to both the horizontal direction 2 and the vertical direction 4 . The plug bushings 22 in the illustrated embodiment are configured as so-called latch-5 bushings. An uncoded plug bushing 22 is therefore disposed behind each coded opening 3 . Depending on the desired embodiment, it is, of course, also possible to leave one or more openings 3 unoccupied—in other words, not to provide any plug bushings 22 behind an opening 3 . In this instance, the openings 3 are simply sealed against the outside by a closing plate 23 . In the embodiment shown in FIG. 6, the third opening 3 from the top in the right vertical row of openings is unoccupied. The embodiment shown in FIG. 5A indicates that the second opening 3 from the top in the left vertical row is unoccupied, and is closed by a closing plate 23 , while, with the exception of the uppermost opening 3 in the right vertical row, all further openings 3 are closed by a mounted closing plate 23 , and thus are inoperative. To connect the external lines 12 , contact shoes are crimped onto the individual conductors 24 of the external line 12 . These contact shoes are seated in the plug housing. The housing that forms the actual plug region of the plug housing is first closed from behind by a lid to form an auxiliary housing. The actual plug housing, namely the bulkhead housing 25 in FIG. 10, is then injected onto the sides and back of this auxiliary housing. The bulkhead housing 25 protects the plug 13 against external influences, and ensures that a switch-cabinet housing equipped with the adapter of the invention attains the degree of protection IP 54 in accordance with EEC 529. It can further be seen from FIG. 10 that the additional sealing ribs 26 are disposed on the bulkhead housing 25 of the plugs. The sealing ribs 26 rest laterally against the collars 19 or the side walls of the plug pot in a sort of frictional lockup, thereby forming a sealing labyrinth with three sealing planes in the illustrated embodiment. Finally, the spring hooks 27 project from the plug ends of the bulkhead housing 25 of the plugs 13 , in the insertion direction 21 . When the plug 13 is inserted, the hook claws of the spring hooks 27 hook behind the edges 17 of the opening 3 associated with the corresponding plug bushing 22 for additionally latching the plugs 13 in the front plate 1 of the adapter. FIG. 11 illustrates a modified embodiment of the plug 13 . In this modified embodiment, the auxiliary housing 28 forms the actual plug region of the plug. The conductors 24 , which are preferably connected with quick-connect receptacles, are laid into the auxiliary housing 28 . The quick-connect receptacles are laid in pockets of the auxiliary housing 28 that have a complementary embodiment. The quick-connect receptacles and the conductors 24 laid inside them are seated to float to some extent inside the auxiliary housing 28 , which assures a certain tolerance compensation relative to the contact tabs to be connected to the quick-connect receptacles in the latch-5 bushings 11 during insertion. The two half shells 30 are inserted onto the rear wall 29 of the auxiliary housing 28 . In the illustrated embodiment, the two half shells 30 have an identical embodiment, and are reversed by 180° relative to one another. In the final state of assembly, the half shells 30 form the sealing housing shown with thin-line hatching in FIG. 11 . Fixing latches 31 project out of the half shells 30 in the insertion direction 21 . These fixing latches 31 extend behind the rear wall 29 of the auxiliary housing 28 . The fixing latches 31 that extend behind the edge of the auxiliary housing 28 form a guide for the half shells 30 . For assembly, the conductors 24 connected to the quick-connect receptacles are inserted into the aforementioned pockets of the auxiliary housing 28 . The half shells 30 are then inserted, with their fixing latches 31 forward, onto the edge of the auxiliary housing 28 , and are pivoted toward one another, so they cover and completely shield the conductor 24 between themselves. At the ends remote from the fixing latches 31 , the half shells 30 are provided with two semicircular-notched ribs 32 . The ribs 32 contact the insulating jacket 33 of the external line 12 , or the insulating jacket 33 for the conductor 24 , when the half shells 30 are mounted. In the final state of assembly, the ribs 32 are tensed relative to one another in the manner of clamping jaws. The ribs 32 therefore form the partial region of the half shells that effects strain relief for the plug 13 in the final state of assembly. At the end located in the region of the ribs 32 , the half shells 30 have form-fit elements for a form-fitting latching of the two half shells 30 . The pre-assembly of the plug 13 is ended when the conductors 24 are laid in the auxiliary housing 28 , as described, and the two half shells 30 are latched together. In a final production step, the sealing housing formed by the two housing-half shells 30 is injection-molded around entirely, and the auxiliary housing 28 positioned in front of the sealing housing, when seen in the insertion direction 21 , is injection-molded around partially, to form a bulkhead housing 25 for the plug 13 . The primary advantages of this embodiment are the floating seating of the plug contacts of the conductors 24 for tolerance compensation in the bulkhead housing 25 , and the strain relief for the plug that is provided by the ribs 32 . As described above, the receiving basket 7 is embodied on the adapter rear side facing away from the front plate 20 in the counter-insertion direction 20 . In the illustrated embodiment (FIG. 9 ), the circuit board 8 acting as the carrier for the functional parts is disposed in the receiving basket 7 . On the side of the circuit board facing the front plate 1 , the plug bushings 22 are fixed to produce contact. In FIG. 9, two latch-5 bushings 11 are disposed on the rear side of the circuit board facing away from the front plate 1 in the insertion direction 21 . FIG. 8 shows an arrangement in the receiving basket 7 that corresponds to the representation of FIG. 2 .
A leadthrough adapter for connecting the components installed in a switchgear cabinet to external electric conductors. The adapter is located in a wall of the switchgear cabinet housing and one or more bushings are situated on the face of the adapter. The bushings can be accessed from the outside of the switchgear cabinet and plug-in connectors can be inserted into the bushings in order to connect the external electric conductors. Electric and/or electronic functional parts for the components that are accommodated inside the switchgear cabinet are arranged directly on the back of the adapter which faces towards the inside of the switchgear cabinet.
7
FIELD OF INVENTION [0001] This invention relates to timing signals within nodes of a telecommunication network, and more particularly to distribution of clock accuracy information within a network. BACKGROUND [0002] In a telecommunications network employing the IEEE 1588 standard, a common time is distributed throughout the network so that network elements within the network are synchronized. According to IEEE 1588-2002, the first implementation of IEEE 1588, a grandmaster clock on a network element transmits timing information to a boundary clock on another network element using PTP (Precision Time Protocol) messages, typically conveying such information to the boundary clock on the order of several times a second. When the boundary clock receives timing information the boundary clock corrects its own local clock with an offset derived from the time stamps in the various PTP messages used to convey the timing information. The boundary clock then transmits its own timing information to other network elements, including possibly other boundary clocks. A clock that only receives timing information and does not convey it onward using IEEE 1588 is a slave clock. The clock delivering timing information to a second clock is referred to as the parent clock of the second clock. On any of these clocks, a port that receives timing information from another clock is referred to as a slave port, and a port that transmits timing information to another clock is referred to as a master port. [0003] A boundary or slave clock may receive supervisory information from more than one clock. In such a case the boundary or slave clock selects one of these clocks as its parent clock by using a “best master clock” algorithm. The boundary clock or slave clock then uses the timing information received from the parent clock to adjust its local clock. [0004] In IEEE 1588-2008, version 2 of IEEE 1588, transparent clocks are introduced. A transparent clock processes PTP messages that transit the transparent clock as they flow from a master port toward a slave port. The transparent clock does not terminate the PTP messages but augments each. PTP message with the time the PTP message requires to traverse the network element containing the transparent clock. [0005] As part of the PTP communications grandmaster and boundary clocks distribute supervisory information using Announce messages. These Announce messages indicate the quality of the grandmaster clock which is the source of timing into the network as well as the distance of the clock from the grandmaster. For example, a boundary clock whose parent clock is the grandmaster would send Announce messages indicating the quality of the grandmaster clock and a distance of one. The grandmaster clock quality information includes an estimate by the grandmaster clock of its own accuracy and stability. Both of these are indicators of how good the clock is, and may be static or dynamic measures, A transparent clock passes Announce messages unmodified. If a boundary clock or transparent clock receives Announce messages from more than one clock, the clock can use the information in the Announce messages in its implementation of the Best Master Clock Algorithm in order to select which of these clocks to use as its parent clock. [0006] In both cases, the boundary clock or the transparent clock (referred to herein collectively as an “intermediate clock”) may initially introduce errors into the timing information. A boundary clock that has recently booted up takes a measurable amount of time to synchronize its own clock with that of its parent clock. The PTP messages transmitted by the boundary clock may therefore not accurately reflect the time signals emanating from the grandmaster clock. Similarly, for a transparent clock its measurement of the transit time of packets through the network element containing the transparent clock may not have stabilized if the network element has recently booted up and the local clock of the transparent clock has not yet synchronized with the grandmaster clock. [0007] In either case, the timing information gleaned by an end application may not match the timing information generated by the grandmaster clock. The Announce messages reaching an end application indicate the accuracy and stability of the grandmaster clock. The Announce messages are silent however regarding the potential decrease in accuracy arising from the presence of boundary clocks and transparent clocks between the grandmaster clock and the slave clocks. SUMMARY [0008] According to one aspect, a method of communicating timing information in a telecommunication network which uses IEEE 1588 messages to convey timing information is provided. At an intermediate clock, reliability of timing information of a local clock is determined. An indication of grandmaster clock reliability is determined at the intermediate clock from a received Announce message. An indication of reliability in an outgoing Announce message is set at the intermediate clock to be a combination of the determined reliability of the local clock and the indication of grandmaster clock reliability. The outgoing Announce message is transmitted by the intermediate clock. [0009] According to another aspect, a network element in a telecommunication network which uses IEEE 1588 messages to convey timing information is provided. The network element includes a local dock, a processor, and memory. The memory includes instructions which, when executed by the processor, cause the processor to determine reliability of timing information of the local clock. The memory also includes instructions which cause the processor to determine an indication of grandmaster clock reliability from a received Announce message, to set an indication of reliability in an outgoing Announce message to be a combination of the determined reliability of the local clock and the indication of grandmaster clock reliability, and to transmit the outgoing Announce message. [0010] The methods of embodiments of the invention may be stored as logical instructions on a non-transitory computer-readable storage medium in a form executable by a computer processor. [0011] Embodiments of the invention allow boundary clocks and transparent clocks to notify downstream clocks of the reliability of the timing information which the downstream clocks are receiving. BRIEF DESCRIPTION OF THE DRAWINGS [0012] The features and advantages of embodiments of the invention will become more apparent from the following detailed description of the preferred embodiment(s) with reference to the attached figures, wherein: [0013] FIG. 1 is a block diagram of a portion of an example telecommunication network; [0014] FIG. 2 is a block diagram of a portion of another example telecommunication network; [0015] FIG. 3 is a flowchart of a method carried out by an intermediate clock of FIG. 1 according to one embodiment of the invention; and [0016] FIG. 4 is a block diagram of a computing environment according to one embodiment of the invention [0017] It is noted that in the attached figures, like features bear similar labels. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0018] Referring to FIG. 1 , a block diagram of a portion of a telecommunication network is shown. A first ordinary clock acts as a grandmaster aster clock 10 . The network element on which the grandmaster clock 10 is located is confident of its clock because the network element is receiving reliable time information to which it can match its clock, such as by using a GPS receiver. The grandmaster clock 10 exchanges Precision Time Protocol (PTP) messages with an intermediate clock 12 located, on a separate network element. The intermediate clock 12 may be a boundary clock or a transparent clock. The intermediate clock 12 exchanges PTP messages with a second ordinary clock 14 located on yet another network element. An end application 16 uses the second ordinary clock 14 as a source of timing information. [0019] The intermediate clock 12 has selected the grandmaster clock 10 as its parent clock, and has a slave port 13 linked to a master port 15 on the grandmaster clock 10 . The second ordinary clock 14 has a slave port 17 linked to a master port 19 on the intermediate clock 12 . [0020] The grandmaster clock 10 sends Announce messages to the intermediate clock 12 indicating the accuracy and stability of the time within the grandmaster clock 10 . If the intermediate clock 12 is a boundary clock, the boundary clock 12 stores this accuracy and stability information, referred to herein collectively as quality information, internally. The boundary clock 12 increments the distance from the grandmaster by one. The boundary clock 12 then copies the stored grandmaster quality information and the distance from grandmaster into a new Announce message. It then adds quality information related to the boundary clock itself to the new Announce message, and then sends the new Announce message to the ordinary clock 14 . [0021] In the case that the intermediate clock 12 is a transparent clock, then the transparent clock modifies the Announce message by adding the quality information of the transparent clock itself and forwards the message toward the ordinary clock 14 . [0022] The telecommunication network shown in FIG. 1 is chosen deliberately as a very simple network in order to best illustrate embodiments of the invention. [0023] More generally there may be more than one intermediate clock between the grandmaster clock 10 and the second ordinary clock 14 . The second ordinary clock 14 may receive PTP messages from more than one intermediate clock, and may receive timing information about more than one grandmaster clock. For example, a more complicated arrangement of clocks is illustrated in FIG. 2 . In the example telecommunication network of FIG. 2 , the ordinary clock 14 has two possible grandmaster clocks 10 and 20 . A transparent clock 18 lies between the first grandmaster clock 10 and the ordinary clock 14 . Two boundary clocks 22 and 24 lie in series between the second grandmaster clock 20 and the ordinary clock 14 . Each intermediate clock 18 , 20 , and 24 adds their quality information to the announce messages forwarded to the next clock. [0024] Broadly, an intermediate clock in a telecommunications network employing IEEE 1588 determines the reliability of its local clock, sets an indication of reliability in an outgoing Announce message to be a combination of the determined reliability of the local clock and of the grandmaster clock reliability indication, and transmits the outgoing Announce message. [0025] Referring to FIG. 3 , a flowchart of a method carried out by the intermediate clock 12 of FIG. 1 according to one embodiment of the invention is shown. At step 30 the intermediate clock receives an Announce message. At step 32 the intermediate clock 12 determines an indication of the reliability of timing information of a local clock of the intermediate clock 12 . The reliability of the timing information is directly related to the stability of the synchronization of the frequency of the local clock to the frequency of the grandmaster clock. In the case of the intermediate clock 12 being a boundary clock, the timing information provided by the boundary clock may be unreliable directly due to lack of synchronization between the boundary clock and its master clock resulting in the boundary clock not “knowing” the correct time. In the case of the intermediate clock 12 being a transparent clock, the time taken by the Announce message to transit the transparent clock may be unreliably known due to lack of synchronization between the transparent clock and the grandmaster clock. [0026] Reliability is distinct from quality and stability. Quality is a (generally) static measure of the accuracy and class of a clock. Stability is a (generally) static measure of the clock's own performance against a PTP reference. In contrast, reliability is a quantity that can change over time. The reliability of timing information can change over time as a device gradually stabilizes. This may be because the local clock of an intermediate clock gradually adjusts to match a master clock of which it has recently become aware. Reliability of timing information can be used by a clock in deciding whether to use the master clock to which the Announce message containing the reliability indication pertains, along with the quality and stability of the clock. For example, the quality and stability information may indicate to a clock that the clock to which an Announce message pertains is a very good clock, but the indication of reliability may indicate that the timing information is not yet very reliable. As time progresses, subsequent Announce messages pertaining to that clock will indicate the same quality and stability, but the reliability of the timing information in the Announce message should improve as the master clock adjusts its local clock to the grandmaster clock. [0027] At step 34 the intermediate clock determines an indication of reliability contained in the received Announce message. [0028] At step 38 the intermediate clock 12 generates an Announce message to transmit to its slave clock. The term “generates” is used loosely and the step is shown in dashed lines in FIG. 3 , because in the case that the intermediate clock 12 is a transparent clock then no new Announce message is actually generated. Rather the Announce message received at step 30 passes through the transparent dock and is forwarded as an outgoing Announce message. Either the step 38 of generating an Announce message may be viewed as optionally implemented based on whether the intermediate clock is a boundary clock or a transparent clock, or the term “generating” may be read as transferring the Announce message received at step 30 to the queue of outgoing packets. [0029] At step 40 the intermediate clock 12 sets an indication of the reliability into the outgoing Announce message (either generated at step 38 if the intermediate clock is a boundary clock or forwarded if the intermediate clock is a transparent clock) to be a combination of the indication of reliability determined at step 32 and the indication of grandmaster reliability determined at step 34 . The indication of the reliability that is set in the outgoing Announce message is as a TLV (type-length-value) element, the value of the TLV element indicating a degree of reliability of the timing information in the Announce message. This can be done in any way which reflects the cumulative reliability of the intermediate clock and all upstream clocks. For example, if the indications were simply an actual measure of reliability, e.g. the clock is reliable to within 10, 50, 100, or 200 ms, then the adjusted. value of the indication of reliability could simply be determined by adding the received value and the value determined at step 32 . This may be the simplest method of adjusting the value but also considers only the worst case scenario of the cumulative reliability, i.e. that every error is in the same direction. In another embodiment, the values are added as root-mean-squares, which may be advantageous if the values change rapidly. At step 42 the intermediate clock 12 transmits the outgoing Announce message through its slave port, which in the network illustrated in FIG. 1 leads to the second. ordinary clock 14 . [0030] In the embodiment described above the intermediate clock sets a TLV element in the outgoing Announce message, the value of the TLV element indicating the degree of reliability of the timing information in the Announce message. Alternatively, the intermediate clock 12 sets the value of a single bit in the outgoing Announce message, the value of the bit indicating whether the timing information of the Announce message is reliable. In such an embodiment, at step 32 the intermediate clock makes a Boolean determination regarding the reliability of its own timing information. For example, if the difference between the frequency of the local clock of the intermediate clock and the frequency of the clock of the grandmaster clock exceeds a threshold (such as 200 parts per billion (or nanoseconds per second)), then the intermediate clock 12 determines that its timing information is not reliable and that the Boolean value if FALSE. If the difference between the frequency of the local clock and the grandmaster clock does not exceed the threshold, then the intermediate clock 12 determines that its timing information is reliable and that the Boolean value is TRUE. The intermediate clock sets the indication of reliability in the outgoing Announce message by performing an AND operation between the determined indication of reliability and the received indication of reliability. The effect of this is that the indication of reliability of timing information ultimately received by the ordinary clock 14 is only TRUE if all upstream clocks are confident in the reliability of their timing information. [0031] In the embodiment described above, when the intermediate clock determines the value of the indication of reliability to insert into the transmitted Announce message, the intermediate clock takes into account the indication of reliability that is included in a received Announce message. Alternatively, the intermediate clock only includes an indication of its own contribution to the reliability of the timing information. In such an embodiment, the step 34 described above with reference to FIG. 3 is excluded. Such an embodiment may provide less accurate reliability information to an ordinary clock, but may also be simpler to implement. The degree of inaccuracy may even be lessened, because the errors introduced by each intermediate clock between. the grandmaster clock and the ordinary clock may tend to cancel each other. For example, some boundary clocks may initially be slower than the grandmaster clock and some may initially be faster than the grandmaster clock. [0032] The methods described above executed by the intermediate clock are preferably implemented as logical instructions in the form of software. Alternatively, the methods may be implemented as hardware, or as a combination of software or hardware. If in the form of software, the logic of the methods may be stored on a non--transitory computer-readable storage medium in a form. executable by a computer processor. If in the form of hardware, the logic of the methods may be implemented by a general purpose processor, a network processor, a digital signal processor, an ASIC, a macroscopic circuit, or multiple such devices. [0033] A simplified block diagram of one embodiment of the intermediate clock is shown in FIG. 4 as a processor assembly 100 . The processor assembly 100 includes a computer processor element 102 (e.g. a central processing unit and/or other suitable processor(s)). The computer processor element 102 has access to a memory 104 (e.g. random access memory, read only memory, and the like). The processor element 102 and the memory 104 are also in communication with an interface comprising various I/O devices 106 (e.g. a user input device (such as a keyboard, a keypad, a mouse, and the like), a user output device (such as a display, a speaker, and the like), an input port, an output port, a receiver, a transmitter, and a storage device (such as a tape drive, a floppy drive, a hard disk, a compact disk drive, and the like)). In one embodiment, the methods described above are implemented as software instructions loaded into the memory 104 and causing the computer processor element 102 to execute the methods. [0034] The embodiments presented are exemplary only and persons skilled in the art would appreciate that variations to the embodiments described, above may be made without departing from the spirit of the invention. The scope of the invention is solely defined by the appended claims.
An intermediate clock, either a boundary clock or a transparent clock, may have to adjust its local clock to match that of a grandmaster clock. If such adjustment is frequent or large, then the intermediate clock may not have much confidence in the reliability of the timing information it passes to a downstream clock in an IEEE 1588 Announce message even if the quality of its local clock is high. The intermediate clock determines a measure of the reliability of its timing information. The intermediate clock inserts an indication of the reliability of the timing information in a transmitted IEEE 1588 Announce message. The intermediate clock may consider an indication of reliability found in an Announce message it receives when inserting an indication of the reliability of timing information into an Announce message which it transmits.
7
BACKGROUND The invention relates to a device for turning a sheet with a simultaneous change in the conveying direction. Devices of this type are needed in case sheets or forms are transferred from a processing station, for example a printer or a copier, to a conveyor chain in order to be carried by the latter past further handling or processing stations, or to be composed, with additional sheets and forms, into a set of sheets or a set of forms. A high operating speed is desirable when handling and processing sheets and forms, e.g. in mail processing machines. Disturbances, paper jams, and the like must be avoided since they can trigger a standstill of the entire facility and can lead to the destruction of documents which has grave consequences, for example, when processing bank mail. Accordingly, it is an object of the invention to design a device for turning a sheet with a simultaneous change in conveying direction in such a way that a continuous flow of the sheets to be handled is ensured with a high operating speed, and breakdowns are avoided. This object has been attained according to the invention by providing that the sheet is transported by means of a driving roller arrangement into an inlet slot defined by guide walls. The inlet slot meets a diagonally-extending bending slot, the axis of curvature of which is oriented substantially in parallel to the plane of the sheet and at an angle of preferably 45 degrees with respect to the leading sheet edge. The bending slot terminates in an outlet slot wherein outlet drive means are provided at least for seizing the sheet corner first entering the outlet slot. The outlet slot is located in a plane that is substantially parallel to the plane of the inlet slot, but spaced therefrom. A multiple juxtaposition of devices of the type briefly described above makes it possible to turn a single sheet and discharge it with an altered conveying direction. It also permits independent processing of a plurality of sheets or form sections, (transported lying side-by-side in a plane) simultaneously with the turning step and the change in conveying direction. In this manner, after individual processing it is possible to correlate individual sheets or form sections, into separate sheet stacks or sets of forms. SUMMARY According to a preferred embodiment of the device proposed herein which, as mentioned above, can be provided in multiple juxtaposition, an inlet slot is formed between a cover plate and a guide plate. The cover plate includes a diagonally-curved rerouting flange extending into a diagonal recess of the guide plate to form a bending slot with the guide plate which exhibits a diagonal, substantially-cylindrical guide member located in opposition to the rerouting flange. Finally, the outlet slot and the outlet drive means are arranged on the side of the guide plate facing away from the cover plate. Suitably, the outlet slot contains, on the one hand, sections of revolving conveyor belts traveling in the discharge direction and, on the other hand, counter-support roll elements, associated therewith, as the outlet drive means, wherein the roll elements are preferably formed by balls retained in cages of the guide plate. It has proven to be advantageous to first convey the sheet or sheets to be handled into the zone of the drive roller arrangement in the inlet slot and, prior to passing the sheet or sheets on, to retain the latter, for example by means of a vacuum retaining unit, against the driving action of the driving roller arrangement. Only thereafter the sheet or sheets are released in a controlled fashion whereby a precise initial position of the respective sheet or sheets is attained during entrance into the rerouting slot. BRIEF DESCRIPTION OF THE DRAWINGS Embodiments will be described in greater detail below with reference to the drawings wherein: FIG. 1 is a schematic perspective view of a device for turning a sheet with a simultaneous change in conveying direction wherein certain supporting-frame parts have been omitted to simplify the illustration and to improve clarity, FIG. 2 is a sectional view of the device taken along the lines II--II in FIG. 1, FIG. 3 is a perspective schematic view of the route of several sheets to be separately processed in devices of the type set forth herein; and, FIGS. 3a to 3d are schematic top views of ways of handling the sheets or forms, conveyed and turned in devices of the type disclosed herein, which are fed, for example in a mail processing machine, to a conveyor chain. DESCRIPTION Upstream of the device 10 in FIG. 1 a feeding unit 11 is arranged so that a feeding slot 12 is formed between pairs of mutually-opposed guide bars 13 and 14. The guide bars 13 can be held together by means of transversely extending connecting rods 15 (FIG. 2) while the guide bars 14 are held together correspondingly by transversely extending connecting rods 16. Means arranged upstream of the feeding unit 11 transports a sheet, such as might be cut from an endless form by a cutter, into the feeding slot 12 in the direction of arrow 17. The sheet is fed into the inlet slot 12 until the leading sheet edge projects past the feeding slot 12 and passes into an inlet slot 18 (FIG. 2) for turning and changing the conveying direction. In this respect, a driving-roller arrangement 21 and 22 projects by way of cutouts of guide walls 19 and 20 into the inlet slot 18. These rollers 21 and 22 seize the forward edge of the sheet 12 and pull it further into the inlet slot 18. Before the sheet to be handled has been pulled by the driving roller arrangement 21 and 22 completely into the inlet slot 18, however, a vacuum retaining unit 23 (FIG. 2) blocks further movement of the sheet. In this respect, the idler rollers 21 are freewheeling while the lower driving rollers 22 are driven by motor 24 of the driving roller arrangement, but rollers 22 are not equipped with a friction coating and do not overcome the retaining force of the vacuum retaining unit 23. The vacuum of the retaining unit 23 is obtained from a vacuum source 27 and delivered through a control valve 26 and ducts 25 to vacuum retaining openings of the guide bars 14. The respective sheet position at which the vacuum retaining unit 23 is turned on or deactivated is determined by means of a conventional position indicator 28 in the form of a photocell and a control unit 29. The guide walls 19 and 20 converge, in the manner shown in FIG. 2, from the inlet side toward the inlet slot 18. The upper guide wall 19 and the rollers 21 are attached to a swivel yoke 30 which is swingable upwardly about a swivel axle 31 supported in bearing blocks 32 (FIG. 1) to lift the upper guide wall 19 and the rollers 21 off the lower guide wall 20 and driving rollers 22. In this manner, the inlet slot 18 is accessible. As can be seen from FIGS. 1 and 2, a diagonally-extending bending slot 33 is defined, on the one hand, by a diagonal, curved rerouting flange 34 of the upper guide wall and, on the other hand, by a diagonal, substantially-cylindrical guide member 35 located in opposition to the rerouting flange. The upper guide wall 19 and the lower guide wall 20 extend in the conveying direction of the driving roller arrangement up to the diagonally-extending bending slot 33; and, the axis of curvature of the slot 33 is oriented substantially parallel to the plane of the inlet slot and thus to the plane of the sheet to be handled. The illustrated slot 33 is at an angle of 45 degrees with respect to the leading sheet edge. The upper guide wall 19 is thusly fashioned as a comparatively-rigid cover plate which projects into a diagonal recess of the lower guide wall 20, oriented at 45 degrees to the conveying direction of the driving roller arrangement wherein the diagonal forward edge of the lower guide wall 20 is terminated by the guide member 35. The lower guide wall 20 also forms the upper termination of a guide member 36, a central layer 37 of which is comprised, for example, of polytetrafluoroethylene and is provided with cage recesses 38 wherein roll elements or balls 39 are accommodated. These balls are retained in the cage recesses 38 by means of a lower, end wall 40 of the guide plate 36. The lower end wall 40 is equipped with conventional recesses of adequate diameter and oriented toward the cage recesses 38 in such a manner that the roll elements 39 project in the downward direction through the cutouts of the lower, end wall 40. It can also be seen from FIG. 2 that the central layer 37 of the guide plate 36 is provided with recesses in such a way that the driving rollers 22 of the driving roller arrangement can be accommodated therein. These rollers extend upwardly into the inlet slot 18 through the cutouts of the lower guide wall 20. A table 41 is located underneath the guide member 36 and the top sides of conveyor belts 42 and 43 are guided over this table as shown. These conveyor belts are placed over drive rollers 44 and 46 (driven by motor 48) and idler rollers 45 and 47 arranged at the beginning and at the end of the table 41 respectively. The lower end wall of the guide plate 36, on the one hand, and the table 41, on the other hand, define an outlet slot 49 lying in a plane oriented in parallel to the plane of the inlet slot 18 and spaced therefrom by a distance corresponding essentially to the thickness of the guide member 36. The upper sections or the upper faces of the conveyor belts 42 and 43, on the one hand, and rows of roll elements 39 respectively aligned with the conveyor belts, on the other hand, are effective in the outlet slot 49 as the transport means. This relationship can be readily seen by one skilled in the art from FIGS. 1 and 2. On the outlet side of the conveyor belts 42 and 43, are a pair of casters 50, indicated in dot-dash lines in FIG. 1 and located in opposition to the rollers 45 and 47. Between the casters of the caster pair 50 a disk traveling therewith can be arranged. This is not shown in FIG. 1. The disk is dimensioned in its diameter in such a way that it projects somewhat into the profile of the outlet slot 49 and thus imparts to the discharged sheet a slight transverse bulge whereby the stability of the discharged sheet is increased in a desirable fashion. During operation, a sheet, cut off, for example, from an endless form, is introduced from a cutter in the direction of arrow 17 into the feeding unit 11 and advanced to such an extent that the forward edge of the sheet is finally seized by the driving roller arrangement (21, 22) in the inlet slot 18 and is further advanced in the inlet slot 18. During this step, the rearward sheet-edge finally travels past a feeler 28 which produces a signal and causes a control unit 29 to activate the vacuum retaining unit 23 by opening the valve 26. In this manner, at this point, the sheet is retained by the vacuum suction openings at the outer end of the ducts 25, and the driving rollers 22 initially merely idle underneath the portion of the sheet that is present in the inlet slot 18. When the sheet is released again by closing the valve 26 and shutting off the vacuum retaining unit 23, the driving roller arrangement 21, 22 pushes the sheet forward in the inlet slot so that initially the sheet corner located on the left in FIG. 1 will reach the bending slot 33 and is bent downwards at an angle of 45 degrees. This continues until the sheet corner has reached the outlet slot 49 and is seized between the conveyor belt 42 and the ball denoted by 39A in FIG. 1. The conveying speed of the conveyor belts 42 and 43 in conjunction with the roll elements 39 is preferably higher than the conveying speed of the driving roller arrangement 21, 22. Hence, the sheet to be handled, as soon as its corner lying on the right in FIG. 1, is seized between the conveyor belt 42 and the roll element or the ball 39A and is pulled with increased velocity from the inlet slot 18 into the outlet slot 49. The initially-prevailing contact with the inside of the rerouting flange 34 is then changed to contact with the outer surface of the guide member 35 and the sheet precisely follows the diagonal bend of the guide member 35 in such a way that, based on the 45 degree orientation of the guide member 35, the conveying direction of arrow 51 is obtained in the outlet slot 49 which is at 90 degrees with respect to the feeding direction of arrow 17. In practical embodiments of the device set forth herein and schematically shown in FIGS. 3, 3a, 3b, 3c, and 3d, the feeding unit 11 as well as the unit 10 comprise several juxtaposed sections, wherein the swivel yoke 30 and the swivel axle 31 extend in one piece over these several sections and are equipped in each case with sets of rollers 21 corresponding to the arrangement shown in FIG. 1. Cover-plate sections 19 with rerouting flanges 34, respectively associated with the aforementioned sections, are attached to the swivel yoke 30 and extend over several sections. The rerouting flanges 34 enter in each case into diagonal recesses, provided with guide members 35, of a guide plate 36 of a relatively great length extending in the transverse direction over all of the sections. On the underside of the guide plate 36 is the table 41 which also extends correspondingly over all of the sections of the device; and, correspondingly-lengthened conveyor belts 42 and 43 are extended over the topside of the table 41. The above-described device solves the problem of turning several sheets that are fed side-by-side in a plane and separated from one another in the longitudinal direction, and to individually process and discharge the sheets in a direction perpendicular to the feeding direction, as shown schematically in FIGS. 3a-3d and in a perspective view in FIG. 3. After having been fed and turned and subjected to a change in the conveying direction, the handled sheets succeed one another in this new conveying direction in overlapping relationship. Sheet 52d lying on the right with reference to the illustration of FIG. 3, for example, is transported by the discharge unit as the uppermost sheet while sheet 52a shown to lie on the left-hand side in FIG. 3 is discharged as the lowermost sheet. Thereafter, separation can be conventionally effected and does not cause any difficulties. FIG. 3a schematically illustrates a top view of a two-section device of the invention. FIG. 3b shows a three-section device of the invention; and, FIG. 3c shows four sections of juxtaposed units 10 of the type shown in FIG. 1. FIG. 3d schematically illustrates that feeding units 11 can service a series of juxtaposed units 10 from both sides by merely respectively changing the orientation of the diagonal guide slots 33. While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. For more-secure guidance and rerouting of the sheets to be handled in the guide slot 33 and in the outlet slot 49, for example, it is possible to provide more than two conveyor belts such as 42 and 43 accompanied by associated rows of roll elements 39.
Sheets or sets of sheets are turned very rapidly and reliably, especially after the cutting of endless stationery, conveyed further in a different transport direction and separated in that the leading edge of each sheet is taken to a diagonal bending slot (33) via which a corner of each sheet first reaches an output slot (49).
1
FIELD OF THE INVENTION The present invention relates to a rekeyable padlock of the type comprising a lock housing, a generally U-shaped recess formed in said lock housing and having an entry side, a guide channel defined within said housing, a shackle movable within said channel between an open position in which it is retracted into said housing and frees said entry side of said recess, and a closed position in which it is partly located outside of said housing and closes off said entry side, a lock cylinder, means removably mounting said lock cylinder in said lock housing, a cam movable by said lock cylinder and having an abutment member engageable with said shackle to move said shackle from an open position to said closed position and vice versa. DESCRIPTION OF PRIOR ART A padlock of this kind is known from U.S. Pat. No. 4,998,423 and is basically a minor modification of the so-called "Diskus" type padlocks or padlocks which were first introduced by the company August Bremicke Sohne KG of 58300 Wetter, Germany, many years ago and which have been sold since the early 1950's under the name "DISKUS" (Registered Trade Mark). Such locks have in the past been sold with lock cylinders which were not readily exchangeable, so that the locks were not rekeyable. The term rekeyable will be understood to mean that if a key is lost, or if it is suspected that a key has been acquired by an unauthorized person, it is possible to change the lock cylinder for a new one, operable with a different key without having to rekey the whole lock. In the modification provided by U.S. Pat. No. 4,998,423 the lock cylinder or lock gore is secured by a screw insertable through a threaded bore in a plate member disposed within the lock housing inside of the open ring-shaped shackle. The screw is accessible to permit a removal of the lock cylinder only when the shackle in an intermediate position between the closed and the open position. In this intermediate position a cut-out in the shackle is disposed largely opposite to said recess and access to the locking screw securing the lock cylinder in the lock is achieved through the recess in the shackle. Since the recess is not very deep or long and the abutment member of the cam is also present in this recess, access to the locking screw is not very convenient and thus exchange of the lock cylinder is awkward. In addition, the relatively small screw can be lost within the lock mechanism, which causes a substantial further complication because the lock itself is generally of a sealed construction and cannot easily be opened. Furthermore, the initial assembly of the lock is rather complicated, which increases the cost of manufacture. SUMMARY OF THE INVENTION The principal object underlying the present invention is to provide an alternative way of making known padlocks rekeyable and indeed to ensure that it is relatively forward forward to exchange the lock cylinder when necessary, to ensure that the lock is easy to assemble during manufacture and thus cost-favorable to produce, to ensure that the lock is secure against tampering by an authorized person, and to effect the redesign in a manner which requires only a stall modification to known locks of the "Diskus" type. Although the invention is particularly directed to improving discus; type padlocks, it is also more generally applicable to padlocks, as will be later explained in more detail. In order to satisfy the above object, there is provided a padlock of the initially named kind, which further includes a latch member biased into position in front of a shoulder of said mounting means prohibiting withdrawal of said lock cylinder, and means accessible through said recess when said shackle is in said open position, but not when said shackle is in said closed position, for releasing said latch member from said shoulder to permit the withdrawal of said lock cylinder from said lock housing and replacement of said lock cylinder by a substitute lock cylinder. Thus, it is basically only necessary to provide an additional latch member in the existing lock and to provide the means for mounting the lock cylinder within the lock with a suitable shoulder capable of cooperating with the latch member in order to make the existing lock rekeyable. Because the latch member is accessible through the opening in the side of the recess, into which the shackle normally engages in the closed position of the lock, it is completely inaccessible when the lock is closed, so that the lock is secure against tampering. On the other hand, when the lock is opened, it is easy to disengage the latch member from the shoulder, which permits withdrawal of the lock cylinder from the lock housing. In a preferred embodiment, in which a catch member is provided which is biased in the closed position of the shackle against an abutment provided thereon to prevent an opening movement of the shackle, the mounting means is provided with a second shoulder at a side generally opposite from the first said shoulder, and the catch member is provided with a second latch member engageable in the closed position of the shackle in front of the second shoulder. This means that the mounting means for the lock cylinder is restrained at two opposite sides against movement out of the lock housing. This is a particularly stable arrangement and one in which, in the closed position of the shackle, it is virtually impossible to remove the lock cylinder without destroying the lock. It should be noted that the lock cylinder may be integral with the mounting means, which is then simply formed by correspondingly shaped features such as the first and second shoulder provided on the lock cylinder, or the lock cylinder may be separate from the mounting means. When the lock cylinder is separate from the mounting means, then the mounting means conveniently has a recess complementary to an outer profile of the lock cylinder for receiving at least a portion of the lock cylinder and an abutment engageable with a first end of the lock cylinder to prevent movement of the lock cylinder through the mounting means. A driving dog provided at the other end of the lock cylinder is engageable within a recess or aperture of complementary shape in the cam in order to transmit torque to the cam on rotation of the key. The cam, or means associated therewith, then prevents movement of the lock cylinder away from the mounting means. Thus, the lock cylinder is restrained from movement away from the mounting means in both directions and is thus securely mounted in the lock. In a particularly preferred embodiment of the padlock, the latch member and the catch member are disposed between first and second internal plates of the housing, and spacer means is provided between the first and second plates, maintaining them at a predetermined spacing from one another. The mounting means then conveniently has a spigot member of non-circular cross-rection which merges via a step into a portion of greater diameter. The non-circular spigot portion engages into a complementary aperture in at least one of the front plate and a front wall of the lock housing and prevents rotation of the mounting means relative to the plate and to the lock housing. The first said shoulder, and the second shoulder if provided, are defined on the opposite side of the first plate from the step and the first said latch member and, it provided, the second latch member engage(s) between the respective shoulders and the first plate. This arrangement has the advantage that the latch member or members only need to prevent movement of the mounting means for the lock cylinder out of the lock housing, and the step on the mounting means prevents movement of the mounting means in the opposite direction The torque required to restrain the mounting means from moving when the key is turned in the lock cylinder is achieved by engagement of the non-circular spigot in the correspondingly shaped aperture in the first said plate and/or in the front wall of the housing. The portion of the mounting means of greater diameter, which may, for example, be circular--if a circular aperture is provided in the front wall of the look housing--or flattened at one or more sides, preferably has a radius blending from the point of which it merges from the wall of the lock housing into its exposed end face. This makes it very difficult for a person intent on tampering with the lock to obtain a grip on the mounting means with a tool in an attempt to force it out of the lock housing. Although it is preferred to have the spigot member of non-circular cross-section engage in both the first plate and in a complementary shaped aperture in the front wall of the lock housing it is also possible to dispense with the said first plate altogether, in which case the spacer members would be permanently fixed to the front wall of the lock housing, for example by welding. A particularly important advantage of the present invention is that the latch member can be pivotally supported on a spacer member provided between the first and second plates without the need to provide any additional locating or mounting means within the lock housing, A spring similar to a clothes peg spring can be disposed with its coils around the spacer, with one leg mounted against the lock housing and the other leg against the latch member to bias the latch member towards the position in which it is engaged in front of the first shoulder. Thus, only a spring member and a latch member need additionally be provided in order to realize the present invention. It is, of course, also necessary to provide the shoulder on the mounting means. However, this can be done, for example, simply by machining a groove into the spigot of the existing mounting means. The second latch member provided on the catch simply represents an extension of one limb of the U-shaped catch member, traditionally used in Diskus type locks. Again, this extended limb, i.e. the second latch member, simply engages into a shoulder which can again be conveniently formed by a second groove machined into the previously known spigot portion of the mounting means for the lock cylinder. It is also possible, in accordance with a particularly preferred embodiment of the invention, to arrange the first latch member so that it contacts the shackle, or almost contacts the shackle, in the closed position of the lock, i.e. of the shackle, but can be moved into a recess of the shackle in the fully or partially opened position of the shackle to release the lock cylinder or the mounting means therefor. This design means that the first latch member functions as a deadbolt and cannot be opened in the closed position of the lock because its movement is blocked by the shackle. Since, in a design of this kind, it is possible to prevent movement of the first latch member in the closed position of the shackle, i.e. of the lock, the opening providing access to the first latch member for its release need not be provided in the area of the U-shaped recess but can be provided elsewhere in the lock, for example close to the bottom end of the first latch member. That is to say, access to the first latch member is always possible, but it can only be moved when the lock is fully or partly open. Although the present invention is preferably used with a padlock of a discus type, it is also of more general application. In this respect, there is provided in accordance with the present invention a lock comprising a housing having a guide channel, a key cylinder, a shackle or bolt member movable in said guide channel between a retracted opened position and an advanced closed position, an abutment member mounted in said housing for moving said shackle or bolt member in response to movement of a key in said key cylinder, means associated with said key cylinder and engageable by a latch member disposed within said lock housing to retain said key cylinder in said lock housing, and means accessible when said shackle or bolt member is in said open, retracted position, permitting access to said latch member to release said key cylinder from said lock housing and permit removal and replacement of said key cylinder. BRIEF LISTING OF THE FIGURES The present invention will now be described in further detail by way of example only and with reference to a preferred embodiment as shown in the accompanying drawings, in which are shown: FIG. 1 is a view of the front side of a padlock in accordance with the present invention, FIG. 2 is a view in the direction of the arrow II in FIG. 1, FIG. 3 a view of two spaced plate members used inside the lock of FIG. 1 as seen from the front in the same direction III of FIG. 2, FIG. 4 is a view in the direction of the arrow IV in FIG. 3, but with certain parts omitted for the sake of clarity, FIG. 5 a view of the lock of FIG. 1 seen in the same direction as the view of FIG. 1, but with the front wall of the lock housing and the front plate removed, with the lock in the closed state, FIG. 6 is a view similar to that of FIG. 5, but with the lock in the open state, FIG. 7 is a view similar to that of FIG. 6, but in which a pin member is used to disengage the first latch member, FIG. 8 is a view on a mounting means for a lock cylinder used in the lock of FIG. 1, with the view of FIG. 8 corresponding to the view in direction II in FIG. 1, but with the mounting means rotated through 180° relative to FIG. 1, FIG. 9 is a view in the direction IX in FIG. 8, FIG. 10 a view in the direction X of FIG. 8, but with the lock cylinder removed, FIGS. 11 and 12 are two drawings closely similar to FIGS. 5 and 7 but showing a slight modification of the lock, and FIG. 13 a perspective view of a modified shackle 14. DESCRIPTION OF THE PREFERRED EMBODIMENT Turning now to FIG. 1, there can be seen a padlock or padlock of the discus type having a lock housing 10 which is circular in side view and which has a generally U-shaped recess 12, which in this drawing is closed at its uppermost side in the drawing of FIG. 1 by a shackle 14. The lock can be opened by moving the shackle 14 by means of a key (not shown) inserted into the lock cylinder 16 by turning the key in the clockwise direction "a" in FIG. 1. This results in a rotation of the shackle 14, which generally has the shape of an open ring, in the same direction "a". This rotation of the shackle 14 takes place from the closed position shown in FIG. 1, in which its end 18 is located within the housing at the left hand side of the U-shaped recess 12, to an open position in which its end has moved to the position 18' at the right-hand side of the U-shaped recess 12 as shown in FIG. 1. In this case the U-shaped recess 12 is open at the top, i.e. at the entry side, so that for example two end links 19, 19' of a chain shown partly sectioned in FIG. 1 can be engaged around the shackle 14 within the U-shaped recess 12. On subsequent closing of the lock by rotation of the key in the anti-clockwise direction, the shackle returns to the position shown in FIG. 1, thus securely retaining the two end links 19, 19' of the chain. It will be noted from the drawing of FIG. 1 that only the front end of the lock cylinder 16 is visible and that the remainder of the lock cylinder, for example as shown in broken lines at 26, is hidden within a mounting means 28 for the lock cylinder, which will later be described in more detail. Referring to FIG. 2, it can be seen that the mounting means 28 has a rounded edge 30 at the transition from the front wall 32 of the lock housing to the end face 34 of the mounting means. This makes it very difficult for a person trying to tamper with the lock to get a firm grip on the mounting means 28, such as might be expected in an attempt to break or vandalize a lock. FIG. 2 also shows that the lock housing has, in addition to the front wall 32, a rear wall 36 of substantially identical shape except that the rear wall has a bulge 38 corresponding generally in shape to the front portion of the mounting means 28 for the lock cylinder 16. It will also be apparent from the view of FIG. 2, and in particular from the broken lines shown in FIG. 2, that the front and rear walls 32, 36 of the lock housing which meet at the partition line 40 form a generally ring-shaped guide channel 42 which serves to guide the open ring-shaped shackle 14 represented in cross-section by the broken lines in FIG. 2. It will also be noted that the rounded outside rim portions of each of the front and rear walls 32 and 36 of the housing merge via respective, generally circular, ring steps 44 and 46 into front and rear parallel wall portions 48 and 50. The purpose is to form internal recesses 49, 51 to accommodate first and second plate members 52 and 54, as shown in FIGS. 3 and 4, which accommodate the mechanism of the lock and also serve to join the two halves of the lock housing together. More specifically, it can be Been from FIG. 4 that the front and rear plates 52 and 54 are spaced apart parallel to one another by four spacer members 56, 58, 60, 62 (the ends of which can also be seen in FIG. 3). The ends of the four spacers 56, 58, 60, 62 are both stepped (as can be seen, for example, from the drawings of FIGS. 5, 6 and 7) and are riveted over at the positions at which they protrude through the front side of the first plate 52 (the lower side in FIG. 4) and the rear side of the second plate 54 (the top side in FIG. 4). Thus, the spacers 56, 58, 60, 62 and the plates 52, 54 form a rigid assembly. In addition, two hemispherical protrusions 64 and 66 can be seen at the rear side of the plate 54 (in FIG. 4). During assembly of the lock a current is first transmitted through the second plate 54 and through the rear wall 36 of the housing to cause the plate 54 to be welded to the housing at the positions of the protrusions 64, 66. This secures the rigid assembly of the spacers 56, 58, 60, 62 and plates 52, 54 relative to the lock housing 10. During final assembly, after addition of the front plate of the housing, the front and rear walls 32, 36 of the lock housing 10 are welded together along the partition line 40. This welding is effected from about the 1 position to the 11 position in FIG. 1. In FIG. 4 only part of the lock mechanism is actually shown, namely the cam 68 which is riveted via a tubular rivet 70 to the second plate 54. The riveting is effected in such a way that the cam 68 is rotatable on the tubular rivet 70. In addition, the view of FIG. 4 allows a protruding abutment member 72 on the cam 68 to be seen, which--as will later be explained--engages into a recess in the ring-shaped shackle. Furthermore, the view of FIG. 4 permits a lug 74 to be seen which limits the rotation of the cam relative to the lock cylinder (by abutment against part 26, FIGS. 1 and 9). Turning now to FIG. 5, the lock is shown with the front wall 32 of the lock housing 10 and the first front plate 52 of the lock mechanism removed. In the view of FIG. 5 it is first possible to see the recess 76 in the open or C-shaped shackle 14. It is also possible to see the abutment 72 engaged in the recess 76 of the shackle. Moreover, it will be noted that the abutment member 72 is in contact with the spacer member 62 limiting rotation of the shackle 14 in the closing direction. The drawing of FIG. 5 also shows in side view a catch member 78 which is pivotally journalled on the spacer 60 between the first and second plates 52, 54. The catch member 78 is of U-shape and has a rear limb 80 which is represented in part by the broken line in FIG. 5. The rear limb 80 has a rounded nose 82 which engages with a cut-out 84 in the cam 68. The reference numeral 86 indicates a spring which has coils around the spacer member 60, a first limb 88 which abuts against the spacer 62, and a second limb 90 which abuts against the web portion 92 of the catch member 78 and biases the catch member 78 in the clockwise direction "a" as seen in FIG. 5. That is to say, the spring 86 serves to keep the nose 82 engaged in the recess 84 of the cam and also serves to keep the web 92 of the catch member engaged in a recess 96 in the shackle 14, which prevents rotation of the shackle 14 in the opening direction shown by the arrow "a". It will be noted that the second limb 102 of the catch member 78 extends parallel to the first limb 80 and terminates in a straight edge portion, to which the lead line for the reference numeral 102 extends, the purpose of which will be explained later. A latch member 104 can be seen to the left of the cam 68 in FIG. 5, which is again of generally U-shape, having a first limb 106 represented by the broken line, a second limb 108 overlapping the front of the cam 68 in FIG. 5 and a web member 110 which joins the front and rear limbs 106, 108 of the latch member 104. The latch member 104 is pivotally mounted about the spacer 58 and is biased by a second spring 112 resembling the spring 86 for the catch member 78. The second spring 112 has a first limb 114 contacting the spacer member 56, coils around the spacer member 58 and a second limb 118 engaged with the web 110 of the latch member 104. The spring 112 serves to bias the latch member 104 in the anti-clockwise direction into the position shown in FIG. 5. FIG. 6 shows the same situation as in FIG. 5, but with the shackle 14 in the open position after the cam 68 has been rotated by the key and the lock cylinder through about 120° in the clockwise direction. First of all it will be noted that the abutment member 72 is now engaged with the opposite side of the recess 76 and has rotated the shackle 14 in the direction of the arrow "a" of FIG. 5 into the open position in which the entry 19 to the U-shaped recess 12 is free (enabling the chains to be removed or inserted into the lock, as the case may be). At the start of this rotation, the cam nose 120 adjacent the cam recess 84 first rotates the catch member 78 in the anti-clockwise direction so that the web 92 disengages from the recess 96 in the open ring-shaped shackle 14. After this initial opening movement of the catch member 78, the nose 82 thereof slides on the circular surface 122 of the cam 68, so that no further rotational movement takes place. During this opening movement the latch member 104 remains in the position shown in FIG. 5. It will also be noted from the drawings of FIGS. 5, 6 and 7 that the tubular rivet 70 actually has a D-shaped aperture 71, and this serves to accommodate a corresponding dog 98 of D-shaped section of the lock cylinder (shown in FIGS. 8 and 9,) so that torque can be transmitted from the lock cylinder to the cam 68 in both directions of rotation of the key in the lock cylinder. The drawing of FIG. 7 shows basically the same situation ms in FIG. 6 but indicates that a pin 113 can be inserted between the spacer 58 and the web 110 of the latch member 104, and indeed through an opening 132, into which the end 18 of the shackle 14 engages in the closed position of the lock. By pushing the tapered end of the pin 113 through the space between the spacer 56 and the web 110, optionally with a small turning movement in the anti-clockwise direction, the latch member 104 can be pivoted against the force of the spring 112 in the position shown into FIG. 7. That is to say, the latch member 104, more specifically the limb 108 of the latch member 104, is now also disengaged from the shoulder 130 of the mounting means 28 for the lock cylinder 16, as shown in FIGS. 8 and 10. FIG. 8 shows that the shoulder 130 is defined by a groove 142 milled into one side of a spigot 144 of the mounting means 28. In addition, FIG. 8 also shows the second shoulder 146, again formed by a groove 148 milled into the mounting means 28, with the groove 148 accommodating the second latch member formed by the limb 102 of the catch member 78, when the latter is in the position shown in FIG. 5, i.e. when the lock is closed. The groove 148 can be seen in side view in FIG. 9. The same side view indicates that the groove 142 for the latch member 104 is extended downwardly further than the groove 148. In addition, FIGS. 8, 9 and 10 show the step 150 formed between the spigot portion 144 of the mounting means 28 and the portion 30 of greater diameter, which protrudes from the front face of the lock in FIG. 1. In this design a second step 151 contacts the front face of the plate 52, i.e. the lower plate in FIG. 4. The distance "d" between the step 151 and the edges of the grooves 142, 148 close to it corresponds to the thickness of the first plate 52. This means that the mounting means 28 is securely trapped in the first plate 52 between the shoulder 150, on the one side, and between the first and second latch members on the other side. In addition, FIGS. 8 and 10 show a shoulder 152 within the mounting means 28, which prevents the lock cylinder 16 from moving out of the mounting means 28 in the direction of the arrow 154 in FIG. 9. The other end face 156 of the lock cylinder confronts directly the front face of the tubular rivet 70 securing the cam 68 (apart from the driving dog which projects beyond it) and this prevents the movement or the lock cylinder 16 away from the shoulder 152. Thus, the operation of the lock as described above will be understood to be as follows: In FIG. 5 the padlock is shown in its closed position within the circular casing 10 having the U-shaped recess 12. The open, ring-shaped shackle 14 is located within the casing 10 and is slidable between the locked position of FIG. 5 and the open position of FIG. 6 by movement in the direction indicated by the arrow a. The sliding of the shackle 14 is initiated by turning a key (not shown) in the lock cylinder (also not shown in FIG. 5), thereby turning the control cam 68, which is connected to the lock cylinder. The control cam 68 is provided with the projection 72 which engages into the recess 76 in the shackle 14. In order to open the lock, the control cam 68 is rotated in direction b via the lock cylinder 16 and in this way the shackle 14 is moved to the position shown in FIG. 6. In the closed position (FIG. 5) the shackle 14 is locked by the catch 78, which engages the locking edge 96 of the shackle 14. In order to move the shackle 14 into the open position (FIG. 6), the control cam 68 rotates catch 78 in direction c so that catch 78 no longer blocks shackle 14 via engagement of the web 92 with the side 96 of the locking recess. It is an important feature of the lock that it is rekeyable, which means that the lock cylinder can be exchanged. To achieve the possibility of exchanging the lock cylinder 16, catch 78 has a double function in the present lock. On the one hand, catch 78 serves to block the shackle 14 in the closed position. On the other hand, the portion 102 of catch 78 engages into the groove 148 (FIG. 8) of the cylinder housing or mounting means 28 in front of the shoulder 146 in order to fix the cylinder housing 28 in the lock. By turning the catch 78 in direction c, portion 102, the second latch member, is moved away from the groove recess 148, so that the cylinder housing 28 is no longer fixed in the lock by catch 78. The corresponding position of catch 78 is shown in FIG. 6. To prevent the cylinder housing 28 from being removed from the lock in the open position (FIG. 6), the first latch member 104 is provided, which is biased in direction "d" (FIG. 5). Latch 104 engages the second groove or recess 142 (FIG. 8) of the cylinder housing 28 in front of the shoulder 130 and therefore secures the cylinder housing 28 in the lock when the lock is open. In order to remove the cylinder housing 28 (with the lock cylinder 16) from the lock, an instrument, for example the nail 131, can be inserted in the lock via the opening 132 (see FIG. 7). The latch 104 can be turned by the nail 131 against its biasing force in direction e so that the latch 104 no longer engages with the groove 142 of the cylinder housing 28. In this position, which is shown in FIG. 9, the cylinder housing 28 can be removed from the lock. Thereafter, the latch cylinder (if separate from the cylinder housing 28) can be simply withdrawn axially from the cylinder housing and replaced by a new lock cylinder operable with a new key. The process of inserting the rekeyed lock cylinder into the lock takes place in reverse sequence to its removal, as described above. It will be noted that the lock as described above can also be realized in a special way, making it even more secure and also permitting access to the first latch member in an alternative and possibly more convenient manner. This modification is shown in FIGS. 11, 12 and 13, which are very similar to FIGS. 5 and 7. It will be noted that in FIG. 11 the bottom end of the first latch member 104 has been deflected at a bend or jog 160 towards the central plane of the lock, i.e. the plane containing the partition line 40, so that it now contacts or nearly contacts the surface of the C-shaped shackle 14 in the closed position of the lock. This is not the case in FIG. 5 (although it may appear so in the drawing) because the relevant limb of the latch member is laterally displaced from the central plane of the lock, where the shackle 14 has the smallest internal diameter. Thus, in the modification of FIGS. 11 and 12 the first latch member acts as a deadbolt and cannot be released when the shackle is in the closed position. However, the shackle is provided with a cut-out 162 adjacent the recess 76 which provides sufficient clearance for the first latch member 104 to be moved in the direction of the arrow "e" when the shackle 14 is open. Clearly the cut-out 162 could also be positioned such that movement of the first latch member 104 to release the lock cylinder is also possible in an intermediate position of the shackle 14. Since the first latch member 104 cannot be opened when the shackle 14 is closed, i.e. the lock is closed, it is possible to provide the access opening for the latch member outside of the unshaped recess 12, for example as indicated by the opening 164 in FIG. 11. Finally, FIG. 13 shows the shackle on its own and indeed in this case in a modified version with a flattened portion 166 adjacent the bottom end of the latch member on which the bottom end of the latch member 104 rests in the closed position of the shackle. This makes the positioning of the bottom end of the latch member less critical and can obviate the need for the bend 160 in the first latch member.
A rekeyable padlock comprises a lock housing, a generally U-shaped recess formed in said lock housing and having an entry side, a guide channel defined within said housing, a shackle movable within said channel between an open position in which it is retracted into said housing and frees said entry side of said recess, and a closed position in which it is partly located outside of said housing and closes off said entry side, a lock cylinder, means removably mounting said lock cylinder in said lock housing, a cam movable by said lock cylinder and having an abutment member engageable with said shackle to move said shackle from said open position to said closed position and vice verse, a latch member biased into position in front of a shoulder of said mounting means prohibiting withdrawal of said lock cylinder and means accessible through said recess when said shackle is in said open position, but not when said shackle is in said closed position, for releasing said latch member from said shoulder to permit withdrawal of said lock cylinder from said lock housing and replacement of said lock cylinder by a substitute lock cylinder
4
[0001] This application is based on Japanese Patent Application No. 2008-136364 filed on May 26, 2008, which is incorporated hereinto by reference. BACKGROUND OF THE INVENTION [0002] The present invention relates to a sheet ejection device that aligns a position of a sheet in its width direction on a sheet ejection tray, an image forming apparatus equipped with the sheet ejection device and a sheet finisher equipped with the sheet ejection device. [0003] In a sheet ejection device that ejects a large quantity of sheets, the large quantity of sheets are ejected on a sheet ejection tray and are stacked, and after that, a bundle of sheets is given processing treatment. Therefore, the plenty of sheets are sometimes conveyed to another processor. In that case, a bundle of sheets prior to the processing treatment is required to have high compatibility. Accordingly, there is known a sheet ejection device equipped with an alignment member that aligns a bundle of sheets stacked on the sheet ejection tray. [0004] Further, there is available a sheet ejection device by which a bundle of sheets is moved through shifting to a different position in the direction perpendicular to a sheet ejecting direction in a unit of one set of sheets so that dividing of sheets stacked on the sheet ejection tray in a unit of one set may become easy. In the sheet ejection device having the shifting function of this kind, high compatibility is required for each bundle of sheets at each shifting position. [0005] Further, an image forming system that contains an image forming apparatus and is capable of processing at high speed is in a trend to be used as a shortrun printing apparatus, and when it is used as a shortrun printing apparatus, there is a growing trend wherein the image forming system is required to have capabilities to align a sheet on which an image has been formed with a sheet which has been processed by another apparatus to eject them. [0006] In Unexamined Japanese Patent Application Publication No. 2002-211829, there is proposed to shift under the highly-aligned configuration and thereby to integrate by providing a shifting function on a sheet ejection tray. [0007] In the case of a high-speed image forming apparatus and an image forming system composed of a high-speed image forming apparatus and a sheet finisher, a large quantity of sheets are integrated on a sheet ejection tray. [0008] An integrated sheet is conveyed from a sheet ejection tray to another processing station, to be sent to the succeeding processing progress. [0009] When conveying a sheet from a sheet ejection tray to the succeeding processing progress, the sheet is taken out of the sheet ejection tray manually in many cases. [0010] However, handling of a sheet having a large volume and large mass is not easy, and there are sometimes generated accidents including destroyed alignments caused by contact between aligned sheets and surrounding mechanical parts, and injures caused by contact between an operator's hand and mechanical parts. [0011] In particular, when an alignment member is provided at the position near a sheet ejection tray, the number of chances to come in contact with the alignment member grows greater. [0012] The alignment device disclosed in Unexamined Japanese Patent Application Publication No. 2002-211829 is not equipped with a safety device for the aforesaid accidents. SUMMARY OF THE INVENTION [0013] An aspect of the invention is as follows. [0014] 1. A sheet ejection device equipped with a sheet ejection tray on which ejected sheets are stacked and an alignment member that aligns positions of the ejected sheets in their width directions, which is characterized to have a supporting unit that supports the aforesaid alignment member so that the alignment member may be displaced in the direction for the alignment member to intersect the direction of ejection for sheets when an external force is applied on the alignment member. [0015] 2. An image forming apparatus is characterized to have a sheet ejection device described in the Item 1 above. [0016] 3. A sheet finisher is characterized to have a sheet ejection device described in the Item 1 above. BRIEF DESCRIPTION OF THE DRAWINGS [0017] FIG. 1 is a diagram showing an overall structure of an image forming system equipped with a sheet ejection device relating to the embodiment of the invention. [0018] FIG. 2 is a front sectional view of sheet ejection device 100 . [0019] FIG. 3 is a diagram showing a mechanism to detect a height of an alignment member. [0020] FIG. 4 is a block diagram of a controlling system that conducts shifting control. [0021] FIG. 5 is a diagram showing a shifting process. [0022] FIG. 6 is a diagram showing an alignment position, the first receding position and the second receding position. [0023] FIG. 7 is a diagram showing a safety mechanism of a shifting section showing a safety mechanism of an alignment member. [0024] FIG. 8 is a diagram showing a safety mechanism of a shifting section showing a safety mechanism of an alignment member. [0025] Each of FIGS. 9( a )- 9 ( c ) is a diagram showing a safety mechanism of a shifting section showing a safety mechanism of an alignment member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0026] FIG. 1 is a diagram showing an overall structure of an image forming system composed of image forming apparatus A, automatic document feeder DF, sheet finisher FS and large capacity sheet feeding device LT. [0027] The illustrated image forming apparatus A is equipped with image reading section 1 , image processing section 2 , image writing section 3 , image forming section 4 , a sheet conveying section and fixing device 6 . [0028] The image forming section 4 is composed of photoreceptor drum 4 A, charging unit 4 B, developing unit 4 C, transfer unit 4 D, separation unit 4 E and cleaning unit 4 F. [0029] The sheet conveying section is composed of sheet feed cassette 5 A, first sheet feed section 5 B, second sheet feed section 5 C, first conveyance section 5 D, second conveyance section (automatic two-sided copy conveyance section) 5 E and sheet ejection section 5 F. [0030] Sheet finisher FS is connected to the sheet ejection section 5 F side on the illustrated left side of the image forming apparatus A. [0031] Images on one side or both sides of document “d” placed on a document table of the automatic document feeder DF are read out by an optical system of the image reading section 1 , and are read in by CCD image sensor 1 A. [0032] Analog signals converted photo-electrically by CCD image sensor 1 A are subjected to processing such as analog processing, A/D conversion, shading correction and image compression processing, in image processing section 2 , and are stored in an image memory (not shown). [0033] In image writing section 3 , photoreceptor drum 4 A of the image forming section 4 is irradiated with light outputted from a semiconductor laser, and a latent image is formed. In the image forming section 4 , there are carried out treatments such as charging, exposure, developing, transfer, separation and cleaning. An image is transferred by transfer unit 4 D onto sheet S that is fed from the sheet feed cassette 5 A and from the large capacity sheet feeding device LT by the first sheet feed section 5 B. The sheet S carrying the image is subjected to fixing processing by the fixing device 6 , and is fed into sheet finisher FS from sheet ejection section 5 F. [0034] The sheet S which has been subjected to the fixing processing is fed into second conveyance section 5 E by conveyance path switching plate 5 S, then, is fed again and in the image forming section 4 , and it is ejected from sheet ejection section 5 F after being subjected to image forming on the reverse side of the sheet S. [0035] The large capacity sheet feeding device LT is composed of sheet stacking unit 11 and of first sheet feed unit 12 , and it stores a large number of sheets S stacked, and feeds sheet S into image forming apparatus A. [0036] The sheet finisher FS is one that conducts folding processing and shifting processing for sheet S and addition sheet F to eject them to fixed sheet ejection tray 28 or to rising and falling sheet ejection tray 29 . [0037] The sheet finisher FS is equipped with sheet carry-in section 21 , horizontal conveying section 22 , lower conveying section 23 , folding processing section 24 , addition sheet conveying section 25 and with upper conveying section 26 . [0038] Sheet S ejected from the image forming apparatus A passes through the horizontal conveyance section 22 and the upper conveying section 26 to be ejected to fixed sheet ejection tray 28 , or passes through the horizontal conveyance section 22 to be ejected to the rising and falling sheet ejection tray 29 , or passes through the lower conveying section 23 to be ejected to the rising and falling sheet ejection tray 29 after being subjected to the folding processing in the folding processing section 24 . [0039] Addition sheets F such as sheets for interleaf and sheets for a cover are stored in addition sheet feed section 27 , and addition sheets F are added to recording sheets coming from the image forming apparatus A, and they pass through the aforesaid conveyance section to be ejected to the rising and falling sheet ejection tray 29 . [0040] Sheets S are ejected to the fixed sheet ejection tray 28 , in the mode to form a small number of images and in the image forming mode wherein neither folding processing nor shifting processing is carried out. [0041] Under the modes including a folding mode, a mode of forming a large quantity of images for forming a large number of image sheets, and a shifting sheet ejection mode, sheets S and addition sheets F are ejected to the rising and falling sheet ejection tray 29 . [0042] The folding processing section 24 is equipped with functions to conduct various types of folding processing such as twofold and various types of folding in three, as is widely known, whereby, folded sheets S and addition sheets F are conveyed upward, and then, are ejected in the rising and falling sheet ejection tray 29 by sheet ejection roller 30 provided on horizontal conveying section 22 . [0043] Sheet ejection device 100 including the rising and falling sheet ejection tray 29 is equipped with shifting sheet ejection functions. [0044] Next, the sheet ejection device 100 having shifting sheet ejection functions will be explained as follows. [0045] Incidentally, in the following explanation, sheet S includes addition sheet F. [0046] FIG. 2 is a front sectional view of sheet ejection device 100 . [0047] The sheet ejection device 100 is structured to be a sheet ejection device of sheet finisher FS. However, it is also possible to make it to be a sheet ejection device of image forming apparatus A. [0048] As stated above, sheet S and addition sheet F are ejected to rising and falling sheet ejection tray 29 representing a sheet ejection tray, and in the following explanation, a general name of sheet S is given to both of the sheet S and the rising and falling sheet ejection tray 29 . [0049] Though the sheet S ejected by sheet ejection roller 30 is ejected to the rising and falling sheet ejection tray 29 , as stated above, FIG. 2 shows sheet S stacked on the rising and falling sheet ejection tray 29 . [0050] An upper surface of the sheet S is detected by sensor 105 that is composed of a photo-electronic sensor, and the rising and falling sheet ejection tray 29 is moved up and down so that the upper surface of the sheet S may be kept constantly at the fixed height. The up-and-down movement of the rising and falling sheet ejection tray 29 of this kind is carried out by a drive of a motor (not shown) controlled by a controller. [0051] On the rising and falling sheet ejection tray 29 , there is formed concave portion 29 A that is positioned just beneath alignment members 101 and 102 . [0052] When sheet S is stacked on the rising and falling sheet ejection tray 29 , there is formed a gap between the sheet S and the rising and falling sheet ejection tray 29 , by the concave portion 29 A as illustrated. [0053] When an operator takes sheet S out of the rising and falling sheet ejection tray 29 , it is possible to take out sheet S by inserting a hand into the gap formed by the concave portion 29 A. [0054] Above the rising and falling sheet ejection tray 29 , there are arranged side by side a pair of plate-like alignment members 101 and 102 which align sheet S in a horizontal direction (hereinafter referred to as width direction) that is perpendicular to the direction for conveyance and ejection of sheet S. [0055] The paired alignment members 101 and 102 can swivel in the direction to recede from the rising and falling sheet ejection tray 29 around axis of gyration AX, and they are established at an alignment position shown with solid lines, a first receding position shown with dotted lines ( 101 A, 102 A) and a second receding position shown with dotted lines ( 101 B, 102 B). [0056] The alignment members 101 and 102 are swiveled by a drive of motor 104 and are established at the aforesaid alignment position, first receding position and a second receding position. [0057] At the alignment position shown with solid lines, the empty weight of the alignment member 101 or 102 makes it to be on sheet S. [0058] The alignment members 101 and 102 reciprocate in the width direction of sheet S as will be explained later, and this reciprocating movement is conducted by a drive of motor 103 in which the driving force of the motor 103 is transmitted to the alignment members 101 and 102 through a transmission mechanism employing a belt and a pulley. [0059] Positions of rotation of the alignment members 101 and 102 , in particular, alignment positions, the first receding position and the second receding position are set based on signals outputted by sensor 106 (shown in FIG. 3 ) composed of the photo-electronic sensor. [0060] FIG. 3 shows a mechanism that constitutes a detecting device which detects a height of each of alignment members 101 and 102 . Encoder 107 is fixed on axis of gyration AX for alignment members 101 and 102 , and sensor 106 detects a position of rotation of the encoder 107 . [0061] FIG. 4 is a block diagram of a control system that conducts shifting sheet ejection control in sheet ejection device 100 . In the drawing, the numerals 103 and 104 represent motors which drive respectively alignment members 101 and 102 , as explained earlier, and 106 represents a sensor that detects positions of rotations of alignment members 101 and 102 . [0062] SE represents a sheet sensor provided at sheet carry-in section 21 in FIG. 1 . [0063] Controller 110 conducts shifting control based on detection signals of sensor 106 and of sheet sensor SE. [0064] Next, shifting control will be explained, referring to FIG. 5 . [0065] In FIG. 5 , directions shown by arrow V 1 , V 3 and V 5 represent a first direction that is perpendicular to the conveyance ejection direction for sheet S and is in parallel with sheet surface on the rising and falling sheet ejection tray 29 (hereinafter referred to as width direction). [0066] Bundle of sheets SS 1 in quantity of sheets constituting one unit of an established shift is stacked on the rising and falling sheet ejection tray 29 , as shown in step SP 1 . [0067] In the step SP 1 , alignment members 101 and 102 are set to the alignment height that is a lower position shown with solid lines in FIG. 2 . This lower position is a position where a position of a lower end of alignment members 101 and 102 is slightly lower than a sheet supporting surface for the sheet of the rising and falling sheet ejection tray 29 . [0068] Therefore, when the alignment member 101 or 102 is set to the lower position, the empty weight thereof makes it to be existent on the rising and falling sheet ejection tray 29 . [0069] The alignment member 102 reciprocates in the width direction of sheet as shown with arrow V 1 to align sheet S. Sheet alignment is carried out in a way that the alignment member 102 moves each time a sheet of the sheet S is ejected. [0070] At a step when bundle of sheets SS 1 arrives at the established number of sheets, which is notified by signals coming from sheet sensor SE, alignment members 101 and 102 move by about 2 mm outwards in step SP 2 to part from the side edge of bundle of sheets SS 1 , and then, the alignment members rise as shown with arrow V 2 . Incidentally, “outwards” means a direction toward an outside from the center of sheet S in terms of its width direction. [0071] A distance of the movement shown with arrow V 2 is a distance by which a lower end of each of alignment members 101 and 102 parts from the upper surface of the bundle of sheets SS 1 . [0072] In step SP 2 , alignment members 101 and 102 are set to a receding height at which the alignment members are away from the upper surface of the bundle of sheets SS 1 . [0073] In the meantime, the receding height of the alignment members 101 and 102 shown in step SP 2 corresponds to the second receding position in FIG. 2 . [0074] The second receding position shown with 101 B and 102 B in FIG. 2 is lower than the first receding position (shown with 1 - 1 A and 102 A) at which the alignment members 101 and 102 are positioned when sheet ejection device 100 is in the shutdown condition. [0075] After rising, the alignment members 101 and 102 moves horizontally toward the right side (in the width direction) as shown with arrow V 3 . A distance of the movement shown with arrow V 3 is a distance corresponding to an amount of shifting. [0076] Next, as shown in step SP 3 , the alignment members 101 and 102 fall as shown with arrow V 4 . [0077] The alignment members 101 and 102 fall so that their lower edges may become lower slightly than the upper surface of the bundle of sheets SS 1 . As a result, the alignment member 102 mounts on the bundle of sheets SS 1 , and the lower edge of the alignment member 101 becomes to be slightly lower than the uppermost surface of sheet S. [0078] In step SP 4 , the alignment member 101 reciprocates in the width direction as shown with arrow V 1 , to align a sheet. [0079] Step SP 5 is a step identical to step SP 2 wherein alignment members 101 and 102 rise as shown with arrow V 2 , and then, move horizontally toward the left side as shown with arrow VS. [0080] In step SP 6 following the step SP 5 , alignment members 101 and 102 fall as shown with arrow V 4 , to be set at shifted alignment positions. [0081] In succeeding step SP 7 , alignment member 102 reciprocates as shown with arrow V 1 , to align sheet S. [0082] Bundles of sheets SS 1 , SS 2 and SS 3 which have been subjected to shifting processing by aligning processes in steps SP 1 -SP 7 are formed. [0083] In FIG. 6 , alignment positions of alignment members 101 and 102 , the first receding position and the second receding position as positions in the width direction. [0084] As illustrated, the first receding position is on the outside of the second receding position in terms of the width direction. [0085] Namely, the first receding position is a position in the case when the alignment members 101 and 102 are in the standby state, and the first receding position is set to be outside of the operation range of the aforesaid position. [0086] Further, the second receding position is a position wherein each of the alignment members 101 and 102 is shifted outward slightly (for example, 2 mm) from the alignment position, as stated earlier. [0087] The alignment members 101 and 102 are set to the home position, namely, the first receding position, based on signals of sheet ejection completion. [0088] In this case, each of the alignment members 101 and 102 is at the outside of an operation range parting greatly from the rising and falling sheet ejection tray 29 as shown in FIG. 2 , and it is set to be high and to the position in the outside in the width direction as shown in FIG. 6 . [0089] Each of FIGS. 7-9( c ) shows a safety mechanism for the alignment member. [0090] FIG. 7 is a front elevation of alignment member 101 , FIG. 8 is an exploded view of an installing structure for the alignment member and each of FIGS. 9( a )- 9 ( c ) is a plane view of the alignment member viewed from the upper part and it is a diagram showing operations of the safety mechanism. In the mean time, a safety mechanism shown in FIGS. 7-9( c ) and explained as follows is one for alignment member 101 , and a safety mechanism that is the same as the aforesaid safety mechanism is provided also on alignment member 102 . [0091] The alignment member 101 has shaft 112 on the edge portion on the upstream side in the sheet ejection direction, and it is attached on intermediate supporting member 110 and on supporting member 111 by which the alignment member 101 is attached on a sheet finisher. Namely, the alignment member 101 is connected with the intermediate supporting member 110 and with the supporting member 111 , y getting the shaft 112 that forms a base portion of the alignment member 101 through a hole (not shown) of the intermediate supporting member 110 and through a hole provided on the supporting member 111 . [0092] Coil springs 113 and 114 are wound around the shaft 112 . [0093] A bottom end of the coil spring 113 is fixed on the alignment member 101 , and its top end is fixed on the intermediate supporting member 110 . [0094] Further, a bottom end of the coil spring 114 is fixed on the supporting member 111 , and its top end is fixed on the intermediate supporting member 110 . [0095] On the right side of the intermediate supporting member 110 in each of FIGS. 9( a )- 9 ( c ), there is formed projection 110 A, and on the left side thereof, there is formed projection 110 B. [0096] The projection 110 A hits the supporting member 111 , while, the projection 110 B hits the alignment member 101 . [0097] The alignment member 101 can swivel around the shaft 112 . The shaft 112 is in parallel with a sheet ejection direction in FIG. 2 . [0098] Namely, the alignment member 101 can swivel in the second direction around the shaft that is in parallel with a sheet ejection direction. [0099] FIG. 9( a ) shows a posture of the alignment member 101 on the occasion when no external force is applied, FIG. 9( b ) shows a posture of the alignment member 101 on the occasion when external force shown with F 1 is applied, and FIG. 9( c ) shows a posture of the alignment member 101 on the occasion when external force shown with F 2 is applied. [0100] When external force F 1 is applied on the alignment member 101 , the alignment member 101 swivels clockwise as shown with W 1 . The direction W 1 is a direction toward the outside for the sheet stacking area (sheet width area) on rising and falling sheet ejection tray 29 , namely, it is a direction toward the outside from the center in the width direction. The relationship between sheet S on the rising and falling sheet ejection tray 29 and the alignment member 101 is as shown in FIG. 9( a ). As is illustrated, the direction W 1 is a direction to be displaced toward the outside while being pressed by an edge portion of sheet S in the width direction. [0101] In the case of swiveling shown in FIG. 9( b ), an engagement action of projection 110 A prevents intermediate supporting member 110 from swiveling. Therefore, there is caused relative swiveling between the alignment member 101 and the intermediate supporting member 110 . [0102] For this relative swiveling, stress of coil spring 113 acts upon the swiveling as resisting force. [0103] Accordingly, if the external force F 1 is removed, the alignment member 101 returns to the state shown in FIG. 9( a ). [0104] Namely, when sheet S or a hand of an operator comes in contact with alignment member 101 in the course of operation to take out sheet S from rising and falling sheet ejection tray 29 , the alignment member 101 swivels as shown with arrow W 1 , but it makes its comeback if contact is broken off. [0105] When external force F 2 is applied on the alignment member 101 , the alignment member 101 swivels counterclockwise as shown with arrow W 2 . The direction W 2 is a direction toward the inside for the sheet stacking area (sheet width area) on rising and falling sheet ejection tray 29 . [0106] In the case of swiveling shown in FIG. 9( c ), an engagement action of projection 110 B of the intermediate supporting member causes intermediate supporting member 110 and he alignment member 101 to swivel integrally, and the intermediate supporting member 110 swivels relatively to he supporting member 111 . [0107] For this relative swiveling, stress of coil spring 114 acts upon the swiveling as resisting force. [0108] Accordingly, if the external force F 2 is removed, the alignment member 101 returns to the state shown in FIG. 9( a ). [0109] Namely, when sheet S or a hand of an operator comes in contact with alignment member 101 in the course of operation to take out sheet S from rising and falling sheet ejection tray 29 , the alignment member 101 swivels as shown with arrow W 1 and arrow W 2 , but it makes its comeback if contact is broken off. The meantime, after completion of ejection of sheets for series of jobs on rising and falling sheet ejection tray 29 , the alignment member recedes upward to part from the rising and falling sheet ejection tray after conducting the last aligning operations. Therefore, even when external force shown with F 2 is applied on the alignment member during operations to take out sheet S, and even when the alignment member swivels in the inner direction W 2 for a sheet stacking area on rising and falling sheet ejection tray 29 , it does not happen that the alignment member hits a bundle of sheets stacked on the rising and falling sheet ejection tray 29 , and the alignment is disturbed accordingly. [0110] The supporting mechanism of the alignment member 101 explained above, namely, intermediate supporting member 110 that supports the alignment member 101 to be capable of being displaced in the second direction, supporting member 111 , and coil springs 113 and 114 constitute a supporting device that supports the alignment member. [0111] As stated above, for alignment member 101 , a mechanism is one wherein the alignment member 101 always recedes independently of the direction for right and left for external force to be applied, thus, destruction of alignment of sheets can be prevented, and a safety mechanism that prevents injures of an operator can be provided at a sheet ejection section. [0112] Incidentally, it is preferable to use coil spring 113 having the spring constant wherein displacement resisting force in the case for alignment member 101 to be displaced in W 1 direction is greater than the stress from the sheet receiving in the case of alignment conducted when alignment member 101 is in contact with a sheet on rising and falling sheet ejection tray 29 . The alignment member 101 reciprocates in the width direction to align the sheets as shown in FIG. 6 , and in the alignment operations, the alignment member 101 receives the force toward the outside in the width direction caused by the stress of the sheet, namely, the force F 1 shown in FIG. 9( b ). In the alignment operations, it is not desirable that the alignment member 101 is displaced by the force received from the sheet. By making displacement resisting force in the case when the alignment member 101 is displaced in the direction of W 1 to be greater than the stress received from sheets in the case of alignment, it is possible to secure safety while securing the sufficient alignment operations. [0113] On the other hand, for the force toward the inside in the width direction, it is preferable that the alignment member 101 is displaced easily. To satisfy the conditions of that kind, it is also possible to establish the spring constant of the coil spring 113 to be higher than that of coil spring 114 , and thereby to make the displacement resisting force in the case of displacement in the direction of W 1 and the displacement resisting force in the case of displacement in the direction of W 2 to be different each other. Owing to this, it is possible to secure the structure that is easily displaced toward the inside and has high safety. [0114] In the mean time, a supporting device of alignment member 102 is also the same as explained earlier, with respect to directions W 1 and W 2 , they are opposite to the occasion of the alignment member 101 . Namely, direction W 1 is a direction toward the inside, and direction W 2 is a direction toward the outside.
A sheet ejection device includes: a sheet ejection tray adapted to stack a sheet ejected thereon; an alignment member which aligns a position in a width direction and a direction perpendicular to a sheet ejection direction of the sheet on the sheet ejection tray; and a supporting unit which supports the alignment member so that the alignment member is displaced in a direction intersecting the sheet ejection direction when outer force is applied to the alignment member.
1
TECHNICAL FIELD This invention relates to telecommunication systems, and, more particularly, to a hybrid telephony system comprising both circuit-switched and packet-switched networks. BACKGROUND OF THE INVENTION With the extensive use of personal computers and other data processing facilities both at home and in the office, there are great needs for improved data communications. Hence, packet-switched public networks are being rapidly developed and increasingly interconnected with each other. These existing packet networks have mostly been serving data communications traffics as opposed to voice telephony. Voice and data traffic, have significantly different characteristics. Voice is typically continuous in one direction for relatively long intervals and tolerant of noise, but sensitive to variations in delay. Data is bursty and sensitive to noise errors, but tolerant of moderate delays and variations in arrival times. Two fundamental different switching techniques have therefore been traditionally applied to voice and data transmissions. Circuit switching, where switched connections between users are dedicated for call duration, is the basis of the present-day switched voice telecommunication network. On the other hand, packet switching, where data packets from multiple terminals share a single, high-speed line and are switched based on logical channel numbers attached in the packets, is being rapidly adopted as the basis of the present-day switched data telecommunication network. Packet switching was pioneered in the ARPANET network of the U.S. Department of Defense, and has been widely implemented in a variety of public data networks. However, most public telephone systems are fundamentally circuit-switched, which is an inherently inefficient system because typically each subscriber utilizes the allotted channel for a relatively small amount of the total connection time. Furthermore, the number of simultaneous circuit-switched communications are limited because only a portion of the available bandwidth is allocated to such communications. Another disadvantage is that, because circuit switching is centralized, a failure at the switching center can result in failure of the entire network. A further disadvantage of circuit-switched telephony is due to the proprietary nature of the telephony switches currently in use. Because the switching software is often proprietary and not shared with other manufacturers, the cost and delay in adding and interfacing new services are often frustrating and installation prohibiting. It has been proposed, that packet-switched techniques replace, or at least be combined with some, circuit-switched telephony so that the entire system bandwidth may be made available to each subscriber on a random access basis. For this purpose, there are currently emerging software products that make use of the Internet, which is a constantly changing collection of interconnected packet-switched networks, for telephony. VOCALTEC software provides half-duplexed long-distance telephone capability through the Internet. Camelot Corp is another entry in the Internet telephone business with a MOSAIC front end software that supports full-duplexed voice conversation. These products offer an alternative to long-distance analog telephone service for the subscribers by digitizing and compressing voice signals for transport over the Internet. Some limitations of this type of hybrid telephone system are: (1) Both the caller and the callee must have computers, (2) they must have sound systems on their computers, (3) they must have full Internet access, (4) they must have both purchased compatible software, (5) they must both connect to the Internet at the time the call is made, and (6) the telephony software must be in execution at both ends at the same moment. These limitations translate into a considerable amount of investment in hardware and software, which has to be made by the individual subscribers to implement such a telephony system. The last limitation also means that the calls have to be scheduled in advance in most cases, which clearly does not provide the convenience of conventional telephone calls. An additional problem with such software products is that the performance is constrained by the capabilities of each computer, such as processor speed, memory capacity, and modern functional features. SUMMARY OF THE INVENTION In accordance with the principles of the present invention, a hybrid packet-switched and circuit-switched telephony (HPCT) system routes a telephone call mostly through packet-switched networks, except for the caller and callee ends where the subscriber telephone sets are directly connected to the circuit-switched networks of the respective local exchange carriers (LEC's). A gateway computer (GC) or equivalent interconnects the packet-switched network to each of the circuit-switched networks, and converts voice signals into data packets and vice versa, and resolves the call destinations while routing the packets. In this invention, the GC's are preferably managed by the telephony service provider, as opposed to the end-user. Because the GC's are a set of resources shared by many subscribers, they can be managed with higher efficiency and utilization than calls managed by a subscriber's personal computer. By incorporating the HPCT system into the current long-distance telephony, lower cost of communication can be achieved due to better utilization of available channels by packet-switched networks over purely circuit-switched networks, and the benefits of packet switching can be made available to many subscribers without significant subscriber investment Moreover, there can be special hardware components added to the GC to improve performance, such as a DSP or an ASIC based compressor, decompressor, speech recognizer, encryptor and decryptor, etc., which would be much less cost-effective to added to each home computer. Additional advantages of the hybrid packet and circuit switched telephony of the invention are; (1) lower cost of transport due to better circuit utilization as compared to a pure circuit-switched network; (2) availability to any subscriber at no initial investment as would be required by pure packetswitched telephony, such as requiring the purchase of a multimedia personal computer, Internet access, and Interact telephony software; (3) the potential for quickly adding intelligent services due to computer based telephony, such as a caller's personalized speed dialing list, a callee's personalized virtual destination number, and integration with electronic-mails; and (4) avoidance of the inconvenience of current packetswitched telephony using Internet phones, which includes the burden of learning each callee's IP address and carrying a portable computer when traveling or commuting. BRIEF DESCRIPTION OF THE DRAWINGS The features of the invention and its objects and advantages may be further understood from the detailed description below taken in conjunction with the accompanying drawings, in which: FIG. 1 is a block diagram showing a first embodiment of the present invention; FIG. 2 is a block diagram illustrating a voice telephony system before and after incorporating the first embodiment of the present invention; FIG. 3 a is a system block diagram of the first embodiment illustrating structural components of the gateway computer; FIG. 3 b is a system block diagram of the first embodiment illustrating functional components of the gateway computer; FIG. 4 is a block diagram showing a second embodiment of the present invention; FIG. 5 is a flow diagram, of the calling process for providing a charge call in accordance with the present invention; FIG. 6 is a sequence diagram of the call signaling for providing the charge call of FIG. 5 ; and, FIG. 7 is a flow diagram of the calling process for providing a call from a caller's dedicated telephone in accordance with the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to FIGS. 1 to 3 b , a hybrid packet-switched and circuit-switched telephony (HPCT) system according to a preferred embodiment of the present, invention comprises originating and terminating gateway computers (GC's), which interconnect corresponding circuit-switched networks with a packet-switched network for voice and data communications. As shown in FIG. 1 , an originating (local) telephone set 1 is connected with an originating (local) GC 3 through a circuit-switched network 2 of an originating local exchange carrier (LEG). At the other end of the telephony system, a terminating (remote) telephone set 8 is connected with a terminating (remote) GC 6 through a terminating (remote) circuit-switched network 5 of a terminating (remote) LEC 7 . A packet-switched network 5 is provided for communications between originating GC 3 and terminating GC 6 . FIG. 2 shows diagrammatically how a conventional circuit-switched network 10 is replaced by the two GC's 3 and 6 and the packet-switched network 5 . FIG. 3 a shows one of the GC's in more detail. Preferably both the originating and terminating GC's include a plurality of digital trunk interfaces 16 , a Random Access Memory (RAM) 17 , a signaling network interface 18 , a non-blocking Time-Division Multiplexing (TDM) bus 19 , a plurality of packet network interfaces 20 one of which is connected through the packet-switched network 5 to other gateway computers 3 ′ and 6 ′, a plurality of Central Processing units (CPU's) 21 , a plurality of Digital Signal Processors (DSP's) 22 , a plurality of Application-Specific Integrated Circuits (ASIC's) 23 , a plurality of disk controllers 24 with disks 25 , and a system back plane in the form of either a shared bus or cross connection 29 . An analog subsystem 13 , comprising analog trunks 14 and AID and DIA converter pairs 15 , is needed only if analog trunks are to be supported by the GC, and therefore may be considered optional. FIG. 3 b shows the functional components of GC's 3 and 6 arranged into media conversion modules 31 , optional analog trunking modules 49 , MF and DTMF digit modules 43 , speech processing modules 48 , routing resolution modules 39 , and special services modules 38 . Speech processing modules 48 include a spoken digit recognizer 44 implemented with DSP 22 , and a voice prompt playback unit 47 also implemented with DSP 22 . Routing modules 39 include an address resolution logic 45 implemented with CPU 21 , and a network routing database 46 also implemented with CPU 21 and possibly shared with other GC's in a distributed manner. MF and DTMF digit, modules 43 include a tone detector 41 implemented with DSP 22 or ASIC 23 for both user keypad dialing and in-band signaling if needed, and a tone generator 42 also implemented with DSP 22 or ASIC 23 for prompting and in-band signaling if needed. Media conversion modules 31 include a plurality of channelized voice bit stream buffers 32 implemented with DSP 22 or ASIC 23 , a compressor/decompressor 33 also implemented with DSP 22 or ASIC 23 , hardware supervision logic 34 implemented with digital trunk interfaces 16 , and a packetizer/unpacketizer 36 implemented with CPU 21 , DSP 22 or ASIC 23 . Special services modules 38 may include an encryptor/decryptor 37 also implemented with CPU 21 , DSP 22 or ASIC 23 . As indicated in the preceding paragraph, the analog trunking modules 49 , which include the plurality of analog-to digital and digital-to-analog converter pairs 15 , are optional. Digit modules 43 and special services modules 38 are also optional. With GC's 3 and 6 having these functions, the expected voice compression ratio may reach 25:1, or even better with emerging technology. The presence of the usual amounts of silence in voice communications may double that ratio to 50:1, making the HPCT even more efficient and cost-effective. To achieve even, further compression, ratios, special compression schemes may also be used, which are expected to be both tolerated by the human ear and used to facilitate a low cost of the service. The HPCT may provide a virtual end-to-end connection. In the absence of such a virtual connection, the buffering mechanism at the receiving end can recover the stream of voice from packets arriving with the variable delay introduced by the packet-switched network. The HPCT telephony network of FIG. 1 , along with its associated service protocols, is symmetric. However, sometimes a caller may have a multimedia-capable computer and a packet-switched network connection, thereby enabling advanced services or features. However, if the callee does not have (a) a terminating multimedia computer, (b) direct access to the packet-switched network, or (c) a compatible packet-switched telephony application currently running on the terminating computer, then the call can not be completed over just a packet-switched network. In this case, a terminating circuit-switched LEC 7 supported by a terminating GC 6 may be used in the same way as in the first embodiment of the present invention, but the telephony system will have an asymmetric configuration as shown in FIG. 4 . In this system, the caller's multimedia computer 4 will run a digital communications program comparable to an originating GC's protocol and therefore will serve as the originating GC from the view point of the packet-switched network 5 and the terminating GC 6 , except the billing and validation of the caller may be performed by the terminating GC 6 based on the caller's access point to the packet-switched network. Similarly, where the callee has a multimedia capable computer and a packet switched network connection but the caller does not, the telephony system of the invention may have an asymmetric configuration that is the reverse of the FIG. 4 configuration. On the other hand, where the HPCT utilizes gateway computers at both ends of the packet-switched network, each GC provides a set of resources that are shared by many users and thus achieves much higher utilization in the telephony than a personal computer. Optimization of performance can be achieved by using Digital Signal Processors (DSP's) or Application Specific Integrated circuits (ASIC's). Furthermore, the users do not have to make a large investment, operate special computer equipment and programs, or schedule calls in advance. In fact, as described below relative to FIGS. 5 and 7 , the users may not tell any difference between using the HPCT and using their regular long-distance services, except for a much lower cost. Considering the 50:1 compression ratio discussed above, the utilization of the circuits in circuit-switched telephony can be only 1/50 as efficient as that of the HPCT; in other words, the cost of the former can be as much as 50 times higher than that of the HPCT. Another important problem with circuit-switched telephony is the proprietary nature of the telephony switches which are the foundation of this telephony. Because switch software development is only done by the manufacturers, the cost and delay in adding new services are often frustrating and prohibiting. The HPCT, however, is based on general-purpose computers with open architecture, which can open up development and bring very cost-effective new services in a much shorter time frame. The packet-switched network 5 of the HPCT system can be one of many types of packet-switched public data networks, such as X.25 or the emerging Asynchronous Transfer Mode (ATM) network. The ATM network is a special packet-switched network with low delay and low delay deviation, in which data is formatted into special types of packets, referred to as “cells”, to achieve fast-switching. Accordingly, ATM networks are sometimes referred to as having a third type of networking, namely “cell-switched networking”. A caller can use the HPCT system as an alternative long distance telephony service (“charge service”), or the caller can use it as his/her primary long distance telephony service (“dedicated service”). Charge service can be reached from any telephone while dedicated service can be reached only from a subscriber's dedicated telephone, such as a home phone or office phone. The alternative service is referred as “charge service” because the caller does not need to have a dedicated telephone account with the service provider: instead, the authorization is via a credit card or calling card inquiry. To implement the charge service and the dedicated service, the invention provides two respective protocols for processing calls within the hybrid telephony system. The first protocol is for the charge service and is illustrated in FIGS. 5 and 6 . The process of this protocol includes the following steps: (1) The caller first calls a local originating GC through a circuit switched originating LEC from any telephone, and the caller's address (caller's telephone number) is relayed to the originating GC by the originating LEC. (2) The originating GC plays a voice prompt (a greeting message asking for input) to the caller asking for the callee's destination address (callee's telephone number). (3) The caller provides the address either through telephone keypad digits or through spoken digits which are recognized by the originating GC. (4) The originating GC resolves the call routing information in a manner similar to the Domain Name Service for the Internet, obtains the packet network address (such as the IP address of the Internet) of the terminating GC, which is usually local to the callee (otherwise a toll call may be involved), and estimates the unit charge for a call going through, that terminating GC. (5) The originating GC informs the caller about the charge rate, and asks for the caller's preferred payment method, such as by credit card, or through a prearranged calling card account. (6) The caller specifies the payment method either through keypad digits or through spoken digits which again are recognized by the originating GC (if this Is a collect call, then the caller's spoken information about both parties is recorded and digitized to be announced later to the callee). (7) The originating GC validates the payment method through an internal or external database. (8) The originating GC sends a control message to the terminating GC, along with both party's addresses and, if the terminating GC does not know where to route the call or does not have the resources to serve the call, it responds with a negative acknowledgment and an alternative terminating GC is searched for and selected, or the caller is informed that the call can not be routed at that moment. (9) The terminating GC dials out to the callee through a circuit switched terminating LEC using the destination address it obtained from the originating GC. (10) If the call proceeds successfully through the terminating LEC, the terminating GC sends an acknowledgment back to the originating GC (or if the call proceeds unsuccessfully, such as due to busy telephone lines, the terminating GC sends this status to the originating GC in the form of a busy message). (11) The originating GC then passes the status of the acknowledgment back to the caller through the originating LEC, the effect being a ring back tone (or a busy tone). (12) The callee answers the call. (13) The terminating GC passes this state change to the originating GC, which may begin billing at that time. (14) The callee starts the conversation by greeting the caller. (15) The terminating GC either receives the digitized voice data stream over a digital trunk or continuously digitizes all the voice signals over an analog trunk from the LEC which the callee is connected to, and, after possibly encrypting and compressing, packetizes the data into packet form, the packets then being sent over the packet-switched network to the originating GC. (16) The originating GC, after possibly rearranging the packets to maintain proper packet order, unpacketizes the received data and, after possibly decompressing and decrypting, optionally converts the digitized data back to the voice signal if the connection with the LEC to 5 which the caller is connected is analog. The digital, or voice signal is then routed to the caller over the circuit-switched network of the originating LEC. (17) The same process as described in steps 14 through 16 is performed for the caller's voice in the opposite direction. The resulting processing in both directions supports the conversation between the two parties participating in the call. Each GC preferably provides out-of-band signaling, and the call signaling sequence for providing the charge call of FIG. 5 will now be described with reference to FIG. 6 . (1) The caller's telephone number is sent to the originating GC to access a call. (2) The originating GC prompts for a destination address, such as by a dial tone. (3) The caller inputs the callee's address, such as by dialing the callee's telephone number. (4) The originating GC may provide a voice message regarding rate, and prompts for a payment method, such as by a special tone or by a voice message. (5) The caller inputs the desired method of payment, such as keypad numbers corresponding to a credit card. (6) The originating GC validates the payment method and then sends a connection request to the terminating GC. (7) The terminating GC dials the callee through the terminating LEC. (8) Depending on whether the callee's telephone is available or busy, the terminating GC sends a corresponding acknowledgement to the originating GC. (9) Depending on whether the callee's telephone is available or busy, the originating GC sends a ring back tone or a busy signal to the caller's telephone. (10) If the callee answers the telephone, an off-hook signal is sent to the terminating GC. (11) The terminating GC then sends an answer indication to the originating GC, which starts billing and sets up the in-band routing for both digitized voice data and analog voice transmission. (12) At this stage, either the callee or the caller may initiate the conversation. If initiated by the callee, the callee's telephone sends the voice greeting to the terminating GC. (13) The terminating GC either receives digitized voice data in a bit stream from the terminating LEC or digitizes the analog voice, and may also perform the additional functions previously described, and then sends the digitized voice data to the originating GC. (14) The originating GC converts the voice data to analog voice by performing the functions previously described, and sends the analog voice to the caller. The second protocol is for the dedicated service on the HPCT telephony system of the invention and is shown in FIG. 7 . The process of this protocol includes the following steps: (1) The caller initiates a long-distance call by dialing a destination address (callee's telephone number) through the circuit-switched network of an LEC from his/her dedicated telephone, such as a home phone or office phone, for which a routing configuration to an originating GC is present within the LEC. The LEC routes the call to this GC, and the caller's address (caller's telephone number) is passed to the GC by the LEC, along with the destination address. (2) The originating GC authorizes the call by checking the caller's account Information, through an internal database or may communicate with a centralized database for the account information, and it also resolves the call routing Information using the dialed destination address, (3) The originating GC then sends a control message to a terminating GC, along with both party's addresses. If the first terminating GC does not know where to route the call or does not have the resources to service the call, it responds with a negative acknowledgment and an alternate terminating GC is searched for and selected, or the caller is informed of the negative acknowledgement. (4) The terminating GC dials out to the callee through the circuit-switched network of the terminating EEC. (5) If the call proceeds successfully through the terminating LEC, the terminating GC sends an acknowledgment back to the originating GC (the handling of the unsuccessful, most likely busy, scenario is similar to that in the first protocol). (6) The originating GC then passes the status back to the caller through the originating EEC, the effect being a ring-back tone. (7) The callee answers the call. (8) The terminating GC passes this state change to the originating GC which may start charging. (9) The callee initiates the conversation by greeting the caller. (10) The terminating GC either receives digitized voice data in a bit stream from the terminating EEC or continuously digitizes all the voice signals from the callee, possibly encrypts and compresses, and packetizes the data into packets, the packets then being sent over the packet-switched network to the originating GC. (11) The originating GC, after possibly rearranging the packets to maintain, proper packet order, unpacketizes the data, possibly decompresses and decrypts, and optionally converts the digitized data back to the voice signal if the connection with the originating EEC is analog. The digital or voice signal is then routed to the caller over the circuit-switched network of the originating LEC. (12) The same process described in steps 9 through 11 is performed for the caller's voice, except in the opposite direction. This processing in both directions supports the conversation between the two parties participating in the call. While the present, invention has been described in connection with a system having a circuit-switched network, in the form of both a digital and an analog local exchange carrier (LEC) serving analog telephone sets, it is likely that there are many instances where only the digital network interface is needed to connect to the LEC. With a digital, circuit-switched network, the configuration of the corresponding GC's is simplified since it is no longer necessary for the data manipulator to convert the voice signal into digital data, and vice versa. From the foregoing, it can be seen that the present invention provides an improved telephony system which effectively integrates voice and data in a hybrid circuit-switched and packet-switched telephony network, while ensuring real-time high quality voice communication and calling services with low transmission and access costs. By utilizing gateway computers of telephony service providers to route calls between circuit switched and packet-switched telephone networks, HPCT provides the benefits of packet switching to any telephone subscriber, with none of the substantial initial investments required by pure packet-switched telephony. The potential for vastly increased intelligent services due to computer based telephony, such as caller's personalized speed dialing list, callee's personalized virtual destination number, integration with electronic mails, and many others, allows for even further enhancement of the HPCT system. Furthermore, the HPCT system, which is based on general purpose computers with open; architecture, can open development of a host of new services and make them cost-effective in a much shorter time than would be required, for complete conversion from conventional circuit-switched networks to entirely packet-switched networks. While this invention has been described in the context of preferred embodiments comprising at least one circuit-switched network of an EEC, It should be clear that the principles of the invention will work equally well with other telecommunications networks and with variations of the preferred embodiments. These and many other modifications and alternatives are possible and will occur to those skilled, in the art who become familiar with the present invention. Such modifications and alternatives are intended to be within the scope of the invention as defined by the claims set forth below.
A hybrid telephony system with packet switching as well as circuit switching optimizes utilization of transport networks, and is accessible from any conventional telephone set. A call originating from a circuit-switched network is passed through a gateway computer to a backbone packet-switched network, and then through a second gateway computer to a second circuit-switched network where it terminates. The voice of both the originating party and the terminating party is converted to data packets by the near-end gateway computer and then converted back to voice by the far-end gateway computer. In an alternative scenario, the originating party uses a computer on the packet-switched network, which replaces the originating circuit-switched network, and the originating computer. Powered by CPUs, DSPs, ASICs disks, telephony interfaces, and packet network interfaces, the gateway computers may have media conversion modules, speech processing modules and routing resolution modules, and are capable of translating telephony call signaling as well as voice between circuit-switched and packet-switched networks. Optionally, the gateway computers may also have analog trunking modules, MF and DTMF digit modules and special services modules, in order to support analog circuit-switched networks and secure telephone calls.
7
TECHNICAL FIELD The present invention generally relates to wireless communications, and is specifically concerned with clear channel assessment techniques to determine the presence or absence of a valid inbound signal. BACKGROUND OF THE INVENTION The past few years has witnessed the ever-increasing availability of relatively cheap, low power wireless data communication services, networks and devices, promising near wire speed transmission and reliability. One technology in particular, described in the IEEE Standard 802.11b-1999 Supplement to the ANSI/IEEE Standard 802.11, 1999 edition, collectively incorporated herein fully by reference, and more commonly referred to as “802.11b” or “WiFi”, has become the darling of the information technology industry and computer enthusiasts alike as a wired LAN/WAN alternative because of its potential 11 Mbps effective throughput, ease of installation and use, and transceiver component costs make it a real and convenient alternative to wired 10 BaseT Ethernet and other cabled data networking alternatives. With 802.11b, workgroup-sized networks can now be deployed in a building in minutes, a campus in days instead of weeks since the demanding task of pulling cable and wiring existing structures is eliminated. Moreover, 802.11b compliant wireless networking equipment is backwards compatible with the earlier 802.11 1 M/2 Mbps throughput standard, thereby further reducing deployment costs in legacy wireless systems. 802.11b achieves relatively high payload data transmission rates or effective throughput via the use of orthogonal class modulation in general, and, more particularly, 8-chip complementary code keying (“CCK”) and a 11 MHz chipping rate to bear the payload. As such, previously whitened or scrambled bitstream data of interest is mapped into nearly orthogonal sequences (or CCK code symbols) to be transmitted, where each chip of the CCK code symbol is quaternary phase modulated using QPSK (“quadrature phase shift keying”) modulation techniques. Meanwhile the common phase of each CCK symbol is jointly determined by the current and previous symbols using differential QPSK or DQPSK modulation scheme. Subsequent conversion into the analog domain prepares these CCK symbols for delivery over a wireless medium RF modulated on a carrier frequency within the internationally recognized 2.4 GHz ISM band to form the payload or PLCP Service Data Unit of an 802.11b compliant Physical Layer Convergence Procedure (“PLCP”) frame, a type of packet. The high-rate physical layer PLCP preamble and header portions forming the frame overhead are still modulated using the 802.11 compliant Barker spreading sequence at an 11 MHz chipping rate. In particular, the preamble (long format—144 bits, short format—72 bits) is universally modulated using DBPSK (“differential binary phase shift keying”) modulation resulting in a 1 Mbps effective throughput, while the header portion may be modulated using either DBPSK (long preamble format) or DQPSK (short preamble format) to achieve a 2 Mbps effective throughput. An IEEE 802.11b compliant receiver receives and downconverts an incident inbound RF signal to recover an analog baseband signal bearing the PLCP frame, and then digitizes and despreads this signal to recover the constituent PLCP preamble, header and payload portions in sequence. The preamble and header portions are Barker correlated and then either DBPSK or DQPSK demodulated based on the preamble format used to recover synchronization data and definitional information concerning the received PLCP frame, including the data rate (Signal field in the PLCP header) and octet length (Length field in the PLCP header) of the variable-length payload or PSDU portion. The CCK encoded symbols forming the PLCP payload portion are each correlated against 64 candidate waveforms in received per symbol sequence in combination with DQPSK demodulation to verify and reverse map each into the underlying bitstream data of interest, at either 4 bits per symbol (5.5 Mbps) or 8 bits per symbol (11 Mbps) increments. It should be appreciated that 802.11 and 802.11b signals operate in the 2.4 GHz ISM band and must therefore coexist with quite an array of dissimilar signals operating in the same frequency, including microwave ovens and digital phones. By definition, there are no licensure restrictions within the available RF channels of the ISM band, so 802.11 and 802.11b compliant transceivers must employ clear channel assessment techniques to determine if it is safe to transmit. In particular, there is an expected amount of ambient noise that the 802.11/802.11b transceivers must tolerate but still be able to transmit, but should not attempt to transmit while another in-range 802.11/802.11b transceiver is transmitting so as to maximize channel use and system throughput. In other words, it is desirable for 802.11 and 802.11b transceivers to know when the operating channel is occupied with valid traffic, and thus enter receive mode without attempting to transmit over such traffic. Likewise, it is desirable that these transceivers should be free to transmit on the operating channel while that channel is free of 802.11/802.11b traffic, even in the presence of a tolerable amount of noise or interference. To this end, the 802.11 and 802.11b standards specify clear channel assessment (CCA) guidelines which are used to determine if a tuned RF channel contains valid PLCP frame traffic. Inbound signals in the tuned or operating RF channel which do not meet these CCA guidelines are considered to bear either corrupted frames, or represent interference or noise in the channel. The 802.11/802.11b CCA guidelines are organized in modes as follows: CCA Mode 1: Energy above threshold. CCA shall report a busy medium upon detecting any received energy above the ED threshold. CCA Mode 2: Carrier Sense only. CCA shall report a busy medium only upon detection of a DSSS signal. This signal may be above or below the ED threshold. CCA Mode 3: Carrier Sense with energy above threshold. CCA shall report a busy medium upon detection of a DSSS signal with energy above the ED threshold. CCA Mode 4 (802.11b): Carrier sense with timer. CCA shall start a timer whose duration is 3.65 ms and report a busy medium upon the detection of a High Rate PHY signal. CCA shall report an IDLE medium after the timer expires and no High Rate PHY signal is detected. The 3.65 ms timeout is the duration of the longest possible 5.5 Mbps PSDU. CCA Mode 5 (802.11b): A combination of carrier sense and energy above threshold. CCA shall report busy at least while a High Rate PPDU with energy above the ED threshold is being received at the antenna. The 802.11 DSSS PHY receiver must perform CCA according to at least one of modes 1–3, and the 802.11b High Rate PHY must perform CCA according to modes 1, 4 or 5. Three of the five conventional CCA modes require thresholding inbound signal energy, and so this guideline is believed important. However, conventional transceivers simply compare inbound signal energy against the specified threshold, and report an energy threshold validation signal whenever the threshold is exceeded. Thus, the presence of strong interference in the operating channel, will cause (in the case of a CCA mode 1 implementation) or potentially may (in the case of a CCA mode 3 or 5) cause a false busy to be reported, and thus prevent the transceiver from transmitting, which may in turn cause transmission delay and lower effective data throughput. Moreover, to implement CCA modes 2–5, conventional CCA carrier sense techniques are used to determine if a DSSS or High Rate PHY inbound signal is present, typically by thresholding a measure of the perceived Barker code lock. However, known techniques are relatively complex and are thus power inefficient and expensive to implement. Both cost and power consumption reduction are critical design goals in 802.11/802.11b transceiver implementation, it would be advantageous if simpler carrier sense techniques could be incorporated without materially affecting carrier sense sensitivity or recognition performance. Further, while conventional CCA techniques look for valid PLCP header information (via CRC validation), there is no post-demodulation confirmation during receipt of the preamble. Checking for valid preamble receipt would be advantageous, especially where the inbound signal fades potentially below the inbound signal energy threshold, but the receiver is still able to successfully recover recognizable preamble information from the signal. Finally, while the defined 802.11/802.11b CCA modes account accommodate a range of operational environments, they are not appropriate for every environment and channel condition. Therefore, it would advantageous to provide a transceiver capable of handling further CCA modes other than those defined by the 802.11/802.11b standards, preferably while retaining backwards compatibility with such standards. SUMMARY OF THE INVENTION To address these and other perceived shortcomings and desires, the present invention is directed in part to a packet detection unit and signal recognition method that includes at least one of relative energy detection operable on assessment of a relative energy threshold for an inbound signal borne across an RF channel, carrier sense operable upon on assessment of at least one of a peak-to-sidelobe ratio and peak-to-peak distance defined by the inbound signal, and comparison operable upon demodulated data corresponding to the inbound signal as compared to predetermined preamble data. Clear channel assessment is performed based on determinations undertaken by one or more of the aforementioned relative energy detection, carrier sense and comparison operations. Further aspects of the present invention include a transceiver, network interface apparatus, and information processor incorporating this packet detection unit, as well as a computer program product including computer readable program code capable of causing an information processor to perform one or more of these signal recognition aspects. Additional aspects and advantages of this invention will be apparent from the following detailed description of certain embodiments thereof, which proceeds with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a high level block diagram of a wireless transceiver in accordance with an embodiment of the invention. FIG. 2 is a more detailed block diagram of a receive baseband processing unit shown in FIG. 1 . FIG. 3 is a detailed block diagram of a packet detection unit according to an alternative embodiment of the invention. FIG. 4 is a state transition diagram for the CCA unit shown in FIG. 2 . FIG. 5 is a state transition diagram for the CS unit shown in FIG. 2 . FIG. 6 is a state transition diagram for the ED unit shown in FIG. 2 . FIG. 7 is a sample plot of gain perceived by the ED unit over time. FIG. 8 is a block diagram for the ED unit shown in FIG. 2 . FIG. 9 is a block diagram of the CS unit shown in FIG. 2 . FIG. 10 is a block diagram of the CCA unit shown in FIG. 2 . DETAILED DESCRIPTION OF THE EMBODIMENTS Turning now to the figures, FIG. 1 illustrates a wireless communications transceiver 100 according to an embodiment of the invention. In this embodiment, inbound RF signals potentially conveying an 802.11 or 802.11b compliant PLCP frame are picked up by the duplex antenna 10 and routed to the RF receiver unit 115 of a receiver 150 arranged in a manner consistent with the present invention. The RF receiver unit 115 performs routine downconversion and automatic gain control of the inbound RF signals, and presents an analog baseband signal containing the aforementioned 802.11b PLCP frame to the receive baseband processor 120 . The functions of the receive baseband processor 120 will be detailed below with reference to FIG. 2 , including packet detection and channel busy consistent with the present invention, along with conventional symbol correlation and/or demodulation of the preamble, header and payload portions of each inbound 802.11b PLCP frame to recover bitstream data for receiver synchronization (preamble), frame or packet definition (header), or the actual inbound data of interest (payload). Once recovered by the receive baseband processor 120 , the inbound data contained in the PSDU of each received 802.11b PLCP frame is delivered to a network interface such as the MAC layer interface 125 and then on to higher layer applications and devices being serviced by the transceiver 100 . Outbound data intended for wireless transmission originating from the device(s) or application(s) being serviced by the transceiver 100 are delivered to the transmit baseband processor 135 of the transmitter 160 from the MAC interface 125 . Directives from the PMD sublayer (not shown) forming part of the MAC interface 125 and expressing the desired transmission mode, including the 802.11b 1, 2, 5.5 and 11 Mbps effective throughput modes are transferred to the transmit baseband processor as well for each PLCP frame/packet. The transmit baseband processor 135 formulates appropriate 802.11b PLCP frame, and symbol encodes the outbound data as specified by the PMD sublayer to generate a complete outbound 802.11b PLCP frame. As the frame or packet is being developed, it is converted into analog form suitable for upconversion and RF transmission by the RF transmitter unit 140 consistent with 802.11b physical layer requirements. Though not shown in FIG. 1 , the transceiver 100 may form an operational part of a network interface apparatus such as a PC card or network interface card capable of interfacing with the CPU or information processor of an information processing apparatus such as a desktop or laptop computer, and may be integrated within and constitute a part of such information processing apparatus. This network interface apparatus may alternatively form an operational component of a wireless communications access point such as a base station as will be appreciated by these ordinarily skilled in the art. Turning now to FIG. 2 , FIG. 2 is a more detailed block diagram of the receive baseband processor 120 shown in FIG. 1 . So as not to obfuscate the teachings of the present invention, several 802.11 and 802.11b compliant directives and signals are not shown. As such, an inbound analog baseband signal potentially conveying an inbound 802.11/802.11b PLCP frame recovered by the RF receiver unit 110 of the receiver 150 is fed to the input of the automatic gain control unit (AGC) 210 . With the assistance of a feedback loop tied to the input of the FIR filter 315 , the AGC 210 adjusts the gain of the inbound baseband signal to maximize the dynamic range and performance of the analog to digital converter 310 , as is known in the art, assuming the inbound signal is valid. The AGC 210 also reports the gain adjusted signal to the RSSI unit 220 of the frame detection unit 200 for channel busy, as will be described in greater detail below. The gain adjusted inbound analog signal generated by the AGC 210 is then sent to the digital converter 310 to convert it into digital form. With the aid of the 44 MHz clock, the ADC produces a corresponding digital signal sampled at 44 MHz. Next, this digital signal passes through the digital FIR LPF 315 to reject out-of-band interference, and the down sampler 320 to provide a 22 Mhz digital signal potentially bearing a PLCP frame of interest. This 22 MHz signal next encounters two parallel baseband demodulation pathways. The first demodulation pathway, including the Barker correlator 330 , down sampler 335 , Rake 340 and the down sampler 345 is used to recover a despread 1 MHz signal representing the preamble and header portions of the inbound frame for symbol demodulation by the combination DBPSK/DQPSK demodulator 375 . This first demodulation pathway-demodulator combination 375 is also used for symbol decoding a base 802.11 PLCP frame payload in 1 Mbps/2 Mbps modes. The second demodulation pathway is used to symbol demodulate a high rate 802.11b payload portion of the inbound frame, and includes a 22 MHz to 11 MHz down sampler 350 following by a decision feedback equalizer 355 . To begin the CCK symbol decode process for 802.11b compliant payloads at 11 Mbps or 5.5 Mbps transmission modes, a CCK correlator 360 is provided. An 802.11b compliant receive state machine (not shown) issues the HI_RATE_PSDU semaphore to control the modulation pathway selection mux 370 based on which portion of the inbound frame is being demodulated, as well whether 5.5 Mbps+ payload modulation modes are specified. The combination DBPSK/DQPSK demodulator 375 is used to recover the symbol encoded inbound data presented in the preamble, header and payload portions. The DBPSK/DQPSK demodulator is clocked at the symbol rate; i.e., 1 MHz for 1 Mb and 2 Mb modes, and 1.375 MHz for 5.5 Mb and 11 Mb modes. After symbol demodulation, the recovered inbound data is descrambled by the descrambler 380 in a known fashion, and delivered to the MAC interface 125 ( FIG. 1 ). Still referring to FIG. 2 , the frame detection unit 200 is provided to determine if the inbound baseband signal recovered from an RF channel tuned by the RF receiver 115 ( FIG. 1 ) is a valid signal at least capable of bearing an 802.11b compliant PLCP frame, and if so, keep the transceiver 100 in receive mode for the duration of the frame. To implement relative energy threshold detection consistent with the invention, in the frame detection unit 200 of the embodiment shown in FIG. 2 , an RSSI unit 220 is provided to receive and down sample the digital adjusted gain signal for the inbound baseband signal generated by the AGC 210 to a 2 MHz gain signal E, with E k representing the signal E at the kth 2 MHz sample in time. E is sent directly to one input of the relative energy detection unit 235 , and is concurrently sent to a noise floor unit 230 . The noise floor unit 230 here constitutes an IIR low pass filter to generate a 0.5 μsec delayed signal n which tracks the original signal E using the following relationship: n k =αE k +(1−α)n k−1 The relative energy threshold detection unit 235 receives both E and n, and calculates the difference between the gain values each represents (via the gain differential unit 810 shown in FIG. 8 ) as a gain change over time. Through the control unit 820 , the relative energy threshold detection unit 235 compares the gain change over time against one of two preferably programmable energy detection thresholds, based on the current state of the control unit 820 . Though not required, the relative energy threshold detection unit 235 of the present embodiment operates on a 1 MHz synchronized clock, and so E and n are effectively downsampled at a 1 MHz rate before their difference is compared against one of these thresholds. As shown in FIG. 6 , the control unit 820 functions as a finite state machine capable of switching between two states 610 , 620 . Referring to FIG. 6 , the control unit 820 ( FIG. 8 ) of the energy threshold detection unit 235 ( FIG. 2 ) is initialized to state 610 at the beginning of each frame detection processing sequence (such as when a new inbound signal is first received on the operating RF channel). As such, the energy threshold validation signal (ED) is set to false (e.g. logic level 0). While in state 610 , the control unit 820 monitors the gain change over time generated by the gain differential unit 810 . The control unit 820 remains in state 610 while the gain remains relatively stable (transition or trans. 3). If the gain change over time exceeds a first energy detection threshold, meaning that the gain is changing rapidly with the AGC 210 in a gain unlock condition and attempting to transition to receive mode from transmit protect mode in response to an inbound signal having relatively significant energy, the control unit 820 transitions to state 820 (trans. 2) and the energy threshold validation signal transitions to true (logic level 1). In turn, assertion of true energy threshold validation signal may cause assertion of the channel busy signal (CCA) true by the CCA unit 250 , depending on the CCA mode being implemented. The control unit 820 remains at state 620 (trans. 4) while the gain change over time continues to exceed a second energy detection threshold to hold energy threshold validation signal true. However, once the gain change over time settles and the gain stabilizes, the control unit 820 transitions back to state 610 ( 2 ), and the energy threshold validation signal transitions back to logic level 0 or false. Note that in this embodiment the second energy detection threshold is less than the first energy detection threshold to lengthen the window in which the energy threshold validation signal is asserted high by the control unit 820 . However, in alternative embodiments, the first and second thresholds may be equal or even reversed depending on particular CCA implementation goals. Due to this “relative energy thresholding”, certain gain signal transitioning rather than the receive/transmit state of the AGC 210 is used to toggle the energy threshold validation signal. This difference is subtle, yet important in handling relatively strong, persistent interference in the operating channel. In conventional absolute RSSI thresholding, the energy threshold validation signal would be held as long as the strong interference is perceived by the AGC 210 as the inbound signal, thus at least potentially causing a conventional CCA unit implementing legacy CCA modes to consider the channel to be busy for the duration of the interference and erroneously holding the transceiver in receive mode. Take, for example, the gain curves shown in FIG. 7 . The left curve 710 illustrates the RSSI output E, and the conventional absolute threshold is shown as horizontal line 730 . As E transitions from a relatively high value to a relatively low value over time (indicating that the AGC has unlocked and is transitioning from the high gain transmit protect state to a low gain receive state) a conventional energy threshold validation signal would transition true once E crosses the absolute threshold 730 and would remain so until the inbound signal diminishes significantly or disappears, thereby permitting E to drift upward towards high gain or receive mode. However, in “relative energy thresholding” according to the present embodiment, the energy threshold validation signal is only held high between the point from where the difference between the n 720 and E 710 curves exceed the first energy detection threshold T RED1 to where it no longer exceeds the second energy detection threshold T RED2 . This helps the CCA unit discriminate between interference and a valid signal and respond more quickly with an idle channel determination in the presence of such interference, especially where additional validating criteria based on the content of the inbound signal such as preamble, carrier sense and header validation is assessed. In the embodiment shown in FIG. 2 , the noise floor unit 230 is only operational (and so tracks the RSSI output E) while the channel busy signal (CCA) is false and the AGC is not in the aforementioned gain unlock state (as indicated by the GAIN_UNLOCK signal). When not operational the output of the noise floor unit 230 , n is frozen to the last tracked value. For example, if the inbound energy is a valid 802.11/802.11b signal, the noise floor computation will stop upon gain unlock or CCA assertion. Thus, in this case and though not shown in FIG. 7 , curve 720 representing n would remain constantly high while the inbound energy is detected. Thus, the energy threshold validation signal would hold true for the duration of the 802.11/802.11b packet. If, however, strong noise is instead detected, the noise floor unit 230 is initially held high due to the AGC 210 unlocking (GAIN_UNLOCK is asserted true). However, if the channel busy signal (CCA) remains idle for a few microseconds while the AGC is still in the unlock state, the AGC 210 of the present embodiment resets the GAIN_UNLOCK signal to false and the noise floor unit 230 begins to track (n curve 720 ) the falling gain signal E 710 as shown in FIG. 7 . Before the noise floor unit 230 completely tracks the noise level, the energy threshold validation signal is temporarily asserted true—from where the difference between the n 720 and E 710 curves exceed the first energy detection threshold T RED1 to where it no longer exceeds the second energy detection threshold T RED2 , as previously discussed. Thus, CCA can still temporarily report a false busy depending on the CCA mode being utilized. In particular, if 802.11/802.11b CCA mode 1 is supported (ED only) the CCA will report a false-busy once the difference between n and E exceed the first energy detection threshold T RED1 . In the configuration shown in FIG. 2 , this will cause the noise floor unit 230 to suspend tracking of the gain signal E. To counteract this, the CCA unit 250 , and the comparison unit 1020 in particular, can be used verify that the inbound signal is 802.11/802.11b compliant through preamble or header verification, such as through looking for the presence of the Start Frame Delimiter (“SFD”) situated at the end of a proper PLCP frame preamble. If the selected field is found in the correct sequence, e.g. the SFD field is confirmed immediately after the end of the sync symbols, approximately 128 μsec (long preamble format) or 28 μsec (short preamble format) after the signal begins, it may be assumed that the inbound signal is valid, and that CCA unit 250 will report a busy channel for the remaining duration of the packet. If, however, the SFD or other selected field not found at its predesignated place, the inbound signal is presumed invalid and the CCA unit will override the ED mode logic and transition CCA false, indicating that the channel is free and the transceiver 100 may transmit. Alternatively, if the selected CCA mode also includes carrier sense thresholding (e.g. 802.11/802.11b modes 3 or 5), it is less likely, though still possible, for the CCA unit to still report a false busy, particularly where the carrier sense threshold levels are kept low. Again, SFD or other predefined field verification can be used to clear a false busy a number of microseconds after perception of the inbound signal by the AGC 210 begins. Though not shown in FIG. 2 , an absolute energy thresholding unit may be provided in addition to or as an alternative to the relative energy detection unit 235 to perform routine absolute energy thresholding of the inbound signal. Referring back to FIG. 2 , the frame detection unit 200 also includes the capability of providing carrier sense feedback to the CCA unit 250 through the carrier sense unit 240 . This carrier sense unit 240 takes the results of Barker correlation to the inbound signal to verify the presence of a valid DSSS signal. In particular, the Barker correlator 330 , in addition to feeding the div2 downconverter 335 and RAKE filter 340 , presents the correlation result of the digital form of the inbound baseband signal against the 802.11 Barker PN code to the input of the carrier sense unit 240 . A peak-to-sidelobe ratio determination unit 910 ( FIG. 9 ) examines the real (I) and complex (Q) components of this correlation result to help determine that, in fact, the inbound signal presents a valid Barker modulated preamble or header. In particular, the determination unit 910 calculates a peak-to-sidelobe average ratio as follows: SQ1 = max i ⁢ (  I i  +  Q i  ) 1 16 ⁢ ( ∑ i ⁢  I i  +  Q i  - 2 × max i ⁢ (  I i  +  Q i  ) ) , where i=half-chip index=0 . . . 21. Or, alternatively: SQ1 = max i ⁢ (  I i  +  Q i  ) 1 16 ⁢ ( ∑ i ⁢ (  I i  +  Q i  ) - 2 × max i ⁢ (  I i  +  Q i  ) - ∑ k ⁢ (  I k  +  Q k  ) ) , where i, k are half-chip indexes each ranging from 0 . . . 21, where k is the index of four sidelobes relatively distant from a local peak in the received signal. In the latter case, near-peak sidelobes are excluded from the SQ1 computation to counteract potential multipath interference and more effectively validate the inbound signal as being 802.11/802.11b compliant. In order to better validate the inbound signal as bearing valid Barker modulated information, the carrier sense unit 240 also includes a peak-to-peak detection unit 920 ( FIG. 9 ) to calculate the distance between consecutive peaks in the Barker correlation results provided by the Barker correlator 330 . In particular, the consecutive peak-to-peak distance is calculated as follows: pp n =|max — ind n −max — ind n−1 | After the peak-to-sidelobe average ratio and the peak-to-peak distance are calculated, their results are thresholded against preferably programmable signal quality thresholds, again based on the current state of the control unit 930 ( FIG. 9 ). As shown in FIG. 5 , the control unit 930 of the carrier sense unit 240 functions as a finite state machine capable of switching between two states 510 , 520 . Referring to FIG. 5 , the control unit 930 of the carrier sense unit 240 is initialized to state 510 at the beginning of each frame detection processing sequence. At state 510 , the control unit 930 issues the carrier sense validation signal (CS) as false. While in state 510 , the control unit 930 monitors the peak-to-sidelobe average ratio (SQ1) generated by the peak-to-sidelobe determination unit 910 along with the consecutive peak-to-peak distance (pp n ) calculated by the peak-to-peak distance determination unit 920 (trans. 3). In this embodiment, if the SQ1 signal meets or exceeds a first signal quality threshold at least 3 out of 4 preceding SQ1 calculation iterations undertaken by the determination unit 910 and the pp n is less than a maximum acceptable distance in at least 3 out of the 4 preceding pp n calculation iterations undertaken by the determination unit 920 , the control unit 930 transitions to state 520 (trans. 1) and the carrier sense validation signal transitions to logic level 1 or true, thereby indicating that an 802.11/802.11b DSSS signal (e.g. PLCP preamble/header) has been perceived. Note, that in alternative embodiments consistent with the teachings of the present invention, satisfaction of either these SQ1 or pp n , conditions alone and/or setting different threshold criteria for the SQ1 or pp n , may be used to trigger the transition from state 510 to state 520 . Returning to the embodiment shown in FIGS. 5 and 9 , the control unit 930 maintains this state (trans. 4) and continues monitor SQ1 and pp n , while asserting the carrier sense validation signal true. If, at state 520 , the SQ1 signal meets or exceeds a second signal quality threshold no more than once out of the preceding four calculation iterations undertaken by the determination unit 910 , and/or (depending on the desired carrier sense tolerance) the pp n meets or exceeds the maximum acceptable distance more than once during the preceding 4 calculation iterations undertaken by the determination unit 920 , the control unit 930 will transition back to state 510 and the carrier sense validation signal will transition back to false. This can occur in the case of a corrupted PLCP frame preamble or header, or in the case of a valid PLCP frame that has transitioned to the High Rate PPDU. The latter case is expected, and consistent with 802.11 and 802.11b CCA guidelines, the CCA unit 250 will nevertheless report the channel busy until the end of the packet (as indicated by the packet length in the received PLCP frame header) has been reached, and CS is ignored. Note here that the number of calculation iterations used to assess the SQ1 and pp n signals in this embodiment is a matter of design choice, and, consistent with the present invention any number of calculation iterations and thresholding may be used as long as a valid symbol-modulated signal can be recognized within relevant CCA tolerances such as those specified in the 802.11/802.11b standards. Returning to FIG. 2 , the ED and CS validation signals are sent to the CCA unit 250 of the embodiment shown in FIG. 2 in order to at least assist in determining whether the transceiver 100 should consider the inbound signal as valid. This CCA unit 250 is configured to operate and support at least a subset of the conventional 802.11/802.11b CCA modes 1–5 described above as well as support additional signal validation modes A–E as detailed below. As shown in FIG. 10 , the CCA unit includes a control unit 1010 configured as a finite state machine (as depicted in FIG. 4 ) operating in one of two states 410 , 420 based on either the ED and/or CS validation signal semaphores in isolation, or in combination with a PLCP preamble validation to be described below, depending on the desired signal validation mode A–E. In this embodiment, though not required, the CCA control unit 1010 assesses the ED, CS and/or preamble validation signals every microsecond. The operation of the CCA unit 250 , including the CCA control unit 1010 will now be described with reference to the following signal validation modes. State 410 is in the initial state at the beginning of each frame detection processing sequence. Signal Validation Mode A: ED Only The ED validation signal is initially assumed to be false. While in state 410 (trans. 3), the CCA control unit 1010 monitors or polls ED, preferably every microsecond. The channel busy signal is held false, indicating that the operating RF channel is free of traffic and is idle. If the ED validation signal transitions to true (logic level 1), The CCA control unit 1010 transitions from state 410 to state 420 (trans. 1), and the channel busy signal transitions to true, indicating that the operating RF channel is considered to be busy with valid traffic. In this embodiment, State 420 is maintained (trans. 4) and the channel busy signal is held true until ED transitions false after the earlier of either antenna selection in a diversity implementation is complete or the CCA timer (default of 12 μsec) expires, the SFD field in the PLCP preamble is not found and the comparison unit 1020 of the CCA unit 250 determines that valid PLCP frame preamble symbols are not being received. The CCA comparison unit 1020 determines this in this embodiment by comparing the output of the descrambler 380 against predetermined preamble data including strings of 8 consecutive 1's or 0's identifiable with the 802.11/802.11b long preamble format or strings of 16 consecutive 1's or 0's identifiable with 802.11b's short preamble format. Consistent with the 802.11/802.11b standards, if the PLCP header is found to be corrupted or the SFD field is omitted, the CCA control unit 1010 will consider the inbound signal as invalid noise and consider the channel to be idle, thus transitioning the control unit 1010 back to step 410 . Further, if frame transmission is deemed complete, transition to state 410 will occur. Though not required, the CCA control unit 1010 can be configured to delay a transition back to state 410 if, for example a recent antenna switch was performed in a receiver selection diversity implementation so as to allow e.g. the AGC 210 to retrain and settle. Signal Validation Mode B: ED & CS→Busy, ED & CS→Idle In this mode, the CCA control unit 1010 will transition from idle state 410 to busy state 420 if both the ED and CS validation signals are concurrently asserted true. In this embodiment, state 420 will be held until both the ED and CS validation signals transition false, the SFD field in the PLCP header is not found and the comparison unit 1020 of the CCA unit 250 determines that valid PLCP frame preamble data is not being received. Again, a recent antenna selection in a diversity implementation can forestall, at least temporarily, the transition back to state 410 . Signal Validation Mode C: ED& CS→Busy, ED∥CS→Idle The operation of the CCA control unit 1010 is similar to that as described for validation mode B previously discussed, but for the 420 to 410 transition requires only that one of the ED and CS validation signals to transition false. Signal Validation Mode D: ED with Timer The transition from idle state 410 to busy state 420 occurs similarly to that described previously for signal validation mode A. However, the CCA control unit 1010 remains in busy state 420 with the input validation signal held true unit either the first of an 802.11/802.11b standards compliant 3.65 millisecond timer (e.g. timer 1030 shown in FIG. 10 ) initiated at the beginning of the frame detection processing sequence times out or the end of the recognized frame is reached. Signal Validation Mode E: ED & CS with Timer The transition from idle state 410 to busy state 420 occurs similarly to that described previously for signal validation mode B, and the transition back from busy state 420 to idle state 410 occurs when the first of either the 3.65 millisecond timer expires or the end of the recognized frame is reached. The above embodiments were described with reference to an 802.11/802.11b PLCP frame format. However, several aspects and features of the present invention are not limited to the particular wireless frame format chosen. For example, since relative energy thresholding according to the present invention is not dependent on the content of the inbound signal, it could be applied to a range of wireless communications which could benefit from clear channel assessment, including, but not limited to, those compliant with one or more of IEEE 802.11a, IEEE 802.16a, and the forthcoming IEEE 802.11g High Rate PHY supplement to the 802.11 standards. Moreover, carrier sense determination according to the present invention, though dependent on the type of modulation used, can accommodate a wide range of orthogonal class modulated communications, including, but not limited to, the aforementioned Barker modulated communications, CCK modulated communications consistent with 802.11b, and OFDM modulated communications consistent with IEEE 802.11a, IEEE 802.16a, and the forthcoming IEEE 802.11g High Rate PHY supplement to the 802.11 standard. In the case where the inbound signal may be modulated in one of several ways at the outset, such as proposed in draft IEEE standard 802.11g, a frame detection unit such as that shown in FIG. 3 as frame detection unit 390 may be used which includes plural carrier sense units 240 and 380 , to determine the inbound signal bears either Barker or OFDM modulated information. In such case, the CCA unit 385 here may include appropriate processing logic to handle plural carrier sense validation signals (which in this case would have an XOR relationship). Moreover, while the above described embodiments describe certain componentry in terms of function and functional relationships, it should be realized that such functions and relationships can be conveniently implemented using a wide variety of discrete circuitry and logic, in combination with or alternatively through one or more general purpose or specific purpose information processors such as a microprocessor or digital signal processor programmed in accordance with these functions and relationships, as will be appreciated by those of ordinary skill in the art. It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments of this invention without departing from the underlying principles thereof. The scope of the present invention should, therefore, be determined only by the following claims.
Techniques for and apparatus capable of implementing packet detection and signal recognition in wireless communications systems are disclosed. In particular, the disclosed techniques and apparatus incorporate at least one of relative energy detection operable on assessment of a relative energy threshold for an inbound signal borne across an RF channel, carrier sense operable upon on assessment of at least one of a peak-to-sidelobe ratio and peak-to-peak distance defined by the inbound signal, and comparison operable upon demodulated data corresponding to the inbound signal as compared to predetermined preamble data. Clear channel assessment is performed based on determinations undertaken by one or more of the aforementioned relative energy detection, carrier sense and comparison operations.
7
BACKGROUND In conventional heat exchangers structural strength for pressure containment of the fluids dominates design considerations. Metal tube-in-tube and tube-in-shell exchangers are examples of such designs. The need has arisen for a low cost, low pressure heat exchanger that is not susceptible to the corrosion and scaling which typifies similar devices constructed of metal. The heat exchanger of the present invention reduces operating pressures to the level that pressure containment does not dictate the shape or form of the mechanical configuration. This design freedom allows the usage of previously unacceptable materials of construction such as structurally strong plastic extrusions and thin plastic membranes for heat transfer surfaces. The use of low cost materials and the low pressure design of the system also allow the use of more complex flow patterns to achieve novel and heretofor unexpected results from coolers or evaporators using direct contact between liquid and gas. The reduction in operating pressure is achieved with two significant departures from the prior art. First, heat transfer starts with the establishment of a uniform falling liquid film on a membrane type of heat exchange surface. The falling film is established with low pressure nozzles, (e.g. open pipes), which require only 1-2 p.s.i.g. operating pressure in the distribution manifolds, and even less pressure in the gravity fed fluid collection manifolds. Secondly, air plenums coupled with pressure relief ports and ducts are used to reduce the gauge pressure across the heat transfer surface to nearly zero. In the apparatus of the present invention the uniform falling film of highly concentrated solutions, established with very low pressure nozzles, avoids air entrainment due to splashing. Entrainment due to surface stripping of water droplets is avoided by controlling the relative velocity between the air draft and the falling film. With this background it is seen that the primary object of the invention is to provide a low pressure heat exchanger apparatus having a large degree of design flexibility to enhance the operating effectiveness of direct liquid-gas contact and liquid to liquid heat transfer. A further object of the invention is to provide a heat exchange device which has low area unit cost for fabrication and operation. Another object is to provide a heat exchanger which can simultaneously or alternatively perform liquid to liquid heat exchange, liquid to gas heat exchange and liquid to gas mass transfer. Other and still further objects features and advantages will be apparent upon a reading of the following detailed description of the invention taken in connection with the accompanying drawings in which: FIG. 1 is a fragmentary cross-sectional view of a simplified form of the heat exchanger of the present invention showing a series of alternatingly disposed hot water compartments and air ducts. FIG. 2 is a fragmentary cross-sectional view of a preferred form of the heat exchanger of the present invention showing a series of alternatingly disposed hot water compartments and brine flowing passages, which passages may function also as air ducts. FIG. 3 is a top fragmentary view of the heat exchanger of FIG. 2 with a portion thereof broken away and shown in cross section. FIG. 4 is a fragmentary cross-sectional view of the preferred form of the invention taken along lines 4--4 of FIG. 2 and with a portion thereof broken away and shown in cross-section. FIG. 5 is an enlarged fragmentary cross-sectional view taken along lines 5--5 of FIG. 3 showing alternately disposed hot water and brine distributors and the distribution nozzles. FIG. 6 is a fragmentary cross-sectional view of a third embodiment of the heat exchanger of the present invention with the brine distributors superimposed on the hot water distributors. FIG. 7 is an enlarged fragmentary cross-sectional view of the heat collector troughs taken along line 7--7 of FIG. 1. FIG. 8 is an enlarged fragmentary cross-sectional view taken along lines 8--8 of FIG. 2 showing the bottom side of the hot water and brine distributors of the preferred form of the heat exchanger of the present invention showing the distribution nozzles. DESCRIPTION OF THE INVENTION A simplified form of the invention is shown in FIG. 1 where a plurality of non-metalic mutually parallel sheets 4 of heat transfer material are vertically disposed with interspacing between the sheets. A header or hot liquid distributor 6 is located above each pair of facing sheet surfaces and a liquid collector trough 8 is disposed at the bottom edge of each pair of facing sheets at the top of which there is the distributor 6. A plurality of longitudinally spaced apart nozzle pairs 10 located in a line lengthwise of the distributors 6 dispense the liquid A flowing within the distributor 6 as an even film to fall by gravity down the facing surfaces of the sheets 4 and to be collected at the bottom edge of the sheets in the collector trough 8. Alternately between each pair of sheets 4, whose facing surfaces carry the liquid film A from the distributor 6, there is provided an air space or duct 12 through which air B or other gas may be made to flow, either upwardly, downwardly or transversely therethrough. The difference in temperature between the hot liquid A and the cooler air stream B provides a thermal gradient across the heat transfer surface 4 and thermal energy moves via sensible heat transfer from the hot liquid film, through the sheet 4 and into the air B passing through the air duct 12. FIGS. 2 through 5 and 7 and 8 depict a preferred embodiment of the invention utilizing the basic concepts of the simplified form of FIG. 1. Each of the parts in the preferred form which correspond to parts in the FIG. 1 embodiment will contain similar reference numerals. The spaces beneath each of the hot liquid distributors 6, including the collectors 8, will be referred to as hot water compartments 15. In the FIG. 2 embodiment a plurality of hot water compartments 15 are alternately interspersed with secondary liquid chambers 16 which are provided along the top thereof with lengths of liquid carrying tubing 17, similar to that used for the the hot water distributor 6. Longitudinally spaced apart nozzle pairs 20 are disposed to depend from the floor of each of the tubes 17 and communicate with the interior thereof so as to dispense the liquid C flowing in the tubes 17 onto the outside surfaces of the pairs of sheets 4 which form the sides of each hot water compartment 15. The nozzles are sized and positioned such that the individual streams of liquid C exiting the nozzles impinge on, spread and join so as to decend as a falling film down the outside surfaces of the sheets 4, similar to the falling film of hot water A on the inside surfaces of the sheets. In such an embodiment there is a transfer of heat energy from the hot water A falling down the inside walls of the compartments 15 to the liquid C falling down the outside surfaces of the sheets 4. The interspace below the tubes 17 and in which the liquid C is confined as it falls as a film may advantageously be constructed as an air duct, similar to the air ducts 12 of the FIG. 1 embodiment. Because the FIG. 2 air ducts also contains a flowing liquid the reference numeral 16 is used to identify the air duct spaces of the embodiment of FIGS. 2-5, 7 and 8. The liquid C which forms a falling film on the sides of the air duct compartment 16 is collected by a basin 19 located underneath the lower edges of the compartments 16 of the heat exchanger. When the air stream B traverses the air duct compartment 16 and the walls of that compartment are wetted with the falling liquid C, heat and mass transfer occurs between the two streams. A fraction of the liquid C evaporates and liquid C is cooled by a combination of latent and sensible heat transfer to air stream B, a process commonly known as evaporative cooling. The heat transfer sheets 4 are constructed of thin film, preferably non-metalic material such as three to five mil thickness polyester plastic such as "Mylar". The sheets are secured within a rectangular frame comprising the distributor 6 at the top, the hot water collector 8 at the bottom and vertical end pieces 24. There may be intermediate vertically disposed stiffeners between the top and bottom frame members to reduce the size of the unsupported sheet area. In operation the sheets 4 are subjected to the static loads induced by the weight of the clinging liquid film and the dynamic loads created by the moving air currents in the duct spaces 12 or 16. The hot water compartments 15 are virtually dead air spaces, being enclosed at the top by the distributor 6, at the bottom by the collector 8 and on the ends by the end plates 24. Depending on several physical factors, such as the air current velocity or the structural strength of the sheets 4, it may be desirable to provide for pressure equalization across the sheets 4 or between the adjacent compartments 15 and 16. One method of providing such relief is to provide pressure balancing ports or openings 26 in the upper portion of each of the sheets 4 which will provide for the transfer of air from one compartment to another to equalize the pressure across the sheets 4. The equal widths shown for the air duct 16 and the hot water compartment 15 are for illustration only. It is advantageous to minimize the thickness of the compartment 15 and thereby maximize the total heat transfer or evaporation per unit volume of the heat exchanger. While the preferred form of the invention, as illustrated in FIGS. 2-5, 7 and 8, is intended to accommodate a cross-flow of air through the ducts 16, another form of construction, as seen in FIG. 6, can be utilized for co-flowing air or counter-flow air. For this latter embodiment the secondary liquid distributor 17' is placed on top of the hot water distributor 6', the nozzle pairs 20' coming out of the sides of the distributor 17' in order to provide the necessary top opening for the air flow. In this embodiment, liquid distributor 6' is unchanged over the FIG. 2 embodiment except that stream A' enters distributor 6' from an end rather than from the top due to the placement of the distributor 17' above the distributor 6'. The heat transfer functions which are capable of being performed by the heat exchanger of the present invention are liquid-to-air dry cooling, as shown and described relative to FIG. 1, liquid-to-liquid cooling across the heat transfer membranes and evaporative cooling from direct liquid-to-air contact. By mechanically derived valving and shunting these functions may be performed singly, in combination, alternately, or in combination and alternately. These several functions of the apparatus are beneficial in the various heat and mass transfer functions required in processes for the removal of dissolved solids from water utilizing a combination of heat exchange and evaporation. In such a process there may be a liquid stream A, air stream B, and liquid stream C, all flowing simultaneously. Liquid stream A may be an industrial waste heat product such as the hot condenser discharge coolant in a steam electric power station. Liquid stream C is concentrated industrial waste water, such as conventional cooling tower blowdown or deionizer waste water. The air stream B is the air draft through a cooling tower. Using the device of the present invention in such an arrangement, the liquid stream A transfers thermal energy to the liquid stream B via liquid-to-liquid heat transfer across the heat transfer surface 4. The transferred thermal energy propels the evaporation and volume reduction of the liquid stream C. Liquid stream C is cooled by transfer of latent and sensible heat to the air stream B and stream C in turn then cools liquid stream A by liquid to liquid heat transfer. In a conventional cooling tower setting, dry cooling can be achieved with a closed hot water loop. The falling film heat exchanger of FIG. 1 for example, is disposed within a cooling tower in lieu of the normal fill. Sensible heat is transferred from the hot liquid stream A to the air stream B. On the other hand, where water is available for evaporative cooling, the hot water can be diverted into the distributor 17 and the nozzles 20 to provide direct liquid to air contact. In both cases the air stream B is provided by the draft created by the cooling tower configuration. Stream C in the "cooling by waste water evaporation" mode will typically have a dissolved solids content of 10-20% by weight, and entrainment of this liquid in air stream B is environmentally unacceptable. In the present invention, stream C is distributed as a uniform falling film on sheets 4 without splashing and with virtually no entrainment of droplets or mist. The non-metalic construction of the heat transfer sheets 4 and the other elements of the heat exchanger are advantageous in the environment of a high concentration of dissolved solids in order to avoid scaling and corrosion. These three operating modes for a cooling tower with the internally disposed heat exchanger of the present invention are summarized as cooling by water evaporation, cooling by conventional evaporation, and dry cooling. Changing from mode to mode can be done by turning and diverting streams on or off with conventional valves. The availability of the three modes provides flexibility to respond to various combinations of cooling and waste water reduction requirements. Although the description of the operation of the invention has highlighted uses in a cooling tower environment, it is to be understood that the heat exchanger can function for any low guage pressure heat transfer process.
The invention relates to a low pressure heat exchanger for use in an environment where metal parts would be subject to corrosion or scaling comprising a plurality of vertically disposed mutually parallel membranes acting as heat transfer surfaces and including fluid distributors and dispensing nozzles disposed near the top edge of the membranes so as to distribute hot liquid as a falling film down the membrane surface. From a second distributor set, a second liquid may be passed down the opposite surface of each membrane to provide liquid-to-liquid heat transfer. A draft producing device is employed to either allow a gas to flow directly over the heat transfer membrane or over the second liquid as it falls down the membrane surface to obtain a liquid-to-gas heat transfer or evaporative cooling of the second liquid.
8
This application claims priority benefit of U.S. Provisional Application No. 60/122,353, filed Mar. 2, 1999 and U.S. Provisional Application No. 60/122,696, filed Mar. 3, 1999. FIELD OF THE INVENTION The present invention involves a process for melt forming conductive compositions comprising ionomers into multi-layer electrochemical cells suitable for use in electrochemical applications such as batteries, fuel cells, electrolysis cells, ion exchange membranes, sensors, electrochemical capacitors, electro-chromic windows, and modified electrodes. Of particular interest is the use in lithium batteries. BACKGROUND Cook et al., U.S. Pat. No. 4,818,643, discloses an extrusion process of polymer electrolyte materials and/or cathode materials, optionally extruded onto other components of a cell, including current collectors, sequentially or by coextrusion. Example 8 therein describes the addition of propylene carbonate to a melt blend of polyethylene oxide and salt in a second extrusion stage. Gozdz et al., U.S. Pat. No. 5,418,091, discloses a “dry film” process involving the use of a temporary plasticizer in an electrolyte composition comprising a copolymer of vinylidene fluoride (VF2) and hexafluoropropylene (HFP), the temporary plasticizer being employed to provide voids in the solid polymer after removal thereof, and the temporary plasticizer being removed in a later step and subsequently replaced by of the hygroscopic lithium salt solution. The temporary plasticizer permits the early stages of the cell formation process to be run without undue concern about moisture. Gozdz does not disclose a melt extrusion process. Schmutz et al., U.S. Pat. No. 5,470,357, discloses melt extrusion of the compositions of Gozdz, op.cit. Schmutz teaches a process of pretreating the current collector with a solution of a polymer similar to the polymer of the solid polymer electrolyte to facilitate lamination. The lamination may be performed utilizing calender rolls. The process otherwise is similar to that of Gozdz. Chern et al., WO 97/44847 discloses an extrusion process for forming an activated electrode suitable for use in batteries, the process comprising mixing a non-ionic polymer, an electrode-active material, a salt, and organic carbonates and feeding the mixture to the feed zone of an extruder, mixing the ingredients therein, and extruding a film suitable for laminating to other components of the battery. Keller et al., U.S. Pat. No. 5,725,822 discloses extrusion of an activated electrode composition the process comprising feeding a mixture of a (non-ionic) polymer, an electrode-active material, a salt, and organic carbonates to the upstream end of a screw extruder, and feeding additional solvent (or possibly a mixture of polymer and solvent) at a downstream port. The amount of solvent in the first feeding stage is adjusted to provide a melt undergoing sufficient shear that good mixing will occur, and the amount of solvent being fed in the second stage being adjusted so that the total amount of solvent represents the final amount in the finished electrode material. The extruded electrode may be deposited onto a current collector and/or coated with a layer of solid polymer electrolyte. Assembly of a lithium battery cell from thus extruded components is also disclosed. Doyle et al., WO 98/20573, disclose the use of perfluoroionomers to form the electrodes and separators of electrochemical cells. In particular, the lithium ionomers are employed to form lithium-ion cells. The electrodes and separators are formed by casting solutions and dispersions onto a substrate, followed by a drying step, which in turn is followed by a solvent contact step. Combination of these components into electrochemical cells is also disclosed. SUMMARY OF THE INVENTION The present invention provides for a process for forming ionically conductive shaped articles, the process comprising: combining in a vessel provided with a mixing means a polymer comprising monomer units of vinylidene fluoride and 2-50 mol-% of a perfluoroalkenyl monomer unit having a pendant group comprising the radical represented by the formula —(OCF 2 CFR) a OCF 2 (CFR′) b SO 2 X − (M + )[YZ c ] d   (I) wherein R and R′ are independently selected from F, Cl or a perfluoroalkyl group having 1 to 10 carbon atoms, optionally substituted by one or more ether oxygens; a=0, 1 or 2; b=0 to 6; M + is H + or a univalent metal cation; X is O, C or N with the proviso that d=0 when X is O and d=1 otherwise, and c=1 when X is C and c=0 when X is N; when c=1, Y and Z are electron-withdrawing groups selected from the group consisting of CN, SO 2 R f ,SO 2 R 3 , P(O)(OR 3 ) 2 , CO 2 R 3 , P(O)R 3 2 , C(O)R f , C(O)R 3 , and cycloalkenyl groups formed therewith wherein R f is a perfluoroalkyl group of 1-10 carbons optionally containing one or more ether oxygens; R 3 is an alkyl group of 1-6 carbons optionally substituted with one or more ether oxygens, or an aryl group optionally further substituted; or, when c=0, Y may be an electron-withdrawing group represented by the formula —SO 2 R f ′ where R f ′ is the radical represented by the formula —(R f ″SO 2 N−(M + )SO 2 ) m R f ″ where m=0 or 1, and R f ″ is —C n F 2n — and R f ′″ is —C n F 2n+1 where n=1-10 and, a polar aprotic liquid to form a composition; mixing said composition at least until it is plastically formable; and, forming a shaped article from said plastically formable composition by the application of heat and/or pressure thereto. The present invention further provides a shaped article made by the process of the invention. The present invention further provides an electrochemical cell formed from one or more shaped articles of the invention. The present invention still further provides for a process for forming an electrochemical cell, the process comprising combining in a vessel provided with a mixing means a polymer comprising monomer units of vinylidene fluoride and 2-50 mol-% of a perfluoroalkenyl monomer unit having a pendant group comprising the radical represented by the formula —(OCF 2 CFR) a OCF 2 (CFR′) b SO 2 X − (M + )[YZ c ] d   (I) wherein R and R′ are independently selected from F, Cl or a perfluoroalkyl group having 1 to 10 carbon atoms, optionally substituted by one or more oxygens; a=0, 1, or 2; b=0 to 6; M + is H + or a univalent metal cation; X is O, C or N with the proviso that d=0 when X is O and d=1 otherwise, and c=1 when X is C and c=0 when X is N; when c=1, Y and Z are electron-withdrawing groups selected from the group consisting of CN, SO 2 R f ,SO 2 R 3 , P(O)(OR 3 ) 2 , CO 2 R 3 , P(O)R 3 2 , C(O)R f , C(O)R 3 , and cycloalkenyl groups formed therewith wherein R f is a perfluoroalkyl group of 1-10 carbons optionally containing one or more oxygens; R 3 is an alkyl group of 1-6 carbons optionally containing oxygen, or an aryl group optionally further substituted; or, when c=0, Y may be an electron-withdrawing group represented by the formula —SO 2 R f ′ where R f ′ is the radical represented by the formula —(R f ″SO 2 N—(M + )SO 2 ) m R f ′″ where m=0 or 1, and R f ″ is —C n F 2n — and R f ′″ is —C n F 2n+1 where n=1-10. and, a polar aprotic liquid to form a composition; mixing said composition at least until it is plastically formable; and, forming a shaped article from said plastically formable composition by the application of heat and/or pressure thereto; layering said shaped article with such other shaped articles as are required to make an electrochemical cell; and, consolidating said layered shaped articles to form an electrochemical cell. DETAILED DESCRIPTION Highly conductive compositions comprising fluorinated ionomers provide numerous advantages in use in electrochemical applications such as lithium batteries. They are single ion conductors not susceptible to performance degrading charge polarization, exhibit high stability, and can be combined with aprotic polar solvent to provide highly conductive compositions. It is well-recognized that continuous melt processibility of the components of a battery provides a significant reduction in manufacturing cost over processes which depend upon casting and drying of solutions and dispersions. It is of particular benefit to be able to produce electroactive components in a single processing step rather than through numerous solvent handling steps. However, the fluorinated ionomers known in the art, the best known of which is Nafion® perfluoroionomer film and resin available from DuPont, Wilmington Del., do not exhibit melt processibility, thus placing the fluorinated ionomers of the art at a disadvantage with respect to the alternative approaches in the art which do allow for melt processing. The melt processable ionomers known in the art, such as cation-neutralized ethylene-methacrylic acid copolymers sold under the trade name Surlyn® by DuPont, Wilmington, Del., do not provide conductive compositions with the desirable high levels of conductivity when combined with polar solvents. The present invention provides a process for forming conductive shaped articles, the process comprising combining a fluorinated ionomer with an aprotic polar liquid, mixing the ingredients to form a plastically formable composition, and forming the composition into a shaped article. The process depends upon the surprising plastic formability of the composition. The present process provides immense benefits over the art. For the first time, a fluorinated ionomer can be processed into conductive components suitable for use in electrochemical cells in a process which does not involve forming solutions or liquid or gelled dispersions, nor liquid casting steps, nor extraction steps. In the process of the present invention, a conductive composition needed to form an electrochemical component having all the benefits provided by fluorinated ionomers is prepared in a single process step. The process of the invention is particularly beneficial as a manufacturing process because it affords considerable improvement in compositional control over methods taught in the art. The fluorinated ionomers suitable for use in lithium batteries need to be combined with the solvents hereinbelow recited in order to provide the conductivity required for practical utility in lithium batteries. However, suitable ionomers often readily absorb excess amounts of solvent, thus actually degrading battery performance. Controlling the process of solvent uptake is therefore a critical quality issue. The process of the present invention allows for the strict control of composition in contrast to the solvent casting processes of the art. In the process of the invention, a fluorinated ionomer is combined and mixed with an aprotic polar liquid to make a plastically formable composition. A plastically formable composition is one which can be molded to a shape by the application of heat and/or pressure, and which will retain the shape to which it has been molded upon removal of the heat and/or pressure by which it was formed. Mixing is performed at a temperature at which the ionomer/liquid combination forms a plastically formable viscous mass. Suitable for the practice of the invention are polymers comprising monomer units of vinylidene fluoride and 2-50 mol-%, preferably 2-20 mol-%, most preferably 4-12 mol-%, of a perfluoroalkenyl monomer unit having a pendant group comprising the radical represented by the formula —(OCF 2 CFR) a OCF 2 (CFR′) b SO 2 X − (M + )[YZ c ] d   (I) wherein R and R′ are independently selected from F, Cl or a perfluoroalkyl group having 1 to 10 carbon atoms, optionally substituted by one or more oxygens; a=0, 1 or 2; b=0 to 6; M + is H + or a univalent metal cation; X is O, C or N with the proviso that d=0 when X is O and d=1 otherwise, and c=1 when X is C and c=0 when X is N; when c=1, Y and Z are electron-withdrawing groups selected from the group consisting of CN, SO 2 R f , SO 2 R 3 , P(O)(OR 3 ) 2 , CO 2 R 3 , P(O)R 3 2 , C(O)R f ,C(O)R 3 , and cycloalkenyl groups formed therewith wherein R f is a perfluoroalkyl group of 1-10 carbons optionally containing one or more oxygens; R 3 is an alkyl group of 1-6 carbons optionally containing oxygen, or an aryl group optionally further substituted; or, when c=0, Y may be an electron-withdrawing group represented by the formula —SO 2 R f ′ where R f ′ is the radical represented by the formula —(R f ″SO 2 N−(M +)SO 2 ) m R f ′″ where m=0 or 1, R f ″ is C n F 2n and R f ′″ is C n F 2n+1 each optionally substituted by one or more hydrogens and where n=1-10. Preferably, a=0 or 1, R=CF 3 , R′=F,b=1, and when X is C, Y and Z are CN or CO 2 R 3 where R 3 is C 2 H 5 , while when X is N, Y is preferably SO 2 R f where R f is CF 3 or C 2 F 5 and M + is H + or alkali metal cation. Most preferably M + is a lithium cation. Most preferred are lithium perfluorosulfonate ethoxy propyl vinyl ether (Li-PSEPVE) and the methide and imide derivatives thereof as hereinabove described. Further encompassed in the present invention are terpolymers comprising 0-20 mol-% of monomer units selected from the group consisting of tetrafluoroethylene, trifluoroethylene, chlorotrifluoroethylene, vinyl fluoride, hexafluoropropylene, perfluoromethyl vinyl ether, perfluoroethyl vinyl ether, ethylene, propylene, 1 -octene, isobutylene, ethyl vinyl ether, acrylic acid and the alkyl esters thereof, and methacrylic acid and the alkyl esters thereof, and mixtures thereof. Aprotic polar solvents suitable for the practice of the invention include the linear and cyclic carbonates, esters, diesters, lactones, amides, sulfoxides, sulfones, and ethers. Preferred solvents are mixtures of cyclic carbonates, diesters, or lactones such as ethylene carbonate, propylene carbonate, butylene carbonate, vinylene carbonate, dimethyl succinate, diethyl succinate, dimethyl glutarate, dimethyl adipate, gamma-butyrolactone, fluoro or chloro-substituted cyclic carbonates mixed with linear carbonates such as dimethyl carbonate, diethyl carbonate, dipropyl carbonate, ethyl methyl carbonate, methyl propyl carbonate, and fluoro and chloro substituted linear carbonates. Especially preferred are mixtures of ethylene carbonate and gamma-butyrolactone, ethylene carbonate and dimethyl succinate, and of ethylene carbonate and propylene carbonate. Most preferred are mixtures of ethylene carbonate with propylene carbonate in weight ratios of from 50:50 to 80:20. In one preferred embodiment the process of the invention is employed to produce an ionically conductive separator membrane. In this embodiment, a composition is formed comprising 10-50%, preferably 15-30%, by weight of a preferred lithium ionomer and 50-90%, preferably 70-85%, by weight of a preferred solvent mixture. The mixture so formed may optionally contain an inert filler at a concentration of less than 50%, preferably less than 20%, by weight of the total weight of ionomer/solvent mixture. Additionally, it is preferable to add a small amount of a mobile lithium salt to the combination the amount being less than 15%, preferably less than 10%, by weight of the total weight of ionomer/solvent mixture. Suitable inert fillers include non-swelling polymers, fibers, or porous substrates such as polyvinylidene fluoride (PVDF) homopolymer, polytetrafluoroethylene (PTFE) homopolymer, or polyolefins, solvent swellable polymers such as polyvinylidene fluoride-hexafluoropropylene copolymers, polyurethane, polyalkylene oxides, polyacrylonitrile, polymethyl methacrylate, or copolymers of any of these, and non-conducting ceramic particles such as TiO 2 , SiO 2 , zeolites, or Al 2 O 3 . Also included are organic compounds such as aromatic compounds such as benzene derivatives such as substituted anisoles added for safety-related purposes or overcharge or overdischarge protection for the battery, or nondissociating salts such as LiX where X=halide or carbonate. Suitable mobile salts for combining with the most preferred lithium ionomer include LiPF 6 , LiPF x R fy , LiBF 4 , LiAsF 6 , LiCIO 4 , lithium borates, LiSO 3 R f , LiN(SO 2 R f )(SO 2 R f ), LiC(SO 2 R f ) (SO 2 R f )(SO 2 R f ), and mixtures thereof, where the “f” subscript denotes partial or complete fluorination. The R f groups are electron-withdrawing, and may respectively be the same or different from one another. Preferably R f =CF 3 , CF 2 CF 3 , or C 4 F 9 . Most preferred are LiPF 6 or LiN(SO 2 CF 2 CF 3 ) 2 . It will be understood by one of skill in the art that such other adjuvants as are commonly employed in the art to facilitate processing, impart oxidative or photochemical stability, or such other desirable modifications as are commonly achieved in the art, may also be employed in the practice of the present invention so long as these adjuvants make no substantive changes in the desirable results of the present invention or the methods employed to achieve them. Mixing in the process of the invention can be accomplished by any convenient means known in the art. Depending upon the melting or softening point of the conductive composition being employed, heating may be necessary to provide sufficient mixing to achieve the desired plastically formable composition. Mixing may be performed in batches or continuously. Examples of suitable mixing apparatus are screw extruders, roll mills, high intensity batch mixers such as Brabenders. In a preferred embodiment of the present invention, the ingredients of the preferred plastically formable composition are fed continuously to an extruder pre-heated to a temperature in the range of 25 to 180° C. wherein the ingredients are mixed to form a homogeneous composition, and the composition is then extruded through a film die to form a separator membrane which is in the electrochemically activated state as extruded. In order to achieve best results, it is necessary to take provision that the feeding and mixing are performed in an anhydrous atmosphere. It will be understood by one of skill in the art that feeding may be performed in a single stage or in multiple stages according to methods known in the art depending upon the particular ingredients employed and the rheological requirements to attain good mixing. Shaped articles can be formed according to the process of the invention by any means known in the art. In a preferred embodiment the plastically formable composition is extruded through a flat or circular film or sheet die. In the alternative, the plastically formable composition may be compression molded into a film or sheet. The film or sheet so formed can be further formed into articles of more complex shape by thermoforming. In another embodiment, the shaped articles can be formed by injection molding. In a further preferred embodiment of the invention, an anode is formed by mixing and extruding into film a composition comprising, by weight, 5-20%, preferably 8-10%, of a preferred lithium ionomer, 10-60%, preferably 20-30%, of a preferred solvent mixture, 40-80%, preferably 60-65%, of electrode-active material, and 1-10%, preferably 2-4%, of a conductive additive. Optionally up to 12% of an inert filler or up to 10% of a mobile lithium salt as hereinabove described may also be added, as may such other adjuvants as may be desired by one of skill in the art which do not substantively affect the achievement of the desirable results of the present invention. It is preferred that no filler be used, and that no more than 5% of a mobile lithium salt be used. The electrode active material suitable for use in the process for forming an anode include carbons such as coke or graphite, metal oxides such as titanium oxides, iron oxides, or tin oxides or lithium-alloy-forming compounds of tin, silicon, antimony, or aluminum such as those disclosed in “Active/Inactive Nanocomposites as Anodes for Li-Ion Batteries,” by O. Mao et al. in Electrochemical and Solid State Letters , 2 (1), p. 3, 1999. Particle size of the active material should range from about 1 to 100 microns. Preferred are graphites such as carbon microbeads, natural graphites, or carbon fibers. Especially preferred are graphite microbeads such as those produced by Osaka Gas in Japan (MCMB 25-28, 10-28, or 6-28). Suitable conductive additives for the anode composition include carbons such as coke, carbon black, carbon fibers, and natural graphite, metallic flake or particles of copper, stainless steel, nickel or other relatively inert metals, conductive metal oxides such as titanium oxides or ruthenium oxides, or electronically-conductive polymers such as polyaniline or polypyrrole. Preferred are carbon blacks with relatively low surface area such as Super P and Super S available from MMM Carbon in Belgium. In a further preferred embodiment of the invention, a cathode is formed by combining and extruding into a film a composition comprising, by weight, 5-15%, preferably 8-10%, of a preferred lithium ionomer, 10-50%, preferably 20-30%, of a preferred solvent mixture, 40-80%, preferably 60-65%, of an electrode-active material, and 1-12%, preferably 5-8%, of a conductive additive. Optionally up to 12% of an inert filler or up to 10% of a mobile lithium salt as hereinabove described may also be added, as may such other adjuvants as may be desired by one of skill in the art which do not substantively affect the achievement of the desirable results of the present invention. It is preferred that no filler be used, and that no more than 5% of a mobile lithium salt be used. Suitable for use as an electrode-active material in the cathode composition include transition metal oxides such as spinel LiMn 2 O 4 , layered LiMnO 2 , LiNiO 2 , LiCoO 2 , LiNi x Co y O 2 , and vanadium oxides such as LiV 2 O 5 , LiV 6 O 13 , or the foregoing compounds modified in that the compositions thereof are nonstoichiometric, disordered, amorphous, overlithiated, or underlithiated forms such as are known in the art. The suitable compounds may be further modified by doping with less than 5% of divalent or trivalent metallic cations such as Fe 2+ , Ti 2+ , Zn 2+ , Ni 2+ , Co 2+ , Cu 2+ , Cr 2+ , Fe 3+ , Al 3+ , Ni 3+ , Co 3+ , or Mn 3+ , and the like. Other electrode active materials suitable for the cathode composition include sulfur compounds such as solid sulfur, organic disulfides, or metal sulfides such as TiS 2 or MoS 2 , electronically-conducting polymers such as polyaniline and its derivatives, polypyrrole derivatives, polyparaphenylene derivatives, polythiophene derivatives, or their copolymers, or mixtures of any of the above compounds. Particle size of the active material should range from about 1 to 100 microns. Preferred are transition metal oxides such as LiMn 2 O 4 , LiNiO 2 , LiCoO 2 , and LiNi x Co y O 2 . The conductive additives suitable for use in the process of making a cathode are the same as those employed in making the anode as hereinabove described. In the most preferred embodiment of the present invention, the anode, cathode, and separator of a lithium battery cell, each as hereinabove described, is made by the extrusion process of the invention into a flat film or sheet, the films being brought together under anhydrous conditions in a layered structure with the separator being disposed between the anode and cathode films and metallic current collectors being disposed on either side of the layered structure, one or more of said layered structures then being thermally consolidated to form one or more lithium-ion cells. In a preferred embodiment, the current collectors are metallic meshes or foils pretreated with adhesion promoters such as mixtures comprising the ionomer employed in the process of the invention. The current collectors could also be metallized plastic materials or metallized carbon fiber webs. Especially preferred are 20 to 100 μm thick copper and aluminum expanded metal meshes for the anode and cathode, respectively. Methods for thermally consolidating multi-layered structures comprising thermoplastic polymers are well known. These include calendering and hot pressing. It will be understood by one of skill in the art that numerous post-fabrication actions may be performed on the membranes and electrode films made by the process of the invention depending upon the particular needs of a specific application. These may include but are not limited to calendering, folding, cutting, stacking, removal of any excess gas volume, drying or extraction, solvent exposure, and the like. The process of the present invention may be integrated into a larger process which also includes the steps of first hydrolyzing the non-ionic precursor polymer, performing the necessary ion exchange procedures to form the lithium ionomer, extracting protic solvent contamination, and further including steps such as battery assembly and packaging. Providing anhydrous conditions throughout the process is an important feature for achieving excellent battery performance. The hygroscopic nature of ionomers makes removal of water preferentially to battery solvents a difficult undertaking. It is preferred to mix and compound dry ionomer with other dry components such as battery solvents and active materials directly prior to melt processing of the electrode and separator formulations. Then all following battery process steps should be kept under anhydrous conditions by using means known in the art such as enclosed environments with nitrogen or other inert gas purge, dry room conditions, or drying agents. The ionomer and other battery components can be dried individually or in combination using means known in the art such as vacuum, heating, or extractions followed by vacuum and/or heating. The ionomers suitable for the practice of the present invention are typically exposed during preparation to protic solvents, most particularly water and methanol. It is known in the art that protic solvents such as these are deleterious to the performance of lithium batteries, even in very small concentrations. It has been found in the practice of the present invention that conventional means of drying, such as drying under vacuum, are ineffective at removing the most tightly bound solvents which have formed solvates with the ionic moiety of the polymer. It is therefore highly preferred that in a step preliminary to combining the ionomer with the desired aprotic liquid in the process of the invention, to subject the ionomer to an additional solvent removal process, as follows. The ionomer is contacted with an inert liquid, such as toluene or xylene, which does not readily swell the ionomer. Introduced into the mixture is at least one additional substance, selected on the basis of its coordinating ability for lithium ion, battery component compatibility with other battery components, and vapor-liquid equilibrium properties, that substance being added in a sufficient quantity that the protic solvent is displaced thereby from the lithium ion, and is subsequently removed from the system by distillation or azeotropic distillation. It is recognized that solvate formation is a consideration for other ionomer applications, and that these may require other choices for the ion-ligating substance to be added. Suitable additional substances include organic carbonates, sulfones, phosphates, phosphine oxides, such as ethylene carbonate, propylene carbonate, tributyl phosphate, butylene carbonate, fluoro ethylene carbonate, g-butyrolactone, or sulfolane, or other uncharged, electron-pair donor substances. Water content is conveniently determined by Karl Fisher titration on solid samples of ionomer powder. Using the above described procedures to dry the ionomer powder, water contents of less than 100 PPM can easily be achieved. Water content below 50 PPM is preferred for the ionomer powder. EXAMPLES In the Examples hereinbelow, ionic conductivity was determined following the method of Doyle et al, WO 98/20573. All chemicals were used as received unless stated otherwise; water contents of anhydrous carbonate-based solvents used hereinbelow were less than 40 ppm as measured using Karl Fischer water analysis. Example 1 A 1-liter vertical stirred autoclave was charged with 500 ml of an aqueous solution of ammonium perfluorooctanoate (7 g) and perfluoro-2-(2-fluorosulfonyl-ethoxy)propyl vinyl ether (PSEPVE) (29.0 g, 0.065 mol). The vessel was closed, twice pressured to 100 psi nitrogen and vented, cooled to about 5° C. and evacuated. Vinylidene fluoride (50.0 g, 0.78 mol) was added and the stirred (750 rpm) contents were heated to 60° C. A solution of potassium persulfate (0.08 g in 20 ml) was added over a 10 minute interval. When the pressure had decreased to ca. 130 psig, another 50 g of vinylidene fluoride was added. After the reaction was complete, the copolymer dispersion was heated to 50° C. and added to an equal volume of isopropanol with stirring. The coagulated product was filtered, washed with water, and dried in a nitrogen-purged vacuum oven at 100° C. There was obtained 97.1 g of white copolymer. DSC exhibited maximum of a broad melting transition at 146° C. (22.1 J/g). The composition was found to be 94.5 mol % VF2 and 5.5 mol % PSEPVE, as determined by a combination of 1 H and 19 F NMR. 19F NMR (acetone-d6): +45.57 (s), −78.0 to −80.0 (m's, a=2.968), −90.0 to −95.0 (m's, a=8.646), −108 to −116 (series of m, a=2.721), −121 to −127 (m's, a=1.004), −143 to −144.0 (m, a=0.499). 97.0 g (62.9 milliequivalents) of the copolymer so produced was suspended in 500 ml methanol and treated with 3.92 g Li2CO3. The resulting mixture was stirred and heated to reflux for 5 hr. After standing at room temperature for 18 hr, an additional 100 mL methanol was added and reflux was continued for 2 hr. 19 F NMR of an aliquot showed >99% conversion of sulfonyl fluoride groups to lithium sulfonate moieties. A portion of the methanol (100 mL) was removed under vacuum, and the resulting cold slurry was treated with 2 liters of cold water. The resulting mixture was subjected to portion-wise centrifuge isolation. The aqueous phase was decanted and the remaining water-laden polymer phase was dried in a nitrogen-purged vacuum oven at 100° C. for 48 hr. The resulting polymer crumb was cryoground to afford smaller particles which were further dried in a final storage bottle to constant weight (24 hr, 100° C.) using a nitrogen-purged vacuum oven. 19 F NMR (acetone-d6): −77 to −82 (bd signals, a=7.00), −91.2 (major s), −91.63, −93.39 and −95.06 (minor s, combined a=37.171), −108 to −112 (bd), bd singlets at −113.5 and −115.8, bd m at −117.2 (combined a=8.065), −123 (center of bd m, a=1.148), −127 (center of bd m, a=0.454), minor s at −125.8 (a=0.198), −145 (center of bd m, a 1.157), consistent with a composition consisting of mol % Li-PSEPVE=4.9%. DSC (2 nd heat) showed peak of broad melting transition at 144.8° C. (15.8 J/g). In a nitrogen purged glove box, 1 gram of the dried ionomer crumb was treated with 3 grams of a 1:1 by volume mixture of ethylene carbonate (EC, Selectipur, EM Industries) and propylene carbonate (PC, Selectipur, EM Industries) in a vial at room temperature and manipulated with a spatula. The vial was sealed and heated in a sand bath maintained at 130° C. Periodically, the contents were mixed with a spatula, until a uniform composition was obtained. The resultant composition was placed between Kapton® sheets which were placed inside a sealed polyethylene bag, all of which was then placed within the preheated platens of a Pasadena hydraulic press at 125° C., and pressed using ca. 1000 lb applied force to produce a membrane sample ca. 10 cm square with a thickness of ca. 1.5 mil. After pressing, the membrane was transferred into a nitrogen-purged Vacuum Atmospheres glove box and opened. A 1.0 by 1.5 cm 2 sample of this membrane was cut using a knife and conductivity determined to be 3.73×10 −4 S/cm. Example 2 A copolymer of VF2 and PSEPVE was synthesized according to the following method. 150 g of PSEPVE liquid was suspended in aqueous emulsion by combining with a solution of 35 g of ammonium perfluorooctanoate in 600 ml of distilled water using a Microfluidics, Inc. microfluidizer. The suspension was then diluted to 1 liter total volume with additional distilled water. The suspension so formed was charged to a nitrogen purged 4 liter horizontal autoclave equipped with a mechanical agitator, along with an additional 1500 mL of distilled water. The reactor was evacuated, then pressurized to 0 psig with vinylidene fluoride three times, then heated to 60° C., pressurized to 400 psig with vinylidene fluoride, and agitated at 200 rpm. A solution of aqueous potassium persulfate (0.6%, 50 mL) was added over a 5 min period. Reactor pressure was maintained at 400 psi until 220 g of VF2 had been fed after initiator addition. Agitation was stopped and the reactor was cooled and vented. The resulting milky dispersion was frozen and thawed to coagulate the product which was filtered through Nylon cloth and washed with water repeatedly to remove surfactant. After air drying, polymer crumb was dried in a nitrogen-purged vacuum oven at 100° C. for 24 hr to give 350 g of product. 19 F NMR data (acetone): +45.2 (s, a=1.00), −78.0 to −80.0 (m's, a=7.876), −90.0 to −95 (m's, a=21.343), −108 to −116 (series of m, a=6.446), −122.0 to −127.5 (m's, combined a=2.4296), −143.0 (bd s, a=1.283), consistent with mol % PSEPVE=9.1%. Within experimental error, all of the liquid comonomer charged to the reactor was accounted for in the collected product copolymer. TGA (10°/min, N2): no weight loss until 375° C. DSC (20°/min): maximum of broad melting transition at 159.1° C. (23.1 J/g); Tg=−23° C. A 3-liter 3-neck flask fitted with overhead paddle stirrer (Teflon* bearing), reflux condenser, and thermocouple port was charged with 200 g of the VF2/PSEPVE copolymer (183.4 mequivalents of SO 2 F), methanol (1700 mL), and lithium carbonate (13.6 g, 184 mequiv.). The mixture was stirred for 24 hr at room temperature. Toluene (300 mL) was added, and the mixture was heated to reflux in order to remove solvent. Methanol/toluene azeotrope was collected while additional toluene was added to keep volume in the reactor unchanged. Distillation was continued until the polymer had precipitated and the distillate temperature had reached ca. 108° C. Propylene carbonate (15.8 mL, 18.8 g distilled, stored over sieves) was added, and distillation was continued until the distillate was free of methanol. The slurry was cooled to room temperature and filtered using a dry, nitrogen-purged pressure funnel. Residual toluene was removed under nitrogen, and the product was transferred in a dry atmosphere to provide 221.7 g as a free-flowing, white powder. 19 F NMR (acetone-d6) featured: −76 to −82 (bd signals, a=7.00), −91.2 (major s), −91.65, −93.4 and −95.06 (minor s, combined a=18.418), −108 to −112 (bd), bd singlets at −113.5 and −115.8, bd m at −117.2 (combined a=5.328), −123 (center of bd m) and −127 (center of bd m, combined a=2.128), −145 (center of bd m, a=1.212). Integration was consistent with 9.5 mol % Li-PSEPVE. 1 H NMR (acetone-d6) was consistent with one propylene carbonate molecule per polymer-bound lithium ion. Example 3 In a nitrogen-purged Vacuum Atmospheres glove box 0.5 g of the dried crumb of the lithium ionomer of Example 2 were mixed with 1.5 grams of a 1:1 by volume mixture of EC and PC (EC and PC both Selectipur grade, EM Industries) in a glass vial which was sealed and heated to 100° C. for several hours to mix thoroughly. This mixture was then cooled to form a gel and then, still in the nitrogen-purged glove box, placed between two 5 mil thick sheets of Kapton® polyimide film (DuPont) and the resulting sandwich placed between the platens of a Carver Hydraulic Unit Model #3912 preheated to 105° C. and pressed with a ram force of 1,000 lbs. The film that resulted was clear and uniform and ca. 125 μm in thickness. Once cooled to room-temperature, a 1.0 by 1.5 cm sample of this membrane was cut using a knife and the conductivity was determined to be 8.18×10 −4 S/cm. Example 4 70.9 g of CF 2 BrCFBrOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 N(K)SO 2 CF 3 , prepared according to the method of Xue (Ph.D. thesis, Clemson University, 1996), was dissolved in 100 ml anhydrous DMF. Zn-dust (7.05 g 108 mmol) was added to the solution and the mixture was stirred for 60 min at room temperature. The mixture was filtered and most of the solvent was removed under vacuum. The residue was combined with 300 mL of 6N HCl forming a brown, oily mixture which was stirred for 5 min and then four times extracted with fresh 100 ml aliquots of diethyl ether. The diethyl ether fractions were combined and washed three times with fresh 100 ml aliquots of deionized water. The ether was evaporated under vacuum and the remaining brown oil was subjected to two shortpath distillations to obtain 50.6 g of the acid product CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 N(H)SO 2 CF 3 . 34.08 g (59.26 mmol) of an acid product synthesized as hereinabove, was dissolved in 25 ml deionized water followed by addition of 121.1 ml of a 0.489N LiOH solution. Water was removed under vacuum and the residue was dried at 100° C. for 24 h. Yield was 34.09 g of CF 2 =CFOCF 2 CF (CF 3 ) OCF 2 CF 2 SO 2 N(Li)SO 2 CF 3 19 F-NMR in D 2 O: (8F, −77.8-−79.5 ppm; 2F, −86.0 ppm; 1F,−115.5ppm; 2F, −117.3 ppm; 1F, −123.4 ppm; IF, −137.7 ppm; 1F, −146.1 ppm); elemental analysis: N (2.45% found, 2.41% theor.), F (49.43% found, 52.31% theor.), Li (1.15% found, 1.19% theor.), S (10.83% found, 11.03% theor.). 12.80 g of the CF 2 =CFOCF 2 CF(CF 3 )OCF 2 CF 2 SO 2 N(Li)SO 2 CF 3 was dissolved in 400 g deionized water and reacted with 29 g of vinylidene fluoride at 60° C. after the addition of 20 ml of a solution of 0.200 g potassium persulfate in 50 g deionized water, according to the teachings of Connolly et al, op.cit. The VF2-copolymer was isolated by lyophilization and dried at 110° C. for 22 h to yield 40.7 g of ionomer having 4.7 mol-% of the lithium imide-functionalized comonomer as confirmed by 19 F NMR. Elemental analysis: H (2.06% found, 2.16% theor.), N (1.78% found, 0.74% theor.), Li (0.32% found, 0.37% theor.). DSC (N2,10° C./min, 2 nd heat) showed melting point at 164.5° C. 1 H NMR (acetone-d6): CH 2 at 3.60 ppm. 19 F NMR (acetone-d6): −77.2-−79.2 ppm (m), −91.2-−130.0 ppm (series of m); −144.6 (sidechain CF). 4.7 mole % PSEPVE imide in VF2 according to the integration. 0.50 grams of the dried ionomer crumb were combined in a glass vial with 0.5 grams of the VF2/Li-PSEPVE ionomer of Example 2 and 2.0 grams of a 1:1 by volume mixture of EC and gamma-butyrolactone (GBL, Selectipur, EM Industries). The contents were mixed by hand using a spatula then the vial was heated to 100° C. while sealed and under nitrogen purge for several hours umtil a homogeneous and clear mixture resulted. This mixture was cooled to form a gel and hot pressed as in Example 3 except that the temperature was 105° C. The film that resulted was clear and uniform and 105-120 microns in thickness. Once cooled to room temperature, a 1.0 cm by 1.5 cm membrane sample from this hot pressed film was cut using a knife and the ionic conductivity was determined to be 8.27×10 −4 S/cm. Example 5 Inside the dry-nitrogen purged Vacuum Atmospheres glove box, 2.375 g of the dried VF2/Li-PSEPVE ionomer of Example 2 was combined in a 50-ml glass jar with 15.5 grams (62 wt %) of LiCoO 2 , from EM Industries, 1.75 grams of Super P carbon black, from MMM Carbon, 5.375 grams of a 1:1 by volume mixture of ethylene carbonate and propylene carbonate, Selectipur, EM Industries, to form an extrudable cathode composition. The mixture was melt-compounded in a CSI-Max extruder, model CS-194. Extrusion conditions were as follows: Rotor temperature: 120° C. Header temperature: 120° C. Gap between rotor and header: 0.13 cm Rotor speed: 140 rpm. The melt-compounded material was extruded through a circular die with a diameter of 0.32 cm, and was collected in a glass jar purged with dry nitrogen. A sample of the extruded material was collected and transferred into a Vacuum Atmospheres Glove Box with a positive pressure of nitrogen inside a sealed container. A 1.0 gram quantity of the extrudate was melt-pressed as in Example 3 except that the temperature was 130° C. and the ram force was 20,000 lbs to form a film of ca. 150 microns thickness. A 12 mm diameter specimen was punched out of this film using a brass punch. An 18 mm diameter separator film was punched out using the melt pressed film of Example 3. Neither of these films were exposed to or contained any mobile lithium salts. While still contained within a glove box environment, these cathode and separator films were assembled into size 2325 coin cells with 3 layers of ca. 100 micron thick lithium metal as the anode. The coin cell was cycled at the C/5 rate for both charge and discharge at room temperature between the voltage limits of 4.2 V and 2.8 V. Capacity during the first charge for the LiCoO 2 cathode was 156.2 mAh/g, while capacity for the first discharge was 135.8 mAh/g, giving a reversibility of 86.9%. The cell still retained 80% of its initial capacity even after over 100 identical charge-discharge cycles. Example 6 Inside the dry-nitrogen purged Vacuum Atmospheres glove box, 1.75 g of the dried ionomer copolymer of VF2 with the lithium sulfonimide derivative of PSEPVE prepared in Example 4 was combined in a 50-ml glass jar with 0.625 g of Kynar Flex® 2801 polyvinylidene fluoride-hexafluoropropylene copolymer from Atochem, 15.5 grams of LiCoO 2 , from EM Industries, 1.625 grams of Super P carbon black from MMM Carbon, and 5.5 grams of a 1:1 by volume mixture of EC and gamma-butyrolactone (GBL), Selectipur, EM Industries to form an extrudable cathode composition. The mixture was melt-compounded in a CSI-Max extruder, model CS−194. Extrusion conditions were as follows: Rotor temperature: 110° C. Header temperature: 110° C. Gap between rotor and header: 0.13 cm Rotor speed: 192 rpm. The melt-compounded material was extruded through a circular die with a diameter of 0.32 cm, and was collected in a glass jar purged with dry nitrogen. A sample of the extruded material was sealed inside the glass jar and transferred into a Vacuum Atmospheres Glove Box with a positive pressure of nitrogen. A 1.0 gram quantity of the above extrudate was melt-pressed as in Example 3 except that the temperature was 110° C. and ram force was 20,000 lbs to form films of ca. 125 microns thickness. A cathode film having a 12 mm diameter was punched out of this film using a brass punch. An 18 mm diameter separator film was punched out from the film of Example 4. Both of these films were immersed for 2 hours into an electrolyte solution composed of 1.0 M LiPF6 in 1:1 EC/GBL using a 20 ml glass vial. This cathode and separator film were assembled into size 2325 coin cells with 3 layers of ca. 100 micron thick lithium metal as the negative electrode. The coin was cycled at the C/5 rate for both charge and discharge at room temperature between the voltage limits of 4.2 V and 2.8 V. Capacity during the first charge for the LiCoO 2 cathode was 157.2 mAh/g, while capacity for the first discharge was 149.7 mAh/g, giving a reversibility of 95.2%. Capacity on the tenth discharge was 147.1 mAh/g and the coin cell achieved nearly 100 cycles to 80% of its initial capacity. Example 7 The reservoir of a Microfluidics Inc. MicroFluidizer™ was charged with a solution of 35 g ammonium perfluorooctanate in 600 ml demineralized water. The pump was started and the fluids allowed to recycle to mix the surfactant solution with the 50 ml of pure demineralized water held up within the apparatus. 150 g of PSEPVE was added to the reservoir and the system allowed to recycle for 20 min to produce a well dispersed PSEPVE emulsion. The outflow was then directed to a 1 liter volumetric flask. After the reservoir was pumped down, 150 ml demineralized water was added and pumped through the system to flush the remaining PSEPVE emulsion through and bring the level in the volumetric flask up to the mark. A 4-L horizontal autoclave with mechanical agitator was purged with nitrogen and charged with the so-formed pre-emulsified PSEPVE. The reactor was flushed by three cycles of evacuating followed by pressurizing to 0 psig with vinylidene fluoride. The reactor was again evacuated and heated to 60° C., pressurized to 300 psig with vinylidene fluoride, and agitated at 200 rpm. A solution of aqueous potassium persulfate (0.6%, 50 mL) was added over a 5 min period. Reactor pressure was maintained at 300 psi until 220 g of the pre-emulsified PSEPVE solution had been fed after initiator addition. Agitation was stopped and the reactor was cooled and vented. The resulting milky dispersion was frozen and thawed to coagulate the product which was filtered through nylon cloth and washed with water repeatedly to remove surfactant. After air drying, polymer crumb was dried in a nitrogen-purged vacuum oven at 100° C. for 24 hr to give 364 g of product. 19 F NMR (acetone): +45.2 (s, a=1.00), −78.0 to −80.0 (m's, a=7.000), −90.0 to −95 (m's, a=17.59), −108 to −116 (series of m, a=5.848), −122.0 to −127.5 (m's, combined a=2.357), −145.4 (bd s, a=1.155), consistent with mol % PSEPVE=9.5%. TGA (10% /min, N2): no weight loss until 375° C. DSC (20%/min): maximum of broad melting transition at 162° C. (23.3 J/g); Tg=−20° C. Example 8 A 3-liter 3-neck flask fitted with an overhead paddle stirrer, reflux condenser, and thermocouple port was charged with 200 g of the VF2/PSEPVE copolymer so formed, 1600 ml of methanol, and 13.71 g of lithium carbonate. The mixture was stirred for 48 hr at room temperature. 400 ml of toluene was added, and the mixture was heated to reflux in order to remove solvent. The methanol/toluene azeotrope was collected while additional toluene was added to keep the volume in the reactor unchanged. Distillation was continued until the polymer had precipitated and the distillate temperature had reached ca. 108° C. 16.7 g of ethylene carbonate was dissolved in toluene and added and distillation was continued until the distillate was free of methanol. The residual slurry was cooled to room temperature and filtered using a dry, nitrogen-purged pressure funnel. Most of the adsorbed toluene was removed under nitrogen, and residual amount was removed under reduced pressure. The product was transferred in a dry atmosphere to provide 218.0 g as a free-flowing, white powder. Karl Fisher titration, which involves measuring the quantity of water evolved at 180° C. showed that the water content of the white powder produced was ca. 24 ppm. 19 F NMR (acetone-d6) featured: −77 to −82 (bd signals, a=7.00), −91.2 (major s), −91.64, and −95.06 (minor s, combined a=17.045), −106 to −112 (bd), bd singlets at −113.5 and −115.8, bd m at −117.2 (combined a=5.243), −122 to −127.5 (center of bd m, combined a=1.988), −145 (center of bd m, a=1.095). Integration was consistent with 9.5 mol % Li-PSEPVE. Anode material was prepared by weighing and hand-mixing the following materials in a 225-ml glass jar inside a glove box under a dry nitrogen atmosphere: 5.4 grams of the lithium ionomer so formed, 34.8 grams of MCMB 6-28 graphite from Osaka Gas Chemicals Co., 2.4 grams of Super P carbon black from MMM Carbon, and 17.4 grams of a 0.1 M solution of bis(perfluoroethyl sulfonyl) imide lithium salt dissolved in a 2/1 mixture by weight of ethylene carbonate and butylene carbonate (0.1 M solution of BETI in a 2/1 mixture of EC/BC). The mixture for mormed was melt-compounded in a CSI-Max extruder, model CS-194. Extrusion conditions were as follows: Rotor temperature: 125° C. Header temperature: 125° C. Gap between rotor and header: 0.13 cm Rotor speed: 192 The melt-compounded material was extruded through a 0.32 cm diameter single strand die, and was collected in a glass jar purged with dry nitrogen. Cathode material was prepared following the same procedure as that for the anode, except that the composition fed to the extruder consisted of: 5.1 grams (8.5 wt %) of the same Li ionomer used in the anode above, 34.8 (58 wt %) of LiCoO2 from EM Industries, 4.2 grams (7 wt %) of Super P carbon black, from MMM Carbon, and 15.9 grams (26.5 wt %) of a 0.1M solution of LiN(SO 2 CF 2 CF 3 ) 2 in a 2/1 mixture of EC/BC. Extrusion conditions were the same except that the rotor and header temperatures were 130° C. Separator material was formed from a composition consisting of: 7.5 grams (25 wt %) of the Li ionomer used in the anode and cathode, 3 grams (10 wt %) of Cab-O-Sil TS-530, from Cabot Co., and 19.5 grams (65 wt %) of a 0.1M solution of LiN(SO 2 CF 2 CF 3 ) 2 in a 2/1 mixture of EC/BC. Extrusion conditions were the same as for the cathode material except that the rotor and header temperatures were 110° C. The extruded strands of cathode, anode, and separator were placed into a second nitrogen-purged dry box. Samples were placed in Kapton® bags, then calendered between hot steel rollers to form films approximately 60 mm wide. Brass foil shims were used to keep the rollers a minimum distance apart. The temperatures of the calendering rollers were 135° C., 125° C., and 125° C. for the cathode, anode, and separator, respectively. The cathode film had a weight of 37 mg/cm 2 , the anode was 18 mg/cm 2 , and the separator was approximately 75 m thick. Inside the dry box, 45×55 mm rectangular electrodes were from the anode and cathode films so prepared. A bicell was fabricated by laminating the layers together to make a stack consisting of Al/C/S/A/Cu/A/S/C/Al, where C is cathode, S is separator, A is anode, Al is aluminum mesh, and Cu is a copper mesh. After lamination, the bicell was immediately packaged into a foil laminate bag, with no extraction or electrolyte addition steps. The bicell was cycled between voltage limits of 2.7 and 4.15 V. The first charge capacity was 148 mAh (142 mAh/g of LiCoO2), the first discharge capacity was 102 mAh, and the 61 st cycle capacity was 76 mAh. Example 9 In ambient laboratory conditions, 58.0 g (58 wt. %) of LiCoO 2 , from FMC Corporation, 5.00 g of Super P carbon black from MMM Carbon, 2.00 g of Ensaco 350 carbon black, from MMM Carbon, 8.00 g of the VF2-Li-PSEPVE ionomer prepared in the manner of Example 2 were mixed manually in a jar. The powder was then added to a Waring blender in a 200 ml mixing bowl. The dry powders were mixed in the blender at a low speed setting with a rheostat setting of 50% for ˜1 minute. 27.00 g of a 1 :1 by weight mixture of ethylene carbonate and propylene carbonate, both from EM Industries, was added to the powder mixture. The mixture was blended again for ˜1 minute and placed into a glass jar. The cathode mixture so-formed was then added to a 75 ml mixing bowl of a Haake Model EU5 Torque Rheometer. The melt temperature of the mixing bowl was set at 120° C. The cathode mixture was added in small portions to the bowl with the mixing drive set at 18 rpm. Powder addition was completed over a period of 2 minutes. The Haake rheometer was then set at 25 rpm, and the cathode mixture was processed for an additional 10 minutes. The resulting cathode mixture was then collected in a jar and enclosed. A sample of the cathode mixture was then pre-densified in a platten press at about 120° C. The compressed sample was then calendered into film form with a Western Magnum laminator with steel rolls. The rolls were set at 110° C. Brass shims were used to control the minimum separation of the two steel rolls and hence the thickness of the film. The resulting cathode film had a weight of 42 mg/cm 2 , and thickness of 0.163 mm. Electronic conductivity of the film was measured to be 292 mS/cm. An anode mixture was also processed in the Haake Torque Rheometer in a manner analogous to the cathode mixture. The composition of the anode mixture was 64.00 g MCMB 25-28 graphite from Osaka Gas Chemicals Co., 8.00 g of the VF2-Li-PSEPVE ionomer, 4.5 g of Super P carbon black, from MMM Carbon, and 23.5 g of a 1:1 by weight mixture of ethylene carbonate and propylene carbonate, both from E M Industries. The melt processing conditions used were the same as for the cathode mixture except that the film calendering temperature used was 90° C. and a thinner brass shim was used to achieve a thinner anode film for cell capacity balancing purpose. The resulting anode film was 0.116 mm thick. Electronic conductivity of the film was measured to be 1480 mS/cm. Inside a dry-nitrogen purged Vacuum Atmospheres dry box, 3.00 g of a 2:1 by weight mixture of ethylene carbonate (E M Industries)/butylene carbonate (Huntsman Chemical Co.) was added to 1.00 g of the VF2-Li-PSEPVE ionomer to form a separator mixture. The mixture was mixed manually with a spatula in a glass vial. A sample of this separator mixture was calendered into a film form inside the same dry box with a laminator with steel rolls. The resulting separator film had a thickness of 0.080 mm. Circular films with diameter of 12.7 mm were cut out of the calendered cathode and anode films with a punch tool. The electrode films were extracted of their ethylene carbonate and propylene carbonate contents by solvent extraction using an excess quantity of diethyl ether. The electrode films were then dried in the antechamber of a dry argon filled dry box and moved inside the box. A 19-mm diameter circular film was cut from the separator film and moved into the argon filled dry box via a glass vial. Having been prepared in a dry nitrogen box, the separator film was not dried through the antechamber. Inside the argon filled dry box, 0.0167 g and 0.0075 g of the 2:1 by weight mixture of ethylene carbonate/butylene carbonate was added to the cathode and anode pieces, respectively. The weights of the dried, carbonate-free, 12.7 mm diameter cathode and anode pieces being 0.0491 g and 0.0225 g, respectively. The cathode, separator, and anode films were assembled into a size 2325 coin cell. The coin cell was charged and discharged at room temperature between voltage limits of 2.8V and 4.2V. The capacity of the coin cell was 155.4 mAh/g of LiCoO2 and 103.4 mAh/g of LiCoO2 for the first charge and first discharge, respectively.
The invention concerns a process for melt forming conductive compositions comprising ionomers into multi-layer electrochemical cells suitable for use in electrochemical applications such as batteries, fuel cells, electrolysis cells, ion exchange membranes, sensors, electrochemical capacitors, and modified electrodes.
7
FIELD OF THE INVENTION The present invention relates to an interactive game method and an interactive game system with a function to protect a user from sports injury. DESCRIPTION OF THE RELATED ART Interactive game systems functioning in response to the 3-dimensional (3D) actions of a user have become very popular, such as the famous Wii game by Nintendo. In such games, a user holds a remote pointing device provided by the interactive game system, and interacts (e.g., to hit a ball or to swing) with the plot displayed on a screen. The interactive game system displays corresponding scenes in response to the movement and other actions of the remote pointing device. However, the virtue reality effect provided by such game systems often makes a user to swing the remote pointing device drastically, that is, to use the remote pointing device with a speed above a predetermined threshold speed, or in a rang larger than a predetermined threshold range, and makes the user to user the remote pointing device for too long, that is, longer than a predetermined threshold time period. This is dangerous because of the likelihood to cause sports injury. In view of this risk, it is desired to provide a sports injury protection function in such interactive game systems. Note that, although the safety issue occurs more often in the 3D interactive game systems, the present invention can be applied to any system in which a remote controller or pointing device is used. SUMMARY OF THE INVENTION A first objective of the present invention to provide an interactive game method, wherein when a user swings a remote pointing device drastically or when a user uses the remote pointing device for too long, a safety mechanism is triggered to give an alarm or to initiate a corresponding countermeasure, so as to reminder the user the risk of sports injury. A second objective of the present invention is to provide an interactive game system. To achieve the foregoing objectives, and from one aspect of the present invention, an interactive game system with sports injury protection comprises: (1) a set-up box electrically connectable with a screen; and (2) a remote pointing device for communicating with the set-up box, the remote pointing device including: (2a) a first action sensor for sensing an acceleration of the remote pointing device; and (2b) a detection module for determining whether to trigger a safety mechanism according to the acceleration of the remote pointing device. In another aspect of the present invention, an interactive game method with sports injury protection comprises: providing a remote pointing device for a user to swing; and triggering a safety mechanism in one or more of the following conditions: (1) when a user swings the remote pointing device drastically; (2) when a count of swings exceeds a first threshold; and (3) when a count of swings in a predetermined time period exceeds a second threshold. In yet another aspect of the present invention, an interactive game method with sports injury protection comprises: providing a remote pointing device; detecting the acceleration of the remote pointing device; and triggering a safety mechanism when the acceleration is larger than a threshold. In a further aspect of the present invention, an interactive game method with sports injury protection comprises: providing a remote pointing device; detecting the acceleration of the remote pointing device; incrementing a count when the acceleration is larger than a first acceleration threshold; and triggering a safety mechanism when the count is larger than a count threshold. Preferably, the count is reset after a predetermined time period. Also preferably, the safety mechanism includes one or more of the following: displaying a warning symbol on the screen; displaying a warning language on the screen; generating an audible sound of alarm; generating an audible sound of a comprehensive language; shutting down the screen; stopping the game; and inducing the user to slow down his action in an interactive way. For better understanding the objects, characteristics, and effects of the present invention, the present invention will be described below in detail by illustrative embodiments with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an embodiment of an interactive game system according to the present invention. FIGS. 2A , 2 B, 3 and 4 are flow charts showing embodiments to make safety judgment according to the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT The present invention will be described in detail with reference to 3D interactive games. However, as explained above, the present invention can be applied to any system in which a remote controller or pointing device is used. Furthermore, there are multiple ways to implement the hardware of a 3D interactive game and to calculate 3D information; what are described below is to demonstrate that the present invention has reached a practicable stage, for enabling those skilled in this art, but should not be taken as limitations to the scope of the present invention. Referring to FIG. 1 , in one arrangement of a 3D interactive game, at least one light emission source 12 (preferably a 940 nm infrared light source) is provided; the light emission source 12 can communicate with a set-up box 10 in wired or wireless manner. A remote pointing device 30 is also provided, which includes two action sensors 31 and 32 , wherein the first action sensor 31 for example can be an accelerometer or a gyro sensor, and the second action sensor 32 can be an optical sensor. The processor 34 of the interactive game system calculates the information provided by the optical sensor which senses the light from the light emission source 12 , and the information provided by the first action sensor 31 , to generate 3D stereo information. The stereo information is transmitted to the set-up box 10 -through a wireless RF (radio frequency) module 36 for the interactive game, such as to display corresponding movements of a character, or to show an explosion, on a screen 20 . Note that what is described above is only one among many possible ways to arrange the interactive game system. Other arrangements are of course possible. For example, the light emission source 12 can be positioned at any other location; the processor 34 can be positioned inside the set-up box 10 ; the communication between the remote pointing device 30 and the set-up box 10 can be done through wires; etc. For simplicity, not all of such possibilities are listed here, but they should all belong to the scope of the present invention. The remote pointing device 30 further includes a detection module 37 . The detection module 37 determines whether a user plays the game safely according to the acceleration or gravity information provided by the first action sensor 31 . In one embodiment, the detection module 37 obtains the acceleration or gravity information directly from the first action sensor 31 ; in another embodiment, the detection module 37 obtains such information from the processor 34 . The determination by the detection module 37 is sent to the processor 34 , to trigger a corresponding action (i.e., the safety mechanism). The “corresponding action” or the “safety mechanism” for example can be: displaying a warning symbol on the screen; displaying a warning language on the screen; generating an audible sound of alarm; generating an audible sound of a comprehensive language; shutting down the screen; stopping the game; inducing the user to slow down his action in an interactive way; etc. The criteria to determine whether a user plays the game safely can include one or more of the followings: (1) whether a user swings the remote pointing device 30 drastically; (2) whether a count of swings exceeds a first threshold; and (3) whether a count of swings in a predetermined time period exceeds a second threshold. More specifically, FIG. 2A shows a flow chart to make safety judgment according to one embodiment of the present invention. First, at step S 21 , the detection module 37 determines whether the acceleration (or gravity variation, depending on whether an accelerometer or a gyro sensor is used) exceeds an acceleration threshold. If yes, in one embodiment (not shown), an alarm is immediately sent out. In the present embodiment, instead of immediately sending out the alarm, a count is incremented by 1 in step S 22 . The count represents an accumulated number of “drastic swings”. When the count is larger than a count threshold (step S 23 ), an alarm is sent out (step S 24 ). FIG. 2B shows a flow chart to make safety judgment according to another embodiment of the present invention, which combines two alarming mechanisms. First, at step S 21 A, it is determined whether the acceleration exceeds a first lower acceleration threshold. If yes, it is further determined whether the acceleration exceeds a second higher acceleration threshold (step S 21 B). If yes, an alarm is immediately sent out. If not, a count is incremented by 1 in step S 22 . When the count is larger than a count threshold (step S 23 ), an alarm is sent out (step S 24 ). FIG. 3 shows a flow chart to make safety judgment according to a further other embodiment of the present invention. In this embodiment, in parallel to the process of the steps S 21 -S 24 , a process including steps S 31 to S 33 is carried out, which begins from the start timer step S 31 . If it reaches a predetermined length of time (step S 32 ), the count is reset to zero (step S 33 ). The count reset step S 33 has a higher priority than the count increment step S 22 ; if a reset and an increment instruction are concurrently generated in the circuit, the reset instruction is carried out, while the count increment step is ignored. FIG. 4 shows a flow chart to make safety judgment in a serial manner, to achieve a comparable result as that of the embodiment of FIG. 3 . In this embodiment, first start the timer and reset the count (step S 41 ). Next, it is determined whether the acceleration exceeds an acceleration threshold (step S 42 ). If yes, the count is incremented by 1 (step S 43 ), and it is further checked whether the timer reaches or exceeds a predetermined length of time (step S 44 ). If yes, the process goes back to step S 41 ; otherwise it goes to step S 45 , to determine whether the count is larger than the count threshold. If yes, an alarm is sent out (step S 46 ). In all of the foregoing embodiments, if necessary, the acceleration thresholds, the count threshold, and/or the length of time, can be open to the user for customized set-up. Alternatively, a simplified option menu may be provided to the user to set the game to “mild use”, “mid-wild use”, “wild use”, etc. Corresponding threshold numbers are determined according to the option selected by the user. In this way, for example, an adult can better manage younger users of the interactive game system. The features, characteristics and effects of the present invention have been described with reference to its preferred embodiments, for illustrating the spirit of the invention and not for limiting the scope of the invention. Various other substitutions and modifications will occur to those skilled in the art, without departing from the spirit of the present invention. For example, one can insert a device between any two devices shown to be in direct connection in the figures, without affecting the primary function of the overall device. As another example, the interactive game system according to the present invention does not have to directly detect the acceleration of the remote pointing device by an accelerometer or a gyro sensor; the acceleration can be calculated by detecting the speed of the remote pointing device and obtaining the difference of the speeds between two time points. The communication between the remote pointing device and the set-up box can be done by any means other than in a wireless manner. Each device shown in the figures does not have to be a stand-alone hardware device; it can be integrated with any other device or function, or achieved in a software manner. For instance, the detection module 37 can be integrated with the processor 34 (embedded in the processor 34 ), or can be a software program executable by the processor 34 , or can be integrated with the first action sensor 31 . Thus, all such and other substitutions and modifications are intended to be embraced within the scope of the invention as defined in the appended claims.
The present invention discloses an interactive game method with sports injury protection, comprising: providing a remote pointing device for a user to swing; and triggering a safety mechanism in one or more of the following conditions: (1) when a user swings the remote pointing device drastically; (2) when a count of swings exceeds a first threshold; and (3) when a count of swings in a predetermined time period exceeds a second threshold.
0
FIELD OF INVENTION [0001] The present invention relates to polymer ceramic composites and to methods of manufacturing said composites. The composites find use as strike faces for both body and vehicle armour. BACKGROUND [0002] Armour systems, designed for use as personnel protection, have developed from natural fibres, through metals and ceramics, to composite systems as modern threat levels have increased from hand held weaponry to high powered ballistic systems. As the threat level increases, so does the efficacy of the armour system which must be designed to mitigate advances in offensive weapons technology. Previous noteworthy advances in armour include the use of aromatic polyamides (Aramids) such as Kevlar™, the development of strike faces to improve the performance of Kevlar™, and the development of ever stronger aromatic polyamide fibre systems. There is a current focus on improving the ceramic strike face systems to further increase ballistic resistance. [0003] The use of monolithic ceramics as strike face media of armour has been very successful due to their relatively high compressive strengths and very high hardness. However, there are a number of shortcomings with their use in ballistic applications. A major drawback is the low tensile strength which reduces the effectiveness when interacting with projectile-induced shockwaves leading to premature failure. Secondly, the brittle nature of ceramics and their large impact fracture zone can result in extensive cracking which can influence multi-hit performance. The main drawback, however, is the mass associated with the strike face, given the high proportion of weight they carry within an armour package. The modern soldier will typically don up to 20 kg of protective gear, in addition to having to carry rations, survival equipment, water, ammunition and offensive weapons. Weight decreases in armour combined with improved performance allow the soldier to move more freely, carry more gear, and generally improve infantry survivability. [0004] A further drawback is one of cost. Conventional ceramics are often processed for hours at elevated temperatures. Large torso sized ceramic plates are complex to manufacture and are subject to cracking in use. [0005] Strike face media for use in armour applications are usually fixed to a backing, for example, an aromatic polyamide backing. [0006] Ceramic filled polymer armour prepared by mixing polymer with ceramic aggregate has been disclosed [Sandstrom D., Los Alamos Science, Summer, 1989]. A polymer ceramic composite prepared by compression moulding a granular alumina ceramic having maximum particle size of 8 mm with a vinylester polymer resin has been disclosed [Arias A. et al, Composite Structures 61, 2003, 151]. [0007] It would be desirable to provide composites that may be fabricated into an armour strike face that are lightweight, easy to manufacture and advantageous with respect to ballistic impact. SUMMARY OF INVENTION [0008] To this end, in one aspect of the invention there is provided a polymer ceramic composite including one or more particulate ceramics and a mixture of polymers at least one of which is an aromatic polyamide. The one or more particulate ceramics may be a carbide or nitride of Groups 13-15 of the Periodic Table. The mixture of polymers preferably includes a particulate epoxy or phenolic resin. [0009] The aromatic polyamide is preferably in the form of a pulp or flock. By pulp or flock it is meant a highly fibrillated chopped fibre that enhances performance by providing excellent reinforcement. The length of the fibres is preferably in the range of between 0.1 to 1 mm. [0010] The particulate ceramic is preferably present in an amount of between 20% and 90% by weight relative to the combined weight of particulate ceramic and polymers. The particulate ceramic is preferably of average particle size from between 100 nm and 5 mm, more preferably from between 1 micron and 1 mm, even more preferably from between 2 micron and 100 micron. [0011] The composite of the present invention is advantageous over monolithic ceramics by using the strength of an aromatic amide/polymer matrix to suspend a ceramic powder aggregate. The short range tensile strength of the system is such that upon impact, the matrix provides enough support to the ceramic particulate to allow deformation of the incoming round to occur, along with impact shockwave attenuation and deceleration, leading to improved performance of the aromatic polyamide backing. [0012] A further advantage of the invention is the reduction in weight which arises from the direct substitution of a higher density ceramic phase with the lower density polymer binder. Accordingly, for a given volume of material, the polymer ceramic composite will have a lower mass than traditional ceramic armour. In addition, polymer ceramics display extremely localised deformation behaviour during ballistic impact. This means they have an extremely improved multi-hit capability over that of traditional monolithic ceramics, which shatter upon impact. [0013] In another aspect of the invention there is provided a polymer ceramic composite including one or more particulate ceramics having an average particle size of between 100 nm and 5 mm, preferably between 1 micron and 1 mm, more preferably between 2 micron and 100 micron, and one or more polymers. The one or more polymers are preferably selected from particulate phenolic or epoxy resins. [0014] In another aspect of the invention there is provided a method of preparing a polymer ceramic composite including the steps of: [0015] a) combining one or more particulate ceramics and a mixture of polymers, at least one of which is an aromatic polyamide; and [0016] b) compression moulding the resulting mixture at elevated temperature and pressure. [0017] Preferably, the resulting mixture is subjected to ball milling prior to compression moulding. [0018] A further advantage of the composites of the present invention is that they do not necessarily require containment, for example, within a frame, such as a steel frame, in order to be effective. [0019] A yet further advantage of the invention is the lower cost of manufacture and more complex geometry accessible using well established polymer processing techniques. Traditional ceramics take hours to form. The cycle time of the polymer ceramic systems disclosed herein are on the order of seven minutes, reducing both labour and energy costs per unit. Other advantages include the ability to form geometries that cannot be created via traditionally fired ceramics. [0020] In a further aspect of the invention there is provided a use of any of the above mentioned polymeric ceramic compositions as a mouldable armour strike face. The armour strike face may be attached or fixed to a suitable backing material such as an aromatic polyamide. [0021] The strike face may find use in personal protective equipment, in armour for land vehicles, watercraft or aircraft, and in further applications where protection from ballistic threat is required. [0022] Accordingly, the invention provides lightweight, ballistically superior, mouldable armour strike faces for both body and vehicle armour applications, at a fraction of the cost and manufacturing time associated with traditional monolithic ceramic systems. DETAILED DESCRIPTION OF THE INVENTION [0023] It will now be convenient to describe the invention with reference to particular embodiments and examples. These embodiments and examples are illustrative only and should not be construed as limiting upon the scope of the invention. It will be understood that variations upon the described invention as would be apparent to the skilled addressee are within the scope of the invention. Similarly, the present invention is capable of finding application in areas that are not explicitly recited in this document and the fact that some applications are not specifically described should not be considered as a limitation on the overall applicability of the invention. [0024] The particulate ceramic for use in the composite of the present invention may be a carbide or nitride of Groups 13-15 of the Periodic Table of the Elements or mixtures thereof. Particularly preferred ceramics are boron carbide, boron nitride or silicon carbide or mixtures thereof. The particle size of the ceramic is not critical and may be in the range of 100 nm to 5 mm. Preferably, the particle size is in the range of 1 micron to 1 mm. The particle size range is not critical and ceramic particulates of broad or narrow particle size distributions may be utilised. The amount of ceramic relative to the total weight of the composite is preferably 20-90%, more preferably 40-85%. [0025] Polymers for use in the polymer mixture may be phenolic or epoxy based resins or mixtures thereof. Preferably, the polymers are in particulate form. The particle size of the polymer is not critical and may be in the range of between 1 micron and 5 mm. The polymer may be present in an amount from between 5% to 50% by weight, relative to the total weight of the composite, preferably from between 10% and 30% by weight. [0026] The polyamide is preferably in the form of a pulp or flock. The polyamide may be present from 0.1% to 10% by weight relative to the total weight of the polymer mixture. A preferred polyamide is Kevlar™. [0027] The particulate ceramic and polymer mixture containing the polyamide are mixed prior to compression moulding. Preferably mixing is achieved by ball milling a mixture of particulate ceramic and polymer mixture containing the polyamide. The time of ball milling is not critical and typically times of the order of one hour yield acceptable results. [0028] Strike faces may be prepared through moulding by traditional compression moulding techniques. Typically, the mixture is compression moulded at elevated temperature. Temperatures in excess of 100° C. are preferred. A particularly preferred temperature is 140° C. The compression pressure may vary widely. Tonnage pressures from between 5 and 200 ton may be utilised, preferably tonnage pressures from between 50 and 150 ton are utilised. [0029] In a particularly preferred embodiment of the invention, boron carbide powder (mixed particle size), boron nitride powder (mixed particle size), epoxy resin powder or phenolic resin powder and Aramid (aromatic polymer) pulp may be compression moulded at 140° C. and 60 tons pressure to form a strike face. [0030] In an alternate embodiment, the composite mixture may be compression moulded in the presence of a preform. A preferred preform is a glass fibre preform. More preferred is glass fibre woven preform. [0031] In this embodiment, the mould cavity is lined with the glass preform and a charge of the powder mixture, preferably after being subjected to ball milling, is added followed by compression moulding to form a strike face. Preferably compression moulding is performed at 140° C. and 60 tons pressure. [0032] The resulting armour systems may comprise a very high volume fraction of ceramic (boron carbide, boron nitride or silicone carbide or combinations thereof at around 50% by weight) aggregate, encased in a polymer matrix (phenolic or epoxy based), plus the inclusion of aromatic polyamide (Kevlar™) pulp or flock. Multiple prototypes have been built and tested both ballistically and mechanically. Armour equivalence has been tested against traditional monolithic silicone carbide tiles of an equivalent areal density (8 kg per meter squared of material) against fragment/shrapnel threats. Like monolithic silicon carbide, polymer ceramics have been shown to effectively deform the projectile. They have also been shown to maintain their ballistic limit during multiple impacts on a single tile, beyond the point at which monolithic ceramics like silicon carbide become ineffective. [0033] Traditional armour systems consist of a strike face (used to slow and blunt the projectile) over a thick backing of aromatic polyamide cloth. The composite of the present invention replaces the traditional monolithic ceramic strike face and is bonded to aromatic polyamide cloth in a similar fashion as the heavier more expensive ceramic which they replace. [0034] Furthermore, the polymer ceramics are formed at relatively low temperatures, and may rely on ceramic aggregate selection, and adhesive bond strength for increases in performance. This is likely due to their effect on incoming projectiles, which consists of deformation and deceleration, all of which increase the efficacy of the aromatic polyamide backing. [0035] The following examples are intended to illustrate the scope of the invention and to enable reproduction and comparison. They are not intended to limit the scope of the disclosure in any way. EXAMPLES Ceramics and Polymers [0036] Silicon carbide was obtained from Pacific Abrasives Pty. Ltd. Boron carbide was obtained from CMIC Heilongjiang Import and Export Co., Ltd. Cubic boron nitride was obtained form Hunan Sukan Ultra-hard material Co., Ltd. The ceramics all had a mean particle size of 5-10 micron. [0037] Three ceramics were examined in the preparation of polymer composites, pure silicon carbide, pure boron carbide and a 1:1 by weight mixture of boron carbide and boron nitride. [0038] The polymer used was a phenolic resin and was a general powder pressing grade obtained from Huntsman Chemical Company Australia Ltd. The polymer resin was added at a level of 15, 20 or 25% by weight. Where utilised, aromatic polymer pulp was added at a level of 1% by weight relative to the weight of polymer resin. Glass Preform [0039] The glass fibre used in the system was a robust, 3D woven material incorporating a z yarn manufactured by 3TEX. Systems were examined having no glass preform, glass on the distal surface or glass on both surfaces. Sample Preparation [0040] All samples were prepared to give a nominal areal density of 8 kg/m 2 . Powder Preparation [0041] Appropriate amounts of sample constituents were pre-weighed with mass loss during pressing taken into consideration. The weighed powder mixture was transferred to a one litre steel ball mill jar along with six, 8.7 mm diameter zirconia grinding media. These containers were then placed inside a single axis ball mill and rotated at 200 rpm for a period of one hour. For specimens containing aromatic polymer pulp, this was added in the last 10 minutes of the process to limit fibre damage. Pressing Methodology [0042] Samples were pressed in a die cavity mould with two floating rectangular aluminium mould plates measuring 203×127×3 mm. Samples were placed within the cavity and wrapped with a release film to both ease de-moulding and limit mass loss from the sample during compression. The compression moulding cycle lasted seven minutes in total dispersed with four “breathe cycles” where all pressure was removed for a period of 10 seconds each. The moulding temperature used was 140° C. with the pressure level required for the particular trial (60, 80 or 100 ton). Mechanical Testing [0043] Compressive Testing Compressive testing was executed on a screw-driven MTS test-frame fitted with a 100 kN load cell with an accuracy of ±0.4% in the range tested. Specimens measuring 30×30 mm were waterjet-cut from a retained portion of plate moulding (the other portion being used for ballistic evaluation). A minimum of six specimens per sample (16 samples in total) were assessed. The specimen was placed upon a polished lower platen and compressed by a hardened 10.0 mm diameter steel dowel pin held within a mounting fixture. The sample was tested at a crosshead speed of 1 mm/min. Flexural Testing [0044] Specimens measuring 105×9 mm were waterjet-cut from a retained portion of plate moulding. A minimum of six specimens per sample (16 samples in total) were assessed. Testing was performed on a screw-driven MTS test-frame fitted with a 100 kN load cell with an accuracy of ±0.4% in the range tested. The flexure test was carried out in accordance with the ASTM C1341-00 Standard Test Method for Flexural Properties of Continuous Fibre-Reinforced Advanced Ceramic Composites. The support span used was 96 mm with a crosshead rate 2 mm/min. Ballistic Testing [0045] Each polymer ceramic coupon (˜100 mm square) was bonded to a standard 10-ply aramid reinforced thermoplastic measuring 200 mm square using a Hysol 9309 adhesive under a pressure of about 1 bar. When ballistically tested, each target was fixed to two horizontal bars using corner clamps. [0046] Fragment Simulating Projectile (FSP) was used as the threat with strike velocities varied by standard charge-adjustment practices. The round was a 1.1 g, 0.22″ calibre in low alloy steel with a Rockwell C value of 27±3. The geometry was a chisel nose. [0047] The points of strike (POS) were at least 40 mm from an edge and/or a previous POS. After each impact the round was recovered and its diameter measured. The bulge height at the rear of the target was also measured. The observed velocities were corrected to strike velocities and duly noted for each round. In the case of those specimens containing one layer of glass reinforcement, the strike face used was the non-reinforced side. The deformation of the particle was quantified by measuring the maximum diameter of the round after impact. Results [0048] All plates produced appeared well formed with a highly homogeneous nature. In the samples employing a glass preform, resin distribution appeared good and bonding to the matrix resin was high. The plates produced had an areal density of 8±0.4 kgm −2 . After the composite ceramics were manufactured, standard Kevlar™ backings were bonded, giving an average areal density of all specimens of 12.4±0.4 kgm −2 . Ballistic Response [0049] Ballistic tests for 16 trials of ceramic/resin samples were carried out and the results are summarised in Table 1. V50 defines the velocity at which 50% of the projectiles penetrate the sample and 50% do not. The results ranged from between 545 and 835 ms −1 . [0000] TABLE 1 Polymer Pulp Glass P ρ V50 Trial Ceramic wt. % wt. % preform (ton) (kgm −3 ) (ms −1 ) V50/ρ CB FSP 1 SiC 15 0 None 60 1926 580 0.301 R, C 5.70 2 SiC 20 0 Single 80 2080 660 0.317 C 5.78 3 SiC 25 1 Double 100 1880 735 0.391 NV 6.88 4 SiC 15 1 None 60 1876 545 0.291 R, C 5.77 5 B4C 15 0 None 100 1481 545 0.368 C 5.56 6 B4C 20 0 Double 60 1607 705 0.439 NV 6.14 7 B4C 25 1 Single 60 1686 835 0.495 NV 7.20 8 B4C 15 1 None 80 1648 610 0.370 R, C 5.57 9 B4C/BN 15 1 Single 60 1760 700 0.398 R, C 6.18 10 B4C/BN 20 1 None 100 1885 680 0.361 R, C 6.11 11 B4C/BN 25 0 None 80 1993 780 0.391 R, C 7.20 12 B4C/BN 15 0 Double 60 1726 750 0.435 NV 6.51 13 SiC 15 1 Double 80 1797 690 0.384 NV 6.26 14 SiC 20 1 None 60 1992 775 0.389 C NR 15 SiC 25 0 None 60 2192 660 0.301 C 6.90 16 SiC 15 0 Single 100 1867 650 0.348 R, C 6.07 P: forming pressure; CB: cracking behaviour wherein R = radial cracking, C = circumferential cracking and NV = cracking not visible; FSP: FSP deformed maximum diameter at V-50
There is provided a polymer ceramic composite which includes one or more particulate ceramics and a mixture of polymers. There is further provided methods of manufacture and application of the polymer ceramic composition. The composition finds use as a mouldable armour strike face, particularly in personal protective equipment and in vehicle or aircraft armour.
2
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates generally to a blind for use in windows to prevent direct sunlight from passing therethrough and, more particularly, to a collapsible blind for convenient installation in a semi-circular arched window, which blind may be easily unfolded and set up to present an attractive and functional window dressing. 2. Description of the Prior Art Venetian blinds have been in use for some time to prevent direct sunlight from entering a house or other building, while allowing the entrance of sufficient light to fully illuminate the interior of the building, as well as to assure privacy of those within a room from the sight of a person outside who might try to look in. Venetian blinds are typically made of a plurality of parallel rectangular slats or blades, each of which is supported by one of the rungs of a ladder-shaped fabric segment installed at each end of the blades. By raising one side of each of the ladder-shaped fabric segments, the blades may all be simultaneously adjusted to prevent the passage of direct sunlight while allowing a variable amount of indirect light to pass therethrough. Due to the design of such blinds, they are limited to an essentially rectangular configuration. With the popularity of the Victorian style house at the turn of the century, and the art deco style of the twenties, arched windows were a popular choice in construction. With the prevalence of such windows came the desire to cover them, at least to prevent the passage of direct sunlight therethrough. While the lower rectangular portion could easily and conveniently be covered by standard blinds or shades, the upper semi-circular portion of the arched window was not so easily covered. With the renewed popularity of both Victorian and art deco architecture, the arched window has come back into style. With the increase in popularity of the arched window has come a substantial demand for a blind designed to fit the semi-circular arched portion of the window. As might be expected, a number of solutions to the problem were invented during the arched window's earlier popularity, with one of the earliest examples being U.S. Pat. No. 602,967, to Wells. Wells discloses a complex and ambitious device designed to operate in a substantially similar manner to Venetian blinds, with sets of fan-like blades on both sides rising to meet in the center. The complexity of the Wells device makes it difficult and expensive to manufacture, as well as difficult to operate. In addition, since the Wells blind has two sets of blades mounted on different pivot points, and a continuous band around the edge, it is not graceful in appearance and would be difficult to market successfully today. Other attempts to provide window dressing for an arched window were mainly shades rather than blinds. Examples of such shades are found in U.S. Pat. No. 1,447,189, to Simon, and U.S. Pat. No. 1,609,877, to Kendall. Unfortunately, shades typically allow only diffused light to pass therethrough, and are therefore undesirable to those who only wish to inhibit the passage of direct sunlight through the windows. For this reason, blinds represent a highly desirable solution while shades represent only a partial solution at best. It may thus be seen that it is desirable to have a semi-circular blind which may be used for arched windows. It is also desirable that the blind be of a relatively simple mechanical design, therefore not presenting the substantial disadvantages of the Wells blind. It has been established that most people would not even change the position of a blind covering the arched portion of a window, but rather would place the blind in a position which blocks direct sunlight. Therefore, it is only necessary that a blind for the semi-circular portion of an arched window have one position--namely the position preventing the entry of direct sunlight. Accordingly, it is an object of the present invention to provide a substantially fixed blind for use with the semi-circular portion of an arched window. It is also desirable that the invention be mounted about a single pivot point for aesthetic enhancement and simplicity in operation. The invention should also be easily installable, without substantial difficulty or the requirement of other than simple hand tools. Finally, it is desirable that the present invention be as inexpensive as possible while solving the aforementioned problems, and that it provide no substantial disadvantages when used. SUMMARY OF THE INVENTION The present invention represents an advantageous solution to the problems mentioned above. A frame is provided for mounting into the arched window at the bottom of the semi-circular portion of the window. The frame supports a plurality of blades which fan out from a common axis of rotation. Half of the blades fan out from one end of the frame, and the other half of the blades fan out from the other end of the frame, with the blades meeting at the top of the semi-circular portion of the arched window. Each group of blades is connected near the end opposite the axis of rotation in sequence to a cord allowing an identical separation of the blades. Each set of half of the blades has a handle connected to the blade farthest from the end of the frame from which the blades fan out. The handles are also rotatably mounted around the same axis and at the front of the blind, with the end of the handle away from the axis of rotation being connected to the end of the last blade away from the axis of rotation. A pair of latches is mounted on the end of a support arm extending from the same axis at the back of the blind. The ends of the handles away from the axis of rotation are secured to the latches in the support arm, completing the assembly of the blind. Alternatively, the latches may be mounted on the wall at the top of the window for retaining the blind in the closed position. The blades may also have a variable degree of twist therein, depending on the amount of light the blind is to admit. By twist, it is meant that the edge of the blade at one end is angularly displaced from the edge at the other end of the blade. If the blades have little or no twist along their length they will admit virtually no light. On the other hand, if they have a great amount of twist, they will admit an amount of light proportionate to the degree of twist therein. The twist may be substantially at one location near the end of the blades fastened to the bolt, or it may be gradual along the length of the blade. It will be appreciated that the blind of the present invention advantageously satisfies the objectives enumerated above, and with no substantial disadvantage whatsoever. The blind may be shipped in a collapsed position, and easily brought to its assembled position without the need for any tools whatsoever. In fact, the only need for a tool is for a screwdriver to fasten the mounting brackets to the window casing. The blind of the present invention neatly fits the semi-circular arched window shape, and effectively prevents the passage of direct sunlight therethrough. Due to the construction of the present invention, it may be appreciated that it is relatively inexpensive to manufacture, and that it presents no difficult mechanical operation which would require particularly close tolerances. Finally, and notably as far as marketing such a blind is concerned, its single pivot point renders the assembled and installed blind aesthetically pleasing, making it a desirable accessory for arched windows. DESCRIPTION OF THE DRAWINGS A better understanding of the present invention may be had from a consideration of the following detailed description, taken in conjunction with the accompanying drawings in which: FIG. 1 is a perspective view of the U-shaped channel frame and the two support portions mounted thereon; FIG. 2 is an end view of the U-shaped channel and the two support portions illustrated in FIG. 1; FIG. 2A shows an alternative to the arrangement of FIG. 2; FIG. 3 is a perspective view of one of the brackets used to mount the U-shaped channel shown in FIGS. 1 and 2 adjacent an arched window casing; FIG. 4 is a partial perspective view of the ends of the handles used to bring the blades into position, the support arm, and the latches on the support arm used to secure the handles and the blades in an open position for one embodiment of the invention; FIG. 5 is a top view of the blind of the present invention in an unopened position; and FIG. 6 is a front view of the blind of FIG. 5 in an open and locked position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT As shown in FIGS. 1 and 2, the preferred embodiment of the present invention uses as a simple frame a segment of standard two-inch by two-inch U-shaped steel channel 10 which will be mounted at the bottom of the semi-circular portion of an arched window with the open side of the U-shaped channel 10 facing upward. The U-shaped channel 10 is mounted to the window casing (not shown) using a pair of standard blind support brackets, the installation of which is well known. One of the brackets 12 is shown in FIG. 3. Referring again to FIG. 1, the length of the U-shaped channel 10 will of course depend on the size of the window the blind is to be installed in, with the length of the U-shaped channel 10 usually being slightly greater than the diameter of the semi-circular portion of the arched window for installation on the face of the wall in which the window is positioned. The semi-circular support pieces 14, 16 made of steel are installed in the interior of the U-shaped channel 10 at the center thereof, with one support portion 14 mounted on the interior of the front side of the U-shaped channel 10 and extending therefrom, and the other support portion 16 mounted on the interior of the back side of the U-shaped channel 10. The support portions 14, 16 are thus parallel to each other and centrally located in the U-shaped channel 10, and have a space therebetween and partially within the U-shaped channel 10, as best shown in FIG. 2. The support portions 14, 16 are approximately semi-circular in shape in the preferred embodiment, with the shape being essentially a pleasing or aesthetic configuration when viewed with the rest of the device when installed in a window. The support portions 14, 16 have apertures 18, 20, respectively, therethrough, with the apertures 18 and 20 being axially aligned and defining an axis of rotation. Alternatively, as shown in FIG. 2A, the pieces 14a, 16a may comprise the side portions of a U-shaped member of hub 15 which is situated within the channel 10, thereby providing structural reinforcement to the channel, and having apertures 18a and 20a recessed below the upper edges of the channel 10. As shown in FIGS. 5 and 6, two sets of blades 22, 24 are movably mounted between the support portions 14, 16 by a pivot member in the form of a bolt 26 passing through one end of each blade in the first and second sets of the blades 22, 24 and the apertures 18, 20 in the support portions 14, 16. All of the blades in the first and second sets of blades 22, 24 are thereby mounted between the support portions 14, 16, with successive blades going alternatively toward one end or the other of the U-shaped channel 10. The blades are typically made of metal such as steel or aluminum. In the embodiment shown in the figures, each of the two sets of blades 22, 24 contains 14 individual blades. The first set of blades 22, which are located on the left side of the U-shaped channel 10, includes blades 22a-22n, and the second set of blades 24, which are located on the right side of the U-shaped channel 10, includes blades 24a-24n. It will, of course, be recognized that different numbers of blades could be included in the first and second sets of blades 22, 24, without departing from the spirit of the invention. Larger size windows will require more blades, while smaller windows can be served with fewer blades. The blades in the two sets of blades 22, 24 are mounted on the bolt 26 in alternating sequence between the support portions 14, 16, in the order 24a, 22a, 24b, 22b, 24c, 22c, etc. The blades in the first set of blades 22 are fastened together with a first length of ribbon or tape 30 such that there are equal distances between successive blades in the first set of blades 22, with the blade 22a at the front of the blind being fastened to the U-shaped channel 10 by the tape 30 or by other means known in the art. The use of the tape 30 is as known in the art to separate succeeding blades by a desired distance, and the blades typically contain two adjacent differing size holes such as those shown in the blades 22n and 24n in FIG. 4. The tape 30 is connected to the blades typically by light rivets, such as is used in leather work. The blades in the first set of blades 22 may thus fan out evenly, with the last blade 22n reaching a position approximately 90° from the left end of the U-shaped channel 10 with the tape 30 drawn tight between the blades in the first set of blades 22. The last blade 22n has its end away from the axis of rotation fastened to a handle 32 which also rotates about the bolt 26. The handle 32 has a U-shaped segment 32a at the end removed from the axis of rotation, which U-shaped segment 32a goes around the blades in the first set of blades 22 to reach to the back side of the last blade 22n at the end of the last blade 22n away from the axis of rotation. The handle 32 is then riveted to the end of the last blade 22n at the point of contact. It may thus be appreciated that when the first set of blades 22 are collapsed into the left side of the U-shaped channel 10 as shown in FIG. 5, by moving the handle 32 in a clockwise direction the first set of blades 22 is fanned out evenly. The handle 32 contains a grip portion 32b which may be conveniently gripped without contacting the blades in the first set of blades 22. Likewise, the blades in the second set of blades 24 are fastened together with a second length of tape 34 such that there are equal distances between successive blades in the second set of blades 24, with the blade 24a at the front of the blind being fastened to the U-shaped channel 10. The tape 34 functions as does the tape 30 to separate succeeding blades in the second set of blades 24 by a desired distance. The tapes 30, 34 preferably comprise lengths of flat webbing about 3/8 inch wide. The blades in the second set of blades 24 may thus also fan out evenly, with the last blade 24n reaching a position approximately 90° from the right end of the U-shaped channel 10 with the tape 34 drawn tight between the blades in the second set of blades 24. The last blade 24n has its end away from the axis of rotation fastened to a handle 36 which also rotates about the bolt 24. The handle 36 has a U-shaped segment 36a at the end removed from the axis of rotation, which U-shaped segment 36a goes around the blades in the second set of blades 24 to reach to the back side of the last blade 24n at the end of the last blade 24n away from the axis of rotation. The handle 36 is then riveted to the end of the last blade 24n at the point of contact. The second set of blades 24 is collapsed into the right side of the U-shaped channel 10 as shown in FIG. 5, and by moving the handle 36 in a counterclockwise direction the second set of blades 24 is fanned out evenly. The handle 36 also contains a grip portion 36b which may be conveniently gripped without contacting the blades in the second set of blades 24. A support arm 40 is also rotatably mounted on said bolt as it passes through the hole 20 in back support portion 16, and the bolt is secured with a nut 42. A pair of latches 44, 46 are fastened to the support arm 40 at the end away from the axis of rotation. The latch 44 extends to the left side of the support arm 40 when the support arm 40 is directed at a 90° angle from the U-shaped channel 10, and the latch 46 extends to the right side of the support arm 40. The U-shaped portion 32a of the handle 32 may be secured into the latch 44 by slightly stretching the tape 30, which will by tension therein retain the U-shaped portion 32a in the latch 44. Likewise, the U-shaped portion 36a of the handle 36 may be secured into the latch 46 by slightly stretching the tape 34, which will by tension therein retain the U-shaped portion 36a in the latch 46, completing assembly of the device. The various components of the blind disclosed herein may be painted prior to assembly. As may be apparent, the blind is shipped collapsed as shown in FIG. 5. The blades of the device may be relatively flat, and if so, the blind will let relatively little light, direct or indirect, pass therethrough. The blades may, however, have a variable degree of twist therein depending on the amount of light the blind is to admit. The twist enables the edge of the blades at one end to be angularly displaced from the edge at the other end of the blades. If the blades have little or no twist along their length they will admit virtually no light. On the other hand, if they have a great amount of twist, they will admit a quantity of light proportionate to the degree of twist therein. The twist may be substantially at one location near the end of the blades fastened to the bolt 26, or it may be gradual along the length of the blades, depending on the particular effect desired. The device as disclosed above provides significant advantages with no relative disadvantage at all. The blind may be shipped collapsed, and easily brought to its assembled position without the use of tools. Only a screwdriver is needed to fasten the mounting brackets to the window casing. The blind of the present invention neatly fits along the face of the semi-circular arched window shape, and effectively prevents the passage of direct sunlight therethrough. It is relatively inexpensive to manufacture, and presents no difficult mechanical operation which would require particularly close tolerances. Also, its single pivot point renders the assembled and installed blind aesthetically pleasing, making it a desirable accessory for arched windows. Although there have been described above specific arrangements of a collapsible blind for semi-circular arched window in accordance with the invention for the purpose of illustrating the manner in which the invention may be used to advantage, it will be appreciated that the invention is not limited thereto. Accordingly, any and all modifications, variations or equivalent arrangements which may occur to those skilled in the art should be considered to be within the scope of the invention as defined in the annexed claims.
A blind for installation adjacent the semi-circular portion of an arched window is disclosed which is based on a U-shaped frame, which frame is adapted for mounting along the face of the window at the bottom of the semi-circular portion thereof. Two sets of blades fan out evenly from the ends of the U-shaped frame around an axis and meet at the top of the window, thereby forming a semi-circular array. Handles rotating from the blade axis are fastened onto the last blade in each set, and meet at the top where they are locked into position by latches mounted on the end of a support arm also rotating from the blade axis.
8
CROSS-REFERENCE TO RELATED APPLICATIONS The invention relates to a flexible analog/digital configuration, preferably on a single silicon or other semi-conductor chip for use in receiving various inputs, processing them, and being able to provide in response an electrical stimuli or control signal which can be generated, for example, by a multi-functional electric stimulator output such as those described in U.S. Pat. Nos. 6,029,090, 6,684,106, and U.S. patent application Ser. No. 11/213,050, all identifying Ewa Herbst as the inventor, the patents and patent application being incorporated herein by reference, in their entirety. This application claims the benefit of and priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 60/926,954, filed Apr. 30, 2007, which is hereby incorporated by reference herein in its entirety. BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates generally to a flexible analog/digital configuration, the system being preferably on a chip, and used for receiving various inputs, processing them, and being able to display/communicate the results and/or provide a response thereto. 2. Status of Prior Art Semiconductor manufacturing technology has progressed substantially to allow more custom definitions of systems on a single chip. Nevertheless, researchers in many fields, including, without limitation, biological and medical sciences, and physiotherapy, and clinicians who make use of electrical stimulators and sensors for activities in which they engage, seek further instrumentation which enables them to treat patients with specialized and customizable equipment, but at a reasonable cost, in conformance, for example, with medical insurance industry guidelines. Such equipment, while often available at high price and for specialized purposes, often does not meet the needs of these workers. As a result, those working in these and other fields of endeavor are limited in their ability to quickly react to and provide for either patient use or experimental use systems meeting their needs. Further, by “patient”, we mean, as used in its broadest sense, human and non-human mammals and other animals, as well as plants (i.e. multicellular organisms). Accordingly, it is desirable to find a method and apparatus to enable such workers to quickly generate and use systems meeting their electrical stimulation and input receiving needs without undue delay or cost. In addition, such systems need to be able to be produced as both one of a kind systems, as well as in production quantities in order to satisfy current needs. SUMMARY OF INVENTION In one aspect, a configurable semiconductor chip module system has analog elements, digital elements, and connection elements between the analog and digital elements. Ones of the analog and digital elements receive inputs from respective sources, and ones of the analog and digital elements output signals for generating control signals having selected electrical and time spatial properties. The connection elements are configurable after creation of the analog elements, the digital elements, and the connection elements. In another aspect, a configurable semiconductor single chip module for use in patient treatment has analog elements, digital elements, and connection elements between the analog and digital elements. Ones of the digital and analog elements receive analog inputs from respective sources, and ones of the digital and analog elements output signals for controlling control signals having selected electrical and time spatial properties useful in medical treatment. The connection elements are configurable after creation of the analog elements, the digital elements, and the connection elements. In a further aspect, a passive (that is, without feedback) configurable semiconductor single chip module for use in making analytical measurements of parameters related to patients' status has analog elements, digital elements, and connection elements between the analog and digital elements. Ones of the analog and digital elements receive analog inputs from respective analog sensors, and ones of the analog and digital elements output signals relating to measurements from the sensors. The connection elements are configurable after creation of the analog elements, the digital elements, and the connection elements. A method of the invention for manufacturing a flexibly configurable semiconductor single chip module for receiving and outputting various signals not specifically known at the time of manufacture; manufactures a plurality of analog elements, digital elements, and connection elements between said analog and digital elements; enables ones of the analog and digital elements for receiving inputs from respective sources, ones of the analog and digital elements for outputting signals for controlling control signals having selected electrical and time spatial properties; and configures the connection elements after creation of the analog elements, the digital elements, and connection elements, to configure the module. BRIEF DESCRIPTION OF DRAWINGS Various objects, features and advantages of the present invention can be more fully appreciated with reference to the following detailed description of the invention when considered in connection with the following drawings, in which like reference numbers identify like elements: FIG. 1 . describes a general block functionality in accordance with embodiments of the present invention. FIG. 2 illustrates a more detailed view of the general block functionality in accordance with one embodiment of the invention. FIG. 3 illustrates in more block level detail, an embodiment of elements of the system on a chip and details as to the acronyms relating to various of the elements. FIG. 4 illustrates a multifunctional stimulator in greater detail. FIG. 5 illustrates a particular implementation of the system on the chip in accordance with an embodiment of the invention. FIG. 6 illustrates details regarding an exemplary sensor interface and conditioning module. FIGS. 7 and 8 are charts illustrating various flexibilities available in constructing elements described herein in accordance with an embodiment of the invention. FIG. 9 illustrates various sensor interface modules in accordance with embodiments of the invention. FIGS. 10A and 10B illustrate a typical system specification for various elements of a system for enabling operation of a module and its manufacturing construction, in accordance with the embodiments of the invention. DETAILED DESCRIPTION The general block functionality of an embodiment of the invention is illustrated in FIG. 1 . Referring to FIG. 1 , the system includes a sensor interface and conditioning module 100 , a multi-functional electrical simulator and output module 102 , a sensor and chip identification module 104 , a phase-lock loop clocking module 106 , a JTAG module 108 , a processor and controller module 110 , a memory module 114 , a communications interface module 116 , a power and thermal management module 118 , and a user-programmable module 120 , which can be implemented as CPLD/FPGA. These elements are designed in particular to be incorporated on a single chip such as a configurable application specific standard product (ASSP) which has for example a plurality of fixed layers, on top of which several layers can be placed to customize the chip and to allow interconnections as desired between elements or modules in the fixed layers. Thus, for example, elements 100 - 118 might be the fixed elements on the chip and the user space would be several layers on top of the fixed layers to effect connections, additional elements needed for the chip, etc. Other chip or multichip configurations could be used as semiconductor manufacturing methods are developed or to minimize the manufacturing cost, for example, separating analog and digital functions between two chips. Further, the layers can be fixed with programmability features as known in the field. A “system on a chip” (SoC) advantageously can measure multiple parameters; and when properly programmed, can easily organize the data from multiple sensors or other analog or digital sources. It can present or display different, or similar, pages for setting up each measurement (or each measured parameter), for example by sensor, class of sensors, etc., to enable an easy to use approach for non-technical individuals without needing to know the specifics as to many parameters. This user-friendly, and lower-cost approach further enables the measurement and interconnection to be performed using a configurable standard basic chip according to the invention. Considering the modules of FIG. 1 in more detail, and referring now to FIG. 2 , the sensor interface and conditioning module 100 can include sensor-specific preamplifiers, precision analog-to-digital conversion circuitry, filters for filtering the signal inputs, and other special features depending upon the particular application to which the circuit is put. And, as described in more detail below, various components can be connected to be grouped as a family, for example by sensor functionality or characteristic, such as impedance, signal levels, etc., to more efficiently connect the analog and digital elements of the modules, in a chip layer, or between chip layers. This can also result in a smaller chip/module footprint. The processor and controller module 110 is thus programmable by the user and/or configurable in hardware to perform the functions of measurement, analysis, diagnostics, operations, and system management, and to enable feedback control algorithms as required. Each of these functions can be the subject of software applications which are stored in memory 114 ( FIG. 1 ). Memory 114 , in some embodiments, includes a DRAM and/or SRAM module 130 , a flash or EE PROM memory 132 and can have available space for memory expansion 134 ( FIG. 2 ). The multi-functional electrical stimulator and output module 102 , in addition to providing a multi-functional electrical stimulation unit, such as that described in the Herbst patents and patent application identified above, can also provide a power stage for controlling current and voltage as well as a pulse width modulator stage (PWM) for effecting the outputs of the module 102 . Furthermore, the communications interface 116 can communicate to various peripherals using video, audio, or any of a number of protocols, all of which can be supported by a suitable design on the chip. Those protocols can include, for example, USB, Ethernet, I2C, SPI, GPIO, and SERDES protocols. Other protocols, as they are developed or as they are required by the user, could also be either preprogrammed into the hardware or programmed into the software depending upon the particular design of the chip or chip set. Further the “peripherals” can include servers and server interfaces, and functions of the electrostimulator module, for example, power, sensing/sensors, feedback controls, and protocol conversions. Referring now to FIG. 3 , which illustrates in more block level detail one embodiment of the elements of a system on a chip and which provides detail as to the acronyms related to various of the elements, the sensor interface and conditioning module preamplifier section 140 can include any (or all) of a number of amplifier types such as a high impedance amplifier, a differential amplifier with or without excitation, a temperature amplifier, a bioamplifier, an ultrasound amplifier, a transimpedance amplifier, and generally a general purpose analog amplifier with or without isolation. The multi-functional electrical stimulation and output module 102 can have in particular an output section which enables the multi-functional electrical stimulator 142 in a manner comparable to that described in the patents identified above to generate output signals in response to instructions or control signals from the processor and/or controller, the signal conditioning and data acquisition module, or the user-programmable module. The output of the multi-functional electrical stimulator can be provided directly to output receiving elements (not shown) or through an amplifier or power drive 144 to such receiving elements. In a particular embodiment, outputs from the output module can be fed back ( 146 ) as an input to the sensor interface and conditioning module 100 through a separate process to help provide closed-loop control of the output stimulation signals. The output module 102 can also be used to generate desired output signals in response to, for example, user programming. The signal conditioning in data acquisition portions 150 of the sensor interface and conditioning module 100 connect to a first bus 152 which in some embodiments connects also to a peripheral bus 154 . The processor and controller module 110 , referring to FIG. 3 , is further broken down to show various elements of the module 110 . The module may include many of the “standard” elements of a standard processor including the CPU or digital signal processing element or multiple processing unit, cache, a user interface module, a direct memory access (DMA) channel or channels, a memory management unit (MMU), an interrupt controller, and an external memory interface. These can be connected through a processor bus 156 to various portions of the memory, such as SRAM, DRAM or the non volatile (NV) storage flash memory. In the illustrated embodiment, the processor and controller module 110 has two processor bus elements 156 and 158 which connect to bus 154 . The communications interface module 116 connects to bus 154 . As illustrated, the communications module can have, in addition to the elements identified in connection with FIG. 2 , a UART, an interrupt/GPIO, an RTC/Watchdog timer, an Ethernet MAC, an optical peripheral device, and the USB protocol identified in FIG. 3 as USB 2.0. FIG. 3 also sets forth many of the acronyms used in the figure for convenience. Referring now to FIG. 4 , the multi-functional stimulator is shown in greater detail with reference to the multi-functional stimulator described in the above-identified patents. The reader is referred to, for example, U.S. Pat. No. 6,029,090 for a more complete and detailed description and understanding of the various elements described in FIG. 4 and which would correspond substantially to portions of module 102 , referring to FIG. 1 . Referring now to FIG. 5 , there is illustrated a particular embodiment of the system showing the general interconnection and operation of the various components, and including some specificity with regard to the sensors which might be connected to the interface and signal conditioning, the ability to provide two analog outputs and eight digital outputs, as an example, the use of a sensor RFID module 510 , and using the power and temperature management module 104 across the chip. On the other side of the chip or module, the ability to wirelessly connect to the module through antenna 518 and remote sending and receiving module 520 is illustrated. Alternatively, a computer can be connected to the module through USB IF (USB interface) element 522 . Other interface connecting signals in this illustrated embodiment are provided through the serial deserializer 524 . The multi-functional electrical stimulator is illustrated as being controlled by the microcontroller or DSP 528 and provides outputs as illustrated. The JTAG module 530 for example, connects also to the microcontroller as well as to an external computer. Referring now to FIG. 6 , further detail is provided with regard to an exemplary sensor interface and conditioning module 100 . As illustrated, different sensors can be provided and treated differently by the high impedance, differential, and transimpedance amplifiers provided in the pre-amplifier module 610 . The output of the pre-amplification is sent in some embodiments to the signal conditioning and data acquisition module where it can be multiplexed, sampled, filtered, and converted to a digital value as illustrated, typically, in that module. Various calibration controls are available as illustrated. The output section contains the electrical controller mentioned above. Various digital to analog converters, here 16 bit DACs, are provided, the output of which is presented to an output stage capable of driving one or more electrical stimulation outputs. Other components illustrated in FIG. 6 are noted and are similar to, if not identical to, the related elements in FIG. 5 . The charts in FIGS. 7 and 8 , illustrate various flexibilities available in constructing any of the elements hereinbefore. This flexibility provides not only for a very useful and “burnable” circuitry over time, but in addition enables the user to substantially design how the system will work. In that respect, therefore, the elements of FIG. 6 , representing the chip level layer, provide, for these embodiments of the invention, a particularly advantageous methodology for building the chip containing the elements and modules described herein. Thus the modules/functions can be configured by the user (for example who may not need to be technically trained) in response to needed application parameters or as a result of available classes or types of sensors/inputs to create a customized chip; that is, a chip having user-selected chip functions and modules/building blocks. In fact, if this occurs early enough in the manufacturing cycle, a smaller footprint, and perhaps fewer “user” layers may be achieved. This interactive process results in a faster and simpler time to use of the system on a chip (SOC). Referring now to FIG. 9 , there are illustrated various sensor pre-amplifier interface modules or masks. Thus, the various sensors and sensor pre-amplifier interface modules are illustrated for various embodiments of the invention. As will be clear to one practiced in this field, various of these modules can be made “standard” for a chip, while others, can be added by the user, depending upon the needs of the user. Referring now to FIGS. 10A and 10B , there is provided a high level typical system specification for the various elements of the system on a chip and for enabling operation of this flexible module and its manufacturing construction based upon the needs described herein. As a result, the structure and system described hereinabove enables a flexible system on a chip to be produced using both analog and digital elements in a side-by-side relationship on a single chip (or if required two or more chips, for example an analog chip and a connected digital chip) to allow both hard-wired burning of connections as well as programmed connections to be made, and thus enable a single multi-layer chip structure or a multi-chip module to be easily modified for many purposes. Those purposes include various purposes described in U.S. Pat. Nos. 6,029,090 and 6,684,106 as well as all the other Herbst issued U.S. Patents Nos. 6,021,347, 6,708,066, 7,526,334, 7,517.311, and 7,160,241, U.S. pending patent application Ser. Nos. 11/063,195, 11/151,967, 11/213,050, 12/098,257, 12/431,730, 12/485,855, and 12/507,506, and International Publication No. WO 2010/065678 A1. While these relate substantially to the medical application field, that is not the only use of such a system on a chip which can be adapted for uses beyond medical applications, including, for example, a wide-range of measurement and control systems.
A configurable semiconductor chip module system has analog elements, digital elements, and connection elements between the analog and digital elements. Ones of the analog and digital elements receive inputs from respective sources, and ones of said analog and digital elements output signals for generating control signals having selected electrical and time spatial properties. The connection elements are configurable after creation of the analog elements, the digital elements, and the connection elements. A method of the invention for manufacturing a flexibly configurable semiconductor single chip module for receiving and outputting various signals not specifically known at the time of manufacture; manufactures a plurality of analog elements, digital elements, and connection elements between said analog and digital elements; enables ones of the analog and digital elements for receiving inputs from respective sources, ones of the analog and digital elements for outputting signals for controlling control signals having selected electrical and time spatial properties; and configures the connections elements after creation of the analog elements, the digital elements, and connection elements, to configure the module.
0
BACKGROUND OF THE INVENTION This invention relates to a bath suitable for the electrodeposition of tin-lead alloys on copper, brass, other copper alloys and steel substrates. This invention also includes methods of accomplishing the deposition of tin-lead alloys by electroplating. This invention, though not specifically so limited, finds particular usefulness in forming a protective and solderable layer over circuitry elements in electronic devices, especially printed circuit boards. Tin-lead alloys are electrolytically deposited in thicknesses typically ranging from about 0.2 to about 2.0 mils when used in printed and other circuitry to provide a solderable finish, a contact material, or an etchant resistant. Tin can be readily deposited from acidic solutions at room temperature and when a lower melting point material is required, tin-lead alloys, such as the typical 60%-40% solder can also be deposited. It is common practice in tin-lead plating to use refined peptone as an additive. Even though its performance as a grain refiner is adequate, it suffers from decomposition in the bath and gives off offensive odors. The breakdown products tend to compound the odor problems. Frequent carbon treatment is necessary to control the bath performance. Excessive levels of the additive or its decomposition products in the bath can also cause out-gassing during reflow due to their inclusion in the deposit during the plating cycle. Although there is economic advantage in operating at higher current densities, peptone baths are conventionally operated at 20 ASF (amperes per square foot) in order to achieve the proper ratio of tin to lead in the plated alloy. It is an object of this invention to provide an improved process for plating eutectic alloy of tin/lead (63%/37%) particularly suitable for improved reflow characteristics in the printed circuit industry. Additional objects of this invention are to provide an improved process for plating an alloy of 93% lead and 7% tin for use on bearing surfaces. Also, a process for plating an alloy of 90% tin and 10% lead for use on electrical contacts. It is a further object of this invention to provide a process to (1) eliminate the need for frequent carbon treatments, (2) eliminate the offensive odors generally associated with peptone baths, (3) provide an additive system that allows extension of the current density range and still retains the desired physical properties and alloy composition, (4) provide improved coverage in low current density areas so that a more uniform thickness ratio is obtained, (5) minimize out-gassing reflow problems by employing a combination of relatively active and stable materials that do not produce undesirable decomposition products, (6) provide smooth nodular free deposits in high current density areas and particularly within printed circuit board holes, (7) provide a process that gives dense, fine grained deposits over a variety of substrates DESCRIPTION OF THE INVENTION The above and other objects of the invention are achieved through the provision of plating baths which include the below listed ingredients in the following ranges: (1) Fluoboric Acid: 100-600 g/l preferred: 200-325 g/l (2) Stannous Fluoborate--(as tin ion): 10-80 g/l preferred: 15-30 g/l (3) Lead Fluoborate--(as lead ion): 5.25 g/l preferred: 10-20 g/l (4) Boric Acid: 10-15 g/l preferred: 12 g/l Baths within the above composition ranges are useful chiefly in the printed circuit industry because lower metal concentrations promote an increase in throwing power sufficient to deposit adequate metal in holes through the boards. Another ingredient employed in the bath used in tin-lead alloy deposition is an ethoxylated alkyl substituted phenol non-ionic wetting agent having the formula: ##STR3## where x=8 to 30; and R is a C 8 or C 9 linear aliphatic chain. The amount of non-ionic wetting agent added to the bath may range from 0.05 to 10 g/l; a preferred range is from 0.1 g/l to 1.0 g/l and a most preferred range is 0.2 g/l to 0.5 g/l. A typical non-ionic wetting agent according to this formula is Igepal CO-630, made by GAF Corporation. This material has a marked effect on reducing burning and roughness in current density areas above 60 ASF because of its ability to lower the solution surface tension and prevent any liberated hydrogen gas from adhering to the surface. In this regard, a desirable surface tension is 40 dynes/cm. Nodular or rough deposits are common on plated areas which have sharp discontinuities such as the holes and we have discovered that this problem can be eliminated by the addition of small amounts of a urea compound, or mixtures thereof, according to the formula: ##STR4## where X=0, S, or NH and R 2 and R 3 are H, or lower alkyl and ##STR5## Lower alkyl is limited to moieties up to C 4 ; with ethyl and methyl being preferred. Specific compounds within this definition which, with a wetting agent of the preferred class, produce smooth, white and fine grained deposits are: ______________________________________(1) Thiourea ##STR6##(2) Tetramethyl thiourea ##STR7##(3) 1,3-diethyl thiourea ##STR8##(4) Methyl thiourea ##STR9##(5) Thioacetamide ##STR10##(6) Acetyl thiourea ##STR11##(7) Thio semicarbizide ##STR12##(8) Urea ##STR13##(9) Guanidine ##STR14##______________________________________ The above grain refining agents, or combinations thereof, are effective from about 0.025 to about 5 g/l. Excellent results are obtained at about 1.0 g/l. When these materials are absent from the bath nodular deposits generally occur at any crystal seed site, such as dirt on the plating surface, exposed fiberglass fibers in drilled holes, etc. The presence of 0.1 g/l of thiourea, for example, gives nodular free deposits up to 45 ASF and at 1.0 g/l, this area is extended to 90 ASF. In addition to this capability, the general grain structure of the entire deposit is finer and appears whiter. The advantages of this invention are apparent from the following examples. EXAMPLE 1 An aqueous plating bath for producing Sn/Pb was prepared by mixing 66 ml of 51% stannous fluoborate, 29 ml of 51% lead fluoborate, 372 ml of 49% fluoboric acid, 15 g of boric acid and making the volume up to one liter to provide 21.5 g/l of stannous ion, 12.5 g/l of lead ion, 250 g/l of free fluoboric acid and 15 g/l of boric acid in the bath. This material was then put into a 1 liter Hull Cell. An anode of 60/40 tin/lead was placed in a 1 liter Hull Cell, such as that described in the Metal Finishing Guidebook & Directory, 1981, on page 404. A sheet of G-10 copper clad fiberglass material (printed circuit board stock) with electrolyte copper plated-thru-holes was used as the cathode in the Hull Cell. The bath was agitated by means of a mechanical stirring arm. The temperature of the bath was maintained at 22° C. After a 10% fluoboric acid dip, the panel was plated at 3 amps for 3 minutes. The deposit was unsatisfactory. It was black, rough and spongy from the high current density edge (100 ASF) down to 18 ASF and white to 3 ASF. There was no deposit from 3 to 0 ASF. EXAMPLE 2 A bath was prepared as in Example 1, but with the addition of 0.2 g/l of Igepal CO 630. An appropriate size copper clad fiberglass printed circuit board was plated at 3 amps for 3 minutes. The overall appearance of the panel was much improved when compared with that plated without the wetting agent as in Example 1. However, the panel had several nodular deposits, known as trees to those familiar with the art, on the face of the panel and through most of the holes in the higher current density areas, i.e., greater than 35 ASF. There was either a lack of or a thin deposit in the area below 6 ASF. EXAMPLE 3 To the bath from Example 2 was added 1.0 g/l of thiourea. A copper clad printed circuit board was plated at 3 amps for 3 minutes. The deposit was white matte, fine-grained, smooth and free from nodular deposits (trees) in the current density range from 0 to 100 ASF. The surface to hole ratio deposit thickness was 1:1. An atomic absorption analysis of the deposited alloy showed a tin content of 60%±3% at 15 to 60 ASF. EXAMPLE 4 With all the conditions from Example 3 the same, panels of brass and mild steel were plated for 3 minutes at 3 amps after the appropriate electrolytic cleaning, rinsing and 10% fluoboric acid dip cycles. The deposits were white, fine-grained, and free from trees in the current density range of 0 to 100 ASF. The alloy was analyzed to be 60%±3% lead from 15 to 60 ASF. EXAMPLES 5-12 Baths were made as in Example 2, i.e., basic ingredients for 60/40 tin/lead deposit plus Igepal CO-630. The compounds listed below were added in the concentrations recited to produce smooth white and fine-grained deposits free from nodular or dendritic growths at the current density ranges shown: ______________________________________Example Concentration RangeNo. Compound (g/l) (ASF)______________________________________5 Tetramethyl thiourea .02-1.0 0-806 1,3-diethyl thiourea 0.06-2.0 0-907 Methyl thiourea .1-2.0 0-808 Thioacetamide 0.04-1.0 0-759 Acetyl thiourea 0.06-2.0 2-9010 Thiosemicarbizide .025-0.5 0-5011 Urea 0.1-2.0 0-8012 Guanidine 0.004-0.12 0-80______________________________________ EXAMPLE 13 An aqueous bath for plating a 90% Sn/10 % Pb alloy was prepared by mixing 91 ml of 51% stannous fluoborate, 10 ml of lead fluoborate, 256 ml of fluoboric acid, 10 g boric acid and making the volume up to one liter to provide 30 g/l of stannous ion, 3.6 g/l lead ion, 200 g/l free fluoboric acid and 10 g/l boric acid in the bath. The additive system to the above bath consisted of 0.1 g/l Igepal CO-630 and 1.0 g/l thiourea. Three substrates were plated in a 1 liter Hull Cell with mechanical agitation for 3 minutes at 3 amps. The deposited metals were white, matte, fine-grained and smooth. The current density range for the various substrates was as follows: Copper clad printed circuit stock: 0 to 30 ASF Mild steel panel: 0 to 36ASF Brass panel: 0 to 60 ASF The tin content from 15 ASF to the high edge of smooth plating was 90±1% for all three substrates. EXAMPLE 14 An aqueous bath for plating 90% Pb/10% Sn was prepared by mixing 120 ml of 49% Pb(BF 4 ) 2 , 10 ml 49% Sn(BF 4 ) 2 , 256 ml of 51% HBF 4 , 10 g boric acid and making the volume up to 1 liter to provide a solution with 44 g/l lead ion, 3 g/l stannous ion, 200 g/l free fluoboric acid, and 10 g/l boric acid in the bath. The bath was agitated by a mechanical stirring arm and maintained at a temperature of 22° C.. A 90/10 lead/tin anode was placed in a 1 liter Hull Cell as in Example 1. When cleaned and 10% fluoboric acid dipped, mild steel, copper and brass substrates were plated in the above bath for 3 minutes at 3 amps. In all cases coverage from 0 to about 12 ASF was either very thin or totally devoid of deposit. In all cases, the panels were spongy, black and rough from the high current density edge to about 45 ASF. From 45 ASF to 12 ASF the deposits were smooth and white. EXAMPLE 15 To the bath of Example 13 was added 0.1 g/l of ##STR15## The smooth white plating range was extended on mild steel, copper and brass substrates from 12 ASF to 0 ASF. EXAMPLE 16 To the bath from Example 15 was added 1.0 g/l thiourea. The smooth white plating range was raised from 45 ASF to 60 ASF on mild steel, copper and brass substrates. Furthermore, the color of the alloy appears lighter than those of Example 15 due to the finer grain structure of the deposit. EXAMPLE 17 A bath was prepared and run similar to the bath in Example 3, except that the Igepal CO-630 was replaced by an equivalent amount of ##STR16## The plating results were the same as in Example 3. EXAMPLE 18 A bath was prepared and run similar to the bath in Example 3, except that the Igepal CO-630 is replaced by an equivalent amount of ##STR17## The plating results were the same as in Example 3. While there have been described what are at present considered to be the preferred embodiments of this invention, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and it is, therefore, aimed in the appended claims to cover all such changes and modifications as fall within the true spirit and scope of the invention.
A process is provided for the electrodeposition of alloys of tin and lead by passing electrical current through an anode, an aqueous acidic plating solution and a cathode, wherein the aqueous acidic plating bath includes at least one organic compound having a formula ##STR1## wherein X=O, S, or NH and R 2 and R 3 are H, or lower alkyl and R 1 is ##STR2## .
2
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a power source device and, more particularly, to means for estimating the remaining electricity of a portable data modem powered by a battery, and the display of the efficient use of the battery. 2. Description of the Related Art A power source device, which executes a power supply to a personal computer or similar electronic apparatus and informs the computer or apparatus of the consumption state of a battery, is described in, for example, Japanese Patent Laid-Open Application No. 36817/1992 (JP-A-04-36817). The power source device has a battery, a current sensor, a voltage sensor, and a capacity detector. The current sensor and voltage sensor measure the source current and source voltage of the battery, respectively. The capacity detector calculates a discharge energy by integrating the measured current and voltage by a time and estimates the remaining capacity of the battery. The estimated remaining capacity is sent to the electric apparatus or computer to be supplied the power from the battery. In response, a controller installed in the electronic apparatus or computer makes the remaining capacity of the battery display. In the conventional power source device described above, it is possible for a user to confirm the remaining capacity of the battery qualitatively. For instance, "60% remaining" is displayed. However, when it comes to the quantitative aspect, such a power source device cannot show specifically a period of time for which the battery is still usable, or how much capacity of a data signal can still be transmitted or received. Moreover, in a data modem for a computer or similar device powered by one of a plurality of batteries, such as manganese battery or alkaline-manganese battery, each battery has a different discharge characteristic. Hence, the estimation of the remaining capacity involves noticeable errors and, therefore, do not withstand practical use. SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide an apparatus or method for detecting a remaining capacity of a battery, capable of estimating a time for when the battery supplies a power. Another object of the present invention is to provide an apparatus or method for a data modem capable of estimating a capacity of a data signal to be transmitted or received. It is a further object of the present invention to provide an apparatus or method capable of estimating a remaining capacity of a battery even though a different kind of a battery is used. It is still further object of the present invention to provide an apparatus or method capable of estimating the remaining electricity of a portable data modem powered by a battery. The apparatus for detecting a remaining capacity of a battery according to the present invention is capable of measuring accurately the remaining time independent of a kind of the battery, and thereafter, calculating an available file capacity to transmit and receive during the remaining time. In addition, the apparatus displays the available file capacity and informs an operator when the available file capacity is smaller than a file which is necessary to be transmitted and received. The apparatus measures two kinds of battery voltages under two kinds of load condition and determines a kind of the battery based on the measured battery voltages. The battery has different characteristics of voltages depending on an internal resistance therein. After determining the kind of the battery, the apparatus detects a remaining time of the battery. In addition, the apparatus includes a radio section to transmit and receive a data signal. The apparatus calculates and displays an available file capacity to transmit and receive during the remaining time. When the available file capacity is smaller than a capacity in which the data signal is transmitted and received, the apparatus generates an alarm. A signal processing system for detecting a remaining capacity of a battery, according to the present invention, includes means for identifying a kind of a battery, means for determining a remaining power of said battery based on said kind of said battery. The remaining power may be a remaining time. The apparatus displays the remaining time. In addition, the signal processing system includes means for transmitting and receiving a data signal. The apparatus determines an available data capacity of the data signal which is transmitted and received during the remaining time. The apparatus displays the available data capacity, and informs an operator when the available data capacity is smaller than a capacity which is necessary to transmit and receive a file. BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects, features and advantages of this invention will become more apparent from the following detailed description taken with the accompanying drawings in which: FIG. 1 is a block diagram of a preferred embodiment according to the present invention; FIG. 2 is a flowchart demonstrating a procedure of measuring a battery voltage according to the present invention; FIG. 3 is a flowchart representative of a procedure for calculating a remaining time on the basis of the voltage information; FIGS. 4(a) and 4(b) illustrate characteristic curves showing how the routine of the procedure showing in FIG. 3 determines the estimated remaining time more accurate; FIG. 5 is a flowchart representative of a procedure in the ARM interrupt processing which indicates that the battery voltage has fallen below the safety critical value; FIG. 6 is representative of a routine in which the CPU hands over a received radio data signal to the personal computer or similar data terminal; FIG. 7 is a flowchart demonstrating a procedure in which a data signal from the data terminal is sent in the form of a radio data signal; FIG. 8 is a flowchart demonstrating a procedure in which the controller deals with a data signal received from the card modem; FIG. 9 is a flowchart demonstrating a procedure which the controller executes for sending a data signal from the data terminal to the card modem; and FIG. 10 is a flowchart demonstrating a procedure which the controller executes an ARM interrupt routine. In the drawings, the same reference numerals denote the same structural elements. DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 is a block diagram of a preferred embodiment according to the present invention. A card modem 20 has a data interface (I/F) 22 for interchanging a data signal with a data terminal 10 including a personal computer 12 or a similar data terminal via a transmission/reception data bus 16 or an alarm (ARM) data bus 18. A radio section 24 includes a transmitting portion 36 and a receiving portion 38. The transmitting portion 36 modulates the data signal from the computer 12 via the data I/F 22 and transmits the modulated data signal to a remote radio station. The receiving portion 38 demodulates a data signal via an antenna 34 from the remote radio station. A battery 26 supplies power to the transmitting portion 36 and receiving portion 38 of the radio section 24, an analog-to-digital (A/D) converter 28, a central processing unit (CPU) 30, and the data I/F 22. The battery 26 supplies the power to the transmitting portion 36 when the data signal from the data terminal 10 is transmitted. The A/D converter 28 transforms the output voltage of the battery 26 to a digital voltage value. The CPU 30 calculates a remaining capacity of the battery 26 as described later, controls the operation of the radio section 24 by processing the digital voltage value from the A/D converter 4 as described later, and interchanges the data signal with a random access memory (RAM) 32 which is used to temporarily save the data signal therein. The data terminal 10 is made up of the personal computer 12, a display 13, and a controller 14. The controller 14 sets a screen for displaying a data transmission/reception instruction information on the display 13, sets a data signal transmission/reception file, and executes the data signal transmission/reception. Preferred operations of the CPU 30 in the card modem 20 will be described in detail with reference to FIGS. 2-7. FIG. 2 is a flowchart demonstrating a procedure of measuring a battery voltage in the CPU 30. To beginning with, a source load condition of the radio section 24 is set into a predetermined first source load condition (Step S101) in which, preferably, only the receiving portion 38 is switched on and the transmitting portion 36 is switched off. Namely, the transmitting portion 36 is not powered by the battery 26. Then, the CPU 30 measures a first source voltage of the battery 26 via the A/D converter 28 (Step S102) and stores a first digital value of the first source voltage into the RAM 32 (Step S103). Subsequently, the source load condition of the radio section 24 is set to a second source load condition in which, preferably, both of the transmitting portion 36 and receiving portion 38 are switched on (Step S104). The load under the second load condition is higher than that under the first source load condition. Then, the CPU 30 measures the source voltage of the battery 26 via the A/D converter 28 again (Step S105) and stores a second digital value of the source voltage into the RAM 32 (Step S106). Thereafter, the CPU 30 cancels the second load condition of the radio section 24 (Step S107) and sets a safety critical voltage VT of the remaining capacity of the battery 26 matching the first and second digital value (Step S108). The setting of the safety critical voltage VT will be described later. The CPU 30 compares the source voltage under the second load condition, as measured in step S105, with the safety critical voltage set in step S108 (step S109). If the source voltage under the second load condition is higher than the safety critical voltage, the procedure ends. If otherwise, the CPU 30 interrupts the processing under way and moves to an alarm (ARM) interrupt processing (Step S110) as described later. In the above-described embodiment, although the source voltage under the second load condition is compared with the safety critical voltage VT, the source voltage under the first load condition may be compared with the safety critical voltage VT when only the receiving portion 38 is used. FIG. 3 is a flowchart representative of a procedure for calculating a remaining time on the basis of the voltage information produced by the above-identified measurement (FIG. 2). The CPU 30 reads the first digital value, or a first source load voltage, stored in the RAM 32 in step S103 of FIG. 2 (Step S201) and then reads the second digital value, or a second source load voltage, stored in the RAM 32 in step S105 of FIG. 2 (Step S202) as described below. Subsequently, the CPU 30 determines the kind of the battery on the basis of the first and second source load voltages, and the difference between the first and second source load voltages (Step S203). As shown in FIGS. 4(a) and 4(b), characteristic curves of each battery are different. Next, the CPU 30 selects, among load characteristic charts stored in the RAM 32 beforehand, a chart matching the kind of the battery identified (Step S204). Further, the CPU 30 sets the radio section 24 into a designated condition, i.e., the first or second load condition, (Step. S205) and measures a current source voltage (Step S206). The CPU 30 calculates an estimated remaining time from the current source voltage to the safety critical voltage VT using characteristic curves of the selected characteristic chart (Step S207), and records the estimated remaining time into the RAM 32 or displays information, such as, the remaining time or capacity of a data file which the card modem can send or receive based on the remaining time (Step S208), and then ends the procedure. In the above embodiment, in Steps S201 and S202, even though the first and second source load voltage stored in the RAM 32 are used, current first and second source load voltages may be measured under the first and second load condition, respectively. This results in deleting steps S205 and S206. FIGS. 4(a) and 4(b) illustrate characteristic curves showing how the routine of the procedure showing in FIG. 3 determines the estimated remaining time more accurate. FIG. 4(a) indicates the load characteristic of a manganese battery or similar battery having a relatively higher internal resistance. FIG. 4(b) indicates the load characteristic of an alkaline-manganese battery or similar battery having a relatively lower internal resistance. In FIGS. 4(a) and 4(b), VN indicates a reference battery voltage which the CPU 30 assumes temporarily. VT is the safety critical voltage of the source voltage which allows the card modem 20 to operate normally. VD is a voltage which, in effect, renders the card modem 20 unable to operate. VW1 and VW2 are each indicative of a difference between the first and second load voltages when the voltage under the first load condition is VN by way of example. TVN1 and TVN2 are each representative of a period of time, as estimated from a load characteristic chart, up to the time for VN to be reached under a load condition in which the first load voltage is assumed. TVT1 and TVT2 are each indicative of a period of time, as estimated from a load characteristic chart, up to the time for the second load voltage to reach the VT. Further, TL1 and TL2 are respectively indicative of the interval between TVN1 to TVT1 and the interval between TVN1 and TVT2. The TL1 and TL2 are corresponding to the remaining time. In the above embodiment, since the second source load condition is a maximum load condition, a minimum time to reach at the safety critical voltage VT is set as the remaining time. In step S203 in FIG. 3, the kind of the battery is determined on the basis of the voltage difference attributable to a change in the two load condition, as represented by VW1 or VW2, relative to the absolute value of the first load voltage. To estimate a remaining time in step S207, the CPU 30 reads the approximate values of the characteristics curves of the first and second loads in FIG. 4(a) or 4(b), out of the RAM 32, and determines TVN1 or TVN2 from the current load voltage. Thereafter, the CPU 30 calculates a difference TL1 or TL2 between TVN1 and TVT1 or TVN2 and TVT2 which is read from the approximate values of the characteristic curves, and uses the difference TL1 or TL2 as an estimated remaining time. In step S207, when the designated condition is the first load condition, the remaining time may be the time from the current load voltage to the safety critical voltage VT under the first load condition. In step S108 in FIG. 2, the safety critical voltage VT is set after the determination of the characteristic chart and curves in steps S202 to S206. As shown in FIG. 2, if the source voltage under the second load condition is not higher than the safety critical voltage, the ARM interrupt processing starts. However, the first source voltage may be compared with the safety critical voltage when the first load condition is designated. FIG. 5 is a flowchart representative of a procedure in the ARM interrupt processing which indicates that the battery voltage has fallen below the safety critical value. Assume that the ARM interrupt processing is requested in step S110 in FIG. 2. Then, the CPU 30 interrupts the procedure under way and saves the data signal in transmission/reception in the RAM 32 (Step S301). Subsequently, the CPU 30 sends the ARM signal to the remote radio station (not shown) and the controller 14 (Step S302). On receiving an acknowledge signal from both of the controller 14 and the remote station (Step S303), the CPU 30 sends to the controller 14 and the remote station the address of the data signal at which the data transmission/reception has been interrupted (Step S304). The CPU 30 ends the transmission/reception modem operation (Step S305) and causes the card modem 20 itself to flash an indicator, produce an alarm tone, or otherwise urges the operator to replace the battery (Step S306). FIG. 6 is representative of a routine in which the CPU 30 hands over a received radio data signal to the personal computer or similar data terminal 10. When a control signal comes in through the antenna 34 to the radio section 24 (Step S401), the control signal reception is reported to the CPU 30. In response, the CPU 30 cancels a sleep mode which has been set up for saving the power of the entire card modem 20 (Step S402). In addition, the CPU 30 sends a reception information signal to the controller 14 via the data I/F 22 (Step S403) and reads the output digital signal of the A/D converter 28, i.e., measures the source voltage (Step S404). Based on the result of measurement, the CPU 30 determines the kind of the battery and calculates the remaining time estimated under the designated load condition as described before (Step S405). The received control signal includes a signal indicating the designated load condition. On receiving a ready-to-receive information signal from the controller 14 (Step S406), the CPU 30 sends the estimated remaining time to the controller 14 as a reception time information signal (Step S407) and then sends the ready-to-receive information signal to the remote radio station (Step S408). When a radio data signal is received via the antenna 34 (Step S409), the CPU 30 executes a received data signal modem processing immediately for handing over the received data signal to the personal computer 12. FIG. 7 is a flowchart demonstrating a procedure in which a data signal from the data terminal is sent in the form of a radio data signal. When a transmission start-up request signal is received from the controller 14 through the computer 12 and the data I/F 22 (Step S501), the CPU 30 switches on the radio section 24 (Step S502). Then, the CPU 30 reads the output digital signal of the A/D converter 28 in order to measure the source voltage (Step S503) and once switches off the radio section in order to save a battery power (Step S504). Subsequently, the CPU 30 determines the kind of the battery on the basis of the operation in step S503, selects a load characteristic chart, and calculates a remaining time estimated under the designated load condition as described before (Step S505). The CPU 30 sends the remaining time to the controller 14 as a transmission time signal indicating how long the modem needs to send a data file (Step S506). On receiving a transmission connection request signal from the controller (Step S507), the CPU 30 switches on the radio section 24 again (Step S508) and the CPU 30 transforms the request signal to a radio data signal and sends the radio data signal via the antenna 34 as a radio transmission connection request signal (Step S509). When an answer signal from the remote radio station is received (Step S510), the CPU 30 delivers a ready-to-send information signal to the controller 14 (Step S511). On receiving a data signal to be transmitted from the controller 14, the CPU 30 executes transmission modem processing immediately for converting the data signal to a radio data signal and sending the radio data signal via the antenna 34 (Step S512). Next, preferred operations of the controller will be described with reference to FIGS. 8 to 10. FIG. 8 is a flowchart demonstrating a procedure in which the controller 14 deals with a data signal received from the card modem 20. The controller 14 receives the reception information signal of a remote station from the card modem 20 via the data I/F 22 (Step S601). In response, the controller 14 sets a data file for a reception and recording (Step S602) and then sets the computer 12 into a data reception condition based on a setting signal including in the reception information signal (Step S603). Subsequently, the controller 14 sends to the card modem 20 the ready-to-receive information signal indicating that it is ready to receive a data signal (Step S604). Next, the controller 14 receives the reception time information signal counted and calculated by the CPU 30 (Step S605). Thereafter, the controller 14 informs a user of receiving the control signal and the content of the reception time on the screen (Step S606). As soon as the data terminal 10 receives a data signal from the card modem 20 via the data I/F 22, the controller 14 processes the data signal (Step S607). The CPU 30 may send the reception time to the remote station. FIG. 9 is a flowchart demonstrating a procedure which the controller 14 executes for sending a data signal from the data terminal 10 to the card modem 20. On receiving a transmission start-up information signal keyed in on, for example, a personal computer (Step S701), the controller 14 sends the transmission start-up request signal to the CPU 30 of the card modem 20 via the data I/F 22 (Step S702). Subsequently, the controller 14 receives the transmission time signal from the CPU 30 (Step S703) and calculates the number of bits of a file which can be sent to the card modem 20 (Step S704). Then, the controller 14 displays the available file capacity on a screen assigned to a transmission file (Step S705). If the transmission file set by the operator exceeds the available file capacity (Step S706), the controller 14 produces an alarm to urge the operator to reduce the file or to replace the battery (Step S707). Otherwise, the controller 14 sends the transmission connection request signal to the card modem 20 (Step S708). On receiving the ready-to-receive information signal from the card modem 20 (Step S709), the controller 14 starts a data transmission processing immediately (Step S710). Assume that the controller 14 has received from the card modem 20 an alarm data signal or ARM interrupt signal, indicating that the remaining capacity of the battery is short of a safety level. Then, the controller 14 executes an ARM interrupt routine shown in FIG. 10. On receiving the ARM interrupt signal (Step S801), the controller 14 interrupts a routine under way and saves the current data transmission/reception conditions in the RAM 32 (Step S802). Subsequently, the controller 14 reads the ARM data signal (Step S803), determines whether or not the data transmission/reception has been under way up to that time (Step S804), and determines whether or not the data transmission has been under way (Step S805). Only if the data transmission has been under way as determined in the step S805, the controller 14 stops the transmission (Step S806). The controller 14 sets a suitable ARM message signal, e.g., "Stop modem" or "Change battery" as a content to be displayed on the personal computer (Step S807), and sends an ARM data acknowledge information signal to the card modem 20 (Step S808). When the controller 14 receives a transmission interrupt address from the card modem 20 (Step S809), it displays a file name sent, destination, transmission interrupt address and other transmission interrupt conditions (Step S810) and awaits the next command to be entered by the operator (Step S811). The measuring operation of the remaining capacity may be executed not only in response to the transmission start-up request signal or the control signal from the remote station but also periodically. As hitherto described, according to the present invention, since the apparatus for estimation a remaining time disclosed herein measures a battery voltage under at least two load conditions and estimates the kind of a battery, the apparatus permits accurately measuring of remaining time based on the kind of the battery. Moreover, the apparatus permits informing the operator of how long the data terminal can be operated or how much file capacity can be transmitted and received with the data modem. While the invention has been described with reference to specific embodiments thereof, it will be appreciated by those skilled in the art that numerous variations, modifications, and embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the invention.
A controller of a card radio modem connectable to a data terminal measures two kinds of a battery voltage under a different load condition of the card radio modem. The controller determines the kind of battery and detects the remaining time of accuracy, based on the kind of the battery. In addition, the controller calculates an available capacity of a file data to be transmitted and received during the remaining time. When the available capacity is smaller than a capacity which is necessary to transmit and receive, the controller generates an alarm to inform an operator. The controller displays the available capacity or remaining time on a display.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to hyaluronate based compositions, and more particularly, to such compositions, including in addition to hyaluronate, a high molecular weight poly(ethylene oxide). The invention also relates to cosmetic formulations comprising such compositions. 2. The Prior Art Hyaluronic acid (hereinafter referred to as "HA") as well as its salts, such as sodium hyaluronate and other alkali metal and alkaline earth metal salts (hereinafter referred to as "NaHA") is a known, naturally occurring high viscosity glycosaminoglycan having alternating β 1-3 glucuronidic and β 1-4 glucosaminidic bonds. The molecular weight of this material is generally within the range of 50,000 to 8,000,000 (although there are reports of HA having molecular weights as high as 13,000,000) depending on the source, method of isolation and method of determination. It is found in animal tissue, e.g., in umbilical cord, vitreous humor, synovial fluid, rooster combs, group A and C hemolytic streptococci and in skin. The isolation and characterization of HA is described in Meyer et al, J. Biol. Chem. 107, 629 (1934); J. Biol. Chem. 114, 689 (1936); Balazs Fed. Proc. 17, 1086 (1958); Laurent et al; Biochim. Biophys. Acta 42, 476 (1960). The structure of HA was elucidated by Weissman et al, J. Am. Chem. Soc. 76, 1753 (1954) and Meyer, Fed. Proc. 17, 1075 (1958). For certain uses, extremely pure HA preparations are required; see, for example Balazs U.S. Pat. No. 4,141,973, which describes the preparation and use of such an HA. Poly(ethylene oxides) are known water soluble non-ionic homopolymers of ethylene oxide having molecular weights up to 5,000,000. Aqueous solutions of these polymers are highly viscoelastic and are known to be used in many areas including adhesives, lubricating agents, coatings, cosmetics, etc. Poly(ethylene oxide) is also known to form strong association complexes with a large number of other materials, such as urea, phenolics, poly(acrylic acid), etc. The reaction products formed between poly(ethylene oxide) and polymeric polycarboxylic acids are insoluble in hot and cold water. (U.S. Pat. No. 3,387,061). Poly(ethylene oxide) is known to be used in cosmetics. See, e.g., U.S. Pat. Nos. 2,991,229; 3,783,872; 3,811,349 and 4,192,862. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a graph showing the specific viscosity of various mixtures of a poly(ethylene oxide) and sodium hyaluronate described in examples 1-5; and FIG. 2 is a graph showing the specific viscosity of an aqueous solution of 1:1 mixture of poly(ethylene oxide) and sodium hyaluronate at differing polymer concentrations (example 6). SUMMARY OF THE INVENTION Water based, highly viscoelastic substances are very useful in cosmetic formulations because they impart to such formulations a smooth, silky texture which is desirable both in terms of the function and aesthetic appeal of cosmetics. One such substance is Hyladerm® (Biomatrix, Inc.) which is described in U.S. Pat. No. 4,303,676. These hyaluronate compositions are expensive and thus, the art has been seeking ways to easily provide such substances at relatively low cost. While U.S. Pat. No. 3,387,061 suggests that the reaction products of a poly(ethylene oxide) and polymeric polycarboxylic acids are water insoluble, we have now found, quite unexpectedly, that when aqueous solutions of a hyaluronic acid salt and a high molecular weight poly(ethylene oxide) are mixed together, no water insoluble products are formed, even though hyaluronic acid is a polymeric polycarboxylic acid. Instead, what is observed is a highly viscoelastic substance in which the viscosity of the mixture is substantially in excess of the sum of the individual viscosities of the hyaluronate and the poly(ethylene oxide). This wholly unexpected property makes the resulting mixtures particularly well suited for use in cosmetic formulations both because of the desirability of the vastly increased viscosity and the reduced cost of the substance as compared with a like amount of a hyaluronate composition without the poly(ethylene oxide). Accordingly, the invention provides, in one aspect thereof, water based, viscoelastic compositions comprising a mixture of a hyaluronate, preferably an alkali metal or alkaline earth metal hyaluronate, and most preferably, sodium hyaluronate and a poly(ethylene oxide). In another aspect, the invention provides cosmetic formulations comprising the composition in admixture with other, conventional additives used in cosmetics, including surfactants, thickeners, moisturizing agents, fibers, pigments and dyes and fragrances. DETAILED DESCRIPTION OF THE INVENTION As noted above, the invention provides highly viscoelastic compositions comprising a mixture of a hyaluronate and a poly(ethylene oxide). Generally speaking, hyaluronates are more viscous than poly(ethylene oxides) and poly(ethylene oxides) are more elastic than hyaluronates. Moreover, suitable hyaluronates are quite expensive to produce. Notwithstanding the teaching in prior U.S. Pat. No. 3,387,061, we have found that when a composition according to the invention is produced, the result is a water soluble product having the desirable properties of both the hyaluronate and the poly(ethylene oxide) at a much reduced cost. In accordance with the invention, as the hyaluronic acid salt there can be used a pure HA salt, for example, an alkali or alkaline earth metal salt; or a mixture of hyaluronates containing proteins and other naturally occurring substances, such as the product described in U.S. Pat. No. 4,303,676, the contents of which are incorporated herein by reference. Generally, the hyaluronate used in the invention will have a molecular weight in the range of about 1×10 6 -5×10 6 . The poly(ethylene oxide) can be any water soluble linear homopolymer of ethylene oxide having a molecular weight of about 1×10 6 -5×10 6 . Such poly(ethylene oxides) are available from Union Carbide Corporation (Polyox® brand) and a particularly suitable grade of Polyox® is that which is identified as "Polyox® Coagulant" in the Union Carbide Corporation publication entitled "Polyox®--Water Soluble Resins Are Unique" © 1967, 1972, 1973, 1978, 1981 by Union Carbide Corporation. This poly(ethylene oxide) has an average molecular weight of 5×10 6 and a viscosity (1% solution) of 4,500-6,500 cps at 25° C. The relative concentration of each of the components in the mixture can be from 0.01 to 2%. The ratio: hyaluronate:poly(ethylene oxide) in the mixture can be from 1:50 to 100:1 by weight. Cosmetic formulations according to the invention can be made containing widely varying amounts of the aforesaid mixtures, i.e., from 0.1 up to about 50% of a hyaluronate-poly(ethylene oxide) mixture depending on the nature of the cosmetic product and the performance characteristics desired by such formulation. Again, depending upon the type of formulation, it will contain various cosmetic ingredients such as emollients, sugar alcohols, neutral or anionic polysaccharides, preservatives (which do not react with or degrade the hyaluronate), fragrances, water and the like. These latter materials are all conventional in the art and well known to cosmetic chemists. Included among the cosmetic formulations are moisturizing creams and lotions, shampoos, liquid soaps, shaving cream, eye cream, lip protective creams and make-up, as well as eye drops. The invention will now be described in greater detail in the following examples which are illustrative of the invention without, however, being a limitation thereof. EXAMPLE 1 A 1% aqueous solution of Polyox® coagulant (molecular weight about 5,000,000, Union Carbide Corp.) was mixed with BIOMATRIX™ sodium hyaluronate (0.5% water solution of sodium hyaluronate, which includes large amounts of proteins, molecular weight about 2,000,000) and water in such proportions to obtain a mixture which contains 0.5% of poly(ethylene oxide) and 0.05% of sodium hyaluronate. The specific viscosity ηsp of the mixture was 451. The individual specific viscosities of an 0.5% solution of poly(ethylene oxide) and an 0.05% solution of sodium hyaluronate were 100 and 11, respectively. Thus, the additive value for the mixture of the two is 111, whereas the real or actual value of ηsp for the mixture is about four times greater than the additive value which would be expected. EXAMPLE 2-5 The above example was repeated with different mixtures having different hyaluronate/poly(ethylene oxide) ratios. The specific viscosities of the mixtures of the solutions of poly(ethylene oxide) and sodium hyaluronate of the corresponding concentrations, and also, the calculated additive values are presented in FIG. 1. They are also set forth in Table I. TABLE I______________________________________ Specific ViscosityExample additive value actual value______________________________________1 NaHA 11 111 451 Polyox 1002 NaHA 12.5 54.5 250 Polyox 423 NaHA 15 35 137.5 Polyox 204 NaHA 15 225 70 Polyox 7.55 NaHA 17.5 20 37.5 Polyox 2.5______________________________________ From these data it can be seen that the real value for each mixture is substantially greater than the calculated or additive value. EXAMPLE 6 Several mixtures were prepared from a 1% water solution of Polyox® coagulant and BIOMATRIX™ sodium hyaluronate with the ratio of two polymers being 1:1 and with different concentrations of polymers in the mixtures. The ηsp values are plotted in FIG. 2 against polymer concentrations. For these mixtures the measured values of ηsp are seen to be substantially greater than the additive values. EXAMPLE 7 A 1% water solution of Polyox® coagulant and Hyladerm® (1% water solution of sodium hyaluronate, protein content 0.01%, molecular weight 4,000,000, Biomatrix, Inc.) were mixed with water in such a proportion that the resulting mixture contains 0.05% of each polymer. The ηsp of the mixture was 91. The specific viscosity of the poly(ethylene oxide) and sodium hyaluronate solutions of corresponding concentrations were, respectively, 1.8 and 39. The additive value thus is 40.8 is less than half of the actual value for the mixture. The following examples (8 and 9) are directed respectively to a shaving cream and a moisturizing eye cream. EXAMPLE 8 A shaving gel formulation as set forth below was prepared. ______________________________________ % by weight______________________________________Sodium hyaluronate, 1% solution 2.56(Hyladerm ®, Biomatrix, Inc.)Poly(ethylene oxide), 1% solution 0.36(Polyox ® coagulant)Polyacrylic acid (thickener) 0.41(Carbopol 940 ®, B. F. Goodrich)Triethanolamine 0.41Hydroxyethylcellulose, 1% solution 8.2(Cellosize ®, Union Carbide Corporation)Squalene 0.20Robane ®, Robeco Chemicals, Inc.)Coconut oil 0.31(Cochin ®, Acme-Hardesty Co., Inc.)Preservative 0.26Fragrance 0.26Water 87.0______________________________________ To prepare this formulation, the Carbopol resin was dispersed in water, after which all the other components but triethanolamine were added with stirring. Then the triethanolamine was stirred in. The formulation obtained is a translucent, viscous gel-like mixture. When tested as a shaving gel it gave very good results by providing a smooth and clean shave. Furthermore, this shaving gel provided moisturizing action and could be left on the skin after shaving. EXAMPLE 9 This example illustrates a moisturizing eye gel. ______________________________________ % by weight______________________________________A. Hyladerm ® 2.0Polyox ®, 1% water solution 0.4Carbopol ® 940 0.4Water 90.9B. Liponic ® EG-1 (Lipo Chemicals, Inc.) 0.55 (Croda, Inc.).1.0Solulan ® C-24 (Amerchol Co.) 1.0Crodafos ® N3 neutral (Croda, Inc.) 0.8Robane ® 1.0Crodamol ® PMP (Croda, Inc.) 0.5Glucam ® E-10 (Amerchol Co.) 0.7Preservative 0.3C. Triethanolamine 0.4Fragrance 0.1______________________________________ This formulation is prepared in separate stages as follows: Part A of the mixture was prepared by dispersing the Carbopol in water and then stirring in the other components. All the Part B components were mixed together and heated to 70° C. Parts A and B were then combined and the triethanolamine and fragrance were added. The resulting cream was stable and smooth and had good moisturizing qualities and an excellent feel on the skin. The following examples 10-11 illustrate, respectively, formulations for a moisturizing hand lotion and an emollient moisturizing cream. EXAMPLE 10 ______________________________________ parts by weight______________________________________Hyladerm ® 2.5Polyox ®, 1% water solution 0.3Glycerine 5.0Ethyl alcohol 15.0Oleth-5 2.0(Lipocol ® 0-5. Lipo Chemicals, Inc.)Glucam ® E-10 0.7Preservative 0.3Fragrance 0.15Water up to 100.00______________________________________ The formulation was prepared by mixing all the components together. EXAMPLE 11 ______________________________________ parts by weight______________________________________A. Hyladerm ® 2.5 Polyox ®, 1% water solution 1.5 Carbopol ® 940 0.5 Water 83.5B. Petrolatum 5.0 Robane ® 2.0 Lanoxide ® 59 2.5 Silicone Copolymer ® F-754 1.5 Preservative 0.3C. Triethanolamine 0.5 Fragrance 0.1______________________________________ This formulation was prepared in separate stages as described in example 9. The resulting cream was rich with excellent moisturizing qualities and did not give a greasy feeling on the skin. The invention also includes within its scope eye drop formulations, including both eye drop formulations containing one or more preservatives to ensure stability of the formulation in an already opened container of the product as well as eye drop formulations in single dose forms without preservative. Such non-preservative containing formulations are desirable because certain users have eyes that are sensitive to the commonly used preservatives. Such formulations according to the invention are feasible because as a result of the very low protein content of the hyaluronate used, the formulation will not support the growth of most microorganisms and, therefore, the need for preservatives is avoided. The following examples 12 and 13 illustrate, respectively, eye drop formulations with and without preservatives. EXAMPLE 12 ______________________________________ parts by weight______________________________________Hyladerm ® 2.00Polyox ®, 1% water solution 2.20Benzalkonium chloride 0.01Disodium edetate 0.05Water up to 100.00______________________________________ The formulation, when applied into an eye, gives a very comfortable feeling. EXAMPLE 13 ______________________________________ parts by weight______________________________________Hyladerm ® 0.45Polyox ®, 1% water solution 0.20Water up to 100.00______________________________________ EXAMPLE 14 Single Dose Non-Preserved Eye Drop The formulation of example 13 which does not contain a preservative was packed in 0.2 ml sterile plastic containers and used as eye drops for a single application. The amount can vary from about 0.1-0.5 ml, but 0.2 ml is the preferred amount. Certain ingredients set forth in the formulations of examples 8-13 are identified by trademarks. The following is a list of the chemical names of these ingredients. ______________________________________Liponic ® Eg-1 Glycereth-26 (polyethylene ether of glycerin)Volpo-5 ® Oleth-5 (polyethylene glycol ether of oleyl alcohol)Solulan ® C-24 Choleth-24 (polyethylene glycol ether of Cholesterol)Crodafos ® N3 neutral DEA-Oleth-3 Phosphate (die- thanolamine salt of a com- plex mixture of esters of phosphoric acid and Oleth-3)Crodamol ® PMP (propoxylated myrisryl pro- pionate) PPG-3 Myristyl Ether Propionate)Glucam ® E-10 Methyl gluceth-10 (poly- ethyene glycol ether of methyl glycose)Lanoxide ® Polyoxyethylene glycol ether of stearic acid, Lanaetex Products, Inc.______________________________________ Variations and modifications can, of course, be made without departing from the spirit and scope of the invention.
Disclosed are water based, viscoelastic compositions comprising a mixture of high molecular weights hyaluronic salts and water soluble poly(ethylene oxides). Also disclosed are cosmetic formulations including said compositions.
8
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a divisional application of U.S. patent application Ser. No. 10/359,770, filed on Feb. 7, 2003, which claims the benefit of U.S. provisional application Ser. No. 60/374,830 entitled “System and Method for the Enablement of Electronic Commerce in Limited Input Environments” filed Apr. 24, 2002 the entirety of which are incorporated by reference. FIELD OF THE INVENTION [0002] The present invention relates to electronic commerce and transactions, and more particularly, to a system and method for facilitating transactions for consumers and commercial entities operating within networks which may offer limited input environments, such as interactive television systems. BACKGROUND OF THE INVENTION [0003] Interactive television is a relatively new phenomenon. Through interactive television, television viewers can use their remote controls or other input devices to affect what is seen and what functionality can be invoked on the television screen. Interactive television moves consumers to actively participate in television. Various forms of functionality, content and applications can be invoked with interactive television, including selecting information to be scrolled like a “ticker” across a portion of the television screen. Such information might be related to sports, weather, news, the stock market, or other information found to be of interest. [0004] Consumer interaction through the television or over wireless devices is currently a difficult task, due in part to poor consumer/service provider interfaces and in part to strict agreements between service providers and their commercial partners. It is obviously advantageous for cable and wireless service providers to be able to provide their customers with the ability to interact with third party commercial partners. However, the service provider typically reaches individual agreements with each specific partner on both a business and technical level, thereby hindering scalability for each commercial partner. For example, the technical level agreement may not only contain mandates on connections and protocols, but also which specific information the partner is looking for on a screen or session level basis, and where that information can be entered by the customer. This can include applications that require completed input fields from the customer through remote controls such as “request for information” advertisements, television-commerce order forms, or games. With the increasing disparity of equipment, software, and environments, third party content providers have difficulty successfully deploying this content and applications in varied environments. [0005] With regard to consumer/service provider interfaces, traditional purchasing methods by television-watching consumers have required the consumer to place a telephone call or log in to an Internet web site to purchase the materials shown on television. Once logged in, the consumer is required to enter text in text fields and make other selections in appropriate dialog boxes to convey necessary information to the vendor, such as billing and shipping information. Both of these methods require an investment of time and effort on the part of the consumer, which can lead to lost sales opportunities. Customization would improve customer interaction, but service providers and commercial partners typically find it unduly burdensome to customize on an individual consumer basis. [0006] There is thus a need for a method of empowering television-watching consumers and wireless Internet surfers with simple access and functionality for purchasing items of interest discovered while interacting with their devices. There is also a need for a system for facilitating automated and simplified presentation of commercial partner information over a content network to users of devices having limited input environments. [0007] By the present invention, there is provided a system and method for automatically storing and loading consumer information into commercial transaction pages. Consumer information can be stored through registration or through system interaction and is associated with tags from commercial participants which are stored based upon informational needs for consummating transactions. New commercial participants are easily integrated into the present system through storage and association of tags or target content markers. Commercial participant branding is maintained, and entry of consumer information is minimized and simplified. BRIEF DESCRIPTION OF THE DRAWINGS [0008] FIG. 1 shows a schematic of the data flow in accordance with one embodiment of the present invention. [0009] FIG. 2 is a flow chart showing the process by which a customer purchase can be made using the system of the present invention. [0010] FIG. 3 is a diagram illustrating vendor integration using markup transformation in accordance with one embodiment of the present invention. [0011] FIG. 4 shows one embodiment of an architecture diagram for use in implementing the system of the present invention. [0012] FIGS. 5 through 8 show the interaction of the various components of the present invention in connection with the initiation and execution of end user and vendor-side activity. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0013] The following terms are defined to enhance the understanding of the invention, but the definitions contained should not be read in a limiting sense. [0000] 1. Provider or Operator: Network operator such as a cable or wireless service provider. 2. Vendor or Commercial Partner: Third party seller of goods and services. 3. Customer or Consumer: Cable service user and consumer of goods and services. 4. Protocol: Means of connection between Customer and Commercial Partner (ie. HTTP/MFS). In one embodiment, the present invention takes the form of a plug-able module for any J2EE compliant application server written in Java™ that intercepts the stream of information between the customer and vendor while still within the confines of the provider's network. 5. Tags: Embedded information keys, such as HTML or XML embedded keys, for customer specific values which can be agreed upon at time of Provider/Vendor agreement. 6. Environment: The private connections between the customer, the provider, and the vendor communicated via pre-determined protocol. 7. Dialogs: Interactive user interface objects displayed by the browser (such as text fields, text areas, check boxes, radio buttons, and list boxes). 8. Standard Information: Groups of values to specific tags that are common across most vendors (such as billing and shipping information). 9. Non-Standard Information: Unique user session information or groups of values to specific tags that are not frequently used by more than one vendor. 10. Page: User interface presentation screen. 11. Data entry page: The page provided by the present invention on the device or television set top browser for entering standard or non-standard information. 12. Data selection page: The page generated by the present invention at the point of sale for the customer to easily select which information to use for the transaction. [0014] In the embodiment of the invention as shown in FIGS. 1 through 8 , there is provided a commerce and transaction platform 10 for use in network platforms having limited user input capabilities, such as interactive television systems or wireless Internet service provider systems. The limitations on consumer input can be inherent, such as where an input device has no keyboard, or can be based on convenience, such as where a binary selection may take a user a few seconds, but a longer field entry may take one or more minutes. The system of the present invention can specifically handle the needs of cable and wireless service providers that have agreements with specific vendors to be able to sell products and/or services to the providers' customers. [0015] I. Holds Preference Data [0016] As shown in FIGS. 1 and 7 , the present invention provides a commerce transaction application system 10 , which can incorporate a subscriber profile management and digital wallet service to serve consumers using a variety of limited input devices. The present invention allows users to store various types of information, including billing and shipping addresses, credit card data, and partner-specific preference data, regardless of type or quantity. User, profile, type or any number of semantics can be used to organize this information in database 24 . [0017] II. Auto Fills Preference Data [0018] a. Data Insertion [0019] The present invention was designed for usability; if a consumer is using a device with restrictive input methods, such as a digital cable set-top box 32 or data capable phone, the invention facilitates the data entry requirements. The invention can insert preference data into the stream of information that is passed between the consumer at 32 , 36 and commercial provider 20 . The invention recognizes markers or tags 22 that commercial partner 20 uses as keys to the customer-entered values or preferences. Since these markers 22 can be agreed upon a priori, the consumer's data is present, and the present invention maintains the customer-specific values for the markers, the values are written to the stream via proxy server 40 as the tags are identified. This is also shown in FIG. 3 . [0020] b. Standard Tags [0021] The present invention can allow for a set of predetermined markers or tags to be used by many commercial partners, given that none of said markers are tags have partner-specific meaning. A specific embodiment of this could be a number of partners and the present invention all conforming to some standard, such as Electronic Commerce Markup Language (ECML). The partner need only notify the present invention through any number of the invention's interfaces that it is a participant in the standard, and the partner can than be fully integrated. As shown in FIG. 6 , vendor 20 can interact with tag database 24 B via servlet 21 using HTTP. The servlet can interact with tag database 24 B using Java Database Connectivity (JDBC). [0022] c. Default Policies [0023] If the information required by the commercial partner is not known, a default entry can be provided to the consumer. For example, if the consumer is ordering a men's dress shirt, and has previously stored credit and identity information in the consumer database, the shirt retailer may send an HTML page having standardized fields (set forth by the network provider and the present invention) for identity and credit information, as well as neck size, sleeve length, collar type and color. Individual tags can be associated with each field such that, when the HTML page is parsed by the application of the present invention, the fields corresponding to identity and credit information are pre-populated into the HTML page, and the remaining fields are left as default values. Default values and/or indicators can be pre-set according to the preferences of the consumer, the commercial partner or the network operator. Dialog types can than be modified and/or pre-set according to preferences and/or default policies. A specific embodiment of a default policy could be to either fill in a class of default values such as marketing opt-in/opt-out options, or simply to fill in nothing. [0024] d. Dialog Modification [0025] The present invention not only can insert preference or choices for certain dialogs, but it can also substitute difficult dialogs for easier ones if the commercial partner and network operator so desire. For example, if the shirt retailer provides text fields for neck size and sleeve length, such dialogs may be difficult to enter for a consumer in a limited input environment without a keyboard. Thus, the consumer may desire that the dialogs be presented in a drop-down menu or radio button format. [0026] III. Interruption of Workflow [0027] If the consumer has stored more than one possible input value (or there are conflicting policies of equal importance), the present invention presents the consumer with a list of selectable options either inline with the page or in an augmented workflow (with the mechanism below), otherwise it automatically fills the appropriate value, rather than cumbersome text areas to make transaction and signup processes more efficient. [0028] FIG. 2 shows a flow diagram of process steps in accordance with one embodiment of the invention. As shown in FIG. 2 , the system can collect any initial information at 50 , and can receive a purchase request 52 from consumer. Next, the proxy server accesses the tag database 54 for the tags associated with the particular vendor involved and fills the information 56 into the vendor page according to data in the consumer database. If further information is required 58 to consummate the transaction, the customer can then be presented with a separate data entry page as at 64 or default values which may or may not require consumer confirmation. Once obtaining any new information at 66 , the database can be updated as at 68 so as to provide even greater efficiencies in future transactions involving the consumer. If no further information is required, yet the user has multiple profile information values for a particular field, for example, the system of the present invention can send a data selection page 60 where the user can select which profile and/or standard information they would like to use, as at 62 . Once all information required for a transaction is presented, the transaction can be consummated as at 69 . As shown in FIG. 8 , once the transaction has occurred, the vendor can send an e-mail confirmation via messaging component 80 , and customer service component 82 can send order confirmation via servlet 83 , accessible via the profile database. [0029] If the consumer has requested content, the network operator can interrupt or augment with additional user interface components the commercial partner's workflow to gather identity or other information from the user. For example, if the consumer is part of a household of five registered purchasers, and the consumer accesses information about toys, the network operator may suspend the consumer's interaction with the commercial partner while determining which profile to invoke for the household. In doing so, the consumer's content requests and the commercial partner's responses can be cached while the identity information is obtained or will be filled after a selection. [0030] Since the present invention does the work of inserting the end consumer's billing and shipping addresses and credit card information, the consumer in one embodiment simply has to select their product and the desired shipping and billing information from outside the commercial partner's interface in order to execute a transaction, which can be automatically chosen as well. [0031] IV. Input Methods [0032] There are a variety of ways of attaining the user's data: [0033] a. Web Page [0034] As shown in FIGS. 1 and 5 , because the client's input device can be limited, the user's profile can be managed via PC 36 using a branded interface 38 on the World Wide Web. The authentication used on the web interface could be the same account information used on the device, allowing for simplified profile management and fewer forgotten passwords. In one embodiment, the user can communicate information to database 24 via servlet 41 using a servlet container. The servlet can interact with profile database 24 A using Java Database Connectivity (JDBC) 42 . It will be appreciated that database 24 can comprise multiple separate databases (for example, 24 A and 24 B in FIGS. 5 through 8 ) or a single database. [0035] b. Interactive Workflow [0036] In a further embodiment of the invention, the unknown information required by the commercial partner can be presented in a separate data entry page for the consumer. Such a page may be desirable where a more difficult data entry process is requested, such as the text of a greeting card, for example. Information requests can be placed in the aforementioned augmented or interrupted workflow as well as a separate area provided by the network operated accessible at any time before possible transactions. [0037] c. Existing Database Import [0038] As shown in FIG. 5 , the present invention can also import data from external databases, such as service provider database 43 . A specific embodiment could be either a batch load as at 45 for a number of accounts from an existing billing system or single account setup from a customer service interface. [0039] d. First Time Transaction Data Entry [0040] The present invention also recognizes when a consumer attempts to use the system does not have an existing profile in the system. When such cases arise, the present invention interrupts workflow (via aforementioned mechanism), and presents augmented workflow for the new consumer to register with the system. A particular embodiment of this is the present invention catching the consumer clicking “checkout” and offering a setup page if the consumer wishes to continue. An additional embodiment is the present invention recognizing that the consumer lacks a profile yet has a default policy registered to not offer registration (opt-out), and the present invention allows the commercial partner workflow to continue. [0041] V. Transaction Recognition [0042] The present invention also interprets appropriate commercial partner documents to determine information that is descriptive or required to consummate a transaction from the partner. The present invention then presents this information to the interactive television, mobile data, or internet consumer in a format which is simple to navigate and complete, and which may be pre-populated with relevant customer data to the extent the data has been obtained. [0043] VI. Tag Registration [0044] a. Introduction [0045] The present invention allows the network provider to expose an interface to the commercial partners for easy integration of standard or custom tags or markers. The present invention allows partners to enter their specific tags or markers through the appropriate protocol plug-in, and match them to internal markers already determined in the system. Through this interface, partners can check what the system is already looking for, what it has the potential to look for, and request new tags or markers to be analyzed. [0046] b. Integration [0047] The present invention provides a solution for commercial partners and network providers who require information and content integration. The present invention not only facilitates this integration, but also provides records of agreement and manages the relationships. The present invention also allows the vendors to maintain their branding and acquire the particular customer information they need, while requiring no more integration than if the vendor had direct access to the customer's browser. Because of this tag matching and modifying procedure, the customer is provided with the look-and-feel intended by the commercial partner, including the page layout, workflow, and custom and non-custom content. [0048] In terms of users, a provider's customer is generally not one person, but instead an entire household. Each household consists of multiple users, and each user may wish to have multiple methods of payment, multiple locations for goods to be shipped to, and multiple preferences that are vendor specific. The present invention accommodates any household type, whether that includes a single user with a single billing and shipping address related to a single credit card, or multiple users, with one or more different addresses per user, and one or more payment types. Furthermore, the present invention enhances the abilities of a roaming user by providing for data entry from a PC, as well as a DTSB or PDA, as shown in FIG. 1 . [0049] c. Mechanism [0050] A specific embodiment of this function can be a web page that displays all known internal HTML tags: CAULDRON_FIRST_NAME, CAULDRON_LAST_NAME, CAULDRON_FULL_NAME. When the partner access the web site, the content developer can register all intended HTML tags to be used or already in use by matching them to the internal tags: CAULDRON_FIRST_NAME & PARTNER_FNAME, CAULDRON_LAST_NAME & PARTNER_LNAME, etc. [0051] d. Motivation [0052] The commercial partner can provide certain field descriptors that depict the information needed from a customer in order to purchase the vendor's goods or services. This information can be provided electronically or “offline” and is stored in a partner transaction or tag database, as shown in FIGS. 1 and 7 , for example. As an example, an airline may need identity and credit information, as well as seating preference, meal preference, and date and time information in order to process a request. Conversely, a shirt retailer may need size and color information in addition to identity and credit information. When such commercial partners register their field descriptor tags with the system of the present invention, they are stored in the partner transaction database. As such, whenever a consumer requests content from a commercial partner or vendor, the partner can provide its generic content page with tags, and the present invention parses the page for tags and inserts consumer values, if known, which correspond to the partner's tags. As shown in FIG. 7 , consumer 32 can request information, which request is processed through proxy server 40 to vendor 20 . Vendor returns content information containing tags, whereby the information is received and parsed by proxy server 40 . In parsing the electronic information, proxy server invokes programming which accesses tags from tag database 24 B and associated consumer information from profile database 24 A to pre-populate the electronic form for the consumer. It will be appreciated that a variety of types of commercial partners are encompassed by the present invention, including merchants of goods and services, content providers, contest operators and other entities who may interact with consumers in the course of conducting commerce and transactions. [0053] e. Standard Tags [0054] In another embodiment, commercial partners need not identify required information prior to involvement in electronic transactions. In such instances, the system of the present invention can parse the electronic pages intended for a consumer to identify fields or tags similar to known tags already stored in the partner transaction database. If the system recognizes common tags, such as those listed in agreed standards like ECML (as discussed above), these tags can be associated with the new commercial partner and stored in the transaction database. The invention can further pull consumer values associated with the particular tags prior to delivering the content page to the consumer. In this way, new commercial partners can be readily integrated into the system of the present invention without previously identifying their tags with the system. Implementation [0055] FIG. 4 identifies one embodiment of a detailed internal code architecture 55 of one implementation in the Java language. This embodiment can handle synchronous HTTP protocol and HTML dialog modification with workflow interruption while using the HTML tag registration, parsing and modification as discussed above. Core Code Components Example Embodiment [0056] The application of one embodiment of the present invention is generally comprised of 6 packages: FlyBuy™.servlet: Core Server objects that exist across all requests FlyBuy™.parser: HTML Parsing classes including 3 rd Party code and adapters. FlyBuy™.state: Request level classes maintained on a per user basis. [0060] FlyBuy™.store: Persistence classes for managing Database interaction. [0061] FlyBuy™.auth: Classes for managing authenticity keys and approvals. [0062] FlyBuy™.action: Handlers for all expected behaviors and required actions of the present invention. Server Startup [0063] flybuy.servlet [0064] On startup, the servlet container loads the FlybuyServlet with the ServletConfig object from the container configuration file. FlybuyServlet then loads its custom configuration file, flybuyConfig.xml, and creates a FlyBuyConfig object (which is a singleton and can be accessed from anywhere). Before finishing, FlybuyServlet instantiates the chosen Authentication scheme for managing authenticity of the client. FlybuyServlet is now ready to receive HttpServletRequest and HttpServletResponse objects from the container. Request Dispatching [0065] flybuy.servlet, flybuy.state, flybuy.action [0066] When the service function is called in FlybuyServlet, the FlybuyServlet must manage two tasks. First, it must request any previously stored session or the creation of a new session depending on whether the client has previously logged in (all sessions, new and old, are managed by the SessionManager). Secondly, the FlybuyServlet must derive the appropriate Action either from internal logic based on what the present application already knows about the client or from what is indicated in a custom request from the client as a result of a system interruption page. Once the Session has been acquired and the appropriate Action is derived and acquired from ActionFactory, FlybuyServlet executes the action and the correct allocated action takes over the remaining service fulfillment. Authentication [0067] flybuy.auth, flybuy.action [0068] Classes wishing to manage authentication must implement the interface. Session keys are stored in secured cookies that are checked by the FlybuyServlet; thus, every request is authenticated. During ServletLoginAction, the Authenticators generate the key that will be used for the duration of the session. For each subsequent request the key is requested from the cookie, and verified by the implemented method in the Authenticator. The only Authenticator included with this release is BasicAuthentication which only checks username and password combinations, and verifies session keys. Session Data [0069] flybuy.state, flybuy.action, flybuy.store [0070] With all requests per user login session, there is an associated Session object. The Session object contains the authentication key for maintaining tight security and any cached HTTP requests and responses that need to be held while the user selects which profiles to use as well as client network connection information. The Session object is also the central point for all data required to manage the request and insert user-defined values into the necessary vendor form fields. [0071] After authenticity of the user has been initially confirmed in ServletLoginAction, the ProfileManager is called upon to gather the entire appropriate vendor and profile data associated to the hostname and user, respectively. The ProfileManager encapsulates all this data into a UserData object, which is returned and maintained in the user's Session object. The UserData object not only maintains the mappings of vendor specific tags to a list of profiles which can have the data to fill the forms, but also a running list of selected profiles, so the user is interrupted as few times as possible. Content Rewriting [0072] flybuy.state, flybuy.action, flybuy.parser [0073] For every request routed through the present application, the Parser and RewritingFilter are instantiated and work together to resolve any fields that may need completion on behalf of the client. If the user has already selected the appropriate data or if there is only one choice, the RewritingFilter automatically fills the data. If there is ambiguity about which profile data to complete the form with, the InterruptAction must be called to present the user with the appropriate options. Handlers [0074] flybuy.action [0075] As stated in Request Dispatching above, the flybuy.action classes are the handlers for every required behavior. System internal logic for deriving the appropriate action is first determined by checking if the session is marked new. If the session is not new, the parameter list of the HTTPServletRequest is checked for an fb_action key, which is an indicator of the submission of an application JSP, and the value is translated into the appropriate action name. If the session is not new, and there is no fb_action in the parameter list, a default action is taken, namely, ServletVendorAction. [0076] Currently there are six flybuy.action classes, each of which extend the AbstractServletAction and are created from the ActionFactory. SessioninitAction is created if the Session object is marked as new, and its job is to store the HTFPServletRequest in the Session, and forward the client to the login.jsp. The login.jsp indicates the next action to take is SessionLoginAction. The SessionLoginAction authenticates the user and gathers the profile and tag data for the user and site, before retrieving the cached HTTPServletRequest and fulfilling it. [0077] ServletVendorAction handles all normal requests routed through FlyBuy, and calls upon the Parser and RewritingFilter objects to check for any forms that may need completion. As mentioned earlier, if there is any choice that user must make for the forms to be filled, an interrupt page must be sent to the client so the user can make his/her choice. Once the Parser and RewritingFilter have determined all the options to be completed by the user, the Vendors response is stored in the Session and a UserDataException with the necessary information is thrown to the ServletVendorAction. The ServletVendorAction then forwards the client to the JSP that presents the options. When the client submits, the InterruptAction is called as per the value of fb_action (embedded in the JSP previously sent) and the choices are then set in the user's Session's UserData object. The InterruptAction then calls the ServletVendorAction with the cached Vendor Response and the process can continue. [0078] The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
An apparatus customizes electronic received information and facilitates electronic transactions with an individual consumer. The apparatus includes a consumer database for storing consumer profiles information corresponding to the individual consumer and a transaction database for storing transaction related information corresponding to individual commercial partners, including target content markers. A first computer program in communication with the databases modifies the electronic information received to include the consumer profile information stored in the consumer database which corresponds to the transaction-related target content markers in the electronic information. A second computer program in communication with the consumer database automatically monitors consumer interaction and automatically monitors consumer interaction and automatically updating the consumer profile data based on the interactions.
6
CROSS-REFERENCES There are no cross-references to nor are there any related applications. FEDERALLY SPONSORED RIGHTS The invention herein was made without any federal sponsorship or contribution. BACKGROUND OF THE INVENTION 1. The Field of the Invention. The field of the invention relates to an improved apparatus for finishing either in mass production or on a custom basis golf wood club head faces. In the golf club art, the term "wood" has come to encompass that class of clubs in which the driver is found, notwithstanding the fact that wood as a manufacturing material may no longer be used. In fact, the art includes heads made of other materials such as plastics, laminates involving wood, fiberglas or graphite composites and cast stainless steel or aluminum under the generic term of golf "wood." The present invention can be utilized to finish any head material. Except as read otherwise in context, the term "wood" as used throughout this application defines the class of club rather than the material. 2. Description of the Prior Art. The prior art is summarized typically by U.S. Pat. Nos. 1,675,437 to Waldron, 4,245,391 and '392 to Hecker, 2,973,581 to Rhodehamel, 3,357,219 to Hunter, 3,439,429 to Sundstrom and 4,094,072 to Erb. Various devices are shown which only treat of adjusting lie and loft and calibrating them in golf clubs, whether woods or irons, by imparting a twist or bend to the shaft. '437 to Waldron is of interest but ignores, as does the rest of the art, the significance of the interaction of the six major factors in golf club head construction, repair or adjustment: loft, lie, face angle, face progression, bulge (curvature of face horizontally) and roll (curvature of face vertically) and that to do so can never produce a satisfactory club, whether newly made or adjusted. '437 appears to teach a device which will apply or correct loft and apply some bulge to a golf wood but one may infer that the art as of 1927 neither understood the importance of the variable nature of bulge and roll as factors nor the relationships among all the factors. It is nevertheless true that automatic wood golf head turning machines which roughly shape laminated or solid head blocks are well-known. However, face finishing remains, essentially a manual art. The present invention permits disposition of all six factors in golf wood construction and their interrelationship all at once and represents a revolutionary advance in the art. The art as practiced is generally set forth in a certain text book, Maltby; Golf Club Design, Fitting, Alteration and Repair (1974; Newark, Ohio, Faultless Sports Div.) An abstract of pp. 137 through 161 is submitted herewith as an appendix on the assumption that the text because of its apparent limited distribution may not be part of the archives of the Office. It is requested that the appendix be filed with the application. Further, the appendix is submitted as a reference but no claim is made by your applicant as to any right to copy the materials therein contained other than for the purpose of this submission. The terminology as used and defined in the text is adopted here as acceptable in the art and followed as closely as possible for the purposes of this application. The six factors in wood head design and production interact with each other and present problems of many kinds to practitioners of the golf wood facing art because no ready means has been available to treat all of them simultaneously. The factors are defined in detail below as necessary for understanding. (Club head weight and shaft flexibility not being pertinent to this application are not considered hereunder). The artisan frequently finds that changing one factor can inadvertently cause changes in another and that simultaneous coordination of all factors can be difficult to achieve. Until now, golf wood face production, repair, or alteration has been a highly skilled manual and judgmental art, requiring special gauges, jigs, templates and limited purpose fixtures as well as especially designed finishing equipment useful to the artisan. None of these combines the flexible and novel features of the present invention which solves all at one time in cooperation with each other and interactively the six major factors enumerated above with great accuracy with a low level of manual skill required by the user who can accomplish face changes without error or ruining his work. A right or left handed club can be accommodated by the present invention and it will be obvious to one skilled in the art that the actual operation of wood face finishing can be automated by means well-known in the machinery arts. SUMMARY OF THE INVENTION The invention described herein is summarized as a boot shaped base with a planar top upon which is mounted a facing assembly with pivoting, adjusting and cutting means for accurately and automatically shaping a golf wood face in 3 dimensions simultaneously. The assembly includes a variable speed, motor driven shaping cutter subassembly which will produce any required bluge or roll and at the same time produce or correct for any defined lie, loft, face angle or reduced face progression, by means of a feedable holder mechanism which holds the golf head (and club shaft) in a defined attitude, face to cutter, during operation so that the face may be shaped continuously by a cutter mounted on a pivotable assembly which moves the cutter against the face simultaneously horizontally and verticallly. An object of the invention is to provide a simple method and apparatus by which a golf wood club regardless of its head material construction can be automatically finished or altered to provide any defined roll, bulge, face angle, lie, loft and reduced head progression, and to provide a method and device by which a golf wood can be customized in its face to correct for the idiosyncratic golf swing of an individual golfer thereby enabling such a person to hit a golf ball in a desired directions, as for example by eliminating through club face shaping a tendency to hook or slice. A further object of the invention is to provide to the golf wood repairer or constructor an automatic, machine operated means and method by which a golf wood face can be repaired, corrected or constructed so as to duplicate any desired roll, bulge, face angle, lie, loft and head progression or any combination of these factors as defined by any manufacturer, professional or player or to induce interactive corrections in the face to compensate for aberrations of swing or grip. A further object of the invention is to enable a person of marginal manual skill to perform the work of a highly skilled golf wood maker or repairer with a minimum of training by use of the methods and devices of the invention. Other objects, advantages and features of the present invention will be apparent to those skilled in the art from the following description taken in conjunction with the accompanying drawings. DESCRIPTION OF DRAWINGS The present invention may be better understood by reference to the drawings wherein thirteen (13) figures are shown on six (6) sheets. The numbers shown on the drawings for the various parts of the invention are consistent throughout so that a number indicating a part in one drawing will indicate the same part in another drawing. FIG. 1a is a front view of a golf wood club head, showing the face. FIG. 1b is a side view of the head as viewed from the shank. FIG. 1c is a plan view of the head. FIG. 1d is a plan view of the head showing an open face angle. FIG. 1e is a plan view showing a zero, or square, face angle and FIG. 1f shows a plan view with a closed face angle. FIG. 2 is a perspective view of the apparatus of the invention with certain cut-a-ways to enhance clarity. FIG. 3 shows the face angle adjustment mechanism prior to shaping. FIG. 4 shows how loft is induced. FIG. 5 shows the operation of roll shaping as a separate operation after desired loft, face angle and face progression have been defined. FIG. 6 shows the operation of bulge shaping which can be accomplished in conjunction with roll shaping or separately. FIG. 7 shows how lie is adjusted and provides an end view of the head holder mechanism and FIG. 8 shows a perspective view of certain interactive holder mechanism members as they pertain to loft adjustment. It is to be noted in FIG. 8 that the loft locking knob and loft index (both hereinafter described) are reversed in position from how they would appear on an actual holder for the purposes of clarity. DESCRIPTION OF THE PREFERRED EMBODIMENTS The preferred embodiments are best described and understood by describing the various parts of the apparatus and its devices and their interrelationship and how the repairer or constructor, utilizing the apparatus of the present invention goes about making, altering or repairing a golf wood head (A), which has a face (B), a face insert (C), face grooves (D), a sweet spot (E), a crown (F), a heel (G), a toe (H), a sole (J), covered by a sole plate (K), a shank or hosel (L), all attached to a shaft (M), the wood having or requiring a defined angular lie (N), loft (P), face angle (Y), face progression (R), bulge (T) and roll (S). The apparatus (10) comprises a base member (12) in the shape of a boot having a planar top (121) which is at a right angle with the boot sides (122) the boot being mounted by means of base mounting lugs (123) to a work surface (not shown) which may be a table or a pedestal. Affixed to the planar top and generally parallel thereto is a pivotable universal facing assembly (14) which is comprised of a variable speed, motor driven cutter sub-assembly (20) to shape the wood's face, a hand fed club head holder mechanism (22) for lie compensation, loft and face angle adjustment and reduction of face progression, a head clamp subassembly (24) to hold the head in a defined orientation, a holder height adjustment subassembly (26) to bring the face generally in plane with the cutter, and a compound shaper subassembly (28) with a roll shaper yoke (280) and a horizontally disposed bulge swivel plate (290) which permit together limited pivoting in both the horizontal and vertical planes simultaneously, see FIGS. 2, 5 and 6, to create a defined bulge and roll. The variability of speed as mentioned above is useful with regard to the materials of the face being shaped. For example, using a speed of 1500 to 1800 surface feet per minute with a 50 grit emery drum sander proved adequate for wood or laminates thereof. Adjustment of speed downward for harder materials, such as graphite, was indicated as is the use of a fluted metal cutter in lieu of emeries of different grit sizes. With stainless steel materials, even slower speeds, finer hardened metal cutters and very light cuts are required as is the application of a coolant during facing. I. The Cutter Subassembly (20) The cutter subassembly (see FIG. 2) comprises a motor (201) mounted upright, shaft down (or alternatively up; not shown) with an exposed end (not shown) thereof having mounted thereon a first variable motor drive sheave (202) attached to a drive belt (203). The motor is rigidly affixed to a rectangular upright motor mount (204) which has at its extremity at a right angle thereto a motor mount base plate (205) bolted by motor base bolts (206) to a flat (207) milled in the forward portion (281) of the shaper yoke (280). Aft of the motor, bolted by tensioning bolts (208) through parallel tensioning slots (now shown) to hold the belt under tension and mounted at a right angle to the flat is an upright cutter stand (209) having a free end portion on which is formed a cutter journal box (210). The journal box holds encasingly a cutter shaft (211) whose longitudinal axis is perpendicular to the flat, the cutter shaft's inferior end having mounted thereto a second, variable sheave (212) responsive to the first sheave which is driven by the belt and whose superior end holds a drum shaped cutter (213) for shaping the club head as hereinafter described. The cutter subassembly, being an integral part of the roll shaper yolk, moves with it. II. The club head holder mechanism (22) The holder mechanism comprises a descending stack of cooperative, generally rectangular plate members (See FIGS. 3, 4, 7 and 8), the topmost of which is a railbed plate member (221) having disposed centrally beginning flush with the cutterside edge thereof on its upper face a pair of rails (222) parallel to each other a defined distance apart and of defined length for receiving the sole plate portion (K) of the head. The railbed is fitted at its cutterside end with a male loft hinge (223) bolted to its lower face. Fitted into the male loft hinge is a female loft hinge (223a) which is bolted to the upper face of a feed plate member (224) whereby the railbed plate can pivot upon the loft hinges by means of a through bolt (225) guidingly upward between a pair of arctuate guide limbs (226) bolted by means of limb bolts (227) to the outer sides of the feed plate, the arcs of the limbs curving cutterward. Each limb has cut therethrough an arctuate limb slot (228) which is of a radius concentric to the arc. Fitted in and passing through one of the limb slots is a loft locking, non-rotatable carriage bolt (229) which passes through the rail plate and the other limb slot, holding the rail plate slidingly and snugly to the limbs and lockingly when a knurled nut (229a) is tightened thereagainst to lock the railbed plate to the limbs at the loft angle (P) defined by loft degree graduations (230) inscribed on one of the limbs and defined by the angular displacement along a radius defined by the bolt holding the loft hinges as center and the limb slot as a circumference and measured by a fixed index mark scribed on the head of the non-rotatable loft locking bolt. As an alternative, the club number may be marked on the graduated limb, typically from 1 to 7, at appropriate defined degree points on the graduated scale, typically beginning at "1" for a driver or a number one wood. In this way, loft may be referred directly to the number of the club locked in the holder and adjusted fractionally upward relative to the club number. The feed plate member has milled into its lower face a beveled channel (231) disposed centrally and longitudinally beginning at the cutterside end of the feed plate and extending through to its rearmost end. The channel is milled such that it snugly and slidingly fits over a raised bevel (232) formed on the upper surface of a rectangular feed guide member (233). The feed plate/railbed combination and feed guid members are held together by means of a shoulder portion (234) of a shoulder bolt which slips through the feed plate and feed guide and which is through bolted to a face angle plate member (235) under the feed guide such that the railbed, feed plate and feed guide pivot together over the face angle plate which has graduations (236) marked thereon contiguous to an arctuate face angle slot (237) milled in the face angle plate's rearmost end and is calibrated from the through bolt as the center of a radius and the slot as a circumference for setting biasingly the face angle, left (238) or right (239) around a zero point (240) as indicated by an index (241; not visible) scribed centrally and vertically in the rear end of the feed guide plate. A knurled lock knob (242) attached to a face angle locking screw (242a) passes through the feed guide and locks it and the railbed, feed plate and guide appended thereto, to the face angle plate biasingly at a defined face angle as indicated by the markings. See FIG. 3. When set at zero (Yo) the outer sides of the rail bed, feed and guide and face angle plates are in alignment squarely with each other imparting a square face to the head. See FIG. 3. The head clamp subassembly (see FIGS. 3 & 4) is bolted by means of clamp assembly bracket bolts (243) to the rear portion of the upper surface of the railbed plate. The head clamp subassembly consists of an upright-standing clamp bracket (244) having a bracket base (245) and an upper, threaded sleeve (246) overhanging the railbed and directed downward toward and over the rails such that the central longitudinal axis of the sleeve is at a right angle to the railbed. Threadingly installed in the sleeve is a clamping screw (247) whose upper end is fitted with a knurled tightening knob (248) and whose railside end has a shoe (249), typically of nylon, to clamp the golf head snugly to the railbed when installed. Bolted on the upper face of the feed plate's rear portion is the feed mechanism (25) consisting of a keeper block (250) which receives rotably a feed screw (251) which passes threadingly through a threaded feeder block (252) bolted to the upper surface of the feed guide such that when a feed knob (253) at the outer end of the feed screw is rotated the feed screw urges the railbed member with head clamp subassembly attached and feed plate member toward or away from the cutter while maintaining their loft orientation and face angle bias, if any, relative to the face angle plate. Height adjustment (26) of the holder mechanism to bring the club face into alignment with the cutter's surface prior to operation is accomplished by means of a height adjustment screw (261) which slips rotably through upper (281) and lower (282) bulge swivel keeper plates and threadingly through a forward bulge plate spacer (262) located between the bulge plate keepers, said height adjustment screw turning freely in a recessed fixed washer (263) retained by a washer retaining plate (264) attached to the underface of the angle plate just aft of the shoulder bolt by retaining screws (265). As the height screw is turned by a height adjustment knob (266) at its free end, the holder assembly is raised or lowered in a plane parallel to the plane of the milled flat upon which the cutter subassembly rests, vertically on guide posts (267) disposed forward and aft of the height adjusting screw. III. The compound shaper subassembly (28) The compound shaper subassembly comprises, as viewed in the horizontal plane, (see FIG. 6), a "U" shaped shaper yoke (280) whose arm portions (279) are "Z" shaped as viewed in the vertical plane (see FIG. 5), the base of the "U" carrying the milled flat (207) and the cutter subassembly mounted thereon. The arms are disposed between inner (282) and outer (283) roll plates which have disposed horizontally and linearly therealong in their top portions (284) a multiplicity of holes (285) parallel to the top of each roll plate a defined distance apart, typically a half inch, or in lieu thereof an elongated slot of equivalent length from first hole to last hole through which are inserted and held counter-oppositely roll radius locator pivot pins (286) which define the center of the radius (Sr) of the roll, which typically is between 9 and 15 inches from either pin to the longitudinal center of the cutter's surface (287) as a circumference. The roll plates are bolted (288) together through (288) roll plate spacers (289) into the horizontal bulge swivel plate (290). The bulge swivel plate is fitted snugly and pivotably between the upper (291) and lower (292) bulge swivel keepers which are separated by a rear shaper spacer (293) the same thickness as the forward bulge plate spacer (262) and the bulge swivel plate such that the bulge plate is held snugly and pivotably between the bulge plate keepers. Disposed centrally, longitudinally and linearly rearward (294) on the upper bulge keeper and bored therethrough and through the bulge swivel plate and lower bulge keeper is a multiplicity of evenly spaced holes (295) a defined distance apart, typically a half inch, or in lieu thereof an elongated slot of equivalent length from first hole to last hole through which is inserted and held a bulge radius locator pin (296) which defines the center of the radius (Tr) of the bulge, which is typically between 9 and 15 inches from the bulge pin to the longitudinal center of the cutter's surface as a circumference. IV. Compensating for improper lie. (See FIG. 1a) The lie of the wood is defined as an angle (N) formed by the intersection of a theoretical ground, or coincident sole, plane (U) which is tangent to the curve of the club sole (J) and perpendicular to a vertical line (O) through the center, or sweet spot (E), of the club face and the center line of the main longitudinal axis (W) of the hosel (L) and shaft (M). Player stance in addressing a golf ball is typically accommodated to the lie since the club is designed by the manufacturer to be gripped such that the sole plane coincides with and is parallel to the ground plane, i.e. the ground adjacent to the ball when the club is properly held. This angle, typically 55° in a driver and by one-half to one degree increments upward starting with a No. 2 wood, is a fixed function of club head manufacture and forms the referent from which at least roll, bulge, loft and face angle are determined. It occasionally occurs, the desires of teaching professionals notwithstanding, that certain players in addressing the ball cause the sole plane to become out of parallel with the ground plane thereby inducing an error in an otherwise correctly formed face and resultant continual bad shots. Factors such club length (not discussed) and physique of the player tend to cause the player to move back from the ball and to cause the sole plane to rotate in a heel-downward direction toward the player. (See FIG. 7). It is, therefore, desirable, in these cases, infrequent though they may be, that the lie angle, which is, in fact, a manufacturing constant, be compensated for in setting up the club head for refacing by revolving the perpendicular line (O) through the sweet spot and its defined sole tangent toward the heel as in FIG. 7 and refacing the club according to the new referent. Measurement with a weighted shaft protractor of a kind frequently found in "pro" or repair shops determines the correction, where the incurable lie defect can be measured in the field and may be duplicated on the protractor by setting the club head, sole down, on the rails (222) face squarely toward the motor and moving the shaft downward as in FIG. 7. If unconventional lie is not a problem, placing the sole on the rails such that the lie angle equals the manufacturer's lie specification is accomplished by setting the sole plate on the rails equidistantly, which should duplicate the manufactured angle. This can readily be verified with the protractor as hereinbefore described. It is neither desirable to bend nor twist the shaft, as prompted by the prior art, to accomplish a lie angle change. Damage to the hosel may ensure and the result will leave the player's swing susceptible other and further faults. Experience has shown that refacing the club with lie compensation built-in as herein described accomplishes the desired correction without distorting the club. Having established the referent lie, the head is clamped firmly to the rails (222) by the head clamp subassembly (24). V. Setting or adjusting the loft. See FIG. 1b Loft (P) is the rake of the club face and is defined as the angle of the plane of the club face (V) through the sweet spot which intersects with a line (Q) on a plane parallel to the longitudinal center line of the shaft (W) and passing through the leading edge of the club face in line of flight. Dynamically, loft determines the angle of flight as the ball leaves the ground. It is well-known in the golfer's art that the greater the loft the higher a trajectory the ball will described in flight, decreasing the linear distance the shot will travel in so doing. Certain conditions of terrain and stance oftentimes make it difficult for a player to make a fairway wood shot; that is, without the benefit of a tee. This is also occasioned by a player's idiosyncratic swing with an otherwise satisfactory club which creates the illusion that the club does not have a sufficient loft. Merely selecting a wood as manufactured with a greater pre-calculated loft inevitably causes an undesirable sacrifice in distance. It has been found in the art that a small increase in defined loft angle in a wood used by a particular player can have a dramatic effect on his ability to make a fairway shot which achieves satisfactory distance. See FIG. 8. To set or adjust the loft according to the present invention, the loft locking screw (229) is loosened and the railbed (221) and club are pivoted upward until the defined amount of loft is found on the graduated limb (226) opposite the index and the loft locking screw is tightened snugly by the knob (229a). VI. Setting or adjusting the face angle See FIGS. 1d-f. Face angle (Y) is defined by the intersection of the leading edge plane (Q) and a line passing through the sweet spot horizontally (e.g. Qs). Typically the face is manufactured with a defined 2° open face angle (Ys); that is, the sweet spot horizontal line (Qs) is rotated away from the line of flight to provide a deliberate but small slice. Slice occurs as the ball fades away from the player at the end of the ball's trajectory relative to the theoretical line of flight (X). An intractable tendency to slice may be compensated for by teaching a player through hand grip adjustment to reduce the face angle (Yo) to zero where the horizontal (Qs) and the edge plane are parallel or beyond. The technique is called "closing the face". Oppositely, a tendency to hook or pull the ball toward the player at the end of its trajectory relative to the theoretical line of flight, i.e. with the face closed (Qh), may be corrected for by opening the face and changing the face angle oppositely (Yh). As is frequently desirable, any face angle can be built into the clubhead to make the compensation for hook or slice a club function independent of grip. This is particularly useful where the player's grip has developed a set which can not be overcome by teaching. The face angle set screw (242) is loosened and the railbed, feed guide combination is rotated according to the graduations (236) on the angle plate from zero (Yo) in either direction to the desired number of degrees open (Ys) or closed (Yh) and locked. The determination of face angle is empirical and calculated from information supplied by and observation of the player shooting. VII. Setting or adjusting roll (vertical face curvature) See FIG. 1b. Roll (S) is the vertical face curvature from sole to crown and is truly circular. Radii (Sr) of 9 to 15 inches are typical. A main function of roll is to affect the quality of loft and attendant distance of the shot. After the lie adjustment, face angle and loft are set in the holder mechanism as heretofore described, the defined roll radius (Sr) is selected by insertion of the first roll pivot pin (286) through the defined radius roll passageway (285), or a defined distance along the slot, from one of the inside roll plates (282) outward (283). The second roll pivot pin is then set in the matching locator passageway, or position in the slot in the other roll plates from the inside out such that the yoke pivots freely vertically. (See FIG. 2) The defined roll is ready for shaping as hereinafter described. VI. Setting or adjusting bulge (horizontal face curvature) Bulge is the horizontal face curvature from toe to heel and is also truly circular. See FIG. 1c. Radii (Tr) of 9 to 15 inches are typical. A main function of bugle is to compensate for a swing which marginally fails to bring the sweet spot into contact with the ball, inherently a difficult maneuver, thereby eliminating a minor tendency to slice or hook and to increase, in combination with roll, the transfer of maximum power from face to ball. The defined bulge radius (Tr) is selected by insertion of the bulge pivot pin (296) in the defined radius passage (295) or a defined distance along the bulge radius slot disposed on the upper bulge swivel keeper (291), through its matching passageway in the swivel plate (290) and through a similar passageway in the lower bulge swivel keeper (292) to establish the bulge radius (297). The face is then shaped as hereinafter described. IX. Reducing the face progression See FIG. 1b. Face progresssion (R) is the horizontal distance between vertical plane (Q) which passes through the leading edge of the club face, and is parallel to the plane through the central axis of the shaft (W) also perpendicular to the ground plane and bisecting the shaft from hosel toward the toe. Dynamically, face progression is significant at the instant the club face impacts with the ball. This occurs by design in advance of the pendular golf swing reaching its bottom. Idiosyncratically, a large face progression may decrease the player's control of a wood shot by magnifying the hook or slice. Since face progression reduction is best accomplished during operation of the apparatus a description of its method of change is set forth therewith below. X. Operation of the universal facing machine; face progression reduction After a defined lie is set, the club head is firmly clamped to the rails on the railbed. A defined loft and face angle are then set as indicated by each graduated scale appropriate thereto and the holder plate members are locked into position as heretofore described. Roll radius and bulge radius are then selected by the defined location of the pivot pins. By means of the height adjustment subassembly the sweet spot is brought generally into alignment with the center of the cutter and the club head is urged toward the cutter by the feed screw subassembly (25) until cutter and clubhead are almost in contact. The motor is started and the shaping process is begun by the artisan urging the face against the cutter and moving the yoke radially and vertically upward or downward (See FIG. 5) and horizontally in passes across the face while simultaneously swiveling the yoke radially on the bulge plate from side to side (FIG. 6). If a new face insert has been installed and, being somewhat oversize, protrudes outward of the face, the feed screw must be urged forward in successive steps until the insert is shaped flush with the face. Thereafter the balance of the shaping on the club face itself may proceed as herein described. The side to side and up and down passes create the defined lie, loft, and face angle in combination with the defined roll and bulge simultaneously. The operation is complete when the artisan determines that no more cutting is taking plate in any direction. By urging the feed screw toward the cutter, as an additional step, all components will be preserved relative to each other and face progression may be reduced by continuous cutting to a defined distance until cutting is complete. The face is then grooved with a saw or similar cutting device. Varnishing the club head and applying whipping over the junction between hosel and shaft complete the process. Since many modifications, variations and changes in detail may be made to the presently described embodiments, it is intended that all matter in the foregoing description and accompanying drawings be interpreted as illustrative and not by way of limitation.
A golf club wood head facing machine is disclosed which comprises a base with a planar top upon which is mounted a face cutting assembly with a movable motor driven cutter which can be pivoted simultaneously both horizontally and vertically to shape the head's face to give it a defined bulge and roll. In addition thereto there is mounted on the assembly a club head holding mechanism consisting of a downwardly directed clamp above a railbed having two parallel rails mounted thereon to permit the seating and clamping of the golf head to be faced. The holder provides loft, face angle, face progression and lie adjustment means, as well as feed means to urge the club face forward against the cutter. Provision is also made to raise or lower the holder so as to locate the club face against the cutter. A method for finishing club head faces is also disclosed which uses the apparatus of the invention and consists of the steps of clamping the golf wood head face to cutter, setting a defined lie on the railbed, clamping the wood to the holder, setting a defined loft by means of the loft setting assembly, setting a defined face angle by means of the face angle subassembly, setting a defined bulge radius; setting a defined roll radius, turning on the machine, adjusting the height of the center of the wood face with the cutter, urging the wood face against the cutter, and shaping the face horizontally and vertically simultaneously.
1
CROSS REFERENCES TO RELATED APPLICATIONS This is a continuation of application Ser. No. 10/882,327 filed 02 Jul. 2004 now U.S. Pat. No. 6,995,939, which is a continuation of application Ser. No. 09/694,372 filed 24 Oct. 2000 now U.S. Pat. No. 6,771,449, the contents of which are incorporated herein by reference. FIELD OF THE INVENTION The present invention relates to a falling sensor, which detects a falling state of a subject and the information processing device which uses the falling sensor, especially to the technology of preparing operation for a shock at the end of the falling and enhancing a shock resistance by such preparation for the shock. BACKGROUND OF THE INVENTION A magnetic disk drive is known as an information processing device, during a falling, which can perform an operation for receiving a shock at the end of the falling and which can improve a shock resistance. In conventional arts, there is a magnetic disk drive provided with a protection function, which can protect itself from data loss or off tracks by detecting a vibration and so on with an accelerometer, by interrupting writing operation before data are written at an off-track position. However, this protection function is not so effective as to alleviate a collision shock that derives from a free falling of the magnetic disk drive. An acceleration of the free falling is only one gravity. One gravity is not enough for such prior sensor to activate the protection function that the prior sensor can start to act with two to ten times of gravity. And if the protection function would not start, magnetic heads be still on magnetic disks, which would cause severe physical damage on the magnetic disks. Therefore, in the present technique when magnetic disk drives are given with shocks while magnetic heads are positioned on the magnetic disks, damage tolerance depends simply on a strength of the magnetic heads and the magnetic disks. While there are magnetic disk drives having accelerometer devices to detect falling state, there are other magnetic disk drives having a simple-structure sensor without complicated electronic circuits. As an example of such simple structure, JP-A-8-29450 discloses a magnetic disk drive, which is provided with a status sensor having a conductive sphere that is sealed within a cavity in order to detect whether the magnetic disk drive is in unstable state, and before shocks attack the drive which can prepare a countermeasure operation preventing erroneous operation. In a conventional art, a shock-detecting sensor is activated immediately after the shock is incurred at the end of the falling of a magnetic disk drive. Instantaneous shock-avoiding operation of such drive as an interruption of read/write operation with data to magnetic disk media can minimize damages to some extent. Regarding to the physical damage by the clash of magnetic heads and so on to a surface of the magnetic disk media, which is caused by a vertical shock to the surface of the magnetic disks, the activation of the sensor incurred after the shock cannot avoid such vertical damage because there is not enough time for the magnetic heads to move from a position on the media to an outside position of the media. Therefore, the prevention of the damage depended on the strength of the magnetic heads and the magnetic disks. The method of detecting the falling by an acceleration sensor device requires an expensive high-sensitivity analog output sensor. This kind of a sensor is so vulnerable to the erroneous operation with noise that a vector arithmetic processing is inevitable. And it needs complicated electric circuits for the erroneous operation and additional amplifying circuits. The JP-A-8-29450 discloses a status sensor having a sphere sealed within a cavity. At a free-falling state with zero initial speed, the sphere is adhered to a wall surface of the cavity, therefore the falling state cannot be detected. As the sphere can travel inside the cavity freely, the falling state cannot be accurately detected. The present invention objects to offer a simple-structure sensor which can sense falling including a free falling using a simple method. The present invention also offers to improve a shock tolerance of a magnetic disk drive or an information processing device by mounting the sensor on them. The present invention also offers an information processing device having this sensor, which performs during a falling anti-shock operation for the end of the falling, for example, a magnetic disk drive moving or evacuating magnetic heads from surface of magnetic disk media, or another information processing device having such magnetic disk drive. They have high shock tolerance because of enabling magnetic heads to evacuate from the surface of the magnetic disk media, while the magnetic disk drive or the information processing device goes into falling state before the end of the falling. SUMMARY OF THE INVENTION The present invention shows to achieve above described objects, as the information processing device which performs during the falling a shock-resistant operation for the shock occurred at the end of the falling, a magnetic disk drive or a information processing device built in with the magnetic disk drive. The magnetic disk drive is provided with a mechanism which can evacuate magnetic heads performing read or write operation to magnetic disk, from the surface of the magnetic disk and have a falling detecting sensor (hereafter called a falling sensor). The falling sensor is provided with a conductive weight, a flexible elastic member which can be deflected by the conductive weight with gravity, and a conductive member arranged to contact or not to contact freely with the conductive weight that contacts with the conductive member when the flexible elastic member is deflected. The falling sensor may be built into the magnetic disk drive which is built into the information processing device, or may be built into the information processing device together with the magnetic disk drive. The information processing device may be these, a mobile PC, a notebook computer, portable terminals, etc. When the magnetic disk drive falls, to which the present invention is applied, the falling sensor goes into no-gravity state and detects the falling because the gravity working to the weight is reduced to zero by the falling, and because the weight apart from the conductive member. On detecting the falling, the drive activates an evacuating operation that an evacuating structure evacuates the magnetic heads from the surface of the magnetic disk media. As for the falling sensor arranged to the magnetic disk drive or to the information processing device built in with the magnetic disk drive, to make the conductive member into cylindrical, to which the weight can contact to an inner side of the cylindrical conductive member, brings freedom in a direction for sensing the falling. As for the falling sensor arranged to the magnetic disk drive or to the information processing device built in with the magnetic disk drive, if one of the conductive member and the conductive weight is made with magnet and the other is made with ferromagnetic material, the contacting state can be more stabilized. If a pair of the falling sensors arranged to the magnetic disk drive or the information processing, and if the elastic members of the falling sensors attached respectively to the directions crossing each other on a same plane, a falling can be detected more reliably regardless of declinations of the magnetic disk drive. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a drawing illustrating the outline of the magnetic disk drive of the preferred embodiment of the present invention. FIG. 2 is a drawing illustrating a first example of a structure of a falling sensor using a flexible beam. FIG. 3 is a drawing illustrating a second example of the structure of the falling sensor using the flexible beam. FIG. 4 is a drawing illustrating a third example of the structure of the falling sensor using two beams. FIG. 5 is a drawing illustrating a fourth example of the structure of the falling sensor using magnetism. FIG. 6 is a drawing illustrating the relations between falling time and falling distance. FIG. 7 is a flow chart illustrating an algorithm of detecting falling state. FIG. 8 is a drawing illustrating the relation between a first example of the output of the falling sensor and the movement of the sensor during free falling. FIG. 9 is a drawing illustrating a second example of the output of the falling sensor during a free falling. FIG. 10 is a drawing illustrating an example of the outline of the magnetic disk drive of another preferred embodiment of the present invention. FIG. 11 is a drawing illustrating the outline of the information processing device built in with the falling sensor and the magnetic disk drive of the present invention. FIG. 12 is a drawing illustrating an outline of the information processing device built in with the falling sensor and the magnetic disk drive of another preferred embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred embodiments of the present invention are described referring to FIG. 1 to FIG. 10 . FIG. 1 is a drawing showing the outline of the magnetic disk drive of the preferred embodiment of the present invention. FIG. 2 to FIG. 5 are the drawings illustrating the examples of the structures of the falling sensors 8 . FIG. 6 is a graph showing the relation between the falling time and the falling distance and FIG. 7 is a flowchart showing the algorithm of detecting falling state. FIG. 8 and FIG. 9 are the examples of the output of the sensors. FIG. 10 is a drawing showing the outline of the magnetic disk drive of another preferred embodiment of the present invention. As shown in FIG. 1 , the magnetic disk drive to which present invention is applied, is provided with at least one magnetic disk 1 for recording data, a motor to rotate the magnetic disk 1 , a base 2 to fix the motor on itself, a magnetic head 3 which reads data from or which writes data to the magnetic disk 1 , a carriage 4 supporting the magnetic head 3 , a coil 5 attached to the carriage 4 for transferring the magnetic head 3 to any positions on the magnetic disk 1 , a voice coil motor 6 forming a magnetic circuit to put the coil 5 between the pole pieces of the magnetic circuit, a ramp 7 for evacuating the magnetic head 3 to the outside of the magnetic disk 1 , and a falling sensor 8 attached to the base 2 . A falling sensor of the present invention attached to the magnetic disk drive has a structure as illustrated in FIG. 2 , which comprises, a conductive weight 10 is attached to the edge of a conductive flexible beam 9 , the flexible beam 9 is bent by the conductive weight 10 , the weight 10 contacts a conductive wall 11 , and a contacted point gives a conduct between the weight 10 and the wall 11 . A component 19 is a housing. When the magnetic disk drive, wherein the conductive weight 10 and the conductive wall 11 are in contact state, falls in the vertical direction of the wall 11 , the deflection of the flexible beam 9 by the weight of the weight 10 disappears by zero gravity state, and the weight 10 moves apart from the wall 11 . The falling is detected by the interruption of the conduction between the weight 10 and the wall 11 . The weight 10 can be placed at other positions than the edge of the conductive flexible beam 9 . FIG. 3 shows a second configuration of the falling sensor in preferred embodiment of the present invention. This falling sensor is provided with a conductive flexible beam 9 of the cylindrical shape and a conductive wall 11 of a tubular shape. At the center of the cross section of the conductive wall 11 , a conductive flexible beam 9 is fixed and electrically-isolated with the conductive wall 11 . Adopted such a shape, the sensor can keep better conductivity and its stability, which results in less change of contact pressure at the contact point while the magnetic disk drive set with the sensor is held on a slightly-inclined plane from a standard plane, for example, while the magnetic disk drive is held on a slightly-inclined plane from a horizontal plane. Compared to the sensors having the shapes of the rectangular cross sections of the flexible beam or the flat walls, the falling sensor of that structure has better stability in contact pressure and keeps conductivity in more stable. Therefore, the flexible beam 9 can be realized by not only a cylinder but also by one or more members of springs, rectangular columns, or plates which can be replaceable. The position of the weight is not limited to the edge of the beam. FIG. 4 shows a third configuration of preferred embodiment of the present invention. The conductive flexible beam 9 is arranged to the center-of the cross section of the conductive wall 11 being insulated from the conductive wall 11 . This falling sensor holds the weight 10 at the middle portion of the flexible beam 9 , and both ends of the conductive flexible beam 9 are fixed with insulation to the conductive wall 11 . In this case, the falling sensor can be also realized with the holding flexible beam of not only a cylinder but also one or more members of springs, rectangular columns, or plates which can replace the cylinder. FIG. 5 shows a fourth configuration of preferred embodiment of the present invention. This falling sensor uses a ferromagnetic material for a conductive wall 13 (a conductive ferromagnetic wall 13 ) and a magnet for a weight 12 (a conductive magnet weight 12 ). Herewith a stability of contact in normal state can be held higher and a strength of a holding part of the weight can be increased. This relative relation can be reversed by forming the conductive wall 13 with a magnet. The position of the weight and the method of holding the weight are similar to those of the configurations described above. FIG. 6 shows the relations between the falling distance and the falling time at the free falling. For example, it takes about 200 ms in the falling time for the falling from the height of 20 cm. FIG. 7 shows the relations between the output of the falling sensor and the movement of the magnetic disk drive. In case the output of the falling sensor indicates the falling state when the acceleration that has a threshold level determined by the difference between a force acted on the weight which tries to recover the bend of the flexible beam 9 , and the gravity acted on the weight 12 , makes the weight 12 isolate from the wall 13 , in other words, when the falling sensor detects the falling state, the magnetic disk drive or the system confirms whether the falling state is continued for a predetermined time period in order to avoid an erroneous operation that considers low frequency vibration for a falling. If the output indicating the falling state is continue, the magnetic head is evacuated from the surface of the magnetic disk medium. Then, the evacuation continues for a while to wait residual vibrations after getting shock are settled, and then the falling sensor restarts the monitoring. For example, if it takes 50 ms for the sensor to generate the response of the falling state with the state exceeding a certain acceleration level, 100 ms for the decision of the continuance of the falling state and 50 ms for the evacuation of the magnetic head from the surface of the magnetic disk, the total of those will be 200 ms. The damage on the magnetic disk media can be avoided if it falls from the 20 cm height or more. FIG. 8 is a first example showing an output of free falling of the falling sensor. The detail is: an output 14 is obtained from a general-purpose acceleration sensor, which showes the falling state; an output 15 is obtained from the falling sensor of present invention. The falling height is 70 cm. After a start of the falling, when 40 ms has passed, the acceleration level decreases under a certain value and a pulse wave form corresponding to the turn ON (or OFF depending on sensors those adopt other logical structures) of the falling sensor is generated. The output is the waveform, which will be turned OFF (or ON) after reaching a certain value. Because such a clean noiseless pulse waveform can be output from the sensor, no special correction to the output is required and the configuration of its control circuit become simple. This figure together with the graph of the falling time, will show that the evacuation of the magnetic head can be completed at the falling. height of 17 cm assigning 100 ms for decision time and 50 ms for evacuation time. The acceleration level on which the falling sensor can detect the falling, is decided by the force exerted to the weight by the deflection of flexible beam 9 and the gravity exerted to the weight 10 . In case, shown in FIG. 2 , the deflected flexible beam 9 gives the weight 10 force back of 0.6 G×(mass of weight), if the acceleration applied to the weight, which is caused by the falling, becomes 0.7 G or more, the deflected flexible beam 9 's force overcomes the acceleration force exerted to the weight 10 and the weight 10 moves apart from the wall 11 . The smaller the force exerted to the weight by the deflection of the flexible beam 9 becomes, the longer the time from the start of the falling to the detection of the falling by the-sensor become, and the larger it becomes, the more sensitive the sensor becomes resulting in being a vulnerable to the erroneous operation by vibrations or shocks. Therefore, the range of the force exerted to the weight by the deflection of the flexible beam 9 stands realistically from (0.4 G)×(mass of weight) to (0.9 G)×(mass of weight). The falling sensor detects the state of falling by detecting the continuance of the state of detachment between the weight 10 and the wall 11 . FIG. 9 shows an example of an output of the sensor with noise. As such noise often becomes a cause of error operation in the detection of the falling state, it is necessary for a signal processing circuit to filter the noise out. Therefore, it is required for the sensor to keep the stable contact state. FIG. 10 shows the magnetic disk drive of another preferred embodiment of the present invention. By using a pair of the falling sensors of the structure shown in FIG. 3 to FIG. 5 (the sensor-shown in FIG. 2 can also be applicable) and by attaching the pair to the magnetic disk drive so that the direction of the flexible beams cross at right angles each other on a same plane, the sensors can operate stably wherever direction the magnetic disk drive Inclines. (For example, the stable contact can be maintained when the magnetic disk drive inclines around the axis of the beam of the falling sensor. But if the axis of the inclination is not the same with the axis of the beam, the stability of the contact may be reduced. However, setting each beam in two sensors crossed at right angles each other on a plane including the beams, either of the falling sensors can respond to the inclination in any directions with stable contact.) With the magnetic disk drive of another preferred embodiment of the present invention shown by FIG. 10 , either of the falling sensors in this structure will be able to detect the falling wherever direction the magnetic disk drive falls. The magnetic disk drive of the present invention can set in the information processing device. In this case, besides setting the magnetic disk drive with the falling sensor of the present invention, in the information processing device, it is possible to arrange the falling sensors in the information processing device and to evacuate the magnetic head of the magnetic disk drive from the surface of the magnetic disk medium when the falling sensor detect the falling. FIG. 11 and FIG. 12 show the information processing device of the preferred embodiment of the present invention, which is built in with the falling sensors of the present invention and the magnetic disk drive. In FIG. 11 , a magnetic disk drive 31 and a falling sensor 8 are connected to an inner circuit 32 of an information processing device 30 . The inner circuit 32 is provided with functions which are objects of the information processing device 30 , general control functions of the magnetic disk drive and a control function similar to the function shown in the flow chart of FIG. 7 . The inner circuit 32 monitors an output of the sensor, and when It detects the falling state, it decides whether the falling state continues more than a predetermined period and if the falling state continues more than the predetermined period, it evacuates the magnetic head from a surface of the magnetic disk medium. An information processing device shown in FIG. 12 has similar structure to the magnetic disk drive of the preferred embodiment of the present invention shown by FIG. 10 , except mounting a pair of the falling sensors 8 outside the magnetic disk drive. Directions of the flexible beams cross at right angles each other on a same plane and the sensors can maintain a stable contact wherever direction the information processing device inclines. Either of the falling sensors in this structure can detect the falling wherever direction the information processing device falls. In the preferred embodiment shown in FIG. 11 and FIG. 12 , the inner circuit 32 has the function of monitoring the output of the falling sensors 8 shown by the flow chart of FIG. 7 , however, the function under the flowchart shown in FIG. 7 can also be processed in the magnetic disk drive by connecting the output of the falling sensors 8 to the magnetic disk drive. As above described, the preferred embodiment of the present invention includes the following configurations and functions. (1) A conductive weight is attached to a conductive flexible beam or a beam member having the similar function of the conductive flexible beam. The weight touches a conductive wall because the beam is deflected with the weight by the gravity. A touched portion between the weight and the wall, namely, a contacting point, has a conductive structure. While the touched portion keeps conductive, if the structure falls, no-gravity state occurs which generates inertia force to separate the weight and the wall with a force of a deflected flexible beam. Sensing the separation by way of monitoring the conductivity is used with the above structure in a falling sensor. When a magnetic disk drive with this sensor falls, the conductive weight attached to the conductive beam goes into no-gravity state, which cancels the weight deflecting the beam in other words. A recovering force of the flexible beam weakens the deflection of the beam, which makes the weight apart from the conductive wall. The falling (falling state) can be detected by a disappearance of the conductivity. (2) A falling sensor having a structure, wherein a conductive weight is held by a pair of flexible beams, the weight contacts the conductive wall by the deflection of the beams by the gravity adding its influence to the weight. A contact portion between the weight and the wall has a conductive structure. While the contact portion keeps conductive, if the structure falls, no-gravity state occurs which generates inertia force to separate the weight and the wall with a force of a deflected flexible beam. Sensing the separation by way of monitoring the conductivity is used with the above structure in a falling sensor. (3) The above structure of the falling sensor, wherein one of the conductive flexible beam and the conductive weight held by the beam uses a magnet and the other of them uses ferromagnetic material, or vice versa. The conductive weight touches the conductive wall by the gravity and magnetic force. A touched portion between the weight and the wall has a conductive structure. While the touched portion keeps conductive, if the structure falls, no-gravity state occurs which generates inertia force to separate the weight and the wall with a force of a deflected flexible beam. Sensing the separation by way of monitoring the conductivity is used with the above structure in a falling sensor. When the above sensors detects the falling state, the recording/reproducing operation of data is interrupted and a evacuating operation, in which a magnetic head is evacuated from a surface of a magnetic disk, is enabled. Therefore, demolitions of the magnetic head and the magnetic disk by a crush between the magnetic head and the magnetic disk, which is caused by a shock at the end of falling, can be avoided. The shock resistance of the magnetic disk drive can be improved. By setting a pair of sensors in the directions crossed at right angles each other on a same plane, the falling state in any directions can be detected. In the present invention, the sensors similar to those of the above examples can be mounted on the information processing device itself in which a magnetic disk drive is installed. In this case, the falling sensor is not needed in the magnetic disk drive. When the falling sensor mounted on the information processing device detects the falling state, the magnetic head is evacuated from the surface of the magnetic disk. The information processing device, which does not have a magnetic disk drive, can be mounted with the falling sensors of the present invention, if the information processing device require to detect the falling. According to the present invention, the falling sensor with simple structure can detect the falling and if it detects the falling, it can have a magnetic head evacuated from a surface of a magnetic disk. Therefore, a demolition of the magnetic head and the magnetic disk by the crush between them caused by the shock at the end of the falling can be avoided. Having described a preferred embodiment of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to the embodiments and that various changes and modifications could be effected therein by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims.
A falling sensor is provided, which detects a falling of a magnetic disk drive or an information processing device installed with said magnetic disk drive and which is effective for avoiding physical damages of magnetic heads and magnetic disk media. The magnetic disk drive or the information processing device, include an unload mechanism moving or evacuating said magnetic head from a surface of said magnetic disk media, and a falling sensor comprising a conductive flexible beams 9 or members having a compatible function, a conductive weight 10 supported by these beams and a conductive wall 11 arranged to be made contact or non-contact with said weight 10 . The sensor can detect a falling of the magnetic disk drive or the information processing device which is typically a notebook personal computer installing with the magnetic disk drive, and evacuate the magnetic head by the unload mechanism. The conductive wall 11 can be formed as a tubular member.
6
BACKGROUND OF THE INVENTION The present invention relates to an apparatus for tunneling holes through the ground, as for example air-operated impact devices for tunneling substantially horizontally for the purpose of laying cables or pipes beneath roadbeds or other surface structures. This invention is related to my earlier U.S. Pat. No. 4,749,050, issued Jun. 7, 1988, which disclosed a tunneling apparatus having lubrication conduits for passing a supply of water to the forward end of the impact tool, thereby wetting the soil surrounding the forward end of the impact tool and reducing the impact resistance of the soil. The prior invention included an elongated outer housing threadably connected to a conically-shaped front tip, wherein the forward end of the front tip has a headpiece mounted thereon which has a discontinuous shoulder and neck section for providing an annular space about the front tip for injecting water. The headpiece has fluid outlets opening into this annular space, through which water or other liquids may be released to lubricate the front tip. The present invention provides an improvement in the water conduits and outlets proximate the headpiece to increase the lubricating efficiency of the apparatus. SUMMARY OF THE INVENTION The present invention comprises a tunneling apparatus having water supply lubricating capabilities, with an elongate housing and a conically-shaped front portion, with a shaft section projecting from the conically-shaped front end and the shaft affixed to a front tip for impacting into soil. Conduits are provided along the elongate outer housing and are joined into conduit channels in the conically-shaped front portion, wherein the channels emerge from the forward end of the front portion adjacent the shaft, to provide a supply of lubricating liquid into the region between the front tip and the conically-shaped front portion. An advantage of the present invention is that the position of the lubricating conduits improves the lubrication function of the apparatus. A further advantage of the present invention is that the lubricating conduits are positioned for ease of access and cleaning. Other and further advantages of the invention will become apparent from the following specification and claims, and with reference to the appended drawings. BRIEF DESCRIPTION OF THE DRAWINGS A preferred embodiment of the invention is disclosed hereinafter, with reference to the appended drawings, in which: FIG. 1 illustrates the apparatus in plan view and partial cross section; FIG. 2 illustrates an enlarged view of the front of the invention in cross section; FIG. 3 illustrates the view taken along lines 3--3 of FIG. 1; FIG. 4 is a cross section taken along the lines 4--4 of FIG. 2; and FIG. 5 is a cross section taken along the lines 5--5 of FIG. 2. DESCRIPTION OF THE PREFERRED EMBODIMENT One form of the impact device is illustrated by the drawings and is described herein as 10. The impact device 10 consists of an elongate cylinder 11 having a conically-shaped front section 12 and enlarged headpiece 43 fitted over the shaft 34 of the anvil portion 17. A plurality of raised, hemispherical buttons 12a are spaced about the exterior surface of front section 12, to assist in the operation of the invention. The outer surface of the cylinder 11 includes fluid conduits 15 which are confined within ribs 67 to form internal passages 16 in the front section 12. Passages 16 are formed as slots in ribs 67, sized to receive fluid conduits 15, so as to guide and protect fluid conduits 15 along the front section 12. Passages 16 communicate through the front end of front section 12 to permit fluid conduits 15 to release fluid through the fluid outlets 14. The interior of the cylinder 11 includes an anvil 17 and a reciprocable piston 18. The piston 18 is slidably mounted within cylinder 11 and is hollow along part of its interior axial length, but has a solid front piece which comprises a hammer 19. Near the rear end of piston 18 are a plurality of ports 20 which open through flat surfaces 21 formed along the outside surface of piston 18. The rear end of the cylinder is threaded to accept an end cap 22. The end cap 22 has longitudinal ports 23 for permitting the exhausting of compressed air from within cylinder 11 in a manner hereinafter described. A spool 24 is positioned in slidable relation with the interior surface of the piston 18. The spool 24 has a bore 25 drilled along its axial length which comprises a passage for compressed air into the interior of the impact device 10 and piston 18 via coupler 26 and air hose 27. The rear end of the spool 24 is threadable through the end cap 22 and includes a narrowed diameter 28 immediately forward of the end cap 22. The hose coupler 26 is designed for attachment to a suitable high pressure air hose 27 and when secure attachment is made, it is possible to twist the attached air hose 27 and cause the spool 24 to be threadably movable relative to cylinder 11, thereby causing the front end of spool 24 to move axially within cylinder 11. The conical portion at the front end of anvil 17 terminates in a forwardly-projecting shaft 34 which extends through the front opening of front section 12. Fluid outlets 14 are adjacent the surface of shaft 34 and the fluid outlets 14 communicate with the fluid passages 16 to enable fluid to flow from the fluid conduits 15 on cylinder 11 to the fluid outlets 14. In the preferred embodiment there are two equally spaced fluid outlets 14. Fluid conduits 15 are affixed against the outside surface of cylinder 11, and each fluid conduit 15 has a front opening into the front portion of a passage 16, and a rear opening sealably connected into a manifold or fluid coupler 29. Fluid conduits 15 are snugly fitted into the passages 16 which take the form of elongate slots or grooves along the inner surface of ribs 67. The grooves emerge from the rear edge 32 of ribs 67, and they converge toward the front of front section 12. The fluid conduits 15 are effectively clamped and held in fluid passages 16 by contact with the outer surface of anvil 17. The front openings of fluid conduits 15 open into a chamber 33 formed proximate the front of front section 12, in flow communication with outlets 14. The fluid coupler 29 is designed for attachment to a suitable fluid hose 30, to permit fluid, preferably water, to flow through the fluid conduits 15 and fluid passages 16 to the fluid outlets 14 located on the front section 12 as shown in FIG. 2. Fluid conduits 15 are preferably made from nylon or other flexible tubing. The fluid hose 30 is preferably connected to an adjustable fluid pump to provide an adjustable fluid supply for controlling the lubrication of the front section 12. As an alternative construction the fluid hose 30 could be carried inside of air hose 27 and be coupled to a rotatable liquid coupler and seal affixed to the rear of cylinder 11 in the proximate position of fluid coupler 29. As a further alternative construction, the fluid conduits 15 could be constructed in the form of elongate passages through the outer wall of cylinder 11 and along the length of cylinder 11. FIG. 3 illustrates a view taken along lines 3--3 of FIG. 1, wherein the location of the ports 20 is shown. Each port 20 is positioned to open on a flat surface 21 of the piston 18. The ports 20 provide air communication paths between the interior and exterior of the piston 18. The ports 20 may be covered by the spool 24 during at least a portion of the piston 18 travel distance over the spool 24, and may be uncovered during a further travel portion of piston 18. In the view shown in FIG. 2, the piston 18 is in its forwardmost position, where the ports 20 are uncovered from the spool 24. In its rearmost position, the piston 18 slides rearward over the spool 24 and the ports 20 are uncovered by the narrowed diameter 28 of spool 34. At intermediate positions the ports 20 are blocked by the larger diameter of the spool 24. FIG. 4 shows a cross-sectional view taken along the lines 4--4 of FIG. 2. The fluid outlets 14 open through the exterior surface of front section 12, and are preferably arranged diametrically opposite each other adjacent the shaft 34 so as to provide a directional fluid flow which permits the region between headpiece 43 and front section 12 to become saturated and allows the surface of front section 12 to become bathed in fluid. The external openings of fluid outlets 14 are preferably arranged behind headpiece 43 so as to create a void to freely permit the flow of fluid into the void. Headpiece 43 preferably has diametrically opposed flats 43a which are preferably oriented in alignment with ribs 67. Flats 43a permit additional flow of fluid over their respective surfaces, thereby providing additional wetting into the soil in the region where the ribs 67 are oriented. This serves to create a supplementary lubricating effect to ease the passage of ribs 67 through the soil. At the same time, ribs 67 to some extent act as stabilizing fins, to provide some directional stability for the tool as it proceeds through the soil. Outer surfaces of the headpiece 43 may also be flattened so as to provide a space for the further flow of fluid over headpiece 43. A wedge-shaped key 45 is forcibly inserted through a slot in shaft 34, to bear against the front edge of front section 12, and thereby to affix front section 12 to the cylinder 11. A detent groove may be provided in the front edge of front section 12 to locate the key 45, and the key 45 may be removed from its position by reversibly tapping the key with a hammer. A similar wedge-shaped key 47 affixes headpiece 43 onto shaft 34. Wedge-shaped key 47 is forcibly engaged into locking position so as to firmly attached headpiece 43 to shaft 34. Key 47 may be removed by tapping the key to dislodge it from locking engagement. In operation, compressed air is applied via the air pressure hose 27, attached to the coupler 26. The compressed air passes through the bore 25 to the interior of piston 18 and exerts a forward driving force against the piston 18. This force causes the piston 18 to move sharply ahead, contacting the hammer 19 against the anvil 17. At its forwardmost position, piston 18 uncovers the ports 20 and the internally pressurized air is vented to the exterior of the piston 18. This vented air passes through the openings created by the flat surfaces 21 on the exterior surface of piston 18, and inside the interior of cylinder 11, and act upon the rear annular piston surface 31 to sharply drive the piston 18 in a rearward direction. The piston 18 proceeds rearwardly until the ports 20 again become uncovered by the narrow diameter 28 of the spool 24. At this point, the compressed air between the piston 18 and the interior surface of cylinder 11 is vented into the rear chamber 32, and then out the longitudinal ports 23 through the end cap 22. When the piston 18 is in its rearward position, compressed air entering via the bore 25 again acts to drive the piston 18 forwardly to repeat the cycle. Each time the hammer 19 contacts the anvil 17, the headpiece 43 on the front of shaft 34 is forced forwardly into the soil. As the headpiece 43 moves through the soil, fluid is released through the fluid outlets 14, thereby lubricating the front surfaces of the tool, and wetting the soil in the region around the front end of the tool. The soil wetting process tends to loosen the adhesion of the soil and to make it easier for the tool to move forwardly through the soil. The spool 24 may be threadably moved along its axis in either direction, thereby varying the stroke range of the piston 18. For example, if spool 24 is positioned in its forward axial position as shown in FIG. 1, the stroke of the piston 18 causes the hammer 19 to sharply contact the anvil 17, and produce a forward-driving impulse. Conversely, if the spool 24 is threaded toward the end cap 22, the stroke of the piston 18 may be shifted so as to prevent any contact between the hammer 19 at the anvil 17. If the spool 24 is fully retracted toward the end cap 22, the stroke of the piston may be adjusted so as to cause contact between the rear outer piston surface 36 against the end cap 22, to create a reverse-driving impulse and cause the apparatus to move in a rearward direction. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
An impact tool having an air-operated hammer for impacting against an anvil in the body of the tool to cause the tool to tunnel through the ground, and having passages and conduits opening to the front region of the tool to pass water to lubricate the tool and wet the soil proximate the front of the tool, to ease the passage of the tool through the soil during the propulsion of the tool.
4
BACKGROUND OF THE INVENTION The present invention relates to apparatus and means for the construction or repair of paved roads, especially the asphalt type. Typically, such roads are surfaced by applying a mixture of asphalt with sand or gravel and then compressing the mixture into place. New roads are generally compressed and smoothed through the use of steamrollers, but such steamrollers have no integral means for driving to and from a job site, rather they must be transported upon a larger vehicle. Because of the transport disadvantage, time and expense, repairs in roads, especially those of a minor nature such as potholes, often are made without the assistance of steamrollers. In such cases, the asphalt mixture is manually tamped into place and reliance is placed upon normal traffic to further compress and smooth the area of repair. Although certainly more expedient and less expensive than steamrolling, manual tamping results in an inferior and usually temporary patch. SUMMARY OF THE INVENTION The present invention is a road-rolling machine which addresses and solves the above-described problems associated with conventional paving equipment and methods. The machine includes a truck and a front end mounted roller assembly consisting essentially of a cylindrical roller and a roller support structure. The support structure is fixed to the front end of the truck and attaches to both ends of the roller such that the roller is revolvable about its own axis. Hydraulic cylinders or other suitable means, integral with the support structure, raise or lower the roller relative to the truck's front end such that at least a portion of the front end truck weight is transferred to the roller when the roller is lowered, and the entire front end is weighted upon the front wheels of the truck when the roller is raised. The truck may be driven with the roller down such that the weight of the truck is used to press the roller against the pavement. Thus, the roller may be hollow or otherwise lightweighted, although rigid, which enables the truck to easily transport the roller assembly from job site to job site without the necessity of both a transport truck and a weighty steamroller. The roller assembly may be designed for interchangeability with plows on snow removal trucks, thereby increasing the usefulness of such vehicles. It is, therefore, an object of the present invention to provide a self-transportable vehicle for use in paving roads. It is also an object of the present invention to improve the quality of road repair. It is further an object of the present invention to increase the utility of snow removal trucks. Other objects and advantages will be obvious to persons skilled in the art from the detailed description of the invention set forth below. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an overall perspective view of a preferred embodiment for the road-rolling machine in accordance with the present invention; FIG. 2 is a partial top view of the road-rolling machine shown in FIG. 1; FIG. 3 is a partial side view of the road-rolling machine in FIG. 1; FIG. 4 is a sectional view of a support bearing for the roller along lines 4--4 in FIG. 3; FIG. 5 is a sectional view of the roller along lines 5--5 in FIG. 3; and FIG. 6 is a perspective view of an alternate embodiment of a piston/cylinder assembly for steering the roller in a road-rolling machine in accordance with the present invention. DETAILED DESCRIPTION OF THE INVENTION FIG. 1 is an overall view of a road-rolling machine, in accordance with the present invention, including a truck 10, a cylindrical roller 11, and a roller support structure 12. Although the truck 10 shown is of the dump type, typically used in cities for snow removal and salt application and for road repair work, no particular type is critical. It is only essential that the particular truck be capable of bearing the loads created by the roller 11 and support structure 12 as described more fully below. Snow removal type trucks are advantageous in that such trucks already have much of the necessary framework and hydraulics for useful employment with the roller 11 and support structure 12 of the present invention. Thus, the present invention provides a means for more efficient year-round utilization of city work trucks. The roller support structure 12, shown in greater detail in FIGS. 2 and 3, includes truss beams 13 and 13a and braces 14 and 14a which are attached to the truck frame 15 at the front end 16 and on each side of the truck 10, and which bear the loads during rolling. Additional reinforcement and integration of the structure 12 is provided by a U-shaped angle iron framework 17, the corners 18 and 18a of which are joined to the truss beams 13 and 13a and the ends 19 and 19a of which are joined to the braces 14 and 14a. Flanges 25 and 25a at the corners 18 and 18a and the braces 14 and 14a at the ends 19 and 19a of the framework 17 project forwardly therefrom, thereby supplying places for attachment of the rest of the support structure 12. The roller 11 is coupled to the support structure 12 by means of two C-shaped channel arms 26 and 26a extending between and joined to each brace 14 and 14a and the ends 27 and 27a of an axle 28 for the roller 11. The assembly of one of the arms 26 to its coupled brace 14 is shown in sectional view in FIG. 4. A load bearing 30 within the arm 26 and the arm 26 itself are linked to the brace 14 by means of a shoulder bolt 31. The shoulder bolt 31 includes a head 32, a washer 33, a journal 34 which extends through the brace 14 and the bearing 30 and abuts the arm 26 to prevent excessive tightening, and a threaded portion 35 which is passed through the arm 26 and secured by a nut 36. By means of this arrangement, the arm 26 and load bearing 30 are capable of pivoting about the journal 34 and sliding relative to the brace 14, for the purposes explained hereafter. Two-way hydraulic cylinders 40 and 40a extend between and are attached in pivotal engagement to each flange 25 and 25a and to apexes 41 and 41a of triangular trusses 42 and 42a which in turn are rigidly secured to the arms 26 and 26a. The function of the cylinders 40 and 40a is to pivot the arms 26 and 26a in the bearing 30, thereby raising and lowering the roller 11. Controls for and the operation of such hydraulic cylinders are well known to persons skilled in the art. Additionally, since the means for raising and lowering the roller 11 is not critical to the present invention, the arms 26 and 26a may be pivoted by an electric motor, by pneumatic cylinder, manually, or by other commonly known mechanisms. The roller 11, illustrated in sectional detail in FIG. 5, comprises a cylindrical shell 45 integrally affixed on a central shaft 46 which, in turn, is supported about the axle 28 by means of bearings 47, such that the shell 45 and shaft 46 revolve about the axle 28. Structural support for the roller 11 may be supplied by disks 48 secured within the shell 45 and by the end caps 49. If the disks are omitted, it may be necessary necessary to increase the wall thickness of the shell 45 to maintain a desired strength in the roller 11. The threaded ends 27 and 27a of the axle 28 are engaged by spacers 50 and 51 and a washer 52 and are secured by castle nuts 53 through which are inserted a cotter pin 54. In operation, the cylinders 40 and 40a lower the arms 26 and 26a until the roller 11 contacts the pavement to be repaired, and then continue to extend until the front end of the truck 10 is partially or wholly uplifted and at least a portion of its weight is placed onto the roller 11. Because of the weight transferred from the front wheels of the truck 10 to the roller 11, the roller 11 need not be as heavy as rollers on conventional steamrollers. However, if additional weight should be considered necessary, the roller 11 is provided with a capped inlet 60 in one end cap 49 for filling the roller 11 with water at the job site. Appropriate slots 61 are provided in each of the disks 48 to allow the water to fill each compartment 62 formed by the disks 48 and the end caps 49. The water may then be drained when the truck is to be driven to another job site. Of course, the roller may be designed to allow its being filled by other mediums such as sand. When the roller 11 is rolled across fresh asphalt or similar paving materials, some of the material may have a tendency to cling to the outer shell 45. A scraper 63 extends from one arm 26 to the other arm 26a and closely abuts the roller 11, such that clinging material is ready and continuously removed from the roller 11. The scraper 63 may be spaced, for example, about 1/4 inch from the roller 11. FIG. 6 illustrates a modification to the U-shaped channel arm 26, consisting of a two-way hydraulic cylinder 65 mounted within the arm 26 and terminating with a swivel self-aligning bearing and bearing block 66. The axle 28 extends through the bearing 66, and the bearing 66 abuts and slides along a sloted faceplate 67 across an open face 68 of the arm 26. Thus, as the cylinder's piston 69 is extended, it slides the bearing 66 along the faceplate 67, thereby pivoting the end 27 of the axle 28 and the roller 11 to steer the truck 10 during rolling. A similar arrangement, of course, may be installed on the other arm 26a so that the truck 10' may be turned faster in either direction. While the above description of preferred embodiments of the invention has been provided in great detail, it should be understood that other modifications will be obvious to persons skilled in the art and may be incorporated without departing from the scope of the invention as defined by the following claims.
The present invention is a self-transportable truck mounted roller for paving or repairing paved roads. The invention comprises a lightweight roller and roller assembly mounted to the front end of a truck, and includes hydraulic cylinders or other means for raising and lowering the roller. In operation, the roller is lowered enough to displace the weight of the truck from the front wheels onto the roller, thereby providing a highly compressive paving force.
4
CROSS-REFERENCE TO RELATED APPLICATIONS This is a continuing application, under 35 U.S.C. §120, of copending International Application No. PCT/EP2005/002007, filed Feb. 25, 2005, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German Patent Applications DE 10 2004 010 479.4, filed Mar. 4, 2004 and DE 10 2004 022 607.5, filed May 7, 2004; the prior applications are herewith incorporated by reference in their entirety. BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a method for preprocessing data which is related to coordinates of a surface, and is referred to in the following text as surface data. The present invention also relates to a method for quality assessment of strip material, a method for quality management of strip materials and an apparatus for controlling the processing of strip materials. Automatic systems for surface inspection are often used when materials in the form of a strip are produced in a quickly flowing form. In particular, those are metals, for example steel, as well as paper, which in some cases are manufactured at speeds of more than 30 m/s in the case of paper, and of more than 20 m/s in the case of steel. Those strip materials are generally processed further by winding them up to form coils, or are transported to a customer who uses the strip material to manufacture end products. In that case, completely different end products can be produced from substantially identical coils, for example on one hand washing-machine parts and on the other hand car parts from similar steel coils. However, it is not possible to use any coil for any end product or intermediate product since the customers for the coils are subject to requirements relating not only to the composition of the material but often also to quality standards, which the condition, in particular the surface, of the strip material must satisfy in order to allow them to be used for a specific end product. So-called “coil grading”, that is to say the quality assessment of a strip material, is of critical importance to the value of a coil and for its further processing. In order to ensure that a specific quality standard is satisfied, the condition and/or the surface of the strip material must be checked, in particular for anomalies, to be precise before being wound up to form coils. Surface inspection is normally carried out by specifically trained personnel who either check the surface itself (by observing it continuously) or use an automatic system for surface inspection. Systems such as those monitor the surface of the strip material using cameras, for example, with different monitoring principles being known. In addition, other data which does not necessarily describe anomalies, for example the thickness of the material, the surface roughness, the temperature profile of a heat treatment etc, can be determined using various measurement methods, and can be associated with the individual surface points. By way of example, International Application No. WO 01/23869 A1, corresponding to Australian Patent Application AU 7658100A, discloses surfaces being observed using the so-called bright-field or dark-field method. International Application No. WO 01/23869 A1, corresponding to Australian Patent Application AU 7658100A, also discloses the results of the two inspections being correlated with one another in order to allow better fault identification to be carried out in that way. Further surface analysis systems and measurement methods for recording material data are likewise known from the prior art. All of those systems have the advantage that considerably more data is gathered and considerably more surface anomalies are detected than in the case of “visual” inspection by an inspector. By way of example, 2 to 5 anomalies per coil are generally found during visual inspection of an average coil, with more than 20 anomalies only in exceptional cases. The number of registered anomalies when using automatic surface inspection systems for a comparable coil is regularly greater by a factor of more than 100. On one hand that is, of course, advantageous because considerably more anomalies can be detected, but on the other hand it presents the operator with hurdles that are virtually impossible to overcome: Due to the large number of registered anomalies (on average hundreds to several thousand per coil), it is virtually no longer possible for the observer to decide on the basis of the large amount of data which registered anomalies are or are not relevant for achieving a specific quality standard for the end product to be produced from the strip material. By way of example, it is possible for only 3 of 2000 registered anomalies to actually be of importance for the quality standard to be achieved. However, the observer frequently has to decide very quickly what quality standard can be complied with and what cannot, since that is normally done during the production of the strip material, that is to say before the wound-up coil is separated from the strip material. Until now, corresponding automatic evaluation of the bulk data has been carried out only in exceptional cases, through the use of specific programming. Furthermore, although the data obtained by automatic surface inspection was in principle available for further processes, for example for financial control purposes or for automatic creation of quality certificates, it has de facto not been possible to process the data further in a worthwhile manner because of the incredibly large amount of data involved. Typical data processing systems cannot be used directly for data which, as in this case, relates to the coordinates of a surface, that is to say data having a geometric reference. SUMMARY OF THE INVENTION It is accordingly an object of the invention to provide a method for preprocessing surface data for the assessment of strip material, which allows analysis of the available surface data on the basis of freely predeterminable criteria and allows further processing of the data in a simple manner, a corresponding method for quality assessment and for quality management of strip material and a corresponding apparatus for controlling the processing of strip material, which overcome the hereinafore-mentioned disadvantages of the heretofore-known methods and apparatuses of this general type. With the foregoing and other objects in view there is provided, in accordance with the invention, a method for preprocessing data for a strip material, in particular for metal and/or paper strips. The method comprises providing the data in the form of data records to be associated with a strip surface according to coordinates and to include information about a condition of the strip and/or the strip surface and/or a possibly present anomaly. At least some of the data records are grouped and stored in cells on the basis of predeterminable grouping rules. The cells are geometrically configured on a screen or another visualization medium having a topological similarity to the strip surface. Contents of the cells are made available for further electronic processing and/or linking to other cells or other data. In this case, in particular, the contents of one cell need not be merely one-dimensional but may contain and make available source data, grouping rules and/or processing formulae. Although cells, once they have been grouped and once their contents have been defined, allow automation of subsequent quality assessments, the accessibility and variability of the cells and cell contents mean that they are in fact not of much use in practice. In this case, a topological similarity between the strip surface and the presentation of the data to a user assists in intuitive action when changes are intended to be made to the cell contents and their links. In this case, topological similarity need not mean that the entire strip surface is imaged using the same scale, but may relate to a distorted representation of the entire surface, or of a part of the surface. The important factor in this case is that the part which is currently being imaged corresponds approximately to the constellation of the surface points or surface areas being considered on the strip surface. In accordance with another mode of the invention, it is particularly preferable to display those cells, in particular on a screen, in the form of at least one spreadsheet having a plurality of cells disposed in rows and columns. Spreadsheets are widely used for displaying and processing data, and can be used without any programming knowledge. An anomaly is understood to be a discrepancy in the surface from a desired nominal state. In the case of steel strips, for example, this may be a roller impression or an oil spot. In the case of paper strips, it may be, for example, a discolored area or a thickened area, in this case. In the case of paper webs, further information can also be obtained, for example by through-lighting, which provides additional information about material anomalies. The provision of surface data in the form of a spreadsheet allows the surface data to be grouped and processed further in a particularly advantageous, flexible and simple manner. In particular, this offers the advantage that even users who fundamentally have little experience with the programming of computers can nevertheless define grouping rules in the form of formulae in a simple manner, as is known from traditional spreadsheets, such as Microsoft Excel or the like. On one hand, this allows the group of people who prepare for and/or carry out a surface inspection to be widened, while on the other hand the surface data which has been obtained by automatic measurement and analysis systems is for the first time available in a practicable manner for further processing by wide user groups. By way of example, the surface data can be grouped in such a manner that the data records are grouped spatially, and can be spatially associated with a subsequent end product. For example, in the case of a steel strip from which, if required, engine compartment hoods can be manufactured for a car, a group rule can be used in which the surface data which is combined is that which corresponds to that part of the surface of a steel strip which will subsequently form the surface of the engine compartment hood. This group of surface data then includes all of the anomalies which have been found in this spatial area during the surface inspection of the strip material. Figuratively speaking, the grouping rules can be used to create a type of map on the strip material, which images the position and orientation on the strip material of the end products which will subsequently be produced from that strip material. The user of the surface inspection system is therefore provided with a tool which allows him or her to focus his or her attention on those areas of the strip material which will be relevant for the subsequent end product. Areas which are not relevant for the end product, for example edge areas of the strip material which are generally cut off and thrown away, can thus be rejected even before making the decision as to whether or not a specific quality standard can be achieved. Faults in these areas can in this case be ignored in the decision-making process even if they are very numerous and serious. The method according to the invention therefore makes it possible to reduce the amount of data for evaluation of surface inspection data, to simplify and speed up the process of making decisions relating to the assignment of quality standards, and to make this assignment process more reliable and reproducible. In addition, automatic decision-making is also actually made considerably simpler and more reliable, once the necessary groupings and processing operations relating to the cell contents have been defined. Adaptation to match new conditions or knowledge is possible in a simple manner at any time. It should be noted that, for the purposes of this invention, an end product represents an end product relative to the strip material, that is to say an end product for the purposes of this invention may also be an intermediate product which will be subject to further processing steps. Furthermore, once a decision has been made on the basis of the surface data that a specific quality standard cannot be met, the system makes it possible to check in a simple manner whether or not other quality standards can be met. By way of example, this is done simply by using a different grouping rule. In the above example, following the decision that the steel strip does not meet the quality standard for an engine compartment hood, it will be possible, for example, to use the appropriate grouping rule to check whether or not a quality standard for a different end product to be manufactured from the strip material can be met. By way of example, this makes it possible to check whether or not the steel strip is suitable for the manufacture of fenders. Furthermore, the data which has been processed in this way can be made available in a simple form to third parties. In the above example, for instance, the data can be made available to a customer or to someone processing the steel strips. This person can thus on one hand check the quality level assignment by the steel manufacturer or can use his or her own grouping rules autonomously in order to check whether or not the steel strip can be used for a different end product, with little scrap. The creation of grouping rules and further processing of the data can be carried out in a simple manner by the programming for formulae in individual cells in a spreadsheet, as is known from conventional spreadsheets. Using a simple example, grouping can mean that, for example, the sum of the faults is formed in an area which can be associated with specific spatial coordinates, such as an end product. Formulae such as these can also be used for comparison with quality standards to be complied with. By way of example, a formula “if the group includes less than two faults of the Type X and the surface roughness is below a value Y” could lead to a specific quality standard being assigned only when all of the relevant groups, or a predeterminable proportion of the relative groups, satisfy this formula. It is also possible to carry out a summary comparison of all of the anomalies in the groups, using predetermined limit values. It is also possible, in the case of a strip, to preprocess and to store both the surface data relating to one face of the strip material (the front face) and that relating to the other face (the rear face) of the strip. With an appropriate distribution of anomalies on one face and on the other face, this makes it possible to change from the front face to the rear face, and this can advantageously lead to a reduction in the scrap. According to one advantageous refinement of the method according to the invention, the surface data includes surface roughness, planarity, a finishing temperature and/or a thickness of the strip material. The surface roughness and surface planarity are of critical importance in the further processing of end products, especially for the production of steel strips. A finishing temperature should be understood as meaning, for example, an annealing temperature in the case of steel strips, which influences the brittleness of the steel. Heat-treatment temperatures such as these can have a critical influence on the subsequent further-processing of the material, and consequently also on the allocation to quality standards. The same applies to the thickness of the strip material, in particular if the thickness is not uniform. This advantageously allows inhomogeneities in these parameters to be taken into account. According to the invention, the surface data can also include further data relating to the condition of the strip and/or the surface. According to a further advantageous refinement of the method according to the invention, a data record for a surface anomaly includes at least one anomaly type, an anomaly size and/or an anomaly severity. An anomaly type should be understood as meaning a classification, as is in each case normal in this field, of the surface anomaly of the strip material, for example rust, an impression, a scratch, scale stippling, a bubble, etc. for steel. The anomaly size may be either relative (smaller than the physical extent of the group, larger than the physical extent of the group) or else absolute (for example two square centimeters). The anomaly severity is understood as meaning the amplitude of the discrepancy from the desired nominal state of the surface, for example in the case of scaling, the extent of blackening or the like. The anomaly severity thus represents a measure of the discrepancy from the desired nominal state of the surface. According to one further advantageous refinement of the method according to the invention, the grouping rules are used to carry out at least one of the following grouping operations: a) combination of data records which correspond to physically adjacent and/or correlated surface anomalies; b) combination of data records which can be physically associated with predeterminable areas of the strip material; c) combination of data records which correspond to identical surface anomalies; d) combination of data records which include surface anomalies which on their own or together with other surface anomalies and/or with other data, in particular relating to the surface roughness or planarity, allow the assignment of a quality level in comparison to at least one quality standard, in particular that of the end product to be manufactured from the strip material; or e) combination of data records which correspond to surface anomalies with an anomaly severity, and which are within a predeterminable value range of the anomaly severity. For the purposes of a grouping operation on the basis of a), correlation means any type of mathematical correlation, that is to say any type of mathematical operation in which a relationship is produced between two variables. Grouping of data records on the basis of a) allows physically adjacent anomalies to be grouped. For example, this makes it possible to identify production faults during the manufacture of the strip material, as a result of which adjacent surface anomalies or correlated surface faults (such as periodic surface faults) occur. For example, these may be scratches which are continuous in the movement direction of the strip, or periodic impressions from the rolling tools. The grouping of data records based on b) allows, for example, the combination of surface anomalies in areas which generally represent scrap because of the production process for the strip material and/or the end product, for example edge areas or end areas of the strip. A further example is the capability described above to combine areas on the strip surface which are associated with the end product to be manufactured. Grouping of data records on the basis of c) makes it possible to combine substantially identical or similar surface anomalies. Grouping on the basis of d) makes it possible to combine data records which are relevant to compliance with or else overcompliance with a specific quality standard. In this case, the quality level refers to a quality indication which is generally associated with the strip material, while the quality standards represent standards which are independent of this strip material, for example standards set by the customers. For example, a quality standard I can represent that quality which the surface of a steel sheet must have in order to allow it to be used to manufacture engine compartment hoods. A quality standard II could represent that quality which the surface of a steel sheet must have in order to allow it to be used to manufacture washing-machine parts. The quality level of one very specific sheet may, for example, then be defined sufficiently simply that it is not adequate to meet the quality standard I, even though it is sufficient to meet the quality standard II. This advantageously allows accurate assignment of strip materials to the end products to be produced later, both at the premises of the manufacturer of the strip material, and at the premises of the customer and processor of these strip materials, who can then assign the optimum use to each strip or coil in their business, in particular minimizing the amount of scrap incurred, or can also reject them. The grouping based on d) may represent not only a purely physical grouping to match the end product to be produced, but also a correlation of surface anomaly data with further parameters such as the surface roughness or the like. However, a grouping based on d) is not restricted to these examples, and in fact a grouping process can be carried out matched to the currently required quality standards in any desired possible manner. By way of example, a grouping operation based on e) makes it possible to estimate faults in the production process of the strip material, in which surface anomalies of a specific anomaly severity are grouped in the form of a map with contour lines. According to one further advantageous refinement of the method according to the invention, during a grouping operation based on b) and/or based on c), areas of the strip material are taken into account which can be assigned to at least one subarea of the end product to be manufactured from the strip material. As described above, this makes it possible to form a type of map of the surface which in its own right includes the position, orientation and size of the end products to be manufactured from the strip material. According to a further advantageous refinement of the method according to the invention, during a grouping operation based on b), the geometric condition of the strip material is imaged, in particular with respect to scrap areas which are governed by the production process of the strip material. This advantageously makes it possible to ignore faults in areas which are not located in the end products to be manufactured, as far as the assignment of the quality level is concerned, thus reducing the amount of data to be considered. According to one further advantageous refinement of the method according to the invention, the individual cells of the spreadsheet can be matched, at least with respect to position, orientation and size, to the geometric condition of the strip material, and/or to the position, orientation and/or physical extent of the anomalies, and/or to the groups on the strip surface. By way of example, this function allows the strip material to be imaged substantially true to scale in the spreadsheet, with the size relationships between the groups on the strip material corresponding substantially to the size relationships between the individual cells. According to a further advantageous refinement of the method according to the invention, the individual cells can be matched with respect to at least one of the following variables: A) color of the background; B) color of the cell content; C) shading of the cell; D) font of the cell content; E) script emphasis of the cell content; or F) script pitch of the cell content, such that these variables A) to F) represent the relevance for the assignment of the quality level of the end product to be manufactured from the strip material. This means that, in addition to any desired representation of the group in the cell, for example a sum of the number of surface anomalies in this cell, further dimensions (color, shading, font, etc.) are in practice opened up for the representation of the relevance of the surface data in this cell for the assignment of the quality level. By way of example, cells which contain groups which prevent compliance with a predetermined quality standard can thus be marked with a red background and script emphasis, or the like, without having to open a further cell. The relevance of this data is evident in a very simple manner to the user. Script emphasis in this context means in particular the representation of the cell content using bold, italic, underlined and/or struck-through script, as well as upper-case script and/or spaced-out script. According to a further advantageous refinement of the method according to the invention, the quality level is assigned relative to predeterminable quality criteria. Based on the above example, this means that the quality level states that a quality standard I is not met, but that a quality standard II is met. The quality level may in a simple manner be in the form of a list of all of the quality standards which are met. According to a further advantageous refinement of the method according to the invention, the quality level is assigned on an absolute basis. One simple case of an absolute assignment of the quality level is, for example, to state the number of anomalies that have occurred, possibly weighted with the anomaly severity and/or the area of the occurrence on the surface of the strip material. According to a further advantageous refinement of the method according to the invention, the assignment is based on a formula in the spreadsheet. By way of example, the formula may include an instruction which states “assign quality level I if the number of anomalies of Type X is less than Y and if the heat-treatment temperature in all groups is greater than Z”. Other formulae as are normal in conventional spreadsheets are possible and are covered by the invention. According to a further advantageous refinement of the method according to the invention, at least one data record or at least one group is represented at least partially in one cell of a spreadsheet. This makes it possible to represent at least one data record or at least one group, in each case at least in parts, in one cell. In each case in parts means that only parts of the data record or of the group are represented, in which case, in particular, the user can choose what he or she would like to have displayed from each data record. By way of example, from each group, it is possible to display the number of surface anomalies registered in this group, the average heat-treatment temperature, the average strip thickness and/or the average surface roughness, etc., of the group or of the data record, in each case in individual cells or jointly. It is also possible to display only the number of anomalies of one specific anomaly type in the group or in the data record, and this is covered by the invention. In this case as well, a display or else corresponding filtering are also possible in the form of a conventional spreadsheet. By way of example, the respective coordinates on the strip material or else any another desired details, which can be adapted by the user, can be used in the column and/or row headings. According to a further advantageous refinement of the method according to the invention, a plurality of spreadsheets are formed with different representations of the surface data. This makes it possible to use different tables (that is to say one sheet of a spreadsheet) for respectively matched filtering of the data. By way of example, it is possible to state the numbers of anomalies per group or data record in each cell, as a function of their position on the surfaces of the strip, in one table in each case. Individual data records can be listed per row in another table, so that each individual data record can be accessed, without major effort, etc. According to a further advantageous refinement of the method according to the invention, the spreadsheets can be linked to one another. By way of example, it is thus possible to program a link, for example in the form of a hyperlink in the Internet, between different tables, so that, by way of example, one cell with a group of data records can be linked to that point in a list of all of the individual data records which corresponds to the first data record in the group, or to the first data record in the group with a surface anomaly. Any desired links between the tables are possible and are covered by the invention. According to a further advantageous refinement of the method according to the invention, it is possible to predetermine which elements of the data in a group or in a data record can be represented in a spreadsheet. The amounts of data to be represented can thus be considerably reduced if, by way of example, data which, although present (for example the finishing temperature), is, however, irrelevant for the end product to be manufactured from the strip material, is not represented. In this case, in particular, it should be possible to make the data which is not displayed visible at any time, by the memory structure which is associated with the cells containing the entire database and the links that have been introduced. According to a further advantageous refinement of the method according to the invention, it is possible to predetermine the breakdown in which the data in a group or in a data record can be represented. In this case, breakdown should be understood as meaning the configuration and the splitting of the spreadsheet, that is to say by way of example the definition of which column will be used to display what element of the data records and/or of the groups, and what will be represented in each row, etc. It is thus possible to configure one or more spreadsheets which each represent data in a form which corresponds to a specific problem. This can be adapted individually by any user in precisely the same way as is possible in conventional spreadsheet calculations. According to a further advantageous refinement of the method according to the invention, individual cells can be linked to representations which the data of the group which is linked to this cell or of a data record which is linked to this cell at least partially shows, in particular at least to a graphical representation of a corresponding surface anomaly. For example, this means that it is possible to provide a type of magnification function, through the use of which all of the available data is displayed, if the display does not cover all of the data in a data record or a group. According to a further advantageous refinement of the method according to the invention, at least some of the surface data is obtained from the signals from at least one measured-value recorder, preferably a camera, and particularly preferably a CCD camera or CMOS camera. In particular, the use of CCD cameras with high time and spatial resolution is advantageous for the surface checking of strip materials moving at high speed. With the objects of the invention in view there is also provided a method for quality assessment of a surface of moving strip materials, in particular metal or paper strips. The method comprises preprocessing surface data on the basis of the method according to the invention for preprocessing of surface data, and assigning a quality level to the strip material based on the preprocessed surface data. This method according to the invention makes it possible on one hand to allocate a quality level to the strip material in a simple manner even during manufacture or only prior to further processing of the strip material, on the basis of the preprocessed data as described above, with this quality level preferably being oriented to predeterminable quality standards. Reference is made to the details and advantages, as stated above, of the method according to the invention for preprocessing of surface data for a strip material. The invention also makes it possible for a customer of strip material to group and to evaluate the available data on the basis of widely differing viewpoints, until he or she has found a way of combining the data that is relevant for his or her requirements. During this process, he or she can carry out adaptation processes and improvements repeatedly. The relevant type of combination that is found can then in each case be used in an automated manner, without repeated assessment by an inspector, for assessment of further coils, and/or can be passed to the manufacturer of the strip material in order to obtain the desired quality there, even in an automated form, during manufacture, or to sort out coils which do not meet this quality. With the objects of the invention in view there is furthermore provided a method for quality management of strip materials. The method comprises assigning a quality level to the strip material on the basis of the method according to the invention for quality assessment, and supplying the strip material, on the basis of the assigned quality level, to-a processing step requiring a specific quality level. With the objects of the invention in view there is additionally provided a method for quality management of strip materials, in particular metal or paper strips. The method comprises preprocessing the surface data with the method according to the invention, and configuring a production process and/or a process used for processing the strip material on the basis of the preprocessed surface data, to produce as little waste as possible during manufacture of an end product from the strip material. The expression quality management should be understood as meaning a complex, multidimensional process, in this case. This not only covers the assignment of a quality level to a specific strip material (coil) even though this represents the basis of the rest of the quality management process. In fact, this term should be understood as meaning an iterative matching process over a plurality of strips, taking into account a plurality of possible end products, possibly also from a plurality of possible end products from different manufacturers in different fields, in each case taking into account the respective field-specific and manufacturer-specific quality requirements and standards. A quality management process such as this can be carried out effectively for the first time by using the method according to the invention for preprocessing of surface data. On one hand, this quality management process can be carried out at the premises of the manufacturer of the strip material, by maintaining a list with the job orders, including the respective quality standards to be met and the size of and requirements for the end product to be manufactured, with multidimensional adaptation being carried out on the basis of the strip material under consideration. In this case, the scrap is minimized while at the same time maximizing the quality standard that can be achieved, for example maximizing the possible price to be achieved. In this case, in particular parameters “outside” the strip material, that is to say a different grouping depending on the end product to be manufactured, as well as parameters “within” a strip material, that is to say by way of example a shift in the grouping in the longitudinal direction, that is to say in the movement direction of the strip material and/or transversely with respect to it, can be used as variation parameters. In this case, it is not only possible to shift all of the associated groups, but also to shift individual groups, so that, by way of example, instead of the shortest possible distance between two adjacent end products to be manufactured, an additional distance is introduced on the strip material, which admittedly at first glance increases the scrap, specifically by this additional piece, but overall reduces the scrap because it is possible to manufacture more end products which meet the necessary quality standard. A further optimization dimension results from a plurality of parallel strip production lines, in which case optimization is in each case carried out for a plurality of strip materials being manufactured at the same time. This optimization can also be carried out within a spreadsheet. A corresponding quality management process can also be carried out at the premises of the processor of the strip materials. In this case, it is also possible to reject the coils, as a further result of the quality management process. The advantages and details disclosed above apply in the same way to the method according to the invention for quality management. With the objects of the invention in view there is provided, as well, an apparatus for controlling the processing of strip materials, in particular metal or paper strips. The apparatus comprises an evaluation unit including at least: a) a storage device for storing at least one of surface data to be associated with a strip surface according to coordinates or quality standard data to be associated with an end product to be manufactured; b) a grouping device for grouping said surface data on the basis of predeterminable grouping rules, with a group including at least one data record of said surface data; and c) a comparison device for comparing groups of said surface data with at least one predeterminable quality standard and supplying comparison data. Data links are connected to said evaluation unit. An input device and an output device are connected to said evaluation unit through said data links, for inputting commands and at least outputting said surface data from said evaluation unit. A control device is connected through said data links at least to said evaluation unit and to said input device and/or said output device. The input device and said output device interact to display and process said surface data, to input said grouping rules and/or comparison rules in a corresponding manner, and to compare said groups with at least one quality standard in the form of at least one spreadsheet. The control device initiates a specific process for processing the strip material to manufacture an end product or rejects the strip material, on the basis of said comparison data supplied by said comparison device and/or a user input. When the invention is used on-line, the control device is preferably connected to a marking device, in particular for coloring, stamping or perforation of a strip material on the basis of predeterminable criteria and/or at parts with particular anomalies. The invention can thus be used in a flexible manner for identification purposes during the production process or at its end, with the identification criteria being easily variable by appropriate processing of the cells in a spreadsheet. In this case, the apparatus is at least suitable for carrying out at least one of the methods according to the invention. According to one advantageous refinement of the apparatus according to the invention, this apparatus has at least one measured-value recorder, preferably a camera, and particularly preferably a CCD or CMOS camera, which records surface data, with the measured-value recorder being connected to the evaluation unit through data links, and transmitting the surface data to the evaluation unit. According to a concomitant refinement of the apparatus according to the invention, the evaluation device is constructed to use the surface data to detect surface anomalies on the surface of the strip material. The details relating to the method according to the invention as disclosed above can be applied directly to the corresponding apparatus through the use of appropriate measures which carry out the method steps, and can be transferred directly. The features, their advantages and details will therefore not be repeated, even though they are likewise applicable to the apparatus. Other features which 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 a method for preprocessing surface data, a method for quality assessment and for quality management of strip material and an apparatus for controlling the processing of strip material, it is nevertheless not intended to be limited to the details shown, since 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, diagrammatic, plan view of a strip material; FIG. 2 is a plan view of a spreadsheet; FIG. 3 is a fragmentary, plan view of a strip material corresponding to the spreadsheet shown in FIG. 2 ; FIG. 4 is a plan view of a first exemplary embodiment of a spreadsheet calculation having a plurality of spreadsheets; FIG. 5 is a plan view of a second exemplary embodiment of a spreadsheet calculation having a plurality of spreadsheets; and FIG. 6 is a schematic and block diagram of an exemplary embodiment of an apparatus 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 seen a diagrammatic representation of a portion of a strip material 1 , for example a portion of a steel strip 1 . The intention is to manufacture car doors 2 from this steel strip 1 . An outline of a car door 2 that is to be manufactured is indicated, by way of example, on the steel strip 1 , and represents an area of the steel strip 1 which is assigned to the car door 2 to be manufactured. In other words, with regard to the steel strip 1 , during the production of the strip or before production of the car door 2 , this is initially purely a virtual assignment in which, in particular, there is no physical marking on the steep strip 1 . The car door 2 has a door area 3 and a window area 4 . An automatic surface inspection of the steel strip 1 is carried out, with the result thereof being data records which can be associated with coordinates of the surface of the steel strip 1 . Each data record thus represents the surface condition of a surface unit at a position which is defined by the corresponding coordinates on the strip surface. In particular, the data records include data relating to surface anomalies, that is to say discrepancies between an actual state of the surface of the steel strip 1 and a desired nominal state of the surface. During the assessment of the surface of the steel strip 1 and, in particular, also for the definition of a quality level of the material, surface anomalies that occur have different importance depending on the coordinates where they occur. For example, if a first surface anomaly 5 occurs in the window area 4 , then this is of lesser importance for the assignment of a quality level for the manufacture of car doors 2 from the steel strip 1 than the occurrence of a second surface anomaly 6 in the door area 3 . A third surface anomaly 7 which occurs in an edge area 8 of the steel strip 1 is likewise of relatively minor importance. However, in conventional surface inspection systems, no reference would be made to the (virtual) configuration of the car doors 2 to be manufactured from the steel strip 1 , so that both surface anomalies 5 , 6 would be used with equal weightings to define the quality level. When taking the overall length of the strip, which may be several hundred to one thousand meters, into account, this leads to a large amount of data which exacerbates reliable and reproducible assignment of a quality level, or makes it virtually impossible. According to the invention, this problem is solved by grouping the data records on the basis of predeterminable grouping rules. In the present example, one grouping of the data records can form the door area 3 , and a further grouping of the data records can form the window area 4 . In this case, those data records which form the door area 3 can be combined in a single group, although it is also possible to form a plurality of groups, each of which form approximately rectangular subareas of the door area 3 . The data which has been grouped in this way is produced within at least one spreadsheet. FIG. 2 shows an example of one such spreadsheet. FIG. 2 shows a detail of a spreadsheet 9 , which is subdivided in the normal manner into cells 12 that form rows 10 and columns 11 , which are illustrated only in an exemplary manner for clarity. The example provided in FIG. 2 shows surface data for a steel strip 1 which has been split into a plurality of groups. In the present case, each cell 12 includes one group of surface data. The size, position and orientation of the cells corresponds to the position, orientation and extent of the corresponding groups of surface data, as is evident from a comparison with a corresponding detail of the steel strip 1 which is shown in FIG. 3 . FIG. 3 diagrammatically shows a detail of a steel strip 1 . This steel strip has first product areas 13 and second product areas 14 , which are formed by the surface of end products to be manufactured from the steel strip 1 . Furthermore, there are third product areas 15 , which will belong to the surface of the end product once that end product has been produced. Additionally, intermediate areas 16 are formed, which are located between the product areas 13 , 14 , 15 but do not contribute to the end product, as well as edge areas 8 which, together with the intermediate areas 16 , form scrap steel, which does not contribute to the end product to be manufactured. Once the automatic surface inspection has been carried out, surface data is available which can be associated with the coordinates on the surface of the steel strip 1 . According to the method of the invention for the preprocessing of surface data, the surface data is grouped, in which case a grouping operation has been selected which is matched to the areas 13 , 14 , 15 of the end product to be manufactured. First groups of surface data are thus formed, which are matched to the first product area 13 . This means that the first groups of surface data include only data records which can be physically associated with the coordinates of the first product area 13 . Second groups of surface data are formed analogously, which can be associated with the spatial coordinates of the second product area 14 , and third groups, which can be physically associated with the third product areas 15 . In addition, intermediate groups and edge groups are formed, which can be physically associated with the intermediate areas 16 and the edge areas 8 . In the spreadsheet 9 illustrated in FIG. 2 , each group is shown in its own cell. The first group is thus shown in each case in a first cell 17 , the second group in a second cell 18 , and third group in a third cell 19 . The first product area 13 thus corresponds to the first cell 17 , the second product area 14 to the second cell 18 , and the third product area to the third cells 19 . The intermediate areas 16 correspond to intermediate cells 20 , and the edge areas 8 correspond to edge cells 21 . The spreadsheet 9 is thus subdivided corresponding to the subdivision on the basis of product areas 13 , 14 , 15 of the steel strip 1 . In this illustration, the cells 17 , 18 , 19 , 20 , 21 contain the number of surface anomalies in the respective area 13 , 14 , 15 , 16 , 8 of the steel strip 1 . The cells 17 , 18 , 19 , 20 , 21 in the spreadsheet 9 are colored with a different background, indicating the relevance of the faults in the cells 17 , 18 , 19 , 20 , 21 for the allocation of a quality level to the steel strip 1 . In this case, a quality level means compliance with specific quality standards which are required for the production of the end product. The relevance for quality-level determination is governed by predeterminable criteria which, as indicated by way of example above, can be stated in the form of a formula in the spreadsheet. Thus, by way of example, despite the relatively large total of thirty-two surface anomalies in the first cell 17 , the relevance of these faults for the end product to be produced is low. This relevance data that is produced makes it possible to easily assign a quality level to the steel strip 1 . This assignment can be carried out either automatically or manually by a user. If the quality level of the steel strip 1 does not allow compliance with a quality standard for an end product to be manufactured, the preprocessing of the data advantageously allows the quality level to be determined with respect to a different end product to be manufactured. This can be done on one hand by using other relevance criteria which are matched to the other end product to be manufactured. On the other hand, regrouping is possible by using grouping rules which, for example, are matched to other product areas 13 , 14 , 15 and, in a corresponding manner, other intermediate areas 16 and edge areas 8 . This advantageously allows quality management in which it is possible to choose an end product, which can be manufactured as optimally as possible therefrom, for each strip material. The comparison of a plurality of surface data items from different strip materials makes it simple to find faults in the production of the strip materials, and thus to overcome them more quickly. FIG. 4 shows a first exemplary embodiment of a view based on the type of spreadsheet calculation with a first spreadsheet 22 , a second spreadsheet 23 , a third spreadsheet 24 , a fourth spreadsheet 25 and a fifth spreadsheet 26 . The spreadsheet 22 contains a list of all of the existing strip materials, in each case listing different parameters of each strip material, such as an identification number, a production start time, the length, width, thickness and the weight of the strip material, in individual cells. Further parameters are the steel quality, as well as the planned purpose, the roughness and the customer for the strip material. Additional parameters can be added easily and quickly in the form of a spreadsheet calculation, by adding rows and/or columns. The second 23 , third 24 , fourth 25 and fifth 26 spreadsheet each contain geometric views of the strip material currently selected in the first spreadsheet 22 , with the corresponding groupings. Each of the four spreadsheets 23 , 24 , 25 , 26 shows the relevance of the detected surface anomalies for a different quality standard to be complied with, with the overall relevance being combined in each of combination cells 27 . On one hand, this allows the number of relevant faults to be read on the basis of the cell content, and on the other hand allows the overall relevance for compliance with the respective quality standard to be read from the coloring of the cell. In the present example in FIG. 4 , the use corresponding to the third spreadsheet 24 would be the most critical, while the use corresponding to the second spreadsheet 23 and the fifth spreadsheet 26 would be less critical. This allows the achievable yield to be optimized on the basis of the price to be achieved for the individual purposes. FIG. 5 shows a second exemplary embodiment of a view in the form of a spreadsheet calculation with a first spreadsheet 22 , a second spreadsheet 23 , a third spreadsheet 24 , a fourth spreadsheet 25 , a fifth spreadsheet 26 , a sixth spreadsheet 28 and a seventh spreadsheet 29 . The first spreadsheet 22 contains a list of all of the available strip materials, in a similar manner to that in the first exemplary embodiment, with parameters such as an identification number for the inspection data record, the production line on which the strip material is produced, the manufacturing start time, the time taken for manufacture, the length of the strip material, the cold strip from which the steel strip is produced, the roughness of the material, the thickness, the width and the weight, etc. The third spreadsheet 24 , the fourth spreadsheet 25 and the fifth spreadsheet 26 contain illustrations which are matched to the geometric relationships of the strip material. The rows each show data at a specific longitudinal coordinate, that is to say in the movement direction of the strip material, while the columns indicate the transverse coordinate of the strip material. The third spreadsheet 24 shows the number of surface anomalies per group of data records associated with each cell, while the fourth spreadsheet 25 shows the planarity discrepancy for each group from the mean planarity. The fifth spreadsheet 26 shows the discrepancy in the finishing temperature for each group from a mean finishing temperature. The sixth spreadsheet 28 shows the combination of the quality-relevant parameters, specifically the number of defects, that is to say the surface anomalies which would prevent classification in one quality standard, as well as the mean planarity of the strip material, the finishing temperature, the mean width and the quality level resulting therefrom. The seventh spreadsheet 29 shows the discrepancy from the mean width of the strip material, resolved for the longitudinal coordinates of the strip material. The second spreadsheet 23 contains individual illustrations of surface anomalies. The spreadsheets 22 , 23 , 24 , 25 , 26 , 28 , 29 are linked to one another so that, for example, if the computer mouse is clicked on one of the cells in the spreadsheets 24 , 25 , 26 , the corresponding illustrations of the anomalies in this cell in the spreadsheets 24 , 25 , 26 are indicated in the second spreadsheet 23 . A click in a different column of the first spreadsheet 22 leads to the corresponding data for this strip material that has now been selected being displayed in the other spreadsheets 23 , 24 , 25 , 26 , 28 , 29 , etc. As has been described by way of example herein, any desired spreadsheets can thus be combined with one another as required, with different displays, filtering operations and/or grouping operations. This is done in a simple manner in the form of a spreadsheet calculation, which even substantially untrained users can carry out. The assignment of the quality level is thus reproducible, and is transparent for third parties. FIG. 6 shows one exemplary embodiment of an apparatus 30 according to the invention for controlling the processing of strip materials 1 , with an evaluation unit 31 . The evaluation unit includes at least a storage device 32 , a grouping device 33 and a comparison device 34 . In addition to further possible components, the evaluation unit 31 in the present example has an evaluation device 35 which, however, is optional. Data links 36 are formed in order to connect the individual components 32 , 33 , 34 , 35 . These links can advantageously represent an addressable bus system, so that all of the connected components 32 , 33 , 34 , 35 as well as further connected components can be addressed individually through one common data link 36 . The data links may either be in the form of a wire, or may at least partially be wireless. Data can be stored in the storage device 32 , to be precise at least surface data and/or quality standard data which can be associated with an end product that can be manufactured from the strip material 1 . The surface data is in the form of data records which can be associated with the strip surface on the basis of coordinates, and in each case include surface data in particular such as surface roughness, planarity, a finishing temperature and/or the thickness of the strip material 1 and, if required, the data relating to at least one surface anomaly that is present. Further data can be stored, according to the invention. The grouping device 33 is used for grouping surface data on the basis of predeterminable grouping rules. The surface data is compared with at least one predeterminable quality standard on the basis of the comparison device 34 . The result of the grouping process in the grouping device 33 and of the comparison in the comparison device 34 (the comparison data) can be transmitted through the data link 36 to other components which are connected to them. The result of the comparison as well as the grouped surface data can thus be transmitted to the storage device 32 , and can be stored therein. Furthermore, an input device 37 and an output device 38 are provided, through the use of which commands can be entered and at least the surface data can be output, with at least one spreadsheet being input and output. The input device 37 and the output device 38 are likewise connected to the data link 36 , so that it is possible to access the data stored in the storage device 32 , as well as the data which has been output from the grouping device 33 and the comparison device 34 , for inputting and outputting. A keyboard and/or a computer mouse or the like can advantageously be provided as the input device 37 and, in particular, a monitor can advantageously be provided as the output device 38 . The input device 37 can also advantageously be used for inputting and/or definition of the grouping rules and/or of the comparison standards and/or of the quality rules for comparison of the groups with at least one quality standard. In addition, the apparatus 30 has a control device 39 which initiates a specific process for processing of the strip material 1 in order to manufacture an end product as a function of the comparison data produced by the comparison device 34 , or reject the strip material 1 , for example as being unusable. Alternatively or additionally, a user action can take place there. In this case, a specific processing process should be understood as meaning, in particular, the supply of the strip material for production of a specific end product. For example, the control device can supply the strip material for production of a first end product (for example a fender) or for production of a second end product (for example an engine compartment hood) as a function of the comparison data produced by the comparison device 34 . The supply to a specific processing process can be carried out through the use of an optional control input 43 , in which the control commands from the control device 39 are passed to appropriate apparatuses. The surface data can be stored in the storage device 32 , or can be saved there by a data storage medium which, for example, is used as material accompanying the strip material 1 . Furthermore, the evaluation unit can optionally be linked directly to a measured-value recorder 40 through the data link 36 , according to the invention. The optical measured-value recorder 40 , preferably a camera, and particularly a CCD or CMOS camera, advantageously makes it possible to record surface data for a surface 41 of a strip material 1 , which may be moving in a movement direction 42 . Anomalies can be found by the evaluation device 35 . The apparatus shown herein can be implemented, at least in parts, in an integrated circuit and/or a computer. The apparatus shown herein is preferably suitable for carrying out the method according to the invention. Reference is expressly made to the statements made above in particular for carrying out the evaluation process, for assignment of the quality level, for grouping, etc. If the system is used on-line, it is also possible according to the invention to make colored markings on this strip, by way of example, when predetermined contents occur in specific cells, or to carry out such markings of the strip end through the use of colored markings, stampings, perforations or the like, in order to identify the characteristics of the strip. The control device 39 is connected to a marking device 44 for this purpose. On the basis of the preprocessing of the surface data for a strip material, according to the invention, this data can for the first time be used to make reliable statements even during the production of the strip material, on the basis on one hand of the strip material and on the other hand of the end product to be manufactured therefrom, relating to the achievable quality of the end product, and/or to use the preprocessed surface data in a simple manner both in production planning and in quality management.
A method for preprocessing data for strip material, i.e. metal or paper strips, provides data records for a strip surface according to coordinates with information about a condition of the strip, its surface or anomalies. Some data records are grouped and stored in cells based on grouping rules. The cells are configured on a screen or other medium similarly to the strip surface. Contents of the cells can be electronically processed or linked to other cells or data and may be one-dimensional or contain and provide source data, grouping rules or processing formulae. The cells are in rows and columns of a spreadsheet. Preprocessing of the surface data allows statements about an achievable quality of an end product based on the material and the end product, even during production of the material, and simultaneous use of the surface data simply in production planning and quality management.
1
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of an earlier filing date from U.S. Non Provisional application Ser. No. 12/564,539 filed Sep. 22, 2009, the entire disclosure of which is incorporated herein by reference. BACKGROUND [0002] In the Drilling and completion industries it is often desirable to affect tools or formations at a great distance from a surface located facility such as a rig. One example of an operation intended to affect a formation is a fracturing operation. In order to perform such an operation, hydraulic pressure is built within a tubing string until the pressure exceeds formation capability for holding that pressure and fractures form in the formation. This type of operation is most effective if done in small incremental sections of a borehole for reasons related to control and distribution of fractures to serve the ultimate purpose of the borehole. Such purposes include hydrocarbon production, Carbon Dioxide sequestration, etc. [0003] In the art, fracturing discrete locations of the borehole tends to require a number of tools related to the pressuring of discrete locations. Such tools increase expense initially and generally create other issues to be overcome after the fracturing process is complete such as removal of the tools that enabled the pressuring of a discrete location. Where multiple fracturing locations are contemplated, generally a staged system must be built and administered correctly for it to work. One such system uses progressively larger seat diameters from the toe back to surface and then progressively increasing diameter balls. While the system works well, it is limited by the number of different size balls that can be used. Tolerance is also required in any system (due to such things as irregular shape of tubing secondary to borehole irregularity), which therefore further limits the number of diameters usable in a particular system. [0004] Since fracturing and other operations where it is desirable to isolate discrete locations continue to become more prevalent and ubiquitous, alternate systems for accessing and manipulating the downhole environment is always well received. SUMMARY [0005] A plug counter including a housing sized to receive and pass plugs; a helix sleeve rotatably positioned relative to the housing, the helix sleeve including a helical track having a plurality of consecutive turns; and, a key positionable relative to the helical track and responsive to movement of the helix sleeve in a first rotational direction, wherein the key prevents further movement of the helix sleeve in the first rotational direction after a selected number of plugs pass through the plug counter. [0006] A downhole tool including a housing having a support and one or more plug passage recesses; a movable plug seat positionable to be supported by the support or aligned with the one or more plug passage recesses; a helix sleeve rotatable in response to movement of the movable plug seat, the helix sleeve having a helical track including a plurality of consecutive turns; and, a key responsive to movement of the helix sleeve and configured to prevent further movement of the helix sleeve and movable plug seat after a selected number of movable plug seat movements. BRIEF DESCRIPTION OF THE DRAWINGS [0007] Referring now to the drawings wherein like elements are numbered alike in the several Figures: [0008] FIGS. 1-4 illustrate a cross sectional view of one embodiment of the tool disclosed herein in four different positions; [0009] FIGS. 5-8 illustrate in partial transparent view a counter portion of the tool disclosed herein in four different positions corresponding to the positions shown in FIGS. 1-4 ; [0010] FIG. 9 is a perspective view of an alternate moveable seat substitutable in the tool; and [0011] FIG. 10 is a schematic view of a portion of an alternate housing of the tool 10 shown in FIG. 1 . DETAILED DESCRIPTION [0012] Referring to FIGS. 1-4 , a plug counter tool 10 is illustrated in longitudinal cross section in four different positions to make apparent not only its structural constituents but its operation as well. It is initially noted that the term “plug” as used herein is intended to encompass tripping balls, darts, and similar structures that can be propagated through a borehole and/or tubing string to reach remote locations therewithin. The plug counter tool embodiments disclosed herein facilitate the use of a single size plug (or fewer sizes, if desired, in a particular application) for multiple actuation sequences. For example, where multiple fracture points are desired in a borehole, traditional fracturing would require a number of different diameter plugs used sequentially from smaller to larger as operations progress up the hole. With the tool embodiments described herein only one size plug is needed. [0013] Referring directly to FIG. 1 , an outer housing 12 includes a support 14 to support a moveable plug seat 16 , which in the case of FIG. 1 is presented by a set of collet fingers 18 . The support 14 and movable seat 16 operate together to catch a plug 20 after which the plug is passed or denied passage as discussed hereunder. The fingers 18 are supported by support 14 while the collet fingers are in the position shown in FIG. 1 . Support for the fingers 18 is dependent upon the position of collet 22 , which is dependent upon the ability of a spring 24 to hold the collet 22 in the position shown in FIG. 1 . More specifically, when a plug is seated in the seat 16 pressure can and will in operation be built uphole of the plug. The spring rate of the spring 24 selected dictates the amount of fluid pressure that can be resisted before the collet 22 moves in a downhole direction and the fingers 18 become unsupported. The spring 24 is a compression spring and as illustrated is a coil spring. It will hold the collet 22 in the illustrated position until a plug 20 engages the seat 16 and sufficient fluid pressure uphole of the plug overcomes the spring force of spring 24 and compresses the same. As the spring 24 is overcome by fluid pressure, the collet 22 moves in a downhole direction (to the right in the Figure) and moves the fingers 18 off of the support 14 . Just downhole of the support 14 is a plug passage recess 28 that will allow radial expansion of the fingers 18 (see FIG. 2 ) by an amount sufficient to allow passage of the plug 20 through the seat 16 . After passage of the plug, fluid pressure equalizes across the seat 16 and the collet 22 returns to the position of FIG. 1 under the bias of the spring 24 . [0014] Connected to the collet 22 is j-slot sleeve 30 . Sleeve 30 moves axially of the tool 10 along with the collet 22 . At a downhole end of the housing 12 , an anti-rotation sleeve 32 is attached to the housing. Sleeve 32 does not move relative to housing 12 in any way once the tool is assembled. Anti-rotation sleeve 32 includes one or more pin openings 34 into which one or more pins 36 will be individually inserted. Each pin 36 will thus be fixed to the anti-rotation sleeve 32 and extend into an alignment groove 38 of which there will be one or more in the j-slot sleeve 30 . The one or more pins 36 and respective alignment grooves 38 ensure that the j-slot sleeve 30 is not rotatable but is permitted to move only axially during operation of the tool 10 . Upon movement of the collet 22 induced by fluid pressure uphole of plug 20 as described above, the j-slot sleeve 30 will cycle back and forth axially of the tool 10 . [0015] Radially inwardly of the anti-rotation sleeve 32 and rotatable relative thereto is a helix sleeve 40 exhibiting a helical track 42 at an outside surface thereof. The helix sleeve 40 includes one or more j-slot followers 44 (one shown), which may be a part of the helix sleeve 40 or may be a separate component that is engaged with the helix sleeve 40 . In either event, the j-slot follower(s) 44 are configured to contact angled surfaces 46 and 48 of a j-slot 50 (see FIG. 5 ) disposed at the j-slot sleeve 30 upon axial movement of the j-slot sleeve 30 . Because followers 44 are fixed to the helix sleeve 40 , the helix sleeve 40 will move rotationally about the j-slot sleeve 30 as the followers 44 move along each angled surface 46 or 48 . The impetus for this movement is the axial cycling of the j-slot sleeve 30 as described above. Each time a plug 20 lands at the seat 16 , thereby allowing pressure to build from uphole against the plug 20 , and hence urging the collet 22 to a position aligning the fingers 18 with recess 28 , the followers 44 will contact and slide along one of the angled surfaces 46 . This will cause a measured rotation of the helix sleeve 40 . Because the spring 24 is compressed during this pressure induced axial movement, energy is stored that will be used to urge the followers 44 along the next adjacent angled surface 48 pursuant to the j-slot sleeve 30 moving uphole under spring bias, causing another measured rotation of the helix sleeve 40 . The spring 24 induces such movement only after the plug 20 , against which fluid pressure had been applied, is released. [0016] As the helix sleeve 40 rotates, a key 52 that is engaged with the helical track 42 moves leftwardly in the drawing closer to an end 54 of a keyway 56 . It is to be appreciated that although the illustrated embodiment moves in an uphole direction, the tool 10 can easily be configured to allow movement of the key 52 in a downhole direction by reversing the helix angle of the helical track 42 and reversing the surface angles of surfaces 46 and 48 . As illustrated in FIGS. 1 and 5 , the key 52 is in a position that will allow the greatest number of plugs to pass before preventing passage of the next plug to be seated. FIGS. 4 and 8 show the key in the position where the next plug to seat will not pass. [0017] As configured the tool 10 will pass a number of plugs and then prevent further passage of plugs because the helix sleeve 40 is prevented from rotating by the contact between key 52 and an end 54 of keyway 56 . The prevention of rotation of the helix sleeve 40 correspondingly prevents the j-slot sleeve 30 from cycling downhole sufficiently to allow the fingers 18 to reach the recess 28 . Consequently the plug 20 cannot pass. This position is illustrated best in FIG. 8 where key 52 is at end 54 and follower 44 is at surface 46 but it cannot slide on surface 46 because the key will no longer allow rotation of the helix sleeve 40 due to having run out of helical track 42 . It is to be understood, then, that the maximum number of plugs that are passable through tool 10 are fixed by design during manufacture by the length of the helical track 42 and the keyway 56 . This is not to say however that this maximum number of plugs is the only number of plugs that will be passable before a plug is denied passage. Rather, because the key is placable in the keyway 56 as the tool is being run into the hole, at any point on the helical track 42 that is exposed to the keyway 56 , any number from the maximum number down to a single plug may be selected. [0018] More specifically, the key 52 is a component of the tool 10 that is removable and replaceable at any point along the keyway 56 where the helical track 42 crosses the keyway 56 . The helix sleeve 40 itself may be marked to show how many plugs will pass before denying passage to make it a simple operation in the field for a rig worker to place the key in the keyway 56 to select a number of plug passages to facilitate a particular operation. It should be noted that because of the high pressures generally encountered in the wellbore for operations related to seating plugs and the potential operations that might be effected by pressuring up on such a plug, for example fracturing at about 10,000 psi, the key 52 should be robust in size and construction as it is, in the end, the key that stops movement of the balance of the components. [0019] Another feature of the tool 10 is that if for any reason, after plug passage has been denied, it is necessary to pass the denied plug, the follower(s) 44 may be released by, for example, shearing and the collet will be able to move to the recess 28 allowing the plug to pass. This is accomplished by pressuring up higher on the tubing to greater than a threshold pressure that is set prior to running the tool 10 in the hole by the number and strength of the followers 44 employed in the tool 10 . Thereafter all plugs will pass and no further counting will be possible with the tool 10 without removal thereof from the hole and replacement of one or more followers 44 . [0020] Referring to FIGS. 9 and 10 , an alternate embodiment of the tool disclosed above is illustrated. The embodiment operates similarly to the tool 10 and identically operating components are not discussed again. The tool is distinct in that a dog-based seat structure 122 , having a plug seat 116 , is substituted for the collet 22 in the FIG. 1 embodiment. For clarity, numerals are mimicked in the 100 series. In normal operation the dogs function, as do the fingers 18 from the previous embodiment. The housing 112 is also distinct in that an additional plug passage recess 150 is provided uphole of the support 114 so that in reverse flow, the one or more dogs 118 can be moved into alignment with the recess 150 to allow passage of one or more plugs in the uphole direction as part of a reverse circulation operation to remove the plugs from the borehole. In order for the structure 122 to move uphole, a plug that had been passed in normal operation of the tool 110 is moved in reverse circulation into a seat 117 on the backside of seat 116 . The pressure of reverse circulation acts on the plug in the same manner as in the original operation but in the opposite direction. A spring 152 is disposed uphole of the structure 122 and will be compressed against a top sub 154 at a selected force from fluid pressure on the plug. Movement of the structure 122 in the uphole direction mirrors that of movement in the downhole direction and aligns the dogs 118 with the recess 128 , which allows the plug to pass. While an embodiment could eliminate spring 152 and simply allow the structure 122 to stay in the uphole position, including the spring 152 provides the added benefit that the device will automatically revert to a functional state after passage of the plug in the uphole direction so that normal operation of the tool 110 could be resumed if desired. [0021] While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.
A plug counter including a housing sized to receive and pass plugs. A helix sleeve rotatably positioned relative to the housing. The helix sleeve including a helical track having a plurality of consecutive turns. A key positionable relative to the helical track and responsive to movement of the helix sleeve in a first rotational direction, wherein the key prevents further movement of the helix sleeve in the first rotational direction after a selected number of plugs pass through the plug counter. Also included is a downhole tool including
4
CROSS-REFERENCES TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/306,646, filed Feb. 22, 2010, the entire content of which is herein incorporated by reference. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] (Not Applicable) BACKGROUND AND SUMMARY OF THE INVENTION [0003] The invention relates to a pricing, marketing and inventory control mechanism that allows patrons the opportunity to participate in and manipulate the pricing of a product by virtue of what exactly they purchase, in what quantity they make the purchase and the timing of the purchase. [0004] The method encapsulates the basic laws of economics and provides instantaneous price changes sensitive to both supply and demand. In a free market, the equilibrium price of a good is that at which the quantity supplied equals the quantity demanded. The method tailors the price of a good to increase or decrease instantaneously per x transactions dependent upon the state of demand. When the demand for a product increases, the price will increase. When demand is scarce or nonexistent, the price will decrease to advertise/stimulate a sale or discount. [0005] The method operates on these elementary business laws and instantaneously responds accordingly. It can be applied to both retail and wholesale transactions. [0006] In an exemplary embodiment of the invention, a pricing, marketing and inventory control method is provided for consumer goods in a retail establishment. The method includes the steps of (a) establishing baseline prices for an inventory of consumer goods; (b) defining price increase indicators and a price increment for each of the consumer goods; (c) defining price decrease indicators and a price decrement for each of the consumer goods; (d) displaying current prices of the consumer goods; (e) adjusting the current prices by the price increment upon occurrence of one of the price increase indicators; (f) adjusting the current prices by the price decrement upon occurrence of one of the price decrease indicators; and (g) repeating from step (d). [0007] Step (d) may be practiced by displaying an upwardly pointing arrow for consumer products with an increasing price and displaying a downwardly pointing arrow for consumer products with a decreasing price. Moreover, the price increment for a specific consumer good may be determined based on anticipated demand for the specific consumer good. In one arrangement, the method includes monitoring a rate of sales of a particular consumer good at various price points. [0008] The price increase indicators may comprise a rate of sale of the consumer goods. The price increase indicators may alternatively comprise a number of the consumer goods sold. The price decrease indicators may comprise an elapsed time period between sales of the consumer goods. [0009] In another exemplary embodiment, a pricing, marketing and inventory control system for consumer goods in a retail establishment includes a system server storing baseline prices for an inventory of consumer goods. The system server includes a price increase module storing price increase indicators and a price increment for each of the consumer goods and a price decrease module storing price decrease indicators and a price decrement for each of the consumer goods. A display communicates with the system server and displays current prices of the consumer goods. A processor communicates with the system server and adjusts the current prices by the price increment upon occurrence of one of the price increase indicators and adjusts the current prices by the price decrement upon occurrence of one of the price decrease indicators. [0010] The display may generate a moving ticker display of the current prices of the consumer goods. [0011] The system may additionally include a client computer communicating with the system server, where the client computer includes user interface structure enabling user input relating to the consumer goods. In this context, the client computer is programmed to accept an order for the consumer goods. BRIEF DESCRIPTION OF THE DRAWINGS [0012] These and other aspects and advantages will be described in the following detailed description with reference to the accompanying drawings, in which: [0013] FIG. 1 is schematic block diagram showing the system and method of the preferred embodiments; and [0014] FIG. 2 shows a pricing model for a consumer product. DETAILED DESCRIPTION OF THE INVENTION [0015] Demand for a product can be said to be very inelastic if consumers will pay almost any price for the product, while demand for a product may be elastic if consumers will only pay a certain price, or a narrow range of prices, for the product. Inelastic demand means a producer can raise prices without much hurting demand for its product, and elastic demand means that consumers are sensitive to the price at which a product is sold and will not buy it if the price rises by what they consider too much. Drinking water is a good example of a good that has inelastic characteristics—in that under certain circumstances and in the absence of competitive suppliers, people will pay anything for it. On the other hand, demand for soda is very elastic because as the price of any given brand or flavor increases there are many substitute goods to which consumers may switch. [0016] In a “bar” application, the system for carrying out the method may include a continuously streaming ticker strip resembling that of a securities exchange that would run at locations within the establishment and be visible to all of the patrons. With reference to FIG. 1 , the ticker strip 20 is driven by a server 12 including a microprocessor 14 and other known components used for operating and interacting with a computer system (e.g., user interface, memory, programming, etc.). Additionally, the ticker strip display 20 itself can be of any known structure, and the structural details thereof will not be described. On the strip would be abbreviations for many of the items on the menu (most likely various drinks), which would electronically and automatically (based upon programming choices made by the bar operator) change in price depending on what the customer purchases, in what quantity they make the purchase, and the timing of the purchase (price increase/decrease indicators). The ticker strip may indicate whether the price of a particular item is rising with an arrow, for example a green arrow, or falling with an arrow, for example a red arrow (see FIG. 2 ). If, for example, Bud Light® is a popular drink on a given night (price increase indicator), the price will continue to rise until demand has diminished (x amount of time, e.g., 10-15 minutes, has passed between purchases—price decrease indicators), at which point the price will begin to decline back to a level that will serve to increase demand. In the meantime, customers would have the opportunity to seek bargain pricing on less popular items or venture to try a new drink, perhaps identified as an “Initial Public Offering.” [0017] A “split” can also be programmed to occur. A range of prices can be predetermined for a given product by the bar operator. A “stock split” can be simulated by the price of, for example, Bud Light® rising from the starting price of $2.00 per unit to $4.00 per unit then “splitting (2 for 1)” to the price of $2.00 per unit again. In the alternative, if the price reaches a height of $3.90 for example and no customer is willing to make the next purchase for $3.90 or above because they anticipate a split at $4.00, MTBP (mean time between purchases—price decrease indicator) becomes an important price manipulating factor bringing the prices down incrementally over time when there are a lack of purchases for a particular product. Therefore, if the price on a good is high and no one is willing to buy, in time (predetermined by the operator), the price will fall until purchases commence again. [0018] Applied to a bar on the holidays, an operator would be able to anticipate demand of various drinks and set price steps accordingly. Instead of the price of Champagne increasing $0.05 per unit sold on New Year's Eve, the steps could be set to $0.10, $0.20 or whatever the operator believes would be the optimal value given the elasticity or lack thereof on any given occasion. Over a predetermined time if demand diminishes for one brand or particular product (price decrease indicator), the price would begin to come down by a predetermined amount to attract more demand as stated before. This gives the operator the flexibility to manage his inventory of specialty products (which have less of a sales history) by changing the price at any given time to increase or decrease sales and subsequently manage inventory. [0019] Another example is Cinco de Mayo. When the operator anticipates high sales of Mexican beer and margaritas on this Mexican holiday, more profitable price increments can be set because the price on these items would most likely be more inelastic. This method would assist business owners in capitalizing on various special occasions, weekends and holidays. It would also provide data about the rate of sales at particular price points, allowing the operator to better understand what customers are willing to pay for specific items and what inventory to maintain. [0020] The method creates constant, active control and more profitability for business owners as well as incentives for the consumer. The business owner has complete control of incremental price increases and decreases as well as the time that must elapse before price adjustments. The method gives more power to the operator and decreases the time, personnel, and paperwork it would take to adjust to variations in demand. [0021] The owner has the ability to change any product's price instantaneously through the system, which would be reflected on the streaming ticker strip of various products for sale. The method creates convenience and enhances profit potential for the business owner. [0022] The consumer has a motivation to purchase more of a given product before others due to the anticipation of price increases. While the business owner has complete control, the consumer will anticipate various price fluctuations and prepare accordingly by potentially purchasing numerous drinks in advance, purchasing “futures.” A futures contract is a standardized contract to buy or sell a specified commodity of standardized quality at a certain date in the future and at a market-determined price, i.e., the futures price. In this method for example, a customer could pre-purchase 10 Bud Light® beers for a fixed price (whatever the current market price happens to be at the time of purchase). A customer (or group of customers at a table) would be motivated to pre-purchase product x if they believed it would rise in price later in the day/evening (with limitations placed upon the purchase such as one drink at a time per person at the table so that one customer doesn't place a large futures order and begin to broker drinks throughout the bar at a price above their purchase price). [0023] The method also creates competition and motivates customers to come earlier than their “competitors” (other consumers competing for the same low prices). By the same token, customers who arrive later in the evening would benefit from price reductions on drinks that are less popular on that particular day and benefit from stock splits on popular items. The method would create a competitive marketplace in any business application, which is extremely beneficial for a business owner. [0024] Consider the situation where someone believes that they ordered a drink at the $2.00 price quoted by the ticker strip, but by the time the waitress gets to place the order, the price has gone up. In operating the system, every order should be confirmed at the time that it is placed. In one embodiment, with continued reference to FIG. 1 , the system includes a plurality of client computers 16 , which may be user terminals at restaurant tables, bar seats, etc. At a particular bar, for instance, the client computers 16 may be hand-held devices allowing the waitresses to place orders at prices that are reflected on the ticker strip and produce a paper confirmation of the trade. As an alternative and to make the experience more interactive for the customers, the client computers 16 may include a touch screen device placed at each table. As a customer finds a menu item that they want to order, they could enter the abbreviation on the touch screen at which time the price would appear next to it (which is the same price being displayed on the ticker strip 20 ). The customer would input the number of units that they want to purchase for that item and either hit “place order” or wait for the price to reach a number that they find attractive. In either case, as soon as they hit “place order,” the order is printed at a separate station, and a “floor trader” comes to their table to confirm the trade (or deliver the requested product). As an alternative, the touch screen could confirm the order and require the customer to acknowledge confirmation before the order is placed. Once the trade is confirmed, it is transmitted to a waitress station or handed to a waitress who fills the order just as in a normal restaurant or bar. At the end of the evening, the multiple order confirmations can be compared against the final bill to confirm the total. The touch screen system could be enhanced to allow customers to place limit/buy orders and purchase “futures” as discussed previously. [0025] Another alternative would require connecting the bar's website to the ticker strip and order confirmation system. For instance, if a customer in the bar already has a web browser on their phone, they could go to the bar's website and order their drinks at the ticker strip prices at which time the floor trader would get a printed order and proceed to their table to confirm the trade. It would also be strategic marketing for businesses to utilize this method by placing their “tickers” online so customers can compare and anticipate the specials or “undervalued securities” in “real time.” [0026] After confirmation of the trade, a waiter/waitress places the order and serves the customers as is customary. They will need to be able to explain the ordering system and ticker strip to new patrons, but it will not be complicated. Regarding gratuity, at the operator's discretion a “brokerage fee” could be programmed into each trade to represent the tip. Otherwise, patrons could compute and leave tips at their discretion. [0027] In a “bar” application, the method would allow the business owner to start at any given time in a state of equilibrium with fixed inputs of supply. Assume a bar has 100x, 100y and 100z drinks to supply in a given evening The bar owner has the power to set price, quantity and time increments for price adjustments both upwards and down. If drinks x and y are more popular in a given time frame than drink z, the prices of drinks x and y would increase thereby testing the elasticity of their demand. Realistically, the prices would eventually reach a level where they become less desirable. Drink z then, which would have fallen in price incrementally by a predetermined amount, would become more desirable at that specific time, until a point at which the same laws of economics occur. If drink z becomes popular, its price would escalate while the prices of drinks x and y would fall until they become more demanded. The law of demand applies to the substitution of cheaper goods for more expensive goods due to a relative change in price. If drink z fails to pick up in demand over a specified timeframe for whatever reason, the operator can trigger a split or crash in either or both drinks x or y to stimulate sales. [0028] Depending on the particular location, an approaching customer may see a streaming ticker strip outside for advertising purposes, as well as a ticker strip on the inside so that he or she can react to the streaming information. This “ticker strip” can be any monitor or device that makes public the price fluctuations occurring. This would mimic a securities exchange as described but will be completely different in subject matter and application. Upon entering a bar or restaurant, for instance, an unfamiliar customer could place their order with a waitress or participate electronically by using the touch screen or web browser as described previously. At the end of the evening, the customer would be presented with a final bill, which could be compared to the individual order confirmations for accuracy. Payment would then occur normally as it does in existing restaurants and bars. [0029] The operator has the ability to start the ticker strip with any set of pricing he chooses. One could close the market where it left off and reopen the following day with the same prices, or adjust the pricing based upon information gained from the previous days' sales, or simply reset to a standard default before every opening [0030] The method does not require the bartenders or waitresses to have an advanced education in finance. The system includes software programming to connect the ticker strip to the touch screen monitors at the tables and to the cash registers so that the purchase of a given item would produce a trade confirmation and influence the ticker strip pricing based upon previously programmed parameters set by the operator (i.e., the sale of 10 units causes an increase in price of $0.10 per unit). As previously mentioned, it may also require connecting the bar's website to the ticker strip and ordering system. The price reflected on the ticker strip would depend on the speed of sales, the quantity of sales, and the particular product sold. After the order is placed and confirmed, a waitress or bartender would handle the order as it is customarily done. [0031] The operator has complete control over their product's pricing. As a novelty, and to keep the experience exciting, the operator would be able to simulate a “market crash” or “recession” by depressing the prices of particular goods, or of every good being sold at any time to “stimulate” the market. The range of possibilities and scenarios is limited only to the imagination of the operator. There could be a “gold rush” where gold tequila goes on discount, and its depressed price would be reflected on the ticker tape until a second scenario occurs. [0032] The method is horizontal in nature; that is, applicable across many industries. In regards to cost, it is up to the means of the operator to implement the method how he/she chooses. One could merely use the idea as a happy hour special or turn on the ticker strip at certain hours of operation. One could have a combination of fixed price items (i.e. tea and coffee) and trading items. One could separate the inventory by class (merlot, cabernet, whiskey, vodka, imported and non imported beer etc.) and have streaming prices that affect the entire class. One could merely have the price variations at the bar (in the “trading pit”) while offering fixed priced drink menus to those sitting at tables who choose not to participate in the “market” trading. Ultimately, an operator could either fit this method into their original business model, or they could build a new business model around this method. [0033] Price setters are those companies that dictate the price its customers pay for goods and services. Price takers are those companies that cannot dictate their prices because their prices are dependent on the market. The method takes benefits from both options and utilizes them in a way that creates competition in the “marketplace” (the individual business in question), while maintaining complete control. With the method and system of the invention, a business is able to not only dictate the price its customers pay for their goods and services by setting a “floor” or minimum price (the starting equilibrium price which should already have costs and a profit built in), but will also “allow” themselves higher margins by giving their patrons full responsibility over driving prices up or down dependent upon their preferences. See FIG. 2 . [0034] With the proper application of this method, patrons will find excitement and novelty in their ability to cause price fluctuations and seek deals. The dynamic environment will also encourage social interaction. The operator will benefit from an inventory control system, a marketing tool and a pricing mechanism that allows him or her to make instantaneous adjustments to maximize revenues or induce the purchase of new or less popular products. Over time, the continuous accumulation of sales data for each item at various price points will allow for strategic planning and a more accurate forecasting of future operations. [0035] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
A pricing, marketing and inventory control system and method provide a unique scenario for selling consumer products. For an inventory of consumer goods, baseline prices are established. Additionally, price increase indicators are defined, and a price increment for each of the consumer goods is defined. Similarly, price decrease indicators are defined, and a price decrement for each of the consumer goods is defined. Current prices of the consumer goods are displayed, and the current prices are adjusted by the price increment upon occurrence of one of the price increase indicators and by the price decrement upon occurrence of one of the price decrease indicators. The process is repeated as sales are made.
6
FIELD OF INVENTION The present invention relates to a waste processing system comprising a first mixing tank system with an agitation system, a first separation system, a slurry tank system with a shearing system, a second separation system and a second mixing tank system with an agitation system. The present invention also relates to methods of processing waste. BACKGROUND OF INVENTION The disposal of waste such as drilling waste (e.g., cuttings, muds, reservoir pit, fluids, etc.) from drilling various types of wells has become an increasingly difficult problem due to restrictions imposed by various governmental authorities and agencies, and the desire to minimize environmental damage. These problems are aggravated or at least amplified in certain wellbore drilling operations, particularly in offshore drilling operations, wherein the disposal of wastes normally requires transport of the waste to a suitable landfill or shore-based processing system or an offsite commercial nonhazardous oilfield waste facility. Disposal of nonhazardous oilfield waste (NOW) can be disposed of by the above methods. Another method of disposing of drilling waste is to dispose of such waste down a wellbore of a non-productive reservoir of an exploratory well. Drilling operators, regulators and government authorities are trying to determine whether the above method can be applied to injecting productive pit solids contaminated with naturally-occurring radioactive material (NORM) either alone or in combination with NOW, into non-productive reservoirs. SUMMARY OF THE INVENTION The present invention relates to a waste disposal system comprising at least one mixing tank system comprising at least one mixing tank having an agitation system situated within each of the mixing tanks, a first separation system having at least one separation device, at least one slurry tank system comprising at least one slurry tank having a shearing system situated within each of the slurry tanks, and a second separation system having at least one separation device. In one embodiment, the waste processing system further comprises a plurality of conduits for connecting the mixing tank system, the first separation system, the slurry tank system, and the second separation system. Conduits or flow conduits are a piping system that connect each component of the waste system to one another and is subsequently connected to an injection pump for injecting the processed waste into a wellbore. In another embodiment, the mixing tank system can comprise at least one mixing tank having a jet line and a sampling system for testing the waste. The sampling system is a system that can be installed throughout different stages of the waste process system that enables the user to test samples of the processed waste in order to obtain a more controllable product. In still another embodiment, the agitation system of the mixing tank system can comprise a gear box, at least one motor and a plurality of blades. In yet another embodiment, the first and second separation system comprises at least one separation device having at least one screen or a plurality of screens with varying screen mesh sizes. The screen mesh sizes are dependent upon the size of the particles of waste being processed. The separation devices include, but are not limited to, vibrating screens such as shale shakers. In still a further embodiment, the slurry tank system can compromise at least one slurry tank having a shearing system situated within each of the slurry tanks. The shearing system can comprise a gear box, at least one motor, a plurality of blades, a shearing mixer, and gun lines. The slurry tanks can also have a manifold system. The manifold system is designed to re-circulate materials throughout the system so that a user can adjust the fluid and flow rates of the waste processing system of the present invention. For purposes of this invention, gun lines are mechanical agitators of the processed fluid and wastes traveling through the waste processing system. In one embodiment, the system of the present invention further comprises a second slurry tank system connected to the second separation system. The second slurry tank system comprises at least one slurry tank having a shearing system situated with each of the tanks. The shearing system is similar to the shearing system of the first slurry tank system. In another embodiment, the waste processing system of the present invention further comprises a second mixing tank system connected to the second separation system. The second mixing tank system comprises at least one mixing tank having an agitation system situated within each of the tanks. The agitation system is similar to the agitation system in the first mixing tank system. The agitation system of the present invention includes shearing devices and shearing systems. In still another embodiment, the system of the present invention further comprises a pump system for pumping waste through the system. The pump system can comprise a plurality of injection pumps and centrifugal pumps. In still yet another embodiment, the mixing tank system may comprise at least one mixing pump and the slurry tank system may comprise at least one shearing pump. In a further embodiment, the waste processing system further comprises at least one holding tank. The holding tank retains the processed waste until it is ready to be injected into the wellbore. In still another embodiment, the holding tank can be adapted to be transported to the injection site. In another embodiment, the present invention relates to a waste processing system comprising: (a) a first mixing tank system comprising at least one mixing tank having a first agitation system situated within each of said mixing tanks, (b) a first separation system comprising at least one separation device and being connected to the first mixing tank system, (c) a slurry tank system comprising at least two slurry tanks having a shearing system situated within each of the slurry tanks, the slurry tank system being connected to the first shale shaker system; (d) a second separation system comprising at least two separation devices and being connected to the slurry tank system; and (e) a second mixing tank system comprising at least two mixing tanks, each of the tanks having a second agitation system within the tanks, the second mixing tank system being connected to the second separation system. In a further embodiment, the first and second mixing tank systems can comprise at least one mixing tank having a jet line. The second mixing tank system can comprise at least one mixing tank having a sampling system for testing the waste. The sampling system can be installed throughout the different stages of the waste processing system. The sampling system enables the user to obtain test samples of the processed waste product. In yet another embodiment, the first and second agitation systems of the first and second mixing tank systems comprise a gear box, at least one motor and a plurality of blades. In still yet another embodiment, the first and second separation system comprises at least one separation device having at least one screen or a plurality of screens with varying screen mesh sizes. The screen mesh sizes is dependent on the size of the waste particles being processed. The separation device can include, but is not limited to, vibrating screens such as shale shakers. In yet a further embodiment, the slurry tank system can comprise at least one slurry tank wherein a shearing system is situated. The shearing system of the slurry tank system can comprise a gear box, at least one motor, a plurality of blades, a shearing mixer, and gun lines. In one embodiment, the waste processing system further comprises a plurality of conduits for connecting the first mixing tank system, the first separation system, the slurry tank system, the second separation system and the second mixing tank system. In another embodiment, the system of the present invention can comprise a pump system from pumping waste through the waste processing system. The pump system can comprise a plurality of injection pumps and centrifugal pumps. The pump system is capable of pumping a certain liquid though the system. The pump system may also comprise at least one pump having impellers for shearing the waste. The mixing tank system may have a mixing pump and the slurry tank system may have a shearing pump. In still another embodiment, the waste processing system can further comprise a holding tank for retaining the processed waste. The holding tank can be connected to the second mixing tank system. In yet another embodiment, the waste processing system of the present invention comprises a wellbore wherein the processed waste is injected. In a further embodiment, the present invention relates to a method of processing waste which comprise the steps of: (a) providing a first mixing tank comprising at least one mixing tank having an agitation system situated within the tank, a first separation system comprising at least one separation device and at least one slurry tank system comprising at least one slurry tank having a shearing system situated within the tank; (b) mixing waste and carrier liquid in the first mixing tank system using the agitation system; (c) separating the mixture using the first separation system into at least two portions, a first portion being solid debris and a second portion being processable waste; and (d) shearing the processable waste using the shearing system of the slurry tank and slurrifying the processable waste using the slurry tank system. The solid debris includes rocks, shackles, boulders, tools, nuts, bolts, logs and any article that cannot be sheared by the system of the present invention. The solid debris can be stockpiled or fragmented into finer particles by a pulverizing system. The pulverizing machine is any apparatus that can fragment or breakdown such large debris into a processable waste size. The fragmented debris can then be processed by the system of the present invention. In a yet further embodiment, the method further comprises the step of (e) further separating the slurrified processable waste of (d) into at least two fractions, a first fraction being coarse fractions and a second fraction being fine fractions. This separation is accomplished using a second separation system comprising at least one separation device. In another embodiment, the method further comprise the step of (f) further mixing the mixture of (e) using a second mixing tank system having at least one mixing tank with an agitation system. In still another embodiment, the mixture of steps (f) can be further sheared and slurrified. In a further embodiment, the further mixing of step (f) is performed prior to the further separation of step (e). In yet another embodiment, the processed fine fraction mixture of the present invention can be injected into a wellbore such as a non-productive reservoir. In one embodiment, the system of the present invention also includes providing a plurality of conduits for connecting the first mixing tank systems, the first separation system, and the slurry tank system. In still another embodiment, the method of the present invention further comprises the steps of pumping waste through the system using a pump system and retaining the processed waste in at least one holding tank. In a further embodiment, the pump system comprises a plurality of injection pumps and centrifugal pumps. The method further comprises the step of disposing of the processed waste product. In still yet a further embodiment, the present invention relates to a method of processing waste comprising the steps of: (a) mixing waste and a certain liquid, (b) separating the mixture into at least two portions, a first portion being solid debris and a second portion being of processable waste, (c) shearing and slurrifying the processable waste, (d) further separating mixture of step (c) into at least two fractions, a first fraction being coarse fractions and a second fraction being fine fractions, and (e) further mixing slurrified fine fractions of step (d). In yet still another embodiment, the processed mixture of step (e) can be injected into a wellbore. In one embodiment, the mixing is performed using at least one mixing tank system with agitation system. In another embodiment, the separation is performed using at least one separation system having at least one separation device. In a further embodiment, the shearing of the mixture is performed using a shearing system of the slurry tank system, wherein the shearing system is situated with the tank and comprises a gear box, at least one motor, at least one blade, at least one shearing mixer, and gun lines. The slurrifying can be performed using the slurry tank system. BRIEF DESCRIPTION OF THE DRAWINGS A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily understood by reference to the foregoing description where considered in connection with the accompanying drawing in which: FIG. 1 is an overhead view of the waste disposal system of the present invention. FIG. 2 is a flow diagram of the waste disposal system and the related method of processing waste. DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings wherein like reference numbers designate identical or corresponding parts throughout the several views, and particularly, the FIG. 1 wherein the waste processing system in accordance with the present invention, generally designated 1 , comprises a first mixing tank system 9 having at least one mixing tank 10 . Each of the mixing tanks 10 have an agitation system situated within the tanks. The agitation system of the present invention both mixes and shears. The agitation system of the present invention includes shearing devices and shearing systems. The agitation system comprises at least one motor, a gear box and a plurality of blades. The motor can be a Blue Chip Motor manufactured by Marathon. The first separation tank may also have a grading situated across the top of the tanks. The size of the mixing tank 10 is dependent upon how fast the operator wants to process the waste and the size and type of particles of waste being processed. At least one modified centrifugal pump 5 is attached to the first mixing tank system 9 . The modified centrifugal pump is modified by increasing the spacing between the holder and impeller of a centrifugal pump. The centrifugal pump may be a Magnum 250 Pump which is manufactured by Harrisburg, Inc. There are jet lines and re-circulation lines attached to the first mixing tank system 9 . A first separation system 11 comprising at least one separation device 12 is attached to the first mixing tank system 9 . The separation device 12 can be any vibrating screen such as shale shaker. The separation device may be a Scalping Shaker manufactured by Fluid Systems Corp. A manifold can be attached to the first separation device to control the speed and flow of the waste processing system 1 . A slurry tank system 13 is connected to the first separation system 11 . The slurry is tank system 13 comprises at least one slurry tank 14 having a shearing system situated within each tank 14 . The shearing system comprises a gear box, at least one motor, a plurality of blades, a shearing mixer and gun lines. The motor may also be a Blue Chip Motor manufactured by Marathon. The shearing Mixer may be a Rotostat mixer manufactured by Admix. The gun lines may be Mud Guns manufactured by Harrisburg. At least one shearing pump 25 is attached to the slurry tank system 13 . The slurry tank system 13 has a plurality of outlets whereby re-circulation lines and conduits can be attached. A manifold system is also attached to the slurry tank system 13 . A second separation system 15 comprising at least one separation device 16 is attached to the slurry tank system 13 . The separation device 16 in the second separation system is similar to the separation device in the first separation system 11 . A second mixing tank system 17 comprising at least one mixing tank 18 is attached to the second separation system 15 . The size of the mixing tank 18 is contingent upon the size and type of particles of waste being processed. The second mixing tank system 17 has an agitation system situated with the mixing tanks 18 . The agitation system is similar to the agitation system of the first mixing tank system 9 . A centrifugal pump 35 is attached to the second mixing tank system 17 and a manifold system is attached to the centrifugal pump 35 . A holding tank 20 is attached to the second mixing tank system 17 . The first mixing system 9 , the first separation system 11 , the slurry tank system 13 , the second separation system 15 , the second tank system 17 and the holding tank 20 are connected by conduits 7 . The re-circulation lines and conduits 7 can be connected to any of the tanks using the manifold system. The holding tank 20 may have a plurality of compartments 20 a - 20 d respectively and each compartment may have gauges to measure the amount of solids that are injected into the well. The holding tank 20 can also have a manifold system. At least one of the compartments can retain water to control the pressure within the compartments 20 a-d . The waste processing system 1 can have a motor control room or a (SCR) service control room wherein control boxes, power sources, etc. are stored. Referring now to FIG. 2, the waste material is fed to the first 250 bbl mix tank 10 by a conveyor belt or by a pump 5 . The main objective of this tank 10 is to fragment the clumps of clay pit solids and mix the solids with water. The tank 10 has two agitators within the tank and at least two centrifugal pumps 5 . As the agitators rotated, the clumps of clay solids were battered by the paddles and broken up into smaller solids. The centrifugal pumps 5 are multifunctional. First, the pump sucks the solids from a bottom manifold and the solids are then pumped to the first stage separation device 12 . To relieve the amount of flow, a circulating or manifold system was installed outside the tank 10 . The circulation or manifold system functions to mix the solids in the 250 bbl tank 10 . Second, the pump 5 is used as a back up pump and to assist in the mixing process within the tank. Third, the pump 5 may also function as a circulation pump. After the material is pumped over the first stage separation device 12 , the device 12 equipped with large mesh screens functions to separate any large debris and unwanted metals out of the slurry mix before allowing the processable waste to enter into the slurry tanks 14 . The debris is collected into an area to be disposed of in another manner or can be further processed. The processable waste is then drained into the slurry tanks 14 at a controlled rate. The slurry tank system 13 has valves to control the amount of flow or the direction of processed waste. Each slurry tank 14 is equipped with a centrifugal pump 25 with a manifold system. The pump 25 has carbon tip blades which assists in the life extension of the blades. The high energy mixing and the grinding action of the slurry unit 14 causes the slurry material to be sheared and therefore reduced in particle size. From the slurry tanks 14 , the slurry is pumped over a second stage separation device 16 where the slurry passes over another set of screens that are sized accordingly to the well specification. The screens catch and separate any coarse fractions that escaped the grinding action from the slurry tank 14 . The coarse fraction can be stockpiled or re-circulate through the waste processing system 1 of the present invention. The fine fractions that passes through the second stage separation device 16 are then fed into the 150 bbl mixing tank 18 which are equipped with agitators and centrifugal pumps 35 . The second mixing tank 18 is used to regulate the control of all the slurry that will be injected into a wellbore. The second mix tank 18 also has a manifold system that enables us to feed the pumps 35 or re-circulate mud to any stage of the waste processing system 1 . The manifold can be use to re-circulate the waste product to the 250 bbl mix tank 10 . The processed slurrified fine particles are sent to the 400 bbl holding tank. The holding tank 20 is set up with four compartments 20 a-d , each compartment being at 100 bbls. The holding tank 20 is set up with a suction manifold that is valved at each compartment. It is also manifolded to discharge into each compartment or back into the receiving line. The compartments of the holding tank 20 has an agitation system. The agitation system comprises a gear box, a motor and a plurality of blades. The 400 bbl holding tank 20 has at least two centrifugal pumps 35 that feed injection pumps 45 that are used for injecting the slurry into the wellbore. Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that with the scope of the claims appended hereto, the invention may be practical otherwise then as specifically disclosed herein.
A waste processing system comprising a mixing tank system with an agitation system; a separation system, and a slurry tank system having a shearing system. The present invention also relates to a method of processing waste which includes the steps of: (a) mixing waste with a carrier liquid, b) separating the mixture into at least two portions, the first portion being solid debris and the second portion being processable waste c) shearing and slurrifying the processable waste, and injecting the processed mixture into a wellbore.
1
TECHNICAL FIELD [0001] The present invention relates to a display apparatus and display method therefor, and particularly to a display apparatus enabling to display multiple menus and a related touch-based display method for the display apparatus. GENERAL BACKGROUND [0002] Generally, a display apparatus is a device to visually output information or graphics on a screen. It is widely and increasingly used in electronic devices. A first conventional display apparatus includes a screen to display data (i.e., an image) thereon, and a frame to support the screen. The frame is further disposed a plurality of mechanical function buttons thereon to actuate any desired function. The more functions the display apparatus has, the more mechanical function buttons the frame is disposed thereon. Therefore, the frame should be designed as large as possible to hold the mechanical function buttons. As a result, a volume of the display apparatus as a whole becomes larger, and an overall appearance of the whole display apparatus looks untidy. [0003] A second conventional display apparatus adopts a touch screen instead of mechanical buttons. The touch screen using graphical user interface (GUI) displays on the display screen thereof buttons, allowing a user to touch by finger or the like for making a selection. However, by directly touching the display screen, the touch screen thereupon is easily scratched or damaged. [0004] Therefore, there is a need for an improved display apparatus and touch-based display method therefore that can overcome the above-mentioned problems. SUMMARY [0005] A touch-based display apparatus is provided. The display apparatus is capable of displaying multiple menus. The display apparatus includes a screen and a frame. The screen has a plurality of menu regions. Each menu region displays a menu therein. The menu further includes a plurality of menu options. The frame connects to the screen and has a plurality of touch strips thereof. Each touch strip corresponds to one of the menu region, and allows to select a desired menu option to perform an associated function therewith. [0006] A touch-based method enabling a display apparatus to display multiple menus is also provided. The method includes the steps of: (a) providing a display apparatus having a screen and a frame connecting to the screen, the screen having a plurality of menu regions and the frame having a plurality of touch strips each mapped to one of the menu regions; (b) receiving and processing any sensing signal from one of the touch strips; (c) displaying an associated menu in the menu region corresponding to the signaled touch strip; (d) hiding at least one of the menu options displayed in the menu region and replacing at least one of the displayed menu options by another hidden menu option when receiving a plurality of new sensing signals from the signaled touch strip; and (e) performing a function indicated by a selected menu option when receiving a sensing signal from the signaled touch strip. [0007] Other advantages and novel features will be drawn from the following detailed description with reference to the attached drawings, in which: BRIEF DESCRIPTION OF DRAWINGS [0008] FIG. 1 is an exemplary schematic diagram of a touch-based display apparatus enabling to display multiple menus in accordance with a preferred embodiment of the present invention, the display apparatus including a screen and a frame, the frame having a plurality of touch strips thereof; [0009] FIG. 2 is a block diagram representing a hardware infrastructure of a sensing signal processing circuit for a touch sensitive unit beneath the touch strips of FIG. 1 with the signal processing circuit connecting to a processing unit; [0010] FIGS. 3A-3D illustrate a series of menus displayed in different menu regions of the screen of FIG. 1 in accordance with a preferred embodiment of the present invention, each menu region corresponding to a touch strip of FIG. 1 ; and [0011] FIG. 4 is a flowchart of a preferred touch-based method for enabling a display apparatus of FIG. 1 to display multiple menus in accordance with a preferred embodiment of the present invention. DETAILED DESCRIPTION [0012] FIG. 1 is an exemplary schematic diagram of a touch-based display apparatus enabling to display multiple menus in accordance with a preferred embodiment of the present invention. The display apparatus includes a screen 10 and a frame 11 . The screen 10 has a plurality of menu regions each for displaying a menu therein. The menu contains a number of menu options and a part of the menu options may be hidden due to the limited space of the screen 10 . The frame 11 includes a plurality of touch strips (symbolically indicated by 110 a , 110 b , 110 c , and 110 d ) thereon selectable by contact to perform a particular function associated with the menu regions. For example, a contact on any one of the touch strips initiates a menu to be displayed on one of the menu regions. After initiating the menu, a further contact on the touch strip selects a desired menu option of the displayed menu. That is, a stroke on the touch strip hides the displayed but undesired menu options out of the menu region until the hidden but desired menu option appears in the menu region. When the desired menu option appears, a further touch on a corresponding location of the touch strip performs the function associated with the menu option such as, for example, expanding a sub-menu of the menu option, executing a particular operation indicated by the menu option, etc. In addition, the sub-menu can be displayed in the same menu region as the menu option, or in other menu regions different from the menu option. [0013] In order to provide a friendly and easy user interface, each touch strip is designed to correspond to one of the menu regions parallel to it. Preferably, a length of each touch strip is designed to correspond to a length of a side of the screen 10 . Furthermore, each touch strip has a plurality of touch sensitive units (not shown) beneath thereof. Each touch sensitive unit is constructed to essentially map to a menu option of the menus. That is, each touch sensitive unit is designed to perform a function associated with the menu option. Moreover, each touch sensitive unit includes a sensing signal processing circuit 112 (described in more detail below) for generating sensing signals to perform the function associated with the menu option in response to a contact on a corresponding location of the touch strip. Each touch sensitive unit beneath the touch strip is further designated a coordinate for identifying itself. [0014] The display apparatus further includes a processing unit 12 (not shown). The processing unit 12 receives and processes the sensing signals from the touch sensitive units beneath the touch strips according to associated coordinates therewith, and performs corresponding functions. For example, in response to a single sensing signal from the touch strips, the processing unit 12 processes the sensing signal, and initiates and displays the menu last displayed thereon in a corresponding menu region associated with the signaled touch strip; in response to a plurality of sensing signals from the predetermined touch strip while the corresponding menu is in display, the processing unit 12 hides at least one of the menu options displayed in the menu region and replaces at least one of the displayed menu options by one of the hidden menu options; in response to a sensing signal from the predetermined touch strip, the processing unit 12 performs the function indicated by the selected menu option in the menu region. In addition, when the menu option has a sub-menu, the processing unit 12 further expands the sub-menu of the menu option in the same menu region as the menu option or in other menu regions different from the menu option. [0015] FIG. 2 is a block diagram representing a hardware infrastructure of a sensing signal processing circuit for the touch sensitive unit beneath the touch strips of FIG. 1 with the signal processing circuit connecting to the processing unit. The sensing signal processing circuit 112 mainly includes an antenna 20 , a clamping circuit 21 , a detector 22 , a feedback line 23 , and a grounding line 24 . The antenna 20 is connected to the clamping circuit 21 . The clamping circuit 21 is connected to an input end of the detector 22 . An output end of the detector 22 is respectively connected to the processing unit 12 and one end of the feedback line 23 . The feedback line 23 forms a positive feedback circuit with the antenna 21 . The grounding line 24 , namely a space between two adjacent touch sensitive units, is for spacing the touch sensitive units therebetween. [0016] The human body is itself electrically charged with noise and static signals. Therefore, when a user contacts the touch strips, the noise and static signals of the user flow through the antenna 20 . The antenna 20 transmits the noise and static signals to the clamping circuit 21 . However, the static electrical signals may cause interference to the noise, and may even fry the detector 22 . In addition, a strong noise may adversely influence a resulting sensing signal for the processing unit 12 ; that is, the sensitivity of the touch sensitive unit may be diminished. Accordingly, the clamping circuit 21 is for eliminating the static signals and for reducing the noise, thus improving the sensitivity accuracy of the touch sensitive unit. The clamping circuit 21 includes a diode 210 , and a capacitor 211 . The anode of the diode 210 is connected to the antenna 20 , while the cathode is connected to ground. Upon receiving the noise and static signals, the diode 210 filters out the static signals to ground so as to avoid frying the detector 22 , and reducing the noise influencing to the capacitor 211 . The capacitor 211 further leaks a portion of the reduced noise to ground. Thus the reduced noise is further weakened, thereby obtaining a more accurate sensitivity. The detector 22 has a high input impedance, so as to easily detect the reduced and weakened noise received from the input end of the detector 22 . The detector 22 then converts the further reduced and weakened noise into digital signals, namely the sensing signals, and transmits the digital signals through the output end of the detector 22 to the processing unit 12 to perform corresponding controls. Furthermore, because the feedback line 23 forms a positive feedback circuit with the antenna 20 , the noise generated as the user touches the edge of the touch sensitive unit is filtered, thereby further improving the sensitivity accuracy of the touch sensitive unit. [0017] FIGS. 3A-3D illustrate a series of menus displayed in different menu regions of the screen of FIG. 1 in accordance with a preferred embodiment of the present invention, each menu region corresponding to a touch strip of FIG. 1 . As described above, a sub-menu of a selected menu option can be displayed in the same menu region as the menu option or in other menu regions different from the menu option. For simplicity, in this embodiment, the later manner is adopted and described in detail below. In addition, contents of the menu options employ information related music as an example, and only four menus are illustrated therein. However, either the content of the menu options or the number of the menus are not to be construed as being limited thereto. [0018] Therefore, each menu region corresponding to one touch strip displays one part of the information. For example, referring to FIGS. 3A-3D , a first menu region corresponding to the touch strip 110 a displays a first menu containing the information related music styles (e.g., Classical, Rock, Hip-Hop, Jazz, Folk, etc.), a second menu region corresponding to the touch strip 110 b displays a second menu containing the information related music singers (e.g., tacky, Kaven, Tony, etc.), a third menu region corresponding to the touch strip 110 c displays a third menu containing the information related music albums (e.g., Album A, Album B, Album C, Album D, etc.), and a fourth menu region corresponding to the touch strip 110 d displays a fourth menu containing the information related music names (e.g., Song A, Song B, Song C, etc.). In other words, the second menu region displays the sub-menu of the menu option in the first menu region, the third menu region displays the sub-menu of the menu option in the second menu region, and the fourth menu region displays the sub-menu of the menu option in the third menu region. Furthermore, the menus except the first menu each have a “Back” menu option displayed in a constant location in the menu regions for easily returning to a former menu. [0019] Accordingly, because touch strips are used instead of function buttons for performing functions, the frame 11 can retain its neatness, regardless of how many functions the display apparatus has. Furthermore, since the surface areas of the touch sensitive strips can be designed in smaller sizes, the frame 11 of the display apparatus thereupon can be designed in a narrower size, whereas the screen 10 thereof can be designed in a larger size, thereby the display apparatus may not only obtain a neater appearance but may also posses a larger screen for display. Moreover, due to the multidimensional touch strips and dynamic menus of the display apparatus, the user can easily select a desired menu option to perform the function associated therewith. [0020] FIG. 4 is a flowchart of a preferred touch-based method for enabling a display apparatus of FIG. 1 to display multiple menus in accordance with a preferred embodiment of the present invention. In step S 400 , the processing unit 12 receives and processes any sensing signal from the touch sensitive units beneath the touch strips. In step S 401 , the processing unit 12 initiates and displays the menu last displayed thereon in a corresponding menu region associated with the signaled touch strip. In step S 402 , the processing unit 12 determines whether it receives any sensing signal mapped to the menu options of the displayed menu. If received, the procedure goes to step S 405 described below. If not, in step S 403 , the processing unit 12 determines whether the duration of not receiving any sensing signal mapped to the menu options of the displayed menu reaches the predetermined value. If the duration reaches the predetermined value, in step S 404 , the processing unit 12 hides the menu displayed on the menu region, and the procedure is finished. If the duration does not reach the predetermined value, the procedure returns to step S 402 . [0021] In step S 405 , the processing unit 12 determines whether it further receives a plurality of sensing signals from the predetermined touch strip. If received, in step S 406 , the processing unit 12 hides at least one of the menu options displayed in the menu and replaces at least one of the displayed menu options by another hidden menu option, and the procedure returns to step S 402 . If not, in step S 407 , the processing unit 12 determines whether it receives the sensing signal mapped to the “Back” menu option. If received, in step S 408 , the processing unit 12 displays a former menu on a corresponding menu region, and the procedure returns to step S 402 . If not, in step S 409 , the processing unit 12 determines whether it receives the sensing signal for performing the function associated with the menu options except the “Back” menu option. If received, in step S 410 , the processing unit 12 determines whether the selected menu option has a sub-menu. If the selected menu option has a sub-menu, in step S 411 , the processing unit 12 expands the sub-menu of the selected menu option in an associated menu region, and the procedure returns to step S 402 . If the selected menu option doesn't have a sub-menu, in step S 412 , the processing unit 12 performs the function associated with the menu option, and the procedure is finished. [0022] Although the present invention has been specifically described on the basis of the preferred embodiment and preferred method thereof, the invention is not to be construed as being limited thereto. Various changes or modifications may be made to the embodiment and method without departing from the scope and spirit of the invention.
A touch-based display apparatus and touch-based display method therefor is provided. The touch-based display method for the display apparatus includes the steps of: providing a display apparatus including a screen and a frame connecting to the screen, the screen having a plurality of menu regions and the frame having a plurality of touch strips each mapped to one of the menu regions; receiving and processing any sensing signal from one of the touch strips; displaying an associated menu in the menu region corresponding to the signaled touch strip; hiding at least one of the menu options displayed in the menu region and replacing at least one of the displayed menu options by another hidden menu option when receiving a plurality of new sensing signals from the signaled touch strip; and performing a function indicated by a selected menu option when receiving a sensing signal from the signaled touch strip.
6
CROSS-REFERENCE TO RELATED APPLICATION [0001] This non-provisional application is based upon U. S. Provisional Patent Application No. 61/891,734, filed Oct. 16, 2013, which is incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION [0002] The present invention addresses a recent need in the consumer product industry regarding the increasing size of premium paper goods, e.g., tissue and towel, and concurrently their packages. As papermaking techniques have improved and the industry has moved to structured base sheets, the attributes of tissue and towel have improved. These improvements are seen in characteristics like softness, bulk, and absorbency of the paper, among others. However, concurrent with these improvements, the tissue plies have also become thicker making rolls of paper, e.g., towels and bathroom tissue, larger. These larger rolls require additional space to store and ship. In addition, while the roll products have gotten larger, consumer carriers have not. Consumers neither wish to change the size of their bathroom tissue or paper towel holders nor do they want to receive smaller rolls containing less paper product. Therefore, a need exists for a paper product that has reduced bulk and increased density that can achieve the consumer's desired size without either requiring reduction of the amount of product or compromising the properties of the paper product. SUMMARY OF THE INVENTION [0003] This disclosure provides a method of increasing the density and reducing the bulk of paper products, thus allowing one to reduce the roll size or increase the roll content of a product made from that paper, while minimizing impact on favorable product attributes. Specifically, the method of this disclosure uses a substantially linear emboss pattern which decreases the bulk of the product without interfering with important consumer characteristics such as strength and absorbency. This disclosure further relates to the paper products having increased density and reduced bulk made by this method. According to one embodiment, this disclosure provides a method of embossing and plying a multi-ply product. [0004] Products such as paper towels, bathroom tissue, facial tissues, napkins, wipers, and like products, are typically made from one or more webs of nonwoven paper. For the products to perform as expected by the consumer, the webs from which these products are formed generally exhibit favorable characteristics of strength, softness, and absorbency. Strength is the ability of a paper web to retain its physical integrity during use. Softness is the pleasing tactile sensation the consumer perceives as the consumer uses the paper product. Absorbency is the characteristic of the paper web which allows it to take up and retain fluids. Typically, the softness and/or absorbency of a paper web increases at the expense of the strength of the paper web. Consumer testing of products having embossed surfaces show that consumers prefer soft products with relatively high caliper (thickness) and exhibiting aesthetically pleasing decorative patterns. The products of the instant disclosure achieve all of the consumer's desired attributes while having a reduced bulk. [0005] Processes for the manufacture of wet-laid paper products generally involve the preparation of an aqueous slurry of cellulosic fibers and subsequent removal of water from the slurry while rearranging the fibers to form a web. Various types of machinery can be employed to assist in the dewatering process. A typical manufacturing process employs, for example, a Fourdrinier wire papermaking machine where a paper slurry is fed onto a surface of a traveling endless wire where the initial dewatering occurs. In a conventional wet press process, the fibers are transferred directly to a capillary de-watering belt where additional de-watering occurs. In a structured web process, the fibrous web is subsequently transferred to a papermaking belt where rearrangement and drying of the fibers is carried out. [0006] As paper production has moved from conventional wet pressing to through air drying (TAD) and other methods for making structured base sheets, for example, using a perforated polymeric belt as described in U.S. Pat. No. 8,293,072, the tissue base sheets have seen improvements in many sheet characteristics including strength, softness, bulk, and absorbency. As the caliper of these structured base sheets has increased, either package size has increased or the sheet count has been reduced. A need exists for a reduced bulk premium paper product exhibiting uncompromised quality which would mirror current commercial products in size and sheet count. Heretofore, embossing and plying were routinely carried out to increase and improve the bulk and absorbency of a paper product. Embossing is known to increase the bulk of the product to which it is applied. It is therefore surprising that an embossing pattern made up of substantially linear elements can be used to emboss, or emboss and ply, a premium paper product without compromising quality but resulting in an end product having a caliper lower than the caliper of the nonwoven web(s) from which it is made. [0007] Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. [0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIGS. 1A and 1B illustrate an emboss pattern that can be used in the method according to the invention, and its counterpart non-linear dot representation, respectively. [0010] FIGS. 2A and 2B illustrate an emboss pattern that can be used in the method according to the invention, and its counterpart non-linear dot representation, respectively. [0011] FIGS. 3A and 3B illustrate an emboss pattern that can be used in the method according to the invention, and its counterpart non-linear dot representation, respectively. [0012] FIGS. 4A and 4B illustrate an emboss pattern that can be used in the method according to the invention, and its counterpart non-linear dot representation, respectively. [0013] FIGS. 5A and 5B illustrate an emboss pattern that can be used in the method according to the invention, and its counterpart non-linear dot representation, respectively. [0014] FIGS. 6A and 6B illustrate an emboss pattern that can be used in the method according to the invention, and its counterpart non-linear dot representation, respectively. [0015] FIGS. 7A and 7B illustrate an emboss pattern that can be used in the method according to the invention, and its counterpart non-linear dot representation, respectively. [0016] FIGS. 8A and 8B illustrate an emboss pattern that can be used in the method according to the invention, and its counterpart non-linear dot representation, respectively. [0017] FIG. 9 illustrates an emboss pattern that can be used in the method according to the invention. [0018] FIGS. 10 to 22 are graphical representations based upon the data presented in Example 2. DETAILED DESCRIPTION OF THE INVENTION [0019] As used herein, the terms “paper web,” “web,” “paper sheet,” “fibrous structure,” “nonwoven web,” and “paper product” are all used interchangeably to refer to sheets of paper products suitable for consumer use in, for example, paper toweling, bath tissue, napkins, facial tissue, wipers and the like. Products of the disclosure can be any paper product in which the bulk and density of the product would benefit from reduction and in which it is important that softness, absorbency and strength not be substantially negatively affected. Products contemplated for production using the disclosed embossing method can be in the areas of tissue and towel, feminine hygiene, adult incontinence and baby products, including, for example, baby wipes or diapers. The paper products as described can be in the form of, for example, stacks or rolls. In one embodiment, the paper products as described may be wound with or without a core to form a rolled paper product. Rolled products may comprise a plurality of connected and perforated sheets that are separable and dispensable from adjacent sheets. [0020] The paper of the present invention may comprise papermaking fibers of both hardwoods and softwoods pulps. “Hardwood pulps” as used herein refers to fibrous pulp derived from the woody substance of deciduous trees (angiosperms). “Softwood pulps” are fibrous pulps derived from the woody substance of coniferous trees (gymnosperms). Blends of hardwood and softwood are also suitable to produce the paper products as described. In one embodiment the plies of the paper product may be heterogeneous web layers. In another embodiment, the plies may be non-heterogeneous or stratified. Also applicable to the present invention are fibers derived from recycled paper, which may contain any or all of the above categories of fibers. According to yet another embodiment, the fibers may include one or more non-wood based fiber. Wood pulps useful herein include chemical pulps such as, sulfite and sulfate (sometimes called Kraft) pulps as well as mechanical pulps including for example, ground wood, ThermoMechanical Pulp (TMP) and Chemi-ThermoMechanical Pulp (CTMP). [0021] Paper products of the present disclosure may be produced according to any art recognized wet laid or air laid method. According to one embodiment, the paper product as described is made from one or more base sheet(s) chosen from conventional wet press (CWP) base sheet(s), structured base sheet(s) including both TAD and e-TAD, air laid base sheet(s) and combinations thereof. [0022] Any art recognized process for making the base sheet(s) is suitable for use in the present invention. Typically, depending upon the desired end use, paper products are generally comprised of papermaking fibers and small amounts of chemical functional agents such as wet strength or dry strength agents, binders, retention aids, surfactants, size, chemical softeners, and release agents. Additionally, filler materials may also be incorporated into the web. All such base sheets may be used in the method described in the instant disclosure. [0023] The paper product of the present invention may exhibit a basis weight of from about 20 g/m 2 to about 120 g/m 2 , for example, from about 30 g/m 2 to about 65 g/m 2 , for example, from about 37 g/m 2 to about 50 g/m 2 . [0024] Paper products as described are embossed. “Embossed” as used herein with respect to a fibrous web means a fibrous web that has been subjected to a process which converts a smooth surfaced fibrous web to a decorative surface by replicating a design on one or more emboss rolls, which form a nip through which the fibrous web passes. Embossed does not include creping, microcreping, printing or other processes that may impart a texture and/or decorative pattern to a fibrous structure. [0025] During a typical embossing process, a web is fed through a nip formed between juxtaposed generally axially parallel rolls. Embossing elements on the rolls compress and/or deform the web. If a multi-ply product is being formed, two or more webs, i.e., plies, are fed through the nip and regions of each ply are brought into a contacting relationship with the opposing ply. The embossed regions of the plies produce an aesthetic pattern and may provide a means for joining and maintaining the plies in face-to-face contacting relationship. [0026] Generally, the embossing apparatus will include one or more rolls having protuberances and/or depressions formed therein. A corresponding backup roll presses the web against the embossing roll such that the embossed pattern is imparted to the web as it passes between the nip formed between the embossing roll and the backup roll. Any art recognized embossing configuration can be used in the method of the present disclosure. [0027] While fiber-to-steel, steel-to-steel or rubber-to-rubber embossing operations can be used, the most common embossing configuration is rubber-to-steel. In rubber-to-steel embossing, the steel embossing roll is provided with protuberances and/or depressions and the web is pressed against the embossing roll by a rubber backing roll as the web passes through the nip formed between the rubber and the steel rolls. The rubber backing roll accommodates the protuberances and/or depressions by virtue of its resilience and the rubber flows about the protuberances and/or depressions as force is applied to urge the rolls together. An alternative rubber-to-steel configuration is a mated configuration. This configuration mates a steel embossing roll having a plurality of protuberances extending therefrom with a patterned rubber backing roll which urges the fibrous web substrate against the embossing roll thereby imparting a highly defined embossed pattern to the paper substrate for forming paper towels, napkins or tissues. As the paper substrate passes through the nip between the rolls, the web is forced about the protuberances and against the land areas of the steel roll, as well as into the indentations and outer peripheral surfaces of the rubber roll. As a result, a highly defined embossed pattern is provided. According to one embodiment of the invention, the embossing operation is a rubber to steel configuration. [0028] The paper products as disclosed bear an emboss pattern that comprises linear embossments. A linear embossment is characterized by having a total embossment length to total embossment width (or an aspect ratio) of at least about 5. Smaller, embossments having an aspect ratio of less than 5 are referred to herein as dot embossments; however they can take any shape. According to one embodiment, linear embossments make up at least about 80% of the embossments on the paper product, for example, at least about 90%, for example at least about 95%. According to one embodiment, the emboss pattern is made up solely (100%) of linear emboss elements. [0029] According to one embodiment, the linear emboss elements have an aspect ratio of at least about 5, for example, at least about 10, for example, at least about 20, for example, at least about 30, for example, at least about 40, for example, at least about 50. [0030] According to another embodiment, the depth of embossments are from about 1.25 to about 3.5 times the caliper of the unembossed base sheet(s), for example, about 1.5 to about 2.5 times, for example, from about 1.5 to about 2.0. In the embodiment where two plies are used, this is sufficient to maintain good ply lamination with a consumer preferred appearance while reducing the finished product caliper to something less than the expected caliper of the two unembossed plies combined. This allows for the production of high performance structured base sheet products with a higher finished product density. Embossing depths for use in the present invention are generally at least about 30 mils (762 μm), for example, at least about 35 mils (889 μm), for example, at least about 40 mils (1016 μm) at least about 45 mils (1143 μm), for example, at least about 50 mils (1270 μm). As described herein embossing depth corresponds to the height of the majority elements on the emboss roll. [0031] Without wishing to be bound by theory, we believe the linear elements, coupled with the defined depth of embossment provide more surface area, which minimizes the impact on sheet properties while resulting in an aesthetically pleasing product that can be packaged in the desired size, e.g., wound to the desired roll size, without giving up sheet count. [0032] According to one embodiment, the embossments cover greater than about 22%, for example, from about 22 to about 50%, for example, from about 25 to about 50%, for example about 22 to about 30% of the total area of the finished product. [0033] A multitude of combinations of emboss coverage, emboss depth, emboss aspect ratio and percent linear embosses would be apparent to the skilled artisan. The combinations set forth below are merely exemplary. [0034] According to one embodiment, the paper products bearing the linear emboss pattern exhibit at least about 1% less caliper than the base sheet(s), for example, at least about 1.5% less caliper, for example, at least about 2% less caliper, for example, at least about 2.5% less caliper, for example, at least about 3% less caliper, for example at least about 3.5% less caliper, for example, at least about 4% less caliper, for example, at least about 4.5%, for example, at least about 5% less caliper. [0000] TABLE 1 Emboss Aspect Ratio of linear embossments and percentage of linear Percent of overall Emboss Coverage embossments at that pattern that is made up (%) Emboss Depth (mils) Aspect ratio of linear embossments 22 to 50 At least 35 At least 5-100% At least 80 22 to 50 At least 40 At least 5-100% At least 80 22 to 50 At least 45 At least 5-100% At least 80 22 to 50 At least 55 At least 5-100% At least 80 22 to 50 At least 35 At least 5-100% At least 90 22 to 50 At least 40 At least 5-100% At least 90 22 to 50 At least 45 At least 5-100% At least 90 22 to 50 At least 55 At least 5-100% At least 90 22 to 50 At least 35 At least 5-100% 100 22 to 50 At least 40 At least 5-100% 100 22 to 50 At least 45 At least 5-100% 100 22 to 50 At least 55 At least 5-100% 100 22 to 50 At least 35 At least 10-100% At least 80 22 to 50 At least 40 At least 10-100% At least 80 22 to 50 At least 45 At least 10-100% At least 80 22 to 50 At least 55 At least 10-100% At least 80 22 to 50 At least 35 At least 10-100% At least 90 22 to 50 At least 40 At least 10-100% At least 90 22 to 50 At least 45 At least 10-100% At least 90 22 to 50 At least 55 At least 10-100% At least 90 22 to 50 At least 35 At least 10-100% 100 22 to 50 At least 40 At least 10-100% 100 22 to 50 At least 45 At least 10-100% 100 22 to 50 At least 55 At least 10-100% 100 22 to 50 At least 35 At least 20-100% At least 80 22 to 50 At least 40 At least 20-100% At least 80 22 to 50 At least 45 At least 20-100% At least 80 22 to 50 At least 55 At least 20-100% At least 80 22 to 50 At least 35 At least 20-at least At least 80 80% 22 to 50 At least 40 At least 20-at least At least 80 80% 22 to 50 At least 45 At least 20-at least At least 80 80% 22 to 50 At least 55 At least 20-at least At least 80 80% 22 to 50 At least 35 At least 30-at least At least 80 50% 22 to 50 At least 40 At least 30-at least At least 80 50% 22 to 50 At least 45 At least 30-at least At least 80 50% 22 to 50 At least 55 At least 30-at least At least 80 50% 22 to 50 At least 35 At least 30-at least At least 90 50% 22 to 50 At least 40 At least 30-at least At least 90 50% 22 to 50 At least 45 At least 30-at least At least 90 50% 22 to 50 At least 55 At least 30-at least At least 90 50% 22 to 50 At least 35 At least 20-at least At least 95 80% 22 to 50 At least 40 At least 20-at least At least 95 80% 22 to 50 At least 45 At least 20-at least At least 95 80% 22 to 50 At least 55 At least 20-at least At least 95 80% 22 to 50 At least 35 At least 40-at least At least 80 50% 22 to 50 At least 40 At least 40-at least At least 80 50% 22 to 50 At least 45 At least 40-at least At least 80 50% 22 to 50 At least 55 At least 40-at least At least 80 50% 22 to 50 At least 35 At least 40-at least At least 90 50% 22 to 50 At least 40 At least 40-at least At least 90 50% 22 to 50 At least 45 At least 40-at least At least 90 50% 22 to 50 At least 55 At least 40-at least At least 90 50% 22 to 50 At least 35 At least 20-at least 100 50% 22 to 50 At least 40 At least 20-at least 100 50% 22 to 50 At least 45 At least 20-at least 100 50% 22 to 50 At least 55 At least 20-at least 100 50% 22 to 50 At least 35 At least 30-at least 100 50% 22 to 50 At least 40 At least 30-at least 100 50% 22 to 50 At least 45 At least 30-at least 100 50% 22 to 50 At least 55 At least 30-at least 100 50% 22 to 50 At least 35 At least 40-at least 100 50% 22 to 50 At least 40 At least 40-at least 100 50% 22 to 50 At least 45 At least 40-at least 100 50% 22 to 50 At least 55 At least 40-at least 100 50% 22 to 30 At least 35 At least 10-at least 100 50% 22 to 30 At least 40 At least 10-at least 100 50% 22 to 30 At least 45 At least 10-at least 100 50% 22 to 30 At least 55 At least 10-at least 100 50% 22 to 30 At least 35 At least 20-at least 100 50% 22 to 30 At least 40 At least 20-at least 100 50% 22 to 30 At least 45 At least 20-at least 100 50% 22 to 30 At least 55 At least 20-at least 100 50% 22 to 30 At least 35 At least 30-at least 100 50% 22 to 30 At least 40 At least 30-at least 100 50% 22 to 30 At least 45 At least 30-at least 100 50% 22 to 30 At least 55 At least 30-at least 100 50% 22 to 30 At least 35 At least 40-at least 100 50% 22 to 30 At least 40 At least 40-at least 100 50% 22 to 30 At least 45 At least 40-at least 100 50% 22 to 30 At least 55 At least 40-at least 100 50% [0035] As seen from table above, the emboss configuration may vary. So, according to the first embodiment set forth in the table above, the paper product would have 22 to 50% of its surface covered with embossments that are at least 35 mils high and where linear embossments make up at least 80% of the total embossments and 100% of the linear embossments have an aspect ratio of at least 5. And, according to the last embodiment set forth in the table above, the paper product would have 22 to 30% of its surface covered with embossments that are at least 55 mils high and where linear embossments make up 100% of the total embossments and at least 50% of the linear embossments have an aspect ratio of at least 40. [0036] According to one embodiment, the paper products bearing the linear emboss pattern exhibit at least about 5% less caliper than the same pattern formed from dots (See, FIG. 1A versus FIG. 1B ). According to another embodiment the paper products bearing the linear emboss pattern exhibit at least about 6% less caliper than the same pattern formed from dots, for example, at least about 8% less caliper, for example at least, about 10% less caliper, for example, at least about 12% less caliper. [0037] FIG. 1A illustrates one pattern that may be used in the method of the present disclosure to reduce the bulk of the paper product. This pattern is made up of linear segments that are curved and flow around each other in a swirling pattern. FIG. 1B illustrates the pattern of FIG. 1A as it would be represented by dot embossments. FIGS. 2A, 3A, 4A . 5 A, 6 A, 7 A and 8 A illustrate other patterns that may be used in the method of the present disclosure to reduce the bulk of the paper product. FIGS. 2B, 3B, 4B 5 B 6 B, 7 B and 8 B illustrates the same patterns of FIGS. 2A, 3A, 4A, 5A, 6A, 7A and 8A , respectively, as they would be represented by dot embossments. FIG. 9 illustrates a pattern for use in the instant invention where the pattern is made up of linear segments of differing sizes. [0038] As used herein, “about” is meant to account for variations due to experimental error. All measurements are understood to be modified by the word “about”, whether or not “about” is explicitly recited, unless specifically stated otherwise. Thus, for example, the statement “an emboss depth of at least 30 mils” is understood to mean “an emboss depth of at least about 30 mils.” [0039] The details of one or more non-limiting embodiments of the invention are set forth in the examples below. Other embodiments of the invention should be apparent to those of ordinary skill in the art after consideration of the present disclosure. EXAMPLES [0040] The product characteristics measured in the Examples, infra, were measured according the following methodologies. Throughout this specification and claims, it is to be understood that, unless otherwise specified, physical properties are measured after the web has been conditioned according to Technical Association of the Pulp and Paper Industry (TAPPI) standards. If no test method is explicitly set forth for measurement of any quantity mentioned herein, it is to be understood that TAPPI standards should be applied. Basis Weight [0041] Unless otherwise specified, “basis weight”, BWT, bwt, BW, and so forth, refers to the weight of a 3000 square-foot ream of product (basis weight is also expressed in g/m 2 or gsm). Likewise, “ream” means a 3000 square-foot ream, unless otherwise specified. Likewise, percent or like terminology refers to weight percent on a dry basis, that is to say, with no free water present, which is equivalent to 5% moisture in the fiber. Caliper [0042] Calipers and/or bulk reported herein may be measured at 8 or 16 sheet calipers as specified. The sheets are stacked and the caliper measurement taken about the central portion of the stack. Preferably, the test samples are conditioned in an atmosphere of 23°±1.0° C. (73.4°±1.8° F.) at 50% relative humidity for at least about 2 hours and then measured with a Thwing-Albert Model 89-II-JR or Progage Electronic Thickness Tester with 2-in diameter anvils, 539±10 grams dead weight load, and 0.231 in/sec descent rate. For finished product testing, each sheet of product to be tested must have the same number of plies as the product as sold. For testing in general, eight sheets are selected and stacked together. For napkin testing, napkins are unfolded prior to stacking. For base sheet testing off of winders, each sheet to be tested must have the same number of plies as produced off of the winder. For base sheet testing off of the papermachine reel, single plies must be used. Sheets are stacked together aligned in the machine direction (MD). Bulk may also be expressed in units of volume/weight by dividing caliper by basis weight. MD and CD Tensile, Stretch, Break Modulus and TEA [0043] Dry tensile strengths (MD and CD), stretch, ratios thereof, modulus, break modulus, stress and strain are measured with a standard Instron test device or other suitable elongation tensile tester, which may be configured in various ways, typically, using 3 inch or 1 inch wide strips of tissue or towel, conditioned in an atmosphere of 23°±1° C. (73.4°±1° F.) at 50% relative humidity for 2 hours. The tensile test is run at a crosshead speed of 2 in/min. Break modulus is expressed in grams/3 inches/% strain or its SI equivalent of g/mm/% strain. % strain is dimensionless and need not be specified. Unless otherwise indicated, values are break values. GM refers to the square root of the product of the MD and CD values for a particular product. Tensile energy absorption (TEA), which is defined as the area under the load/elongation (stress/strain) curve, is also measured during the procedure for measuring tensile strength. Tensile energy absorption is related to the perceived strength of the product in use. Products having a higher TEA may be perceived by users as being stronger than similar products that have lower TEA values, even if the actual tensile strength of the two products are the same. In fact, having a higher tensile energy absorption may allow a product to be perceived as being stronger than one with a lower TEA, even if the tensile strength of the high-TEA product is less than that of the product having the lower TEA. When the term “normalized” is used in connection with a tensile strength, it simply refers to the appropriate tensile strength from which the effect of basis weight has been removed by dividing that tensile strength by the basis weight. In many cases, similar information is provided by the term “breaking length”. [0044] GMT refers to the geometric mean tensile strength of the CD and MD tensile. Tensile energy absorption (TEA) is measured in accordance with TAPPI test method T494 om-01. [0045] Tensile ratios are simply ratios of an MD value determined by way of the foregoing methods divided by the corresponding CD value. Unless otherwise specified, a tensile property is a dry sheet property. Perforation Tensile [0046] The perforation tensile strength (force per unit width required to break a specimen) is measured generally using a constant rate of elongation tensile tester equipped with 3-in wide jaw line contact grips. Typically, the test is carried out using 3 inch wide by 5 inch long strips of tissue or towel, conditioned in an atmosphere of 23°±1.0° C. (73.4°±1.8° F.) at 50% relative humidity for 2 hours. The crosshead speed of the tensile tester is generally set to 2.0 in. per minute. The jaw span is 3 inches. The specimen is clamped into the upper grip and allowed to hang freely. The lower grip is then used to grip the free end of the specimen tightly enough to hold the sample, but not with sufficient pressure to damage the sample. The sample is stretched until it breaks and the perforation tensile is recorded. Wet Tensile [0047] The wet tensile of the tissue of the present invention is measured generally following TAPPI Method T 576 pm 7, using a three-inch (76.2 mm) wide strip of tissue that is folded into a loop, clamped in a special fixture termed a Finch Cup, then immersed in water. A suitable Finch cup, 3-in., with base to fit a 3-in. grip, is available from: [0048] High-Tech Manufacturing Services, Inc. 3105-B NE 65 th Street Vancouver, Wash. 98663 360-696-1611 360-696-9887 (FAX). [0053] For fresh basesheet and finished product (aged 30 days or less for towel product, aged 24 hours or less for tissue product) containing wet strength additive, the test specimens are placed in a forced air oven heated to 105° C. (221° F.) for five minutes. No oven aging is needed for other samples. The Finch cup is mounted onto a tensile tester equipped with a 2.0 pound load cell with the flange of the Finch cup clamped by the tester's lower jaw and the ends of tissue loop clamped into the upper jaw of the tensile tester. The sample is immersed in water that has been adjusted to a pH of 7.0±0.1 and the tensile is tested after a 5 second immersion time using a crosshead speed of 2 inches/minute. The results are expressed in g/3 in., dividing the readout by two to account for the loop as appropriate. Roll Compression [0054] Roll compression is measured by compressing a roll under a 1500 g flat platen of a test apparatus. Sample rolls are conditioned and tested in an atmosphere of 23.0°±1.0° C. (73.4°±1.8° F.). A suitable test apparatus with a movable 1500 g platen (referred to as a height gauge) is available from: [0055] Research Dimensions [0056] 1720 Oakridge Road [0057] Neenah, Wis. 54956 920-722-2289 920-725-6874 (FAX). [0060] The test procedure is generally as follows: (a) Raise the platen and position the roll to be tested on its side, centered under the platen, with the tail seal to the front of the gauge and the core parallel to the back of the gauge. (b) Slowly lower the platen until it rests on the roll. [0063] (c) Read the compressed roll diameter or sleeve height from the gauge pointer to the nearest 0.01 inch (0.254 mm). (d) Raise the platen and remove the roll. (e) Repeat for each roll or sleeve to be tested. [0066] To calculate roll compression (RC) in percent, the following formula is used: [0000] R   C   ( % ) = 100 × ( initial   roll   diameter - compressed   roll   diameter ) initial   roll   diameter SAT Capacity [0067] Absorbency of the inventive products is measured with a simple absorbency tester. The simple absorbency tester is a particularly useful apparatus for measuring the hydrophilicity and absorbency properties of a sample of tissue, napkins, or towel. In this test, a sample of tissue, napkins, or towel 2.0 inches in diameter is mounted between a top flat plastic cover and a bottom grooved sample plate. The tissue, napkin, or towel sample disc is held in place by a ⅛ inch wide circumference flange area. The sample is not compressed by the holder. De-ionized water at 73° F. is introduced to the sample at the center of the bottom sample plate through a 1 mm. diameter conduit. This water is at a hydrostatic head of minus 5 mm. Flow is initiated by a pulse introduced at the start of the measurement by the instrument mechanism. Water is thus imbibed by the tissue, napkin, or towel sample from this central entrance point radially outward by capillary action. When the rate of water imbibition decreases below 0.005 gm water per 5 seconds, the test is terminated. The amount of water removed from the reservoir and absorbed by the sample is weighed and reported as grams of water per square meter of sample or grams of water per gram of sheet. In practice, an M/K Systems Inc. Gravimetric Absorbency Testing System is used. This is a commercial system obtainable from M/K Systems Inc., 12 Garden Street, Danvers, Mass., 01923. WAC, or water absorbent capacity, also referred to as SAT, is actually determined by the instrument itself. WAC is defined as the point where the weight versus time graph has a “zero” slope, i.e., the sample has stopped absorbing. The termination criteria for a test are expressed in maximum change in water weight absorbed over a fixed time period. This is basically an estimate of zero slope on the weight versus time graph. The program uses a change of 0.005 g over a 5 second time interval as termination criteria; unless “Slow SAT” is specified in which case the cut off criteria is 1 mg in 20 seconds. [0068] Water absorbency rate is measured in seconds and is the time it takes for a sample to absorb a 0.1 gram droplet of water disposed on its surface by way of an automated syringe. The test specimens are preferably conditioned at 23° C.±1.0° C. (73.4° F.±1.8° F.) at 50% relative humidity. For each sample, 4 3×3 inch test specimens are prepared. Each specimen is placed in a sample holder such that a high intensity lamp is directed toward the specimen. 0.1 ml of water is deposited on the specimen surface and a stop watch is started. When the water is absorbed, as indicated by lack of further reflection of light from the drop, the stopwatch is stopped and the time recorded to the nearest 0.1 seconds. The procedure is repeated for each specimen and the results averaged for the sample. SAT Rate is determined by graphing the weight of water absorbed by the sample (in grams) against the square root of time (in seconds). The SAT rate is the best fit slope between 10 and 60 percent of the end point (grams of water absorbed). Sensory Softness [0069] Sensory softness of the samples was determined by using a panel of trained human subjects in a test area conditioned to TAPPI standards (temperature of 71.2° F. to 74.8° F., relative humidity of 48% to 52%). The softness evaluation relied on a series of physical references with predetermined softness values that were always available to each trained subject as they conducted the testing. The trained subjects directly compared test samples to the physical references to determine the softness level of the test samples. The trained subjects assigned a number to a particular paper product, with a higher sensory softness number indicating a higher the perceived softness. EXAMPLE 1 [0070] Paper towel base sheets were produced in a consistent manner and were either unembossed or embossed with either the current Brawny® non-linear embossing pattern of FIG. 5B or a linear pattern according to the present invention, i.e., the pattern of [0071] FIG. 5A and variations thereof. The characteristics for the unembossed base sheets and the two ply product are set forth in Table 2, below. [0072] Table 3 sets forth the product characteristics for an embossed paper towel product bearing the current commercial, non-linear embossing pattern, both at a commercial emboss depth and at a depth of 45 mils. In Column 3 of Table 3 a comparison is made between the 45 mils embossed product and the unembossed base sheet described in Table 2. As can be seen from Table 3, column 3, the caliper of the product increased with embossing by 6.22%. The Wet Tensile strength remained largely unaffected. [0073] Table 4 sets forth finished product characteristics for four paper towel products embossed with linear patterns according to the instant method. Table 5 compares those embossed product characteristics to the unembossed base sheet of Table 2. As can be seen in Table 5, when a paper towel was embossed with a substantially linear pattern as described herein, the caliper of the two ply product was less than the caliper of the two base sheets. As can also be seen from Table 5, the impact on sheet strength was minimal, if negative. In two instances, the CD wet tensile increased. Finally, while the absorbency of the final product did go down, the change in absorbency as reflected by the SAT capacity was always less than 10% and in some instances less than 5%. Accordingly, in this embodiment, an embossed paper product results having a lower caliper and higher density than the original base sheets and a significantly lower caliper than paper products embossed with a traditional non-linear pattern. In addition, the lower caliper and higher density do not result in changes in strength or sensory softness and only exhibit minor losses in absorbency. [0000] TABLE 2 Combined Base Description Ply 1 Ply 2 Sheet Basis Weight lb/3000 ft 2 13.55 13.45 27.00 Caliper 8 Sheetmils/8 89.2 92.7 181.9 sht Tensile MD g/3 in 1385.18 1569.31 2954.49 Stretch MD % 15.48 16.76 16.12 Tensile CD g/3 in. 1465.36 1478.55 2943.92 Stretch CD % 8.76 9.30 9.03 Tensile GM g/3 in. 1424.06 1522.78 2946.84 Tensile Dry Ratio 0.95 1.06 1.00 Unitless Perf Tensile g/3 in. Wet Tens Finch 424.63 415.16 839.78 Cured CD g/3 in. Tensile Wet/Dry CD 0.29 0.28 0.29 Unitless SAT Capacity g/m 2 SAT Rate g/s 0.5 SAT Times Break Modulus MD 88.16 92.48 180.64 gms/% Break Modulus CD 169.89 158.09 327.98 gms/% Break Modulus GM 122.38 120.91 243.29 gms/% Modulus MD g/% Stretch Modulus CD g/% Stretch Modulus GM g/% Stretch TEA MD mm-g/mm 2 1.37 1.62 2.99 TEA CD mm-g/mm 2 0.81 0.88 1.69 Roll Diameter In. Roll Compression Value % Roll Compression in. Basis Weight Raw 1.02 1.02 2.04 Wtg. Sensory Softness 5.4 [0000] TABLE 3 Current Product at a Change from penetration of 45 Basesheet based on Description Current Product mils 45 mils penetration Basis Weight lb/3000 ft 2 26.57 26.29 −2.63 Caliper 8 Sheetmils/8 195.05 193.22 6.22 sht Tensile MD g/3 in 3083.12 3128.73 5.90 Stretch MD % 16.68 16.57 2.80 Tensile CD g/3 in. 2837.73 2903.75 −1.36 Stretch CD % 10.03 10.04 11.18 Tensile GM g/3 in. 2957.68 3013.46 2.26 Tensile Dry Ratio 1.09 1.08 7.86 Unitless Perf Tensile g/3 in. 732.25 725.78 Wet Tens Finch 813.27 840.26 0.06 Cured CD g/3 in. Tensile Wet/Dry CD 0.29 0.29 −0.15 Unitless SAT Capacity g/m 2 512.24 521.83 −1.72 SAT Rate g/s 0.5 0.26 0.31 SAT Times 42.03 35.31 Break Modulus MD 184.92 188.78 4.51 gms/% Break Modulus CD 282.17 286.38 −12.69 gms/% Break Modulus GM 228.39 232.47 −4.45 gms/% Modulus MD g/% 41.55 42.65 Stretch Modulus CD g/% 65.35 67.85 Stretch Modulus GM g/% 52.08 53.78 Stretch TEA MD mm-g/mm 2 3.13 3.17 6.10 TEA CD mm-g/mm 2 1.84 1.89 11.64 Roll Diameter In. 6.07 5.64 Roll Compression 3.51 3.72 Value % Roll Compression in. 5.86 5.43 Basis Weight Raw 2.01 1.99 −2.63 Wtg. Sensory Softness 5.60 5.7 [0000] TABLE 4 Invention at Penetration of 45 mils Description Pattern A Pattern B Pattern C Pattern D Basis Weight 26.07 26.47 26.61 26.36 lb/3000 ft 2 Caliper 8 178.46 180.60 179.05 175.09 Sheetmils/8 sht Tensile MD g/3 in 3000.08 3337.16 3086.51 3161.29 Stretch MD % 15.55 16.07 15.83 15.38 Tensile CD g/3 in. 2867.19 3185.83 2954.76 2911.81 Stretch CD % 9.55 9.66 9.46 9.44 Tensile GM g/3 in. 2931.82 3260.20 3019.6 3033.45 Tensile Dry Ratio 1.05 1.05 1.04 1.09 Unitless Perf Tensile g/3 in. 706.15 727.19 709.54 604.07 Wet Tens Finch 822.45 844.51 856.00 809.51 Cured CD g/3 in. Tensile Wet/Dry 0.29 0.27 0.29 0.28 CD Unitless SAT Capacity g/m 2 498.4 491.19 493.76 487.84 SAT Rate g/s 0.5 0.25 0.24 0.27 0.26 SAT Times 35.62 32.22 29.41 28.87 Break Modulus MD 194.47 205.36 195.14 205.07 gms/% Break Modulus CD 296.92 332.89 316.78 307.04 gms/% Break Modulus GM 240.26 261.45 248.60 250.88 gms/% Modulus MD g/% 45.80 50.38 45.43 49.37 Stretch Modulus CD g/% 67.96 77.77 71.27 67.81 Stretch Modulus GM g/% 55.76 62.59 56.89 57.82 Stretch TEA MD mm- 2.90 3.44 3.08 3.02 g/mm 2 TEA CD mm- 1.79 2.01 1.78 1.71 g/mm 2 Roll Diameter In. 5.86 5.76 5.78 5.65 Roll Compression 4.21 5.27 5.48 4.96 Value % Roll Compression 5.61 5.45 5.46 5.37 in. Basis Weight Raw 1.97 2.00 2.01 1.99 Wtg. Sensory Softness 5.30 5.40 5.70 5.50 [0000] TABLE 5 Invention at Penetration of 45 mils (Percent Change from Basesheet) Description Pattern A Pattern B Pattern C Pattern D Basis Weight −3.45 1.94 1.45 2.36 lb/3000 ft 2 Caliper 8 −1.89 0.71 1.57 3.74 Sheetmils/8 sht Tensile MD g/3 in 1.54 −12.95 −4.47 −7.00 Stretch MD % −3.52 0.31 1.81 4.61 Tensile CD g/3 in. −2.61 −8.22 −0.37 1.09 Stretch CD % 5.78 −7.01 −4.74 −4.55 Tensile GM g/3 in. −0.51 −10.63 −2.47 −2.94 Tensile Dry Ratio 4.71 −4.41 −4.88 −8.22 Unitless Perf Tensile g/3 in. Wet Tens Finch −2.06 −0.56 −1.93 3.61 Cured CD g/3 in. Tensile Wet/Dry 1.09 7.06 −1.57 2.50 CD Unitless SAT Capacity g/m 2 −6.13 −7.49 −7.01 −8.12 SAT Rate g/s 0.5 SAT Times Break Modulus MD 7.66 −13.69 −8.03 −13.53 gms/% Break Modulus CD −9.47 −1.49 3.41 6.39 gms/% Break Modulus GM −1.25 −7.46 −2.18 −3.12 gms/% Modulus MD g/% Stretch Modulus CD g/% Stretch Modulus GM g/% Stretch TEA MD mm- −2.77 −15.32 −3.00 −1.18 g/mm 2 TEA CD mm- 5.91 −18.95 −5.50 −1.49 g/mm 2 Roll Diameter In. Roll Compression Value % Roll Compression in. Basis Weight Raw −3.45 1.94 1.45 2.36 Wtg. Sensory Softness EXAMPLE 2 [0074] Example 2 was carried out in the same manner as Example 1, using an emboss penetration of 55 mils. Results are set forth in Tables 6-8, below. [0000] TABLE 6 Current Product at a Change from penetration of 55 Basesheet based on Description Current Product mils 55 mils penetration Basis Weight lb/3000 ft 2 26.57 26.36 −2.38 Caliper 8 Sheetmils/8 195.05 206.23 13.37 sht Tensile MD g/3 in 3083.12 2865.60 −3.01 Stretch MD % 16.68 16.84 4.49 Tensile CD g/3 in. 2837.73 2611.43 −11.29 Stretch CD % 10.03 10.22 13.18 Tensile GM g/3 in. 2957.68 2735.26 −7.18 Tensile Dry Ratio 1.09 1.10 9.77 Unitless Perf Tensile g/3 in. 732.25 667.89 Wet Tens Finch 813.27 744.95 −11.29 Cured CD g/3 in. Tensile Wet/Dry CD 0.29 0.29 −1.64 Unitless SAT Capacity g/m 2 512.24 523.31 −1.72 SAT Rate g/s 0.5 0.26 0.33 SAT Times 42.03 40.09 Break Modulus MD 184.92 170.36 −5.69 gms/% Break Modulus CD 282.17 253.72 −22.64 gms/% Break Modulus GM 228.39 207.88 −14.55 gms/% Modulus MD g/% 41.55 37.07 Stretch Modulus CD g/% 65.35 57.73 Stretch Modulus GM g/% 52.08 46.24 Stretch TEA MD mm-g/mm 2 3.13 2.91 −2.58 TEA CD mm-g/mm 2 1.84 1.74 3.29 Roll Diameter In. 6.07 5.90 Roll Compression 3.51 4.80 Value % Roll Compression in. 5.86 5.62 Basis Weight Raw 2.01 1.99 −2.38 Wtg. Sensory Softness 5.60 6.1 [0000] TABLE 7 Invention at Penetration of 55 mils Description Pattern A Pattern B Pattern C Pattern D Basis Weight 26.12 26.19 26.40 26.18 lb/3000 ft 2 Caliper 8 183.32 192.26 187.54 187.61 Sheetmils/8 sht Tensile MD g/3 in 2793.50 2966.23 2880.07 2864.20 Stretch MD % 15.23 15.90 15.30 14.87 Tensile CD g/3 in. 2492.66 2688.85 2723.01 2501.79 Stretch CD % 9.58 9.52 9.50 8.97 Tensile GM g/3 in. 2638.12 2823.32 2799.58 2676.19 Tensile Dry Ratio 1.12 1.10 1.06 1.15 Unitless Perf Tensile g/3 in. 624.56 682.48 647.34 704.59 Wet Tens Finch 717.31 762.97 790.76 733.06 Cured CD g/3 in. Tensile Wet/Dry 0.29 0.28 0.29 0.29 CD Unitless SAT Capacity g/m 2 481.81 499.80 499.30 494.75 SAT Rate g/s 0.5 0.20 0.26 0.26 0.28 SAT Times 44.07 31.98 29.71 26.31 Break Modulus MD 183.24 185.48 187.84 192.75 gms/% Break Modulus CD 259.48 279.78 285.78 279.27 gms/% Break Modulus GM 218.00 227.76 231.67 231.94 gms/% Modulus MD g/% 46.40 42.64 42.75 42.76 Stretch Modulus CD g/% 64.30 63.57 64.38 61.86 Stretch Modulus GM g/% 54.59 52.04 52.43 51.39 Stretch TEA MD mm- 2.67 2.94 2.72 2.62 g/mm 2 TEA CD mm- 1.55 1.62 1.63 1.41 g/mm 2 Roll Diameter In. 6.03 6.03 5.98 6.04 Roll Compression 4.59 6.63 6.41 6.90 Value % Roll Compression 5.75 5.63 5.60 5.63 in. Basis Weight Raw 1.97 1.98 2.00 1.98 Wtg. Sensory Softness 5.60 5.70 5.90 6.10 [0000] TABLE 8 Invention at Penetration of 55 mils (Percent Change from Basesheet) Description Pattern A Pattern B Pattern C Pattern D Basis Weight −3.24 3.00 2.20 3.05 lb/3000 ft 2 Caliper 8 0.78 −5.69 −3.10 −3.14 Sheetmils/8 sht Tensile MD g/3 in −5.45 −0.40 2.52 3.06 Stretch MD % −5.51 1.35 5.10 7.78 Tensile CD g/3 in. −15.33 8.66 7.50 15.02 Stretch CD % 6.07 −5.44 −5.18 0.63 Tensile GM g/3 in. −10.48 4.19 5.00 9.18 Tensile Dry Ratio 12.30 −10.00 −5.58 −14.23 Unitless Perf Tensile g/3 in. Wet Tens Finch −14.58 9.15 5.84 12.71 Cured CD g/3 in. Tensile Wet/Dry −0.72 0.51 −1.84 −2.73 CD Unitless SAT Capacity g/m 2 SAT Rate g/s 0.5 SAT Times Break Modulus MD 1.44 −2.68 −3.99 −6.70 gms/% Break Modulus CD −20.89 14.70 12.87 14.85 gms/% Break Modulus GM −10.40 6.38 4.78 4.67 gms/% Modulus MD g/% Stretch Modulus CD g/% Stretch Modulus GM g/% Stretch TEA MD mm- −10.50 1.62 9.00 12.21 g/mm 22 TEA CD mm- −8.44 3.90 3.70 16.75 g/mm 2 Roll Diameter In. Roll Compression Value % Roll Compression in. Basis Weight Raw −3.24 3.00 2.20 3.05 Wtg. Sensory Softness [0075] The graphs presented in FIGS. 10 to 22 represent the outcome of Example 2 compared directly to the current product. [0076] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
A method of increasing the density and reducing the bulk of multi-ply paper products allowing one to reduce the roll size or increase the roll content, while minimizing the destruction of favorable product attributes.
3
CROSS-REFERENCE TO RELATED APPLICATIONS This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2005-283045 filed on Sep. 28, 2005, the entire contents of which are incorporated herein by reference. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an injection molding machine for molding an optical element with a mold. More particularly, it relates to an injection molding machine which controls temperature with high accuracy to improve molding accuracy. 2. Description of the Related Art There have conventionally been manufactured various molded items by injection molding. For example, JP Unexamined Patent Publication No. 10-323872 discloses an injection molding machine for molding disks utilized as information recording media. FIG. 4 shows schematic structure of the molding injection machine directed to the Publication No. 10-323872. The molding injection machine includes a fixed platen 101 and a cylinder 103 . Four tie-bars 104 are laid between the fixed platen 101 and the cylinder 103 to link them. The tie-bars 104 are supporting a movable platen 105 which is slidable. The movable platen 105 is driven by the cylinder 103 . A fixed mold 107 and a movable mold 108 are attached to the fixed platen 101 and the movable platen 105 , respectively. The movable mold 108 is clamped to the fixed mold 107 by the cylinder 103 . With this state, resin material is supplied from an injection unit 111 to mold a disk. Such an injection unit of an injection molding machine is required to control temperature with high accuracy so as to carry out stable mold injection with high accuracy. If temperature is too low, molding accuracy deteriorates. If temperature is too high, resin deteriorates or gets stringiness. Therefore, there has conventionally been provided heat adjusting means for a nozzle portion and a cylinder portion. For example, JP Unexamined Patent Publication No. 2005-7629 discloses an injection unit equipped with a heater and a temperature sensor at each zone. In the Publication No. 2005-7629, a thermo couple is disclosed as an example of temperature sensor. Since a thermo couple was cheap and satisfied sufficient accuracy in comparison with conventional accuracy demand, it was used widely. However, with the advance of accuracy of optical elements, temperature control accuracy managed by the conventional injection molding machine has become insufficient. Especially, as to micro molding machine, its one-shot volume is small and its nozzle portion sometimes has volume of several shots. As one-shot volume is smaller, higher accuracy in proportion to the smallness is required for injection performance and temperature control accuracy. In the case the conventional injection molding machine intends to control temperature with high accuracy, it is required to use a temperature sensor of higher accuracy. As an example of a temperature sensor of which accuracy is higher than a thermo couple, a platinum temperature-sensing element, a quartz temperature sensor, and the like can be utilized. However, they are expensive items. As described, the conventional injection molding machine has plural temperature control means at respective zones and if all of them are replaced with highly accurate temperature sensors, the replacement accompanies considerable cost-up. SUMMARY OF THE INVENTION The present invention has been attempted to solve the above-noted problems involved in the conventional injection molding machine. Thus, an object of the invention is to provide an injection molding machine capable of manufacturing an optical element with high accuracy without considerable cost-up by realizing stable and highly accurate injection. According to a first aspect of the present invention, there is provided an injection molding machine comprising: a fixed mold; a movable mold which is capable of contacting to and separating from the fixed mold; and an injection unit which supplies molten resin to a space formed between the fixed mold and the movable mold when being pressed to a non-molding face of the fixed mold, wherein the injection unit comprises: a nozzle portion which injects molten resin to the space formed between the fixed mold and the movable mold; an injecting portion which applies molten resin pressure toward the space formed between the fixed mold and the movable mold through the nozzle portion; a first heater and a first temperature sensor which are provided at a tip side within the nozzle portion; a second heater and a second temperature sensor which are provided at a side near to the injecting portion within the nozzle portion; and a third heater and a third temperature sensor which are provided within the injecting portion, and wherein a target temperature of the first heater is lower than a target temperature of the second heater, and the target temperature of the second heater is higher than a target temperature of the third heater. According to the injection molding machine directed to the first aspect of the present invention, the movable mold is made to get contact with the fixed mold and an optical element is mold by injecting resin to a space formed between the molds in contact with each other. Different target temperatures are set for respective portions appropriately, whereby stringing of resin is avoided. Furthermore, stable molding is carried out with high accuracy. According to a second aspect of the present invention, there is provided an injection molding machine comprising: a fixed mold; a movable mold which is capable of contacting to and separating from the fixed mold; and an injection unit which supplies molten resin to a space formed between the fixed mold and the movable mold when being pressed to a non-molding face of the fixed mold, wherein the injection unit comprises: a nozzle portion which injects molten resin to the space formed between the fixed mold and the movable mold; an injecting portion which applies molten resin pressure toward the space formed between the fixed mold and the movable mold though the nozzle portion; a nozzle heater and a nozzle temperature sensor provided within the nozzle portion; and an injecting portion heater and an injecting portion temperature sensor provided within the injecting portion, and wherein detection accuracy of the nozzle temperature sensor is higher than detection accuracy of the injecting potion temperature sensor. According to the injection molding machine directed to the second aspect of the present invention, since a highly accurate temperature sensor is employed for the nozzle portion only, it does not accompany considerable cost-up. Furthermore, since temperature at the nozzle portion in which about-to-be-injected resin is collected is controlled with high accuracy, stable injection molding can be carried out with high accuracy. Therefore, an optical element is manufactured with high accuracy. According to a third aspect of the present invention, there is provided an injection molding machine comprising: a fixed mold; a movable mold which is capable of contacting to and separating from the fixed mold; and an injection unit which supplies molten resin to a space formed between the fixed mold and the movable mold when being pressed to a non-molding face of the fixed mold, wherein the injection unit comprises: a nozzle portion which injects molten resin to the space formed between the fixed mold and the movable mold; an injecting portion which applies molten resin pressure toward the space formed between the fixed mold and the movable mold through the nozzle portion; a first heater and a first temperature sensor which are provided at a tip side within the nozzle portion; a second heater and a second temperature sensor which are provided at a side near to the injecting portion within the nozzle portion; and a third heater and a third temperature sensor which are provided within the injecting portion, and wherein a target temperature of the second heater is higher than a target temperature of the third heater. According to a fourth aspect of the present invention, there is provided an injection molding machine comprising: a fixed mold; a movable mold which is capable of contacting to and separating from the fixed mold; and an injection unit which supplies molten resin to a space formed between the fixed mold and the movable mold when being pressed to a non-molding face of the fixed mold, wherein the injection unit comprises: a nozzle portion which injects molten resin to the space formed between the fixed mold and the movable mold; an injecting portion which applies molten resin pressure toward the space formed between the fixed mold and the movable mold through the nozzle portion; a first heater and a first temperature sensor which are provided at a tip side within the nozzle portion; a second heater and a second temperature sensor which are provided at a side near to the injecting portion within the nozzle portion; and a third heater and a third temperature sensor which are provided within the injection molding portion, and wherein a target temperature of the first heater is lower than a target temperature of the second heater. According to the inventive injection molding machine, an optical element is manufactured with high accuracy without considerable cost-up by realizing stable and highly accurate injection. BRIEF DESCRIPTION OF THE DRAWINGS These and other objects and advantages of this invention will become more fully apparent from the following detailed description taken with the accompanying drawings in which: FIG. 1 is a front view showing schematic structure of a lens molding device directed to an embodiment; FIG. 2 is a cross sectional view showing schematic structure of an injection unit of the embodiment; and FIG. 3 is a cross sectional view showing schematic structure of a nozzle portion of the injection unit. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. In this embodiment, the present invention is applied to a lens molding device for manufacturing a plurality of lenses of a camera to be installed in a portable terminal at once. The lens molding device of the present embodiment is to mold a small optical element of which outside diameter is 12 nm or smaller, and an optical element to be mold is required to keep accuracy such as Ra 20 nm or smaller surface roughness of its optical surface. The present embodiment is applied to micro injection molding devices of which clamping force is 150 kN or lower. The lens molding device of the present embodiment is such structured as shown in FIG. 1 . That is, a fixed platen 1 and a rear platen 3 are fixedly provided on a frame 2 . Those platens 1 and 3 are substantially square shaped when looked from the left or right side with reference to FIG. 1 . Four tie-bars 4 are laid between the fixed platen 1 and the rear platen 3 to link them. The tie-bars 4 are arranged at respective four corners of the fixed platen 1 and the rear platen 3 fixedly. They are arranged in parallel to one another. A movable platen 5 is provided between the fixed platen 1 and the rear platen 3 . The movable platen 5 is substantially square shaped when looked from the left or right side with reference to FIG. 1 . Each tie-bar 4 penetrates through around each of four corners of the movable platen 5 . Guide bushes 51 are provided at respective penetrating portions for the tie-bars 4 . The movable platen 5 is slidable to the four tie-bars 4 . The movable platen 5 is supported by the tie-bars 4 without getting contact with the frame 2 . A hydraulic press 6 is attached to the rear platen 3 . The hydraulic press 6 and the movable platen 5 are connected with a tie-rod 61 . That is, the movable platen 5 can be moved in left-and-right direction by driving by the hydraulic press 6 . A fixed mold 7 is attached on a face of the fixed platen 1 facing the movable platen 5 . A movable mold 8 is attached to a face of the movable platen 5 facing the fixed platen 1 . Temperatures of the movable mold 8 and the fixed mold 7 are controlled respectively. On the frame 2 , an injection unit 11 is provided at a rear side of the fixed platen 1 (right side of the fixed platen 1 in FIG. 1 ). The injection unit 11 has such structure as shown in FIG. 2 . The injection unit 11 has a nozzle portion 12 , an injection cylinder 13 , an injection plunger 14 , an injection hydraulic cylinder 16 , and a pressure sensor 17 , and these elements compose an injection mechanism portion. At the upper part of the injection mechanism portion, there is provided plasticizing mechanism 21 which plasticizes resin and supplies plasticized resin to the injection cylinder 13 . At some parts of the injection unit 11 , there are some heaters for plasticizing resin and keeping resin in preferable plasticized condition. Furthermore, a temperature sensor is attached near each heater to detect a temperature around there. There is also provided a temperature control portion 50 which controls respective heaters upon receipt of detection results from respective temperature sensors. Thereby, temperatures at respective portions are controlled to keep at their respective optimum ones. For example, different target temperatures as respective optimum temperatures are set for the plasticizing cylinder 21 , the injection cylinder 13 , and the nozzle portion 12 and they are controlled to approximate to their respective target temperatures. In this embodiment, as shown in FIG. 3 , heaters 31 and 32 are arranged on the nozzle portions 12 , and so are heaters 33 and 34 on the injection cylinder 13 . The temperature sensors 41 , 42 , 43 and 44 are attached near the heaters 31 , 32 , 33 and 34 , respectively. For these temperature sensors 41 , 42 , 43 and 44 , target temperatures are predetermined respectively. The temperature control portion 50 controls the heaters 31 , 32 , 33 and 34 to make the temperature of the sensors 41 , 42 , 43 and 44 approximate to their respective target temperatures. In this embodiment, both the number of heaters and that of temperature sensors to be provided on the injection cylinder 13 are “2”, however, they may be more than “2” depending on size and volume of the injection cylinder 13 . Due to demand on quality stability of recent years, mold temperature stability has been required to be one degree or smaller as process variable. On the other hand, measurement accuracy or sensitivity of a conventional temperature measuring device including a thermo couple is ±1.5° C.+0.4%, which is not accurate or sensitive enough. On that account, as further accurate or sensitive temperature sensor, use of a platinum temperature sensing element or a quartz temperature sensor, for example, is required. Measurement accuracy or sensitivity of those sensors including its measuring device are: ±0.05° C. (quartz temperature sensor); and ±0.15° C. (platinum temperature sensing element). On the other hand, in the present invention, it is preferable that detection accuracy or sensitivity of a nozzle temperature sensor arranged within a range of one-shot injection volume from a tip portion of the nozzle is higher than that of the injecting portion temperature sensors arranged off the range. In this embodiment, with consideration of relation between total volume of the nozzle portion 12 and the injection cylinder 13 and one-shot injection volume, detection accuracy or sensitivity of a temperature sensor is selected based on the following criteria. In case one-shot injection volume can be managed within internal volume of the nozzle portion 12 , only the nozzle temperature sensors 41 and 42 arranged on the nozzle portion 12 shall be highly accurate or sensitive temperature sensors, such as the previously mentioned quartz and platinum temperature sensors, and the injecting portion temperature sensors 43 and 44 arranged on the injection cylinder 14 are less sensitive thermo couples which are similar to the conventional ones. In the case one-shot injection volume can be managed with total volume of the nozzle portion 12 and a tip portion of the injection cylinder 13 , the nozzle temperature sensors 41 and 42 on the nozzle portion 12 and the injecting portion temperature sensor 43 on the tip portion of the injection cylinder 13 shall be highly accurate or sensitive temperature sensors, such as the previously mentioned quartz and platinum temperature sensors. Note that portions of nozzle temperature sensors 41 and 42 are positioned within nozzle portion 12 as shown in FIG. 3 . In the case one-shot injection volume is further larger, the nozzle temperature sensors 41 and 42 on the nozzle portion 12 and the temperature sensors 43 and 44 on the injection cylinder 13 shall be highly accurate or sensitive temperature sensors. With such arrangement, temperature of at least one-shot of resin portion is adjusted within temperature monitoring accuracy or sensitivity of ±0.2° C. or smaller, preferably, within a range of ±0.05° C., and a target temperature is adjusted within accuracy or sensitivity of ±0.3° C. or smaller, as more preferable temperature accuracy or sensitivity, within a range of ±0.1° C. In the case highly accurate molding is required, it is preferable that temperatures of mold base members and cavity members are controlled by highly accurate or sensitive temperature sensors. Temperatures of portions other than these, e.g., plasticizing mechanism portions, can be controlled with conventional thermo couples satisfactorily. Furthermore, as for the nozzle portion 12 , a target temperature near the heater 31 arranged at the tip side of the nozzle portion 12 and a target temperature near the heater 32 at the side of the injection cylinder 13 are different. That is, a target temperature of the temperature sensor 42 at the side of the injection cylinder 13 is slightly higher than that of the temperature sensor 41 at the tip side. On the other hand, same target temperatures are set for the temperature sensors 43 and 44 on the injection cylinder 13 . The target temperature of the injection cylinder 13 is set slightly lower than target temperature near the heater 32 arranged at the side of the injection cylinder 13 . Thus, the temperature control portion 50 controls the temperatures at the tip side and at the injection cylinder 13 's side of the nozzle portion 12 to different target temperatures. In the case of molding small optical elements, so is one-shot volume. Accordingly, only resin collected in the nozzle portion 12 can possibly exceed one-shot volume. By varying target temperature part by part in the nozzle portion 12 , temperature of an essential amount of resin is controlled appropriately. In such structured lens molding device of the present embodiment, resin supplied from the external is heated in the plasticizing cylinder 21 and agitated by a plasticizing screw 22 . The plasticizing screw 22 is driven by the hydraulic motor 24 . Of the plasticized resin, predetermined amount of it is supplied to the internal of the nozzle portion 12 from the injection cylinder 13 . In the injection cylinder 13 , temperature is adjusted by the heaters 33 and 34 . In the nozzle portion 12 , temperature is adjusted by the heaters 31 and 32 with high accuracy. After that, the fixed mold 7 and the movable mold 8 are clamped and the injection unit 11 is pressed to the fixed mold 7 with predetermined pressing force. In such a clamped state, the injection plunger 14 is driven by the injection hydraulic cylinder 16 and molten resin is supplied to a cavity formed between the clamped molds from the nozzle portion 12 , whereby lenses formed. Types of resin to be used may be what are disclosed in JP Unexamined Patent Publications No. 2004-144951, No. 2004-144953, and No. 2004-144954, for example. Resins disclosed in the publications generally exhibit high fluidity and therefore, injection molding condition is preferable. On the other hand, provided that the resins are left unused for long time under high temperature, they can possibly get burnt, deteriorate, or turn yellow, which is not preferable. In the present embodiment, of the nozzle portion 12 , temperature is kept comparatively high only at the portion at the side of injection cylinder 13 so as to enhance molding condition. Since temperature inside of the injection cylinder 13 is controlled by the heaters 33 and 34 , deterioration of resin is avoided. As described, the nozzle portion 12 of the present embodiment has the heaters 31 and 32 at its tip side and injection cylinder 13 's side, respectively, and different target temperatures are set for the respective portions. Furthermore, since the heaters 31 and 32 are controlled by using the highly accurate temperature sensors 41 and 42 , difference from their respective target temperatures is significantly small. Thereby, even if only small amount of resin is injected, accuracy to transfer a fine shape with resin is enhanced and highly accurate molding is realized. Furthermore, resin sufficiently which has been heated at the injection cylinder 13 side of the nozzle portion 12 and enhanced its fluidity is slightly cooled down at the tip portion of the nozzle portion 12 , thereby stringing of resin is avoided. As described, according to the lens molding device of the present embodiment, highly accurate temperature control is applied to the nozzle portion 12 only. Since an expensive and highly accurate temperature sensor is just employed at a portion within a range of one-shot injection volume, this does not accompany considerable cost-up. Furthermore, temperature of about-to-be injected resin is controlled with high accuracy. Therefore, optical elements are manufactured with high accuracy by realizing stable and highly accurate injection. The embodiments were described above merely as illustrative examples, but it is nothing to limit the invention in any way. Therefore, the invention can obviously be improved or modified in various ways without deviating from its essentials. For instance, a pre-plasticizing type is described as an example of the injection unit 11 . However, an in-line type injection unit is also applicable. Furthermore, driving means of the movable platen 5 is not restricted to the hydraulic press 6 . Hydraulic cylinder system, hydraulic toggle system, electric motor type cylinder system, electric-motor-drive toggle system, whatever, may be applicable. The present invention is also applicable to a frame-support type lens molding device in which load of the movable platen 5 is supported by the frame 2 .
An injection molding comprises: a fixed mold; a movable mold which is capable of contacting to and separating from the fixed mold; and an injection unit which supplies molten resin to a space formed between the fixed mold and the movable mold when being pressed to a non-molding face of the fixed mold. The injection unit comprises: a nozzle portion which injects molten resin to the space formed between the molds; an injecting portion which applies molten resin pressure toward the space formed between the fixed mold and the movable mold though the nozzle portion; a heater and a temperature sensor provided on the nozzle portion; and a heater and a temperature sensor provided on the injecting portion, and detection accuracy of the sensor of the nozzle portion is higher than that of the injecting potion. There is thus provided an injection molding machine capable of manufacturing optics with high accuracy without considerable cost-up by realizing stable and highly accurate injection.
1
RELATED APPLICATIONS [0001] This is a continuation-in-part of and claims benefit under 35 U.S.C. §120 of International Patent Application No. PCT/PL2004/00003 filed on Apr. 30, 2004, which claims benefit under 35 U.S.C. §119 of Polish Patent Application No. P.359813 filed on May 2, 2003, the content of both applications are incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] The present invention relates to a UBP1 protease mutant and the sequence coding it, their application as well as products and methods for their production. The present invention is used in the production of recombinant proteins, particularly on an industrial scale. [0003] Ubiquitin is a protein commonly expressed in eukaryotes. It has been shown that it is a useful carrier for heterologous proteins obtained through expression in Escherichia coli (R. Baker, Current Opinion in Biotechnology 1996,7:541-546). Ubiquitin is composed of 76 amino-acid residues, with a combined molecular mass of 8,8 kDa. This protein is an element of the universal protein modification system. Ubiquitination is involved in almost all metabolic processes, from cell division to its death. Ubiquitin is involved in the regulation of gene expression, DNA repair, and it influences chromatin activity. It takes part in oncogenesis. It also plays a pivotal role in the proteolysis of regulatory proteins with short half-lives, and proteins with longer half lives as well, which must be removed from a cell for various reasons. [0004] Protein ubiquitination does not occur in bacteria. It has been shown that proteins fused to ubiquitin undergo greater expression in E. coli , and are more stable. Crystallographic analysis of ubiquitin using nuclear magnetic resonance demonstrated that both in solid state and in aqueous solution ubiquitin maintains a dense, globular structure (S. Vijay-Kumar, C. Bugg, W. Cook, J. Mol. Biol. 1987,194:531-544). The hydrophobic core of ubiquitin is composed of five parallel lengths of the peptide chain, held together with regularly spaced hydrogen bonds, forming a so-called β-pleated sheet. Its surface edges are joined with short chain lengths, coiled into 3.5 turns of an α-helix. Such a structure gives ubiquitin an uncommon resistance to high temperatures, a wide range of pH and polarity changes in the environment (Harding M M, Williams D H, Woolfson D N Biochemistry 1991, 30:3120-3128). [0005] The UBP1 protease is an enzyme isolated from yeast, which severs ubiquitin from a protein located at its C-end. The enzyme was described in 1991 (J. Tobias, A. Varshavsky, J. Biol. Chem. 1991,266;12021-12028) and is a subject of patent application WO91/17245 (European Patent EP 531 404). Its activity has been studied, and its culture conditions have been described in E. coli . In accordance to the contents of the description, it is a cysteine protease, which binds ubiquitin with an ester bond. UBP1 is made up of an 809 amino-acid chain. The enzymatic activity depends on its ability to sever the ubiquitin peptide from the polypeptide found at its C-end, regardless of the amino-acid sequence at the N-end of the ubiquitin. [0006] Application WO93/09235 describes other yeast proteins belonging to the same protease family, namely UBP2 and UBP3. This proteins show a similar activity (see also U.S. Pat. No. 5,494,818, U.S. Pat. No. 5,212,058, U.S. Pat. No. 5,683,904). [0007] No improved mutants of UBP1 have been shown to date. [0008] Expression systems are known, which yield fusion proteins composed of ubiquitin or its derivative and a polypeptide of interest. These then apply an enzyme which removes the ubiquitin (ie. UBP1), and recover the protein of interest (for examples see U.S. Pat. No. 5,132,213, U.S. Pat. No. 6,018,102). Such a method contains many advantages, encompassing among others an improvement in the quality and yield efficiency of the protein, and a simplification of the purification process of the protein, a significant feature for the industrial production of recombinant proteins (for an example see WO03/010204). Using an enzyme which removes ubiquitin along with appropriately designed fusion proteins, one may also obtain N-modified polypeptides (for example U.S. Pat. No. 5,847,097). [0009] The application of an enzyme which removes ubiquitin in technological processes requires large amounts of this enzyme. Known methods, however, are not conducive to the efficient expression of said enzyme, and significantly limit the possibilities of its application, particularly in industrial processes. SUMMARY OF THE INVENTION [0010] The goal of the present invention is to obtain an efficient method for the production of a protein for severing ubiquitin and the means for its realisation. A particular goal of the present invention is to obtain the means to produce a protein exhibiting UBP1 activity more easily. [0011] Thus, the goal of this invention is to also obtain a nucleotide sequence facilitating the efficient expression of an enzyme with UBP1 activity. Thus, the goal of the present invention is to also obtain a new, improved polypeptide comprising a protein with UBP1 activity. [0012] Unexpectedly, the above goals were met thanks to the present invention. [0013] A subject of the present invention is a mutant of the UBP1 protease, which contains an amino-acid sequence containing at least one of the following modifications: [0014] a substitution of proline at position 415 of the UBP1 sequence for leucine, [0015] a substitution of phenyloalanine at position 739 of the UBP1 sequence for leucine, [0016] a substitution of glutamine at position 754 of the UBP1 sequence for leucine, [0017] fusion of the polypeptide sequence of ubiquitin to an N-terminal amino-acid with a peptide bond, [0018] deletion of at least a portion of the amino-acids in positions from 1 through 54 of the UBP1 sequence. [0019] Preferentially, the deletion encompasses all amino-acids in positions from 1 through 54 of the UBP1 sequence. In accordance with the particularly preferential embodiment of the present invention mutant, a protease according to the present invention possess one of the amino-acid mutant sequences presented in FIGS. 6 , 8 - 10 . [0020] A subject of the present invention is also the nucleotide sequence coding a UBP1 protease mutant, characterised in that it contains at least one of the following mutations: [0021] a substitution of the proline codon at position 415 of the UBP1 amino-acid sequence with a leucine codon, [0022] a substitution of the phenyloalanine codon at position 739 of the UBP1 amino-acid sequence with a leucine codon, [0023] a substitution of the glutamine codon at position 754 of the UBP1 amino-acid sequence with a leucine codon, [0024] fusion of the sequence coding ubiquitin, preferentially in the starting region of the open reading frame, [0025] deletion of at least a portion of the first 54 codons of the sequence coding UBP1. Preferentially, the deletion encompasses the initial 132 nuclotides. [0026] Preferentially, the nucleotide sequence according to the present invention also contains codon changes accounting for the requirements of the planned expression system. In a particularly preferential embodiment the expressing host is E. coli , and the codon changes encompass the substitution of at least one of the arginine codons in positions 96, 476, 482, 487, 702, 705, 710, 796, 801 of the UBP1 amino-acid sequence with the the CGT or CGC codon. [0027] In one preferential embodiment, the nucleotide sequence according to the present invention contains one of the nucleotide sequences presented in FIGS. 1, 5 , 8 - 10 . [0028] Another subject of the present invention is the application of the UBP1 protease mutant in the production of the enzyme which severs ubiquitin, where the mutant contains the characteristics defined above. Preferentially, the obtained enzyme which severs ubiquitin is used to produce a protein of interest from a hybrid protein composed of ubiquitin and the protein of interest. The protein of interest is a medicinal protein, preferentially interleukin, interferon, growth hormone, insulin or erythropoetin. [0029] The next subject of the present invention is the application of a nucleotide sequence coding the UBP1 protease mutant to obtain an enzyme which severs ubiquitin, where a sequence is used according to the present invention, as defined above. [0030] A subject of the present invention is also the expression vector which contains the nucleotide sequence coding the UBP1 protease mutant according to the present invention, as defined above. Preferentially, the nucleotide sequence coding the UBP1 protease mutant is contained in the pT7-7ArgStop plasmid. [0031] A subject of the present invention is also a host cell transformed with an expression vector containing a nucleotide sequence coding the UBP1 protease mutant according to the present invention, as defined above. [0032] A subject of the present invention is also a method for the production of a protein which severs ubiquitin, characterised in that the host cells which have been transformed with the expression vector containing the nucleotide sequence coding the UBP1 protease mutant are cultured, and the desired enzyme or fraction containing it is isolated, where the nucleotide sequence coding the UBP1 protease mutant is a sequence according to the present invention, as defined above. [0033] Unexpectedly, it turned out that the new UBP1 mutants proposed in the present invention retain the basic enzymatic activity of severing ubiquitin, and are easier to produce. The presented means facilitate the easy and efficient expression of an enzyme with UBP1 activity, for example in the well understood system based on E. coli cells. Thanks to this, mutants according to the present invention are suitable for industrial application, for example in the process of synthesis of recombinant proteins, encompassing the expression of fusion proteins containing ubiquitin. BRIEF DESCRIPTION OF THE DRAWINGS [0034] To better illustrate the nature of the present invention, the description includes the following figures: [0035] FIG. 1 (SEQ ID NO.: 1) represents the sequence coding the hybrid protein Ubiquitin::UBP1 (lower case letters describe the ubiquitin sequence, the UBP1 sequence is in upper case, bold print marks the SacII recognition sequence, the stop codon and the sites of primers UBP1MG and UBP1MD); [0036] FIG. 2 represents a map of the pT7-7ArgStop expression vector, where Amp is the ampicillin resistance gene, ArgU is a gene coding tRNA complementary to the AGA codon, Stop Transkrypcji is a transcription stop nucleotide sequence from the φ10 gene of the T7 phage; [0037] FIG. 3 represents a probability curve for the existence of a transmembrane domain in UBP1, obtained using the TMHMM Prediction of transmembrane helices in proteins (CBS; Denmark) package; a 51 amino-acid transmembrane domain was noted. [0038] FIG. 4 represents a micrograph of Gramm-stained BLD21 E. coli cells containing the plasmid pT7-7ArgStop UBI+UBP1. [0039] FIG. 5 (SEQ ID NO: 3) The sequence coding the hybrid protein UBI::UBP1 ΔC with the transmembrane domain removed (lower case denotes the UBI sequence, upper case denotes the UBP1 ΔC protease coding sequence) [0040] FIG. 6 (SEQ ID NO:2) The amino-acid sequence of the UBP1 protease, and the proposed changes. The sequence of the removed transmembrane fragment is in bold. The active centre is in underlined italics, whereas amino-acids substituted with leucine, called by us mutations A, B and C are in bold underlined type. [0041] FIG. 7 A micrograph representing an in vivo preparation of a BLD21 E. coli culture with the plasmid pT7-7ArgStopUBI+UBP1ΔC with exchanged ariginine codons. [0042] FIG. 8 (SEQ ID NO: 6) The nucleotide and amino-acid sequence of UBI+UBP1ABC, the mutations are substitutions of: proline for leucine (position 415), phenyloalanine for leucine (position 739) and glutamine for leucine (position 754); amino-acid residues are marked with bold, underlined type. [0043] FIG. 9 (SEQ ID NO: 8) The nucleotide and amino-acid sequence of UBI+UBP1BC, the mutations are substitutions of: phenyloalanine for leucine (position 739) and glutamine for leucine (position 754); amino-acid residues are marked with bold, underlined type. [0044] FIG. 10 (SEQ ID NO: 10) The nucleotide and amino-acid sequence of UBI+UBP1C, the mutation is a substitution of glutamine for leucine (position 754); the amino-acid residue is marked with bold, underlined type. [0045] FIG. 11 Examination of the activity of the mutants obtained, digestion products: electrophoretic separation in polyacrylamide gel with SDS. From the left, the lanes are: lane No. 1, molecular mass marker (from the top 97, 66, 45, 30, 20.1, 14.4 [kDa]); lanes 2 and 3, digestion of UBI::INF with the UBP1ΔC protease over 2 h at 37° C.; lane 4, undigested UBI::INF; lanes 5 and 6, UBI::INF digested with the UBP1ΔC protease over 1 h at 37° C. DETAILED DESCRIPTION OF THE INVENTION [0046] The following examples are only meant to present assorted embodiments of the present invention and should not be viewed as the whole of its scope. EXAMPLE 1 Mutants of the UBP1 Protein [0047] Example UBP1 mutants containing point mutations: [0048] I UBP1ABC with the A, B, C mutation, a substitution of proline, phenyloalanine and glutamine for leucine at positions 415, 739 and 754 respectively. [0049] II UBP1BC with mutations at positions 739 and 754, substitutions phenyloalanine and glutamine respectively for leucine. [0050] III UBP1C a mutation at position 754, a substitution of glutamine for leucine. Using these mutants, hybrid proteins were designed which additionally contain the ubiquitin amino-acid sequence at the N-end (proteins: UBI+UBP1ABC, UBI+UBP1BC and UBI+UBP1C). [0051] The next group of mutants was produced by deleting the transmembrane domain of UBP1 or a portion thereof from the above proteins (example proteins: UBP1ΔC, UBI+UBP1ΔC and their mutants containing at least one of the mutations A, B or C). [0052] A1 mutations are located outside of the active centre, composed of cysteine (100-117 aa) and histidine (681-725 aa) residues, marked with underlined italics in FIG. 6 which represents the amino-acid sequence of UBP1 with the modified portions indicated. [0053] The above mentioned protease variants were used as an enzyme severing ubiquitin from proteins fused to its C-end. In our case it was the hybrid UBI: Interferon α. EXAMPLE 2 Construction of a Plasmid with the UBP1 Protease Gene and its Mutants [0054] The UBP1 protease gene, 2430 base pairs long, was obtained using PCR. The template used was genomic DNA of Saccharomyces cerevisiae , strain W303 (ade2-1, leu2-3, 112, trp1-1, his3-11, ura3-1, mit+, rho+). For amplification, the following primers were designed: UBP1P     SacII 5′ AGACT CCGCGG TGGTGATTTGTTTATTGAAA (SEQ ID NO: 12) GCAAGATA UBP1K    BamHI 5′ GG GGATCC TTAGTTTACATCTTTACCAGAAA (SEQ ID NO: 13) TA [0055] The oligonucleotides contained recognitions sites for the restriction endonucleases SacII and BamHI. The amplified DNA fragment was ligated with the pBluescript SK(−) vector, digested with the same enzymes. The ligation mixture was used to transform competent E. coli cells, strain NM522. Plasmid DNA was isolated using the alkaline method. Next, the 2430 bp UBP1 gene was excised from the recombinant using the restriction enzymes SacII and BamHI. DNA obtained in this way was ligated with the expression vector pT7-7ArgStopUBI, which was created by ligating the 240 bp ubiquitin gene sequence into the pT7-7ArgStop plasmid ( FIG. 2 ) into NdeI and EcoRI restriction sites. The PT7-7ArgStop plasmid was created in the laboratory of Prof. Dr. hab. Andrzej Plucienniczak, based on the pT7-7 plasmid (S. Tabor, C. Richardson, Proc. Nat. Acad. Sci. 1985,262:1074-1078). [0056] The pT7-7ArgStopUBI vector was digested with the SacII and BamHI enzymes, and then ligated with the DNA fragment coding UBP1. The ligation mixture was used to transform the competent E. coli strain DH5α. The DNA was then isolated, and the sequence was determined, shown in FIG. 1 . [0057] The protease gene was included into the expression vector pT7-7ArgStopUBI. The obtained plasmids with the hybrid gene UBI::UBP1 were used to transform BLD21 E. coli bacteria. The protein UBP1 was synthesized (produced) while these bacteria were cultyred. The culture was maintained at 25° C. in LB medium with an addition of 50 mg/ml of ampicillin. 30 hours were required for the culture to reach an OD 600 =1. Gramm-stained slides were made. It turned out that the E. coli bacteria were several dozen times longer than usual ( FIG. 4 ). [0058] The UBP1 sequence was examined using the TMHMM software package, which dete3rmines the likelihood of the existence of a transmembrane domain ( FIG. 3 ). The domain discovered could retard bacterial growth and cell division. This might have been the cause of the long time it took for the growth to reach OD 600 =1. [0059] PCR was used to remove this domain from the UBP1 gene. The modification was based on inserting an additional SacII restriction site into the sequence coding UBP1. [0060] Primers were designed for this reason, which were used in for point mutagenesis using the “QuikChange Site-Directed Mutagenesis Kit” from Stratagene: UBP1MG        SacII 5′ GGCATAGTAGTATTTTTTTA CCGCGG TGGTG (SEQ ID NO: 14) ACCATCTAAACTACATTGT UBP1MD           SacII 5′ ACAATGTAGTTTAGATGGTCACCA CCGCGG T (SEQ ID NO: 15) AAAAAAATACTACTATGCC [0061] Using the UBP1MG and UBP1MD primers (marked in bold in FIG. 1 ), recognition sequences for the SacII enzyme (underlined) were inserted into the interior of the UBP1 coding sequence. Thanks to this a 169 bp fragment was removed during the digestion of the pT7-7ArgStopUBI+UBP1 plasmid with the SacII restrictase. This resulted in a new plasmid, which we designated pT7-7ArgStopUBI+UBP1ΔC. It contains the coding sequence shown in FIG. 5 . Other plasmids coding alternate hybrid mutants according to the present invention containing the UBI sequence were produced in an analogous fashion. EXAMPLE 3 Expression of the UBP1ΔC Protease and Enzyme Purification [0062] BLD21 E. coli bacteria were transformed with a plasmid containing the UBP1 protease gene, or one of its mutants. During the culturing it was determined that the removal of the transmembrane domain facilitated the culturing, and shortened the time from 30 to about 12 hours. It was also observed that the cells producing the mutant according to the present invention returned to the original shape ( FIG. 7 ). [0063] BLD21 E. coli bacteria containing the appropriate plasmid were cultured on LB medium containing ampicillin (50 mg/ml) at 25° C. over 12 h until OD 600 =1, and subsequently induced with the addition of IPTG (isopropylthiogalactoside). After 2.5 h, the bacteria were centrifuged. The cell pellet was suspended in lysis buffer, and incubated for 30 min. at 20° C. Triton X-100 was added to a final concentration of 1%. The mixture was sonificated and centrifuged. The supernatant was applied to an SP column (the strong cationite Sepharose FF) and subsequently to a hydrophobic Phenylo Sepharose FF column. The protease activity was measured via the digestion of UBI::Interferonoc with purified enzyme fractions. The results are presented in FIG. 11 . [0064] Additionally, the UBP1 protease gene was modified through the exchange of certain argining codons unfavourable to E. coli (AGA or AGG) for codons which occur in these bacteria E. coli (CGT or CGC). In the ultimate version, the arginine codons at positions 96, 476, 482, 487, 702, 705, 710, 796 and 801 were replaced, marked in bold in FIG. 6 .
A UBP1 protease mutant and the sequence coding it, their application and products and the methods used to produce them may be used in the production of recombinant proteins, particularly on an industrial scale.
2
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority from U.S. Provisional Application No. 61/412,612 entitled “Amino Terminated Phosphonamide Oligomers and Flame Retardant Compositions Therefrom” filed Nov. 11, 2010, which is herein incorporated by reference in its entirety. GOVERNMENT RIGHTS [0002] This invention was developed with Government support under Contract No. FA8650-07-C-5907 awarded by the Department of the Air Force. The Government has certain rights in the invention. PARTIES TO A JOINT RESEARCH AGREEMENT [0003] Not applicable. INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC [0004] Not applicable. BACKGROUND [0005] The phosphorus content of polymer compositions is important to achieving flame retardancy. High molecular weight polyphosphonamides often have poor solubility or miscibility in the host polymer, and due to their high melt viscosity, significantly detract from the melt processability of the host resin. When added to thermosetting polymers, a reduction in glass transition temperature (Tg), heat distortion temperature (HDT), and modulus often results. Additionally, adding high molecular weight polyphosphonamides to other polymers leads to a lower phosphorus content compared to using oligomers. [0006] Amino terminated phosphonamide oligomers can react with a variety of monomers and oligomeric species to form copolymers. For example, they can be co-reacted with epoxy formulations to produce a flame retardant polymer in which the phosphonamide oligomer is chemically incorporated into the matrix via covalent bond formation. Likewise, the amino terminated phosphonamide oligomers can be used as reactants to form copolyamides, copolyureas, copolyimides and any other copolymers that can react with an amine functional group. Therefore, there is a need for phosphonamides prepared by any synthetic route that have reactive amino end groups at sufficient concentration to participate in bond forming reactions with other monomers or reactive species to form copolymers. SUMMARY OF THE INVENTION [0007] Embodiments described herein include a composition comprising an amino terminated phosphonamide of general Formula I: [0000] [0000] where R is a C 1 to C 20 alkyl or, optionally substituted, aryl group, X is an aromatic or aliphatic group, Z is: [0000] and n is an integer of from 1 to about 20. In some embodiments, n can be an integer of from 1 to about 10. In other embodiments, the amino-terminated phosphonamide may include at least about 50% amine end-groups based on the total number of end groups. In certain embodiments, R may be methyl, and in some embodiments, each —NH—X—NH— can be derived from a diamine, a triamine, or a polyamine. [0009] Other embodiment are directed to compositions including an amino terminated phosphonamide of general Formula II: [0000] [0000] where each of R 1-5 is individually a C 1 to C 20 alkyl or, optionally substituted, aryl group, each of X 1-4 is individually, an aromatic, cycloalkyl, or aliphatic group, n and m are each individually an integer of from 0 to about 20 and each Z is, independently: [0000] [0000] In some embodiments, each m and n are each individually integers from 0 to about 10. In other embodiments, the amino-terminated phosphonamide includes at least about 50% amine end-groups based on the total number of end groups. In particular embodiments, each of R 1-5 can be methyl, and in other embodiments, each of —NH—X 1-4 —NH— can independently derived from a diamine, a triamine, or a polyamine. [0010] Further are directed to compositions that include the amino terminated phosphonamide of the invention including those of Formulae I and II and one or more polycarbonates, epoxy derived polymers, polyepoxies, benzoxazines, polyacrylates, polyacrylonitriles, polyesters, poly(ethylene terephthalate)s, poly(trimethylene terephthalate) and poly(butylene terephthalate)s, polystyrenes, polyureas, polyurethanes, polyphosphonates, poly(acrylonitrile butadiene styrene)s, polyimides, polyarylates, poly(arylene ether)s, polyethylenes, polypropylenes, polyphenylene sulfides, poly(vinyl ester)s, polyvinyl chlorides, bismaleimide polymers, polyanhydrides, liquid crystalline polymers, cellulose polymers, and combinations thereof, and in some embodiments, these compositions may further include one or more fillers, fibers, surfactants, organic binders, polymeric binders, crosslinking agents, coupling agents, additional flame retardants, anti-dripping agents, anti-static agents, catalysts, colorants, inks, dyes, antioxidants, stabilizers, or combinations thereof. [0011] Still further embodiments are directed to methods for preparing the oligomeric amino terminated phosphonamides of the invention including those of general Formulae I and II, and methods for preparing compositions including the oligomeric amino terminated phosphonamides and another thermoplastic or thermoset resin. Additional embodiments including articles of manufacture and various coatings and moldings created from the oligoemeric amino terminated phosphonamides of the invention and compositions including these oligomeric amino terminated phosphonamides. DESCRIPTION OF DRAWINGS [0012] Not applicable. DETAILED DESCRIPTION [0013] Before the present compositions and methods are described, it is to be understood that this invention is not limited to the particular processes, compositions, or methodologies described, as these may vary. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present invention, which will be limited only by the appended claims. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred methods, devices, and materials are now described. All publications mentioned herein are incorporated by reference in their entirety. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention. [0014] It must also be noted that, as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a combustion chamber” is a reference to “one or more combustion chambers” and equivalents thereof known to those skilled in the art, and so forth. [0015] As used herein, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50% means in the range of 45%-55%. [0016] The terms “flame retardant,” “flame resistant,” “fire resistant,” or “fire resistance,” as used herein, means that the composition exhibits a limiting oxygen index (LOI) of at least 27. “Flame retardant,” “flame resistant,” “fire resistant,” or “fire resistance,” may also refer to the flame reference standard ASTM D6413-99 for textile compositions, flame persistent test NF P 92-504, and similar standards for flame resistant fibers and textiles. Fire resistance may also be tested by measuring the after-burning time in accordance with the UL test (Subject 94). In this test, the tested materials are given classifications of UL-94 V-0, UL-94 V-1 and UL-94 V-2 on the basis of the results obtained with the ten test specimens. Briefly, the criteria for each of these UL-94-V-classifications are as follows: [0017] UL-94 V-0 the average burning and/or glowing time after removal of the ignition flame should not exceed 5 seconds and none of the test specimens should release and drips which ignite absorbent cotton wool. [0018] UL-94 V-1: the average burning and/or glowing time after removal of the ignition flame should not exceed 25 seconds and none of the test specimens should release any drips which ignite absorbent cotton wool. [0019] UL-94 V-2: the average burning and/or glowing time after removal of the ignition flame should not exceed 25 seconds and the test specimens release flaming particles, which ignite absorbent cotton wool. [0020] Fire resistance may also be tested by measuring after-burning time. These test methods provide a laboratory test procedure for measuring and comparing the surface flammability of materials when exposed to a prescribed level of radiant heat energy to measure the surface flammability of materials when exposed to fire. The test is conducted using small specimens that are representative, to the extent possible, of the material or assembly being evaluated. The rate at which flames travel along surfaces depends upon the physical and thermal properties of the material, product or assembly under test, the specimen mounting method and orientation, the type and level of fire or heat exposure, the availability of air, and properties of the surrounding enclosure. If different test conditions are substituted or the end-use conditions are changed, it may not always be possible by or from this test to predict changes in the fire-test-response characteristics measured. Therefore, the results are valid only for the fire test exposure conditions described in this procedure. The state-of-the-art approach to rendering polymers flame retardant is to use additives such as brominated compounds or compounds containing aluminum and/or phosphorus. Use of these additives can have a deleterious effect on the processing characteristics and/or the mechanical performance of products produced from them. In addition, some of these compounds are toxic, and can leach into the environment over time making their use less desirable. In some countries certain brominated additives and aluminum and/or phosphorus containing additives are being phased—out of use because of environmental concerns. [0021] Embodiments of the invention are generally directed to amino-terminated phosphonamides, and in some embodiments oligomeric amino terminated phosphonamides. Other embodiments are directed to methods for producing amino terminated phosphonamides. Further embodiments are directed to methods for using amino terminated phosphonamides in thermoset resins, and certain embodiments are directed to thermoplastics having amino terminated phosphonamides and oligomeric amino terminated phosphonamides incorporated into the polymer matrix. Still further embodiments are directed to articles of manufacture that include these thermoplastics having amino terminated phosphonamides and oligomeric amino terminated phosphonamides incorporated into the polymer matrix. [0022] Embodiments are not limited to particular phosphonamides. Various known phosphonamides can be reformulated to include amino termini and are encompassed by the invention. In particular embodiments, the amino terminated phosphonamides of the invention may have the structure of general Formula I: [0000] [0000] where R is a C 1 to C 20 alkyl or, optionally substituted aryl group, X is an aromatic, cycloalkylene, or aliphatic group, n is an integer of from 1 to about 20, and Z is: [0000] [0000] In other embodiments, the predominately amino terminated phosphonamide oligomers may include compounds of Formula II: [0000] [0000] where R 1-5 are each individually a C 1 to C 20 alkyl or, optionally substituted, aryl group, X 1-4 are each individually, an aromatic, cycloalkylene, or aliphatic group, n and m are an integer of from 0 to about 20, and each Z is, independently: [0000] [0000] In some embodiments, m and n may each independently be from about 0 to about 10. In other embodiments, m may be an integer of from 0 to about 4, such that the branching, or potential branching, and n may be any integer from 1 to about 10. [0023] In particular embodiments, each —NH—X—NH— provided in Formulae I and II, including the amine containing moieties including X″, may be derived from an amine containing monomer including all known diamine, triamine, or polyamine containing monomer. In certain embodiments, each —NH—X—NH— may be derived from the same amine containing monomer, and in other embodiments, each —NH—X—NH— may be derived from two or more different amine containing monomers. Exemplary amine containing monomers include alkanediamines, alkanetriamines, arylamines, cycloalkylamines, or any combinations thereof, and in various embodiments, the alkanediamines, alkanetriamines, arylamines, cycloalkylamines may have from about 6 to about 12 or about 20 carbon atoms. In particular embodiments, the alkanediamines, alkanetriamines, arylamines, cycloalkylamines may have from about 6 to about 8 carbon atoms. More specific non-limiting examples of suitable diamines, triamines, and polyamines include m-xylylenediamine, di(4-aminophenyl)methane, di(4-aminocyclohexyl)methane, 2,2-di(4-aminophenyl)propane, 1,4-diaminobutane, 1,3-bis-(aminomethyl)-cyclohexane, 1,4-bis(aminomethyl)-cyclohexane, 2,5-bis(aminomethyl)-bicyclo-[2,2,1]heptane and/or 2,6-bis-(aminomethyl)-bicyclo[2,2,1]heptane, bis-(4-aminocyclohexyl)-derivative of an alkane having from 1 to 6 carbon atoms, and p-xylylene-diamine 2,2-di(4-aminocyclohexyl)propane, and triamine derivatives of these diamines, any mixtures, or combinations thereof. In certain embodiments, —NH—X—NH— may be derived from polyether amine or Jaffamine, which are described herein below. [0024] The weight average molecular weight (Mw) of these predominately amino terminated phosphonamide oligomers can vary based on the number of monomers incorporated into the polymer chain and can be form about 200 g/mole to about 10,000 g/mole or about 500 g/mole to about 7,500 g/mole in embodiments (all expressed against polystyrene (PS) standards). The term “predominately” as used herein is meant to infer that at least 50% of the available end groups include an amine group, and in some embodiments, predominately may refer to phosphonamides having from about 50% to about 100%, about 60% to about 90%, about 60% to about 80%, or any range between these exemplary ranges of amine end groups based on the total number of available end groups. [0025] The predominately amino terminated phosphonamide oligomers of such embodiments may be prepared by combining an amine containing monomer and a phosphonate containing monomer and heating this mixture under vacuum. In some embodiments, the reaction mixture may further include a polymerization catalyst such as, for example, magnesium chloride. In general, the vacuum may be sufficient to remove volatile components, such as phenol, produced as the phosphonamide oligomer is made. In some embodiments, the vacuum may be applied in a step wise manner, in which the vacuum is increased and the pressure of the reaction is reduced one or more times, during the polymerization process, and in other embodiments, the pressure may be gradually reduced throughout the polymerization. In still other embodiments, the vacuum may be increased and the pressure reduced both step wise and gradually in the same polymerization method. For example, in some embodiments, the vacuum may be applied to produce an initial pressure of from about 250 mmHg to about 50 mmHg and the pressure may be reduced gradually, in a step wise manner, or both to from about 10 mmHg to about 5 mmHg. In other exemplary embodiments, the initial pressure may be from about 250 mmHg to about 150 mmHg, and this pressure may be reduced to from about 40 mmHg to about 80 mmHg and then reduced again to about 20 mmHg to about 5 mmHg to produce a method with 3 vacuum steps. Other methods may include more than 3 steps, and still other methods may include less than 3 steps, for example, pressure may be gradually reduced throughout polymerization from about 250 mmHg or 150 mmHg to about 10 mmHg or about 5 mmHg. [0026] The temperature of the reaction may be maintained at any temperature at which polymerization may occur. For example, in some embodiments, the reaction temperature may be from about 175° C. to about 300° C., and in other embodiments, the reaction temperature may be from about 200° C. to about 250° C. or 275° C. In some embodiments, a constant reaction temperature may be maintained throughout the polymerization, and in other embodiments, the reaction temperature may change at various times throughout the polymerization reaction. In particular embodiments, the reaction temperature may be increased at steps as the pressure is decreased. For example, in the context of the exemplary embodiments above, the initial reaction temperature may be about 175° C. to about 220° C. when the pressure is from about 250 mmHg to about 150 mmHg. The reaction temperature may be increase to from about 200° C. to about 230° C. when the pressure reduced to from about 40 mmHg to about 80 mmHg, and the reaction temperature may be increased to from about 220° C. to about 275° C. when the pressure is reduced to about 20 mmHg to about 5 mmHg. [0027] The reaction time may be any amount of time necessary to provide sufficient polymerization and may vary with reactants, catalysts, reaction temperatures and pressures, and so on. The skilled artisan may vary the reaction time according to such considerations. In general, the total reaction time may be from about 10 hours to about 40 hours, and in some embodiments, the total reaction time may be from about 15 hours to about 25 hours. The reaction time for various steps or temperature and pressure intervals may also vary, and each step or interval may individually be from about 2 hours to about 20 hours. In certain embodiments, a lower temperature, higher pressure first step or interval may be from about 2 hours to about 6 hours in length, followed by a longer 10 hour to 25 hour step or interval where the temperature is increased and the pressure is reduced. As discussed above, the reaction time for each step or interval may vary and can be determined by the skilled artisan. [0028] In some embodiments, the amine containing monomer may be provided in a molar excess to increase the number of amine end-groups on the phosphonamide oligmers. As discussed above the amine containing monomer may be any diamine, triamine, or polyamine known in the art. In particular embodiments, the amine containing monomer may be provided in a molar excess of at least 10%, and in other embodiments, the amine containing monomer may be provided in a molar excess of from about 10% to about 50%, about 10% to about 30%, or about 10% to about 25%. Without wishing to be bound by theory, when an amine containing monomer is combined with a phosphodiester containing monomer and is provided in a molar excess of 10%, the resulting oligomeric phosphonamide may have about 5% excess amino end-groups versus phosphonate-ester end groups. In still other embodiments, the reaction mixture may include a branching agent, and the ratio of amine to phosphodiester containing monomers may be adjusted to ensure excess amine end-groups in the resulting oligomeric phosphonamide. [0029] In further embodiments, the amino terminated phosphonamides described above can be prepared by reacting diamines, triamines, polyamines, or combinations thereof with phosphinic dihalides. [0030] In various embodiments, amine containing monomer may be any known diamine, triamine, or polyamine containing monomer. Exemplary amine containing monomers include alkanediamines, alkanetriamines, arylamines, cycloalkylamines, or any combinations thereof, and in various embodiments, the alkanediamines, alkanetriamines, arylamines, cycloalkylamines may have from about 6 to about 12 or about 20 carbon atoms. In particular embodiments, the alkanediamines, alkanetriamines, arylamines, cycloalkylamines may have from about 6 to about 8 carbon atoms. More specific non-limiting examples of suitable diamines, triamines, and polyamines include m-xylylenediamine, di(4-aminophenyl)methane, di(4-aminocyclohexyl)methane, 2,2-di(4-aminophenyl)propane, 1,4-diaminobutane, 1,3-bis-(aminomethyl)-cyclohexane, 1,4-bis(aminomethyl)-cyclohexane, 2,5-bis(aminomethyl)-bicyclo-[2,2,1]heptane and/or 2,6-bis-(aminomethyl)-bicyclo[2,2,1]heptane, bis-(4-aminocyclohexyl)-derivative of an alkane having from 1 to 6 carbon atoms, and p-xylylene-diamine 2,2-di(4-aminocyclohexyl)propane, and triamine derivatives of these diamines, any mixtures, or combinations thereof. [0031] In particular embodiments, the amine containing monomer may be polyether amines such as Jeffamines. Jeffamines are well known in the art and any polyether amine or Jaffamine can be used to prepare the phosphonamide oligomers of the invention. In particular embodiments, the amine containing monomer may be a Jeffamine of the structures provided below. [0000] Name Structure x Ave Mw D230 D2000  ~2.5 ~33  230 2000 T403 n = 1 (x + y + z) = 5 − 6 R = CH 2 CH 3  440 [0032] In certain embodiments, the phosphonate containing monomer may be a diaryl alkyl- or arylphosphonates or optionally substituted diaryl alkyl- or arylphosphonates of embodiments may be of general formula (I): [0000] [0000] where R 2 may be C 1 -C 20 alkyl or, optionally substituted, aryl and R 1 may be an aryl group, or a substituted aryl group of formula (II): [0000] [0000] where R 3 , R 4 , R 5 , R 6 , and R 7 may independently be any substituent including but not limited to hydrogen, C 1 -C 20 alkyl, aromatic or aryl group, trifluoromethyl, nitro, cyano, halide (F, Cl, Br, I), C 1 -C 20 alkyl ether, C 1 -C 20 alkyl ester, benzyl halide, benzyl ether, aromatic or aryl ether, or optionally substituted versions of these, and R 3 , R 4 , R 5 , R 6 , and R 7 are essentially unaffected by the reaction. In certain embodiments, the diaryl alkylphosphonate may be diphenyl methylphosphonate. [0033] The amino terminated phosphonamides and oligomeric amino terminated phosphonamides described above may include at least one amino termini, and in certain embodiments, the amino terminated phosphonamides and oligomeric amino terminated phosphonamides may have two or more amino termini. In some embodiments, the molecular weight of the oligomeric amino terminated phosphonamides may be substantially the same. In other embodiments, the oligomeric amino terminated phosphonamides may be present in a statistical mixture of various molecular weight species. In such statistical mixtures, an amino group is present of both ends of the same molecule, one end of the molecule, or on neither end of different molecules. [0034] The oligomeric amino-terminated phosphonamides described herein overcome the problems of toxicity and leaching while satisfying the UL or comparable standardized flame resistance rating performance requirements without detracting from important physical, mechanical and processing properties. This is achieved by formulating a composition of a reactive monomer, oligomer or polymer and an effective amount of an amino terminated phosphonamide oligomer. The amount of the amino terminated phosphonamide may be provided in any appropriate flame retarding amount and can range up to about 50% by weight of the final composition, and in some embodiments, the amount of amino terminated phosphonamide may be from about 10% to about 30%, by weight of the final composition. In some embodiments, the oligomeric amino-terminated phosphonamide can be cured with the host resin, and in other embodiments, the oligomeric amino terminated can be pre-reacted with the host resin. [0035] The amino terminated phosphonamide oligomers of various embodiments can be combined with a variety of other monomers, oligomers, and polymers including, for example, epoxies, ureas, esters, urethanes, and imides. In certain embodiments, the amino terminated phosphonamides and oligomeric amino terminated phosphonamide oligomers may be incorporated into thermoplastic and thermosetting polymers such as, but not limited to, polyester, polycarbonate, polyacrylate, polyacrylonitrile, polystyrene (including high impact strength polystyrene and syndiotactic polystyrene), polyurea, polyurethane, linear and branched polyphosphonates, poly(acrylonitrile butadiene styrene), polyimide, polyarylate, poly(arylene ether), polyethylene, polypropylene, polyphenylene sulfide, poly(vinyl ester), polyvinyl chloride, bismaleimide polymer, polyanhydride, liquid crystalline polymer, epoxies and polyepoxies, such as polymers resulting from the reaction of one or more epoxy monomers or oligomers with one or more chain extenders or curing agents such as a mono or multifunctional phenol, amine, benzoxazine, anhydride or combination thereof, benzoxazine, polyphosphate, cellulose polymer, or any combination thereof. These exemplary thermoplastics and thermosets are well known commercially available commodity engineering plastics that used in a variety of applications. Embodiments of the invention encompass any other such engineering plastics not specifically included in the above lists, and combinations of various thermoplastics and thermoset resins. [0036] In some embodiments, the compositions including a thermoplastic or thermoset resin and an amino-terminated phosphonamide or an oligomeric amino-terminated phosphonamide may further include other additives such as, for example, one or more curing agents, additional flame retardant additives, fillers, anti-dripping agents, and other additives typically used with such polymers. In some embodiments, the additional flame retardant additive may be a complementary flame retardant such as, but not limited to, alumina trihydrate, magnesium hydroxide, organic sulfonate or sulfonamidate salts, siloxanes, (organic) phosphinate salts, metal phosphinate salts, ammonium polyphosphate, melamine, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, melamine cyanurate, red phosphorus, (poly)phosphonates, triphenyl phosphate, or a bisphosphate flame retardant (such as resorcinol bis(diphenyl phosphate), or bisphenol A bis(diphenyl phosphate). [0037] In certain embodiments, the amino terminated phosphonamide or oligomeric amino-terminated phosphonamide may be formulated as fiber reinforced composites. Such fiber reinforced composites may include any of the thermoplastics or thermosets described herein in combination with a fiber or fabric that may be composed of carbon, glass, organic fibers such as polyester, polyaramide, inorganic fibers may include, but are not limited to, silicon carbide. In some embodiments, the reinforcing fiber or fabric may be incorporated into the polymer matrix with the amino terminated phosphonamide or oligomeric amino-terminated phosphonamide, and in other embodiments, the polymer resin, amino terminated phosphonamide or oligomeric amino-terminated phosphonamide can be used to impregnate a reinforcing fiber or fabric. [0038] In particular embodiments, the oligomeric amino-terminated phosphonamide may be provided in epoxy formulations. Such embodiments are not limited to any particular type of epoxy. For example, the epoxy resin may be a bisphenol A epoxy, bisphenol F epoxy, phenolic novolak epoxy, cresol novolak epoxy, bisphenol A novolak epoxy resins, and the like. In some embodiments, the epoxy resins used in embodiments may be halogenated, and in other embodiments, the epoxy resins may be non-halogenated. Such epoxy resins may be used in any application. The epoxies of such embodiments including oligomeric amino-terminated phosphonamides may be incorporated into, for example, circuit boards, housing for electronic components, epoxy encapsulant compositions for use in electronic applications, and in other embodiments, epoxy compositions of the invention can be used for structural applications and as coatings. The oligomeric amino-terminated phosphonamides can be used in place of brominated flame retardants or other phosphorus containing flame retardants, or the oligomeric amino-terminated phosphonamides can be used in combination with such compositions. In some embodiments, epoxy resins compositions including oligomeric amino-terminated phosphonamides may contain other components conventionally used epoxies such as, but not limited to, polyphenylene oxide, imide, phenolic, and benzoxazine resins as well as reinforcement additives such as paper, glass fibers, organic fibers, or carbon fibers. [0039] In some embodiments, the oligomeric amino-terminated phosphonamide of the invention may be used in combination with polyurea. The oligomeric amino-terminated phosphonamides can be incorporated into any polyurea formulation known in the art. For example, in certain embodiments, the polyurea formulations may include diisocyanates, aromatic or aliphatic diamines, or combinations thereof in addition to the amino terminated phosphonamide. [0040] In some embodiments, the oligomeric amino-terminated phosphonamide may be used in crosslinked polymer compositions. In some embodiments, an oligomeric amino-terminated phosphonamides having two or more functional amine groups per oligomer chain such as, but not limited to, those described in Formula I and Formula II can act as a crosslinking agent. These oligomeric amino-terminated phosphonamides can be combined with a thermoplastic or thermoset resin having functional groups that can react with the amine groups of the oligomeric amino-terminated phosphonamide. For example, in particular exemplary embodiments, crosslinked polyureas can be produced by combining polyureas with the amino terminated phosphonamides of embodiments of the invention, and, for example, triisocyanates, diisocyanates, aromatic or aliphatic diamines, or combinations thereof. [0041] In some embodiments, the oligomeric amino terminated phosphonamides can be mixed or blended with other monomers, oligomers, or polymers and these mixtures can be used for preparing articles of manufacture from the blended material. For example, some embodiments include methods for preparing a polymer composition including the steps of blending in a melt a monomer, oligomer, or polymer and a oligomeric amino terminated phosphonamide. The melt blending may be carried out by any mixing technique, for example, melt mixing may be carried out in a brabender mixer or extruder. In some embodiments, the methods may include the steps of extruding the mixture after melt mixing and pelletizing the resulting material. In other embodiments, the methods may include compressing the melt mixed material in rollers to create a film, spincasting a film, blowmolding a film or extruding a sheet product. In still other embodiments, the methods may include molding the melt mixed material into an article of manufacture. In still other embodiments the oligomeric amino terminated phosphonamide can be mixed in solution with other components and, optionally after mixing with another solution, be sprayed to form a film. [0042] Still other embodiments include polymeric compositions prepared from these amino terminated phosphonamide oligomers and other monomers, oligomers or polymers that meet UL fire or comparable standardized fire resistance ratings required for a variety of consumer products without detracting from other important safety, environmental, manufacturing and consumer use requirements. For example, consumer electronics must meet particular fire resistance standards as specified by the Underwriter's Laboratory (UL) or comparable standardized fire resistance rating criteria without compromising other properties such as Tg, HDT, and interfacial adhesion. The electronics often contain circuit boards that include epoxy/glass laminates. The state-of-the-art approach to rendering these systems flame retardant is to use various additives such as brominated compounds or compounds containing aluminum, antimony, and/or phosphorus. However, these compounds are often toxic, and can leach into the environment over time making their use less desirable. In some countries these additives and related additive types are being phased out of use. [0043] Further embodiments include articles of manufacture that include a polymer matrix and the amino terminated phosphonamide or oligomeric amino-terminated phosphonamide of the invention. For example, certain embodiments are directed to consumer electronics and other consumer products that must meet particular fire resistance standards as specified by UL or other standardized criteria. Such consumer electronics and consumer products may contain or include, for example, circuit boards, housings, or other components or subcomponents that include amino terminated phosphonamide or oligomeric amino-terminated phosphonamide containing compositions, filled amino terminated phosphonamide or oligomeric amino-terminated phosphonamide containing compositions, or fiber reinforced amino terminated phosphonamide or oligomeric amino-terminated phosphonamide compositions. The components fabricated from such compositions will generally meet the UI-94 V-0 or similar criteria for fire resistance while retaining good properties such as Tg, HDT, interfacial adhesion, and the like. EXAMPLES [0044] Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other versions are possible. Therefore the spirit and scope of the appended claims should not be limited to the description and the preferred versions contained within this specification. Various aspects of the present invention will be illustrated with reference to the following non-limiting examples. MATERIALS [0045] Jeffamine diamines (D230, D2000 and T403) were purchased from Huntsman Petrochemical Corporation. Expandable graphite—GRAFGUARD® 160-50 was obtained from GrafTech International. Ammonium polyphosphonate (APP) (20 μm powder) was obtained from ICL-LP. Diphenyl methyl phosphonate (DPP) was prepared using methods referred to in U.S. Pat. No. 7,888,534 B2 and U.S. Pat. No. 7,928,259 B2, Dragonshield-BC (DSBC™) was obtained from Specialty Products Inc. (SPI). Example 1 Preparation of Oligomeric Amino Terminated Phosphonamides [0046] The reactions of various aromatic and aliphatic diamines with diphenylmethyl phosphonate were carried out in a round bottom flask fitted with a mechanical stirrer, N 2 /vacuum inlet, and a distillation column (filled with hollow glass tubes) wrapped with electrical heating tape. The reagents were heated to 200° C. for 12-14 hrs., while gradually lowering the vacuum from 400 mmHg to 5 mmHg. The temperature was then increased to 240° C. for 4-6 hrs at <1 mmHg (full vacuum) to drive off residual phenol and any unreacted starting materials. The amino terminated phosphonamide product was isolated as a viscous liquid. The reaction was monitored by gas chromatography-mass spectroscopy (GC-MS) by analysis of the phenol by-product. The amino terminated phosphonamide oligomer was analyzed using nuclear magnetic resonance spectroscopy ( 1 H-NMR) and the % phosphorus was determined using inductively coupled plasma optical emission spectrometry (ICP-OES). Example 2 Synthesis of an Amino Terminated Phosphonamide [0047] 276.0 g (1.2 mol) Jeffamine D230, 297.8 g (1.2 mol) DPP and 3.05 g (0.03 mol) magnesium chloride were added to a 1 L round bottom flask and heated to 200° C. while stirring for 14 hours. The vacuum was gradually lowered to 60 mmHg over 6 hrs., maintained at 40 mm Hg for 4 hrs, and then lowered to 10 mmHg for 4 hrs. The distillation column was maintained at 115° C. for 14 hrs. The distillate was collected in a flask cooled in ice. After 14 hours, full vacuum was applied (<0.5 mmHg) and the temperature increased to 240° C. for 2.5 hrs. The product was isolated as a highly viscous liquid (320.6 g). GC-MS analysis of the distillate indicated the total phenol collected was 170.3 g (1.8 mol), residual diamine 23.2 g (0.1 mol) and residual DPP collected was 53.7 g (0.2 mol). Anal. % P=10.6 wt. %. Example 3 Synthesis of an Amino Terminated Phosphonamide [0048] 301.3 g (1.31 mol) Jeffamine D230, 259.3 g (1.05 mol) DPP and 3.05 g (0.03 mol) magnesium chloride were added to a 1 L round bottom flask and heated to 200° C. while stirring for 19 hours. The vacuum was gradually lowered to 60 mmHg over 9 hrs., and then lowered to 3.0 mmHg over 5 hrs. and held for 4 hrs. The distillation column was maintained at 115° C. The distillate was collected in a flask cooled in ice. After 19 hours, full vacuum was applied (<0.5 mm Hg) and the temperature increased to 230° C. for 1 hr. The product was isolated as a highly viscous liquid (276.3 g). GC-MS analysis of the distillate indicated the total phenol collected was 178.3 g (1.9 mol), residual diamine 66.7 g (0.3 mol) and residual DPP collected was 24.5 g (0.1 mol). Molecular weight (Mw 670, Mn 570) (GPC, PS standards). Anal. % P=10.4 wt. %. Example 4 Synthesis of an Amino Terminated Phosphonamide [0049] 956.2 g (0.48 mol) Jeffamine D2000, 109.2 (0.44 mol) DPP and 2.67 g (0.028 mol) magnesium chloride were added to a 3 L round bottom flask and heated to 200° C. while stirring for 18.5 hours. The vacuum was gradually lowered to 20 mmHg over 3 hrs. and held for 11.5 hrs., and then to 5 mm Hg for 4 hrs. The distillation column was maintained at 115° C. for 6.5 hrs. and then increased to 140° C. The distillate was collected in a flask cooled in ice. After 18.5 hrs., full vacuum was applied (<0.5 mm Hg) for 4.5 hrs. at 200° C. Then, the temperature increased to 215° C. for 1.0 hr., and to 240° C. for 2.5 hrs. The product was isolated as a highly viscous liquid (969 g). GC-MS analysis of the distillate indicated the total phenol collected was 66.2 g (0.7 mol), and residual DPP collected was 13.6 g (0.05 mol). Anal. % P=1.3 wt. %. Example 5 Synthesis of an Amino Terminated Phosphonamide [0050] 175.0 g (0.39 mol) Jeffamine T403, 124.1 g (0.5 mol) DPP and 1.24 g (0.013 mol) magnesium chloride were added to a 500 mL round bottom flask and heated to 200° C. while stirring for 7 hours. The vacuum was gradually lowered to 55 mmHg over 2 hrs, then to 5 mm Hg over 5 hrs. The distillation column was maintained at 115° C. The distillate was collected in a flask cooled in ice. After 7 hrs., full vacuum was applied (0.1 mm Hg) for 2 hrs at 200° C., and then increased to 250° C. for 2 hrs. After 2 hrs. the product cross-linked in the flask and the reaction was discontinued. The product was removed from the flask by breaking the flask and 48.1 g of solid was recoverable. Total phenol collected was 73.0 g (0.8 mol), and residual unreacted triamine 9.6 g (0.02 mol) and 17.6 g DPP (0.07 mol). Anal. % P=6.5 wt % Example 6 Synthesis of an Amino Terminated Phosphonamide [0051] 175.0 g (0.39 mol) Jeffamine T403, 124.1 g (0.5 mol) DPP and 1.24 g (0.013 mol) magnesium chloride were added to a 500 mL round bottom flask and heated to 200° C. while stirring for 14 hours. The vacuum was gradually lowered to 25 mmHg over 3 hrs., then to 5 mm Hg for 11 hrs. The distillation column was maintained at 115° C. The distillate was collected in a flask cooled in ice. After 14 hrs., full vacuum was applied (<0.5 mm Hg) for 4.5 hrs. at 200° C. The product was isolated as a solid (219.1 g). GC-MS analysis of the distillate indicated the total phenol collected was 72.3 g (0.8 mol), and no residual triamine or DPP was collected. Anal. % P=7.3 wt. %. Example 7 Synthesis of an Amino Terminated Phosphonamide [0052] 1789 g (0.90 mol) Jeffamine D2000, 203 g (0.82 mol) DPP and 0.5 g (0.005 mol) magnesium chloride were added to a 3 L round bottom flask and heated to 200° C. while stirring under vacuum (250 mmHg). After 4.5 hrs, the vacuum was gradually lowered to 10 mmHg over 8 hrs. and then to 5 mm Hg for 4 hrs. After 16.5 hrs., full vacuum was applied (<0.5 mm Hg), and the temperature increased to 225° C. for 1.0 hr. and then to 240° C. for 3.5 hrs. The distillation column was maintained at 115° C. for 16.5 hrs. and then increased to 140° C. The distillate was collected in a flask cooled in ice. The product was isolated as a highly viscous liquid (1855 g). GC-MS analysis of the distillate indicated the total phenol collected was 123.6 (1.31 mol), and residual DPP collected was 0.4 g (0.002 mol). Anal. % P=1.3 wt. %. Example 8 Synthesis of an Amino Terminated Phosphonamide [0053] 1789 g (0.90 mol) Jeffamine D2000, 203 g (0.82 mol) DPP and 0.5 g (0.005 mol) magnesium chloride were added to a 3 L round bottom flask and heated to 200° C. while stirring under vacuum (250 mmHg). After 4.5 hrs., the vacuum was gradually lowered to 10 mmHg over 8 hrs and then to 5 mm Hg for 4 hrs. After 16.5 hrs., full vacuum was applied (<0.5 mm Hg), and the temperature increased to 225° C. for 1.0 hr., and then to 240° C. for 3.5 hrs. The distillation column was maintained at 115° C. for 16.5 hrs. and then increased to 140° C. The distillate was collected in a flask cooled in ice. The product was isolated as a highly viscous liquid (1843 g). GC-MS analysis of the distillate indicated the total phenol collected was 90.2 g (0.96 mol), and residual DPP collected was 19.0 g (0.08 mol). Anal. % P=1.3 wt. %. Example 9 Amino Terminated Phosphonamide Oligomers in Polyureas [0054] Polyurea formulations are generally prepared by the reaction of diamines with diisocyanates. In order to produce flame retardant polyureas, several phosphorus based diamines (FZX diamines) were prepared and added to the diamine formulations used to prepare blast mitigation coatings. (Scheme 1). [0000] Example 10 Polyurea Films with Amine Terminated Phosphonamide Oligomers [0055] Polyurea films were prepared by spraying out a combination of diisocyanates (A-side) and diamines (B-side) onto primed concrete boards of 6 inches×18 inches for flammability testing. The thickness of each coating was 90 mils (0.09 inches). The test was conducted in accordance with the ASTM E-162, “Standard Method of Test for Surface Flammability of Materials Using a Radiant Heat Energy Source.” The spray-coated boards are mounted in a frame placed facing the radiant panel, but inclined at an angle of 30 degrees from top downward. A pilot burner adjusted to provide a 6″ to 7″ flame serves to ignite the sample at the top. The material under test burns downward. [0056] Oligomeric amine terminated phosphonamides were added to the B-side of the mixture during formulation. Phosphorus-based additives—diphenyl methylphosphate (DPP) and ammonium polyphosphate (APP)—were also tested as additives in the A-side and the B-side, respectively. Graphite was added to various formulations to prevent dripping during burning. The base formulation was Dragonshield BC™ (DSBC™). [0057] DSBC™ Formulations containing the commercial flame retardant additive ammonium polyphosphonate (APP) were prepared and evaluated in comparison to phosphonamide oligomers. Due to processability during formulation, the optimal loading of the amine-terminated phosphonamide oligomer PA-D2000 was 17 wt. %. [0058] Tables 1-2 provide results from ASTM E162 testing of the FR polyurea samples. The results are recorded as a Flamespread Index determined from progression time of the flame at 3, 6, 9, 12, and 15 inch interval marks measured from the top of the sample. The maximum temperature increase resulting from the burning sample was measured by 8 thermocouples connected in parallel and located in the sheet metal stack above the tested sample. The Flamespread Index (FSI) is derived by the following formula: [0000] Is=Fs×Q [0000] where Is is the Flamespread Index, Fs is the Flamespread Factor, and Q is the Heat Evolution Factor. The flamespread classification system used by most of the model building codes and the National Fire Protection Association Life Safety Code, NFPA No. 101, encompasses the following: [0059] Class A (I)—0 to 25 Flamespread Index [0060] Class B (II)—26 to 75 Flamespread Index [0061] Class C (III)—76 to 100 Flamespread Index [0000] The results of FSI testing of various polyurea compositions including oligomeric amino-terminated phosphonamides are provided in Table 1. [0000] TABLE 1 Polyurea FR Testing: Flame Spread Index (FSI) Results Wt % Additives in DSBC ™ Formulation B-Side A-Side PA-D2000 Total ASTM FSI # DPP Graphite (Example 3) APP % P E162 Class 1 0 0 0 0 0 212 Fail 2 0 2 0 10 1.0 114 Fail 3 0 5 0 10 1.0 64 B 4 0 5 0 20 2.6 54 B 5 0 5 17 0 0.1 89 C 6 8 5 0 10 1.5 70 B 7 8 5 17 0 0.6 47 B [0000] TABLE 2 Polyurea FR Testing: Flame Spread Index (FSI) Results Wt % Additives in DSBC ™ Formulation B-Side A-Side PA-D2000 Total ASTM FSI # DPP Graphite (Example 6) APP % P E162 Class 1 0 0 0 0 0 212 Fail 2 0 10 0 2 0.3 34 B 3 8 10 17 2 0.9 13 A Example 11 Evaluation of FR Behavior of Phosphonamides in Bisphenol-A Epoxies [0062] The FR performance of cured epoxy resin samples with and without phosphonamides was evaluated, and the results are provided in Table 3. The samples were prepared by mixing the amine-terminated phosphonamide oligomers with the epoxy resin and curing in an oven at 60° C. for 48 hr. The FR was evaluated by holding a flame to the sample for 10 seconds and observing for self-extinguishing behavior. The formulation containing the amine terminated phosphonamide oligomer (PA-D230 Example 2) exhibited self-extinguishing behavior, whereas the formulation containing the diamine (D230) continued to burn. [0000] TABLE 3 Epoxy formulations with phosphonamides Amine-terminated PA-D230 compound D230 (Example 2) Weight (g) 6.5 6.5 Epoxy resin (g) 5 5 Diethyl triamine (g) 0 0.5 Total % P 0 5.6 FR evaluation— no yes Self-extinguishing
The invention relates to the use of amino terminated phosphonamides and their oligomers, as flame retardant additives for a variety of polymers to impart flame retardancy while maintaining or improving processing characteristics and other important properties.
2
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority from U.S. Provisional Patent Application 61/014,232, filed Dec. 17, 2007, the entire contents of which are incorporated herein by reference. BACKGROUND The present invention relates to a process for producing prostacyclin derivatives and novel intermediate compounds useful in the process. Prostacyclin derivatives are useful pharmaceutical compounds possessing activities such as platelet aggregation inhibition, gastric secretion reduction, lesion inhibition, and bronchodilation. Treprostinil, the active ingredient in Remodulin®, was first described in U.S. Pat. No. 4,306,075. Treprostinil, and other prostacyclin derivatives have been prepared as described in Moriarty, et al in J. Org. Chem. 2004, 69, 1890-1902 , Drug of the Future, 2001, 26(4), 364-374, U.S. Pat. Nos. 6,441,245, 6,528,688, 6,765,117 and 6,809,223. Their teachings are incorporated by reference to show how to practice the embodiments of the present invention. U.S. Pat. No. 5,153,222 describes use of treprostinil for treatment of pulmonary hypertension. Treprostinil is approved for the intravenous as well as subcutaneous route, the latter avoiding septic events associated with continuous intravenous catheters. U.S. Pat. Nos. 6,521,212 and 6,756,033 describe administration of treprostinil by inhalation for treatment of pulmonary hypertension, peripheral vascular disease and other diseases and conditions. U.S. Pat. No. 6,803,386 discloses administration of treprostinil for treating cancer such as lung, liver, brain, pancreatic, kidney, prostate, breast, colon and head-neck cancer. U.S. patent application publication No. 2005/0165111 discloses treprostinil treatment of ischemic lesions. U.S. Pat. No. 7,199,157 discloses that treprostinil treatment improves kidney functions. U.S. patent application publication No. 2005/0282903 discloses treprostinil treatment of neuropathic foot ulcers. U.S. application Ser. No. 12/028,471 filed Feb. 8, 2008, discloses treprostinil treatment of pulmonary fibrosis. U.S. Pat. No. 6,054,486 discloses treatment of peripheral vascular disease with treprostinil. U.S. patent application Ser. No. 11/873,645 filed Oct. 17, 2007 discloses combination therapies comprising treprostinil. U.S. publication No. 2008/0200449 discloses delivery of treprostinil using a metered dose inhaler. U.S. publication No. 2008/0280986 discloses treatment of interstitial lung disease with treprostinil. U.S. application Ser. No. 12/028,471 filed Feb. 8, 2008 discloses treatment of asthma with treprostinil. U.S. Pat. Nos. 7,417,070, 7,384,978 and U.S. publication Nos. 2007/0078095, 2005/0282901, and 2008/0249167 describe oral formulations of treprostinil and other prostacyclin analogs. Because Treprostinil, and other prostacyclin derivatives are of great importance from a medicinal point of view, a need exists for an efficient process to synthesize these compounds on a large scale suitable for commercial production. SUMMARY The present invention provides in one embodiment a process for the preparation of a compound of formula I, hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof. The process comprises the following steps: (a) alkylating a compound of structure II with an alkylating agent to produce a compound of formula III, wherein w=1, 2, or 3; Y 1 is trans-CH═CH—, cis-CH═CH—, —CH 2 (CH 2 ) m —, or —C≡C—; m is 1, 2, or 3; R 7 is (1) —C p H 2p —CH 3 , wherein p is an integer from 1 to 5, inclusive, (2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 ) alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R 7 is phenoxy or substituted phenoxy, only when R 3 and R 4 are hydrogen or methyl, being the same or different, (3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 )alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, (4) cis-CH═CH—CH 2 —CH 3 , (5) —(CH 2 ) 2 —CH(OH)—CH 3 , or (6) —(CH 2 ) 3 —CH═C(CH 3 ) 2 ; wherein —C(L 1 )-R 7 taken together is (1) (C 4 -C 7 )cycloalkyl optionally substituted by 1 to 3 (C 1 -C 5 )alkyl; (2) 2-(2-furyl)ethyl, (3) 2-(3-thienyl)ethoxy, or (4) 3-thienyloxymethyl; M 1 is α-OH:β-R 5 or α-R 5 :β-OH or α-OR 1 :β-R 5 or α-R 5 :β-OR 2 , wherein R 5 is hydrogen or methyl, R 2 is an alcohol protecting group, and L 1 is α-R 3 :β-R 4 , α-R 4 :β-R 3 , or a mixture of α-R 3 :β-R 4 and α-R 4 :β-R 3 , wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is fluoro only when the other is hydrogen or fluoro. (b) hydrolyzing the product of step (a) with a base, (c) contacting the product of step (b) with a base B to for a salt of formula I s (d) reacting the salt from step (c) with an acid to form the compound of formula I. The present invention provides in another embodiment a process for the preparation of a compound of formula IV. The process comprises the following steps: (a) alkylating a compound of structure V with an alkylating agent to produce a compound of formula VI, (b) hydrolyzing the product of step (a) with a base, (c) contacting the product of step (b) with a base B to for a salt of formula IV s , and (d) reacting the salt from step (b) with an acid to form the compound of formula IV. DETAILED DESCRIPTION The various terms used, separately and in combinations, in the processes herein described are defined below. The expression “comprising” means “including but not limited to.” Thus, other non-mentioned substances, additives, carriers, or steps may be present. Unless otherwise specified, “a” or “an” means one or more. C 1-3 -alkyl is a straight or branched alkyl group containing 1-3 carbon atoms. Exemplary alkyl groups include methyl, ethyl, n-propyl, and isopropyl. C 1-3 -alkoxy is a straight or branched alkoxy group containing 1-3 carbon atoms. Exemplary alkoxy groups include methoxy, ethoxy, propoxy, and isopropoxy. C 4-7 -cycloalkyl is an optionally substituted monocyclic, bicyclic or tricyclic alkyl group containing between 4-7 carbon atoms. Exemplary cycloalkyl groups include but not limited to cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl. Combinations of substituents and variables envisioned by this invention are only those that result in the formation of stable compounds. The term “stable”, as used herein, refers to compounds which possess stability sufficient to allow manufacture and which maintains the integrity of the compound for a sufficient period of time to be useful for the purposes detailed herein. As used herein, the term “prodrug” means a derivative of a compound that can hydrolyze, oxidize, or otherwise react under biological conditions (in vitro or in vivo) to provide an active compound. Examples of prodrugs include, but are not limited to, derivatives of a compound that include biohydrolyzable groups such as biohydrolyzable amides, biohydrolyzable esters, biohydrolyzable carbamates, biohydrolyzable carbonates, biohydrolyzable ureides, and biohydrolyzable phosphate analogues (e.g., monophosphate, diphosphate or triphosphate). As used herein, “hydrate” is a form of a compound wherein water molecules are combined in a certain ratio as an integral part of the structure complex of the compound. As used herein, “solvate” is a form of a compound where solvent molecules are combined in a certain ratio as an integral part of the structure complex of the compound. “Pharmaceutically acceptable” means in the present description being useful in preparing a pharmaceutical composition that is generally safe, non-toxic and neither biologically nor otherwise undesirable and includes being useful for veterinary use as well as human pharmaceutical use. “Pharmaceutically acceptable salts” mean salts which are pharmaceutically acceptable, as defined above, and which possess the desired pharmacological activity. Such salts include acid addition salts formed with organic and inorganic acids, such as hydrogen chloride, hydrogen bromide, hydrogen iodide, sulfuric acid, phosphoric acid, acetic acid, glycolic acid, maleic acid, malonic acid, oxalic acid, methanesulfonic acid, trifluoroacetic acid, fumaric acid, succinic acid, tartaric acid, citric acid, benzoic acid, ascorbic acid and the like. Base addition salts may be formed with organic and inorganic bases, such as sodium, ammonia, potassium, calcium, ethanolamine, diethanolamine, N-methylglucamine, choline and the like. Included in the invention are pharmaceutically acceptable salts or compounds of any of the formulae herein. Depending on its structure, the phrase “pharmaceutically acceptable salt,” as used herein, refers to a pharmaceutically acceptable organic or inorganic acid or base salt of a compound. Representative pharmaceutically acceptable salts include, e.g., alkali metal salts, alkali earth salts, ammonium salts, water-soluble and water-insoluble salts, such as the acetate, amsonate (4,4-diaminostilbene-2,2-disulfonate), benzenesulfonate, benzonate, bicarbonate, bisulfate, bitartrate, borate, bromide, butyrate, calcium, calcium edetate, camsylate, carbonate, chloride, citrate, clavulariate, dihydrochloride, edetate, edisylate, estolate, esylate, fumarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexafluorophosphate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate, N-methylglucamine ammonium salt, 3-hydroxy-2-naphthoate, oleate, oxalate, palmitate, pamoate (1,1-methene-bis-2-hydroxy-3-naphthoate, einbonate), pantothenate, phosphate/diphosphate, picrate, polygalacturonate, propionate, p-toluenesulfonate, salicylate, stearate, subacetate, succinate, sulfate, sulfosalicylate, suramate, tannate, tartrate, teoclate, tosylate, triethiodide, and valerate salts. The present invention provides for a process for producing treprostinil and other prostacyclin derivatives and novel intermediate compounds useful in the process. The process according to the present invention provides advantages on large-scale synthesis over the existing method. For example, the purification by column chromatography is eliminated, thus the required amount of flammable solvents and waste generated are greatly reduced. Furthermore, the salt formation is a much easier operation than column chromatography. Moreover, it was found that the product of the process according to the present invention has higher purity. Therefore the present invention provides for a process that is more economical, safer, faster, greener, easier to operate, and provides higher purity. One embodiment of the present invention is a process for the preparation of a compound of formula I, or a hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof. The process comprises the following steps: (a) alkylating a compound of formula II with an alkylating agent to produce a compound of formula III, wherein w=1, 2, or 3; Y 1 is trans-CH═CH—, cis-CH═CH—, —CH 2 (CH 2 ) m —, or —C≡C—; m is 1, 2, or 3; R 7 is (1) —C p H 2p —CH 3 , wherein p is an integer from 1 to 5, inclusive, (2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 ) alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R 7 is phenoxy or substituted phenoxy, only when R 3 and R 4 are hydrogen or methyl, being the same or different, (3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 )alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, (4) cis-CH═CH—CH 2 —CH 3 , (5) —(CH 2 ) 2 —CH(OH)—CH 3 , or (6) —(CH 2 ) 3 —CH═C(CH 3 ) 2 ; wherein —C(L 1 )-R 7 taken together is (1) (C 4 -C 7 )cycloalkyl optionally substituted by 1 to 3 (C 1 -C 5 )alkyl; (2) 2-(2-furyl)ethyl, (3) 2-(3-thienyl)ethoxy, or (4) 3-thienyloxymethyl; M 1 is x-OH:β-R 5 or α-R 5 :β-OH or α-OR 1 :β-R 5 or α-R 5 :β-OR 2 , wherein R 5 is hydrogen or methyl, R 2 is an alcohol protecting group, and L 1 is α-R 3 :β-R 4 , α-R 4 :β-R 3 , or a mixture of α-R 3 :β-R 4 and α-R 4 :β-R 3 , wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is fluoro only when the other is hydrogen or fluoro. (b) hydrolyzing the product of step (a) with a base, (c) contacting the product of step (b) with a base B to for a salt of formula I s (d) reacting the salt from step (c) with an acid to form the compound of formula I. In one embodiment, the compound of formula I is at least 90.0%, 95.0%, 99.0%. The compound of formula II can be prepared from a compound of formula XI, which is a cyclization product of a compound of formula X as described in U.S. Pat. No. 6,441,245. Wherein n is 0, 1, 2, or 3. The compound of formula II can be prepared alternatively from a compound of formula XIII, which is a cyclization product of a compound of formula XII as described in U.S. Pat. No. 6,700,025. One embodiment of the present invention is a process for the preparation of a compound having formula IV, or a hydrate, solvate, or pharmaceutically acceptable salt thereof. The process comprises (a) alkylating a compound of structure V with an alkylating agent such as ClCH 2 CN to produce a compound of formula VI, (b) hydrolyzing the product of step (a) with a base such as KOH, (c) contacting the product of step (b) with a base B such as diethanolamine to for a salt of the following structure, and (d) reacting the salt from step (b) with an acid such as HCl to form the compound of formula IV. In one embodiment, the purity of compound of formula IV is at least 90.0%, 95.0%, 99.0%, 99.5%. In one embodiment, the process further comprises a step of isolating the salt of formula IV s . In one embodiment, the base B in step (c) may be ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, or triethanolamine. The following abbreviations are used in the description and/or appended claims, and they have the following meanings: “MW” means molecular weight. “Eq.” means equivalent. “TLC” means thin layer chromatography. “HPLC” means high performance liquid chromatography. “PMA” means phosphomolybdic acid. “AUC” means area under curve. In view of the foregoing considerations, and specific examples below, those who are skilled in the art will appreciate that how to select necessary reagents and solvents in practicing the present invention. The invention will now be described in reference to the following Examples. These examples are not to be regarded as limiting the scope of the present invention, but shall only serve in an illustrative manner. EXAMPLES Example 1 Alkylation of Benzindene Triol Name MW Amount Mol. Eq. Benzindene Triol 332.48 1250 g 3.76 1.00 K 2 CO 3 (powder) 138.20 1296 g 9.38 2.50 CICH 2 CN 75.50 567 g 7.51 2.0 Bu 4 NBr 322.37 36 g 0.11 0.03 Acetone — 29 L — — Celite ® 545 — 115 g — — A 50-L, three-neck, round-bottom flask equipped with a mechanical stirrer and a thermocouple was charged with benzindene triol (1250 g), acetone (19 L) and K 2 CO 3 (powdered) (1296 g), chloroacetonitrile (567 g), tetrabutylammonium bromide (36 g). The reaction mixture was stirred vigorously at room temperature (23±2° C.) for 16-72 h. The progress of the reaction was monitored by TLC. (methanol/CH 2 Cl 2 ; 1:9 and developed by 10% ethanolic solution of PMA). After completion of reaction, the reaction mixture was filtered with/without Celite pad. The filter cake was washed with acetone (10 L). The filtrate was concentrated in vacuo at 50-55° C. to give a light-brown, viscous liquid benzindene nitrile. The crude benzindene nitrile was used as such in the next step without further purification. Example 2 Hydrolysis of Benzindene Nitrile Name MW Amount Mol. Eq. Benzindene Nitrile 371.52 1397 g* 3.76 1.0 KOH 56.11 844 g 15.04 4.0 Methanol — 12 L — — Water — 4.25 L — — *Note: This weight is based on 100% yield from the previous step. This is not isolated yield. A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with a solution of benzindene nitrile in methanol (12 L) and a solution of KOH (844 g of KOH dissolved in 4.25 L of water). The reaction mixture was stirred and heated to reflux (temperature 72.2° C.). The progress of the reaction was monitored by TLC (for TLC purpose, 1-2 mL of reaction mixture was acidified with 3M HCl to pH 1-2 and extracted with ethyl acetate. The ethyl acetate extract was used for TLC; Eluent: methanol/CH 2 Cl 2 ; 1:9, and developed by 10% ethanolic solution of PMA). After completion of the reaction (˜5 h), the reaction mixture was cooled to −5 to 10° C. and quenched with a solution of hydrochloric acid (3M, 3.1 L) while stirring. The reaction mixture was concentrated in vacuo at 50-55° C. to obtain approximately 12-14 L of condensate. The condensate was discarded. The aqueous layer was diluted with water (7-8 L) and extracted with ethyl acetate (2×6 L) to remove impurities soluble in ethyl acetate. To aqueous layer, ethyl acetate (22 L) was added and the pH of reaction mixture was adjusted to 1-2 by adding 3M HCl (1.7 L) with stirring. The organic layer was separated and the aqueous layer was extracted with ethyl acetate (2×11 L). The combined organic layers were washed with water (3×10 L) and followed by washing with a solution of NaHCO 3 (30 g of NaHCO 3 dissolved in 12 L of water). The organic layer was further washed with saturated solution of NaCl (3372 g of NaCl dissolved in water (12 L)) and dried over anhydrous Na 2 SO 4 (950-1000 g), once filtered. The filtrate was transferred into a 72-L reactor equipped with mechanical stirrer, a condenser, and a thermocouple. To the solution of treprostinil in reactor was added activated carbon (110-130 g). The suspension was heated to reflux (temperature 68-70° C.) for at least one hour. For filtration, a pad of Celite® 545 (300-600 g) was prepared in sintered glass funnel using ethyl acetate. The hot suspension was filtered through the pad of Celite® 545. The Celite® 545 was washed with ethyl acetate until no compound was seen on TLC of the washings. The filtrate (pale-yellow) was reduced to volume of 35-40 L by evaporation in vacuo at 50-55° C. for direct use in next step. Example 3 Conversion of Treprostinil to Treprostinil Diethanolamine Salt (1:1) Name MW Amount Mol Eq Treprostinil 390.52 1464 g* 3.75 1.0 Diethanolamine 105.14 435 g 4.14 1.1 Ethanol — 5.1 L — — Ethyl acetate — 35 L** — — Treprostinil Diethanolamine — 12 g — — Salt (seed) *Note: This weight is based on 100% yield from benzindene triol. It is not isolated yield. The treprostinil was carried from previous step in ethyl acetate solution and used as such for this step. **Note: The total volume of ethyl acetate should be in range 35-36 L (it should be 7 times the volume of ethanol used). Approximately 35 L of ethyl acetate was carried over from previous step and additional 1.0 L of ethyl acetate was used for rinsing the flask. A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with a solution of treprostinil in ethyl acetate (35-40 L from the previous step), anhydrous ethanol (5.1 L) and diethanolamine (435 g). While stirring, the reaction mixture was heated to 60-75° C., for 0.5-1.0 h to obtain a clear solution. The clear solution was cooled to 55±5° C. At this temperature, the seed of polymorph B of treprostinil diethanolamine salt (˜12 g) was added to the clear solution. The suspension of polymorph B was stirred at this temperature for 1 h. The suspension was cooled to 20±2° C. overnight (over a period of 16-24 h). The treprostinil diethanolamine salt was collected by filtration using Aurora filter equipped with filter cloth, and the solid was washed with ethyl acetate (2×8 L). The treprostinil diethanolamine salt was transferred to a HDPE/glass container for air-drying in hood, followed by drying in a vacuum oven at 50±5° C. under high vacuum. At this stage, if melting point of the treprostinil diethanolamine salt is more than 104° C., it was considered polymorph B. There is no need of recrystallization. If it is less than 104° C., it is recrystallized in EtOH-EtOAc to increase the melting point. Data on Treprostinil Diethanolamine Salt (1:1) Wt. of Wt. of Treprostinil Batch Benzindene Triol Diethanolamine Salt Yield Melting point No. (g) (1:1) (g) (%) (° C.) 1 1250 1640 88.00 104.3-106.3 2 1250 1528 82.00* 105.5-107.2 3 1250 1499 80.42** 104.7-106.6 4 1236 1572 85.34 105-108 *Note: In this batch, approximately 1200 mL of ethyl acetate solution of treprostinil before carbon treatment was removed for R&D carbon treatment experiments. **Note: This batch was recrystallized, for this reason yield was lower. Example 4 Heptane Slurry of Treprostinil Diethanolamine Salt (1:1) Name Batch No. Amount Ratio Treprostinil 1 3168 g 1 Diethanolamine Salt Heptane — 37.5 L 12 Treprostinil 2 3071 g 1 Diethanolamine Salt Heptane — 36.0 L 12 A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with slurry of treprostinil diethanolamine salt in heptane (35-40 L). The suspension was heated to 70-80° C. for 16-24 h. The suspension was cooled to 22±2° C. over a period of 1-2 h. The salt was collected by filtration using Aurora filter. The cake was washed with heptane (15-30 L) and the material was dried in Aurora filter for 1 h. The salt was transferred to trays for air-drying overnight in hood until a constant weight of treprostinil diethanolamine salt was obtained. The material was dried in oven under high vacuum for 2-4 h at 50-55° C. Analytical Data on and Treprostinil Diethanolamine Salt (1:1) Test Batch 1 Batch 2 IR Conforms Conforms Residue on Ignition (ROI) <0.1% w/w  <0.1% w/w Water content  0.1% w/w  0.0% w/w Melting point 105.0-106.5° C. 104.5-105.5° C. Specific rotation [α] 25 589 +34.6° +35° Organic volatile impurities Ethanol Not detected Not detected Ethyl acetate Not detected <0.05% w/w Heptane <0.05% w/w  <0.05% w/w HPLC (Assay) 100.4% 99.8% Diethanolamine Positive Positive Example 5 Conversion of Treprostinil Diethanolamine Salt (1:1) to Treprostinil A 250-mL, round-bottom flask equipped with magnetic stirrer was charged with treprostinil diethanolamine salt (4 g) and water (40 mL). The mixture was stirred to obtain a clear solution. To the clear solution, ethyl acetate (100 mL) was added. While stirring, 3M HCl (3.2 mL) was added slowly until pH 1 was attained. The mixture was stirred for 10 minutes and organic layer was separated. The aqueous layer was extracted with ethyl acetate (2×100 mL). The combined organic layers was washed with water (2×100 mL), brine (1×50 mL) and dried over anhydrous Na 2 SO 4 . The ethyl acetate solution of treprostinil was filtered and the filtrate was concentrated under vacuum at 50° C. to give off-white solid. The crude treprostinil was recrystallized from 50% ethanol in water (70 mL). The pure treprostinil was collected in a Buchner funnel by filtration and cake was washed with cold 20% ethanolic solution in water. The cake of treprostinil was air-dried overnight and further dried in a vacuum oven at 50° C. under high vacuum to afford 2.9 g of treprostinil (Yield 91.4%, purity (HPLC, AUC, 99.8%). Analytical Data on Treprostinil from Treprostinil Diethanolamine Salt (1:1) to Treprostinil Batch No. Yield Purity (HPLC) 1 91.0% 99.8% (AUC) 2 92.0% 99.9% (AUC) 3 93.1% 99.7% (AUC) 4 93.3% 99.7% (AUC) 5 99.0% 99.8% (AUC) 6 94.6% 99.8% (AUC) Example 6 Comparison of the Former Process and a Working Example of the Process According to the Present Invention Working example of the Process according to the Step Former Process present invention No. Steps (Batch size: 500 g) (Batch size: 5 kg) Nitrile 1 Triol weight 500 g 5,000 g 2 Acetone 20 L (1:40 wt/wt) 75 L (1:15 wt/wt) 3 Potassium 1,300 g (6.4 eq) 5,200 g (2.5 eq) carbonate 4 Chloroacetonitrile 470 g (4.2 eq) 2,270 g (2 eq) 5 Tetrabutylammonium 42 g (0.08 eq) 145 g (0.03 eq) bromide 6 Reactor size 72-Liter 50- gallon 7 Reflux time 8 hours No heating, Room temperature (r.t.) 45 h 8 Hexanes addition Yes (10 L) No before filtration 9 Filter Celite Celite 10 Washing Ethyl acetate (10 L) Acetone (50 L) 11 Evaporation Yes Yes 12 Purification Silica gel column No column Dichloromethane: 0.5 L Ethyl acetate: 45 L Hexane: 60 L 13 Evaporation after Yes No column 14 Yield of nitrite 109-112% Not checked Treprostinil (intermediate) 15 Methanol 7.6 L (50-L reactor) 50 L (50-gal reactor) 16 Potassium hydroxide 650 g (8 eq) 3,375 g (4 eq) 17 Water 2.2 L 17 L 18 % of KOH 30% 20% 19 Reflux time 3-3.5 h 4-5 h 20 Acid used 2.6 L (3 M) 12 L (3 M) 21 Removal of 3 × 3 L Ethyl acetate 2 × 20 L Ethyl acetate impurities 22 Acidification 0.7 L 6.5 L 23 Ethyl acetate 5 × 17 L = 35 L 90 + 45 + 45 = 180 L extraction 24 Water washing 2 × 8 L 3 × 40 L 25 Sodium bicarbonate Not done 120 g in 30 L water + 15 L washing brine 26 Brine washing Not done 1 × 40 L 27 Sodium sulfate 1 kg Not done 28 Sodium sulfate Before charcoal, 6 L N/A filtration ethyl acetate 29 Charcoal 170 g, reflux for 1.5 h, Pass hot solution (75° C.) filter over Celite, 11 L through charcoal cartridge ethyl acetate and clean filter, 70 L ethyl acetate 30 Evaporation Yes, to get solid Yes, adjust to 150 L intermediate treprostinil solution Treprostinil Diethanolamine Salt 31 Salt formation Not done 1,744 g diethanolamine, 20 L ethanol at 60-75° C. 32 Cooling N/A To 20° C. over weekend; add 40 L ethyl acetate; cooled to 10° C. 33 Filtration N/A Wash with 70 L ethyl acetate 34 Drying N/A Air-dried to constant wt., 2 days Treprostinil (from 1.5 kg Treprostinil diethanolamine salt) 35 Hydrolysis N/A 15 L water + 25 L ethyl acetate + HCl 36 Extraction N/A 2 × 10 L ethyl acetate 37 Water wash N/A 3 × 10 L 38 Brine wash N/A 1 × 10 L 39 Sodium sulfate N/A 1 kg, stir 40 Filter N/A Wash with 6 L ethyl acetate 41 Evaporation N/A To get solid, intermediate Treprostinil 42 Crude drying on tray 1 or 3 days Same 43 Ethanol & water for 5.1 L + 5.1 L 10.2 L + 10.2 L (same %) cryst. 44 Crystallization in 20-L rotavap flask 50-L jacketed reactor 45 Temperature of 2 h r.t., fridge −0° C. 24 h 50° C. to 0° C. ramp, 0° C. crystallization overnight 46 Filtration Buchner funnel Aurora filter 47 Washing 20% (10 L) cooled 20% (20 L) cooled ethanol-water ethanol-water 48 Drying before oven Buchner funnel (20 h) Aurora filter (2.5 h) Tray (no) Tray (4 days) 49 Oven drying 15 hours, 55° C. 6-15 hours, 55° C. 50 Vacuum <−0.095 mPA <5 Torr 51 UT-15 yield weight ~535 g ~1,100 g 52 % yield from triol) ~91% ~89% 53 Purity ~99.0% 99.9% The quality of treprostinil produced according to this invention is excellent. The purification of benzindene nitrile by column chromatography is eliminated. The impurities carried over from intermediate steps (i.e. alkylation of triol and hydrolysis of benzindene nitrile) are removed during the carbon treatment and the salt formation step. Additional advantages of this process are: (a) crude treprostinil salts can be stored as raw material at ambient temperature and can be converted to treprostinil by simple acidification with diluted hydrochloric acid, and (b) the treprostinil salts can be synthesized from the solution of treprostinil without isolation. This process provides better quality of final product as well as saves significant amount of solvents and manpower in purification of intermediates. Although the foregoing refers to particular preferred embodiments, it will be understood that the present invention is not so limited. It will occur to those of ordinary skill in the art that various modifications may be made to the disclosed embodiments and that such modifications are intended to be within the scope of the present invention. All of the publications, patent applications and patents cited in this specification are incorporated herein by reference in their entirety.
This present invention relates to an improved process to prepare prostacyclin derivatives. One embodiment provides for an improved process to convert benzindene triol to treprostinil via salts of treprostinil and to purify treprostinil.
2
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a trailer hitch to be used with a trailer hitch ball connector on the rear of motor vehicles. 2. Brief Description of the Prior Art Vehicles such as cars and trucks which are used to pull trailers are often equipped with a permanent trailer hitch ball supported on the rear bumper or on a draft bar supported from the frame of the vehicle. A trailer hitch member is provided on the front of the trailer to be towed. The trailer hitch member may be a tongue member or other structure extending from the trailer and having an opening to receive the hitch ball. In the prior art method when it is desired to connect the trailer hitch to the hitch ball on the towing vehicle, the trailer is jacked up to be at about the height of the hitch ball. The towing vehicle is then backed up to the point where it can engage the trailer hitch. It is difficult for the driver of the vehicle to see exactly where to back so he nearly always has an assistant to direct him. Even with the director's assistance, it is difficult to have the proper alignment. It is to be remembered that to have proper alignment there are two dimensions. That is, the hitch ball and the trailer hitch have to be aligned so that they are in the proper horizontal position. They also have to be properly aligned so that they are in the right vertical position so that the trailer hitch member can drop down over the hitch ball or at least be in a position so that it can be lowered over the hitch ball. This requires a considerable amount of alignment. OBJECTIVES It is therefore an object of the present invention to provide a trailer hitch which simplifies the alignment process. It is a still further object of this invention to provide a trailer hitch which simplifies the alignment processes and also provides a unique method and means of locking the trailer hitch to the hitch ball. SUMMARY OF THE INVENTION This is a trailer hitch for securing a trailer to the hitch ball on the back of a towing vehicle or vice versa. A U-shaped hitch ball receiving compartment has two substantially parallel sides which are of greater height than the hitch ball. Two side members or side guards flare out from the end of the compartment. The guide members thus have a wide opening at the outer end and then converge toward the hitch ball receiving compartment at the apex of the generally V-shaped configuration. A U-shaped bottom plate is provided at the bottom side of the hitch ball receiving compartment. There are two opposite lock pin holes through the walls of the compartment. A top plate covers the compartment and extends nearly to the ends of the side guides. A pin and pin locking lever extends through the holes in the compartment. The holes are positioned such that when the hitch ball is in the compartment that the hitch ball is between the pin and the closed end of the compartment and the pin is slightly under the hitch ball so that it cannot be removed as long as the hitch pin is in position. The bottom plate also forms a throat which is smaller than the diameter of the hitch ball. Thus, the ball cannot drop out. There is a lever lock to hold the pin in position once it is inserted through the pin holes in the hitch ball receiving compartment. In operation, the trailer hitch is mounted on the front of a trailer. The vehicle to tow the trailer is provided with a hitch ball. The front end of the trailer is jacked up so that the hitch ball will slide or move under the trailer hitch. The only lateral alignment which is needed is that the hitch ball is between the side guides. As soon as this occurs the towing vehicle is stopped and the front end of the trailer is lowered so that the hitch ball is within the guide area between the side guides or V-guides of the trailer hitch. Then, the next step is quite simple. The towing vehicle moves forward until the hitch ball is in the hitch ball receiving compartment. At this point, the pin is inserted through the pin holes and the latch handle is secured to the lever lock. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing the pin and the pin lock lever removed from the main body of the trailer hitch. FIG. 2 is similar to FIG. 1 except that the pin has been inserted through the pin holes and the pin lock lever is behind the lever lock. FIG. 3 is a plan view of a trailer hitch attached to frame member of a trailer. FIG. 4 is a side elevation view of the trailer hitch with a fragmentary cross section to show the positioning of the hitch ball. FIG. 5 is a view taken along the line 5--5 of FIG. 4. FIGS. 6, 7, 8 and 9 are sequence views showing how the hitch ball is secured and placed in the hitch ball compartment of the trailer hitch. DETAILED DESCRIPTION Attention is first directed to FIG. 1 which is a perspective view of the trailer hitch of my invention. Shown thereon is a first side guide 10 and a second side guide 12. These side guides converge from a wide opening at the outer end to a hitch ball receiving compartment 14 which is essentially U-shaped having a first side 16 and a second side 18 and a curved or ball receiving apex 20. A pin hole 22 extends through side 18. A similar hole extends through side 16. A top plate 24 covers hitch ball receiving compartment 14 and extends along most of the length of side guides 10 and 12. As indicated in FIG. 3 there is a U-shaped bottom plate 26 which follows the contours of hitch ball receiving compartment 14 and allows the neck of a hitch ball to pass through. Also shown in FIG. 1 is a pin 28 and a pin lock lever 30. A lever lock 32 having an upper lip 34 is attached to wing member 36. As shown in FIG. 3, wings 36 and 36A are welded or otherwise secured to frame 52 of a trailer (not shown) which is to be towed. As shown in FIG. 2 when pin 28 is inserted through holes 22 and the opposite hole the lever can be rotated as indicated by the dashed line and dashed arrow to where it is located behind lever lock 32. Attention is next directed to FIGS. 3, 4 and 5 to show the relationship of the trailer hitch with the hitch ball. Shown in these figures is a hitch ball 40 which is connected to neck 42 to a base 44 which has a threaded bolt 46 extending downwardly therefrom. The hitch ball 40 is connected to a frame 48 or bumper as desired of the towing vehicle. This can be secured in the usual manner by, for example, nut 50 being attached to bolt 46 when it is inserted through a hole in frame 48. Ball 40 fits into apex 20 of hitch ball receiving compartment 14 so that when the hitch ball is in the position shown in these figures that it is in contact with the ball receiving apex and the pulling force between the towing vehicle and the trailer is transmitted through this area of contact. Holes 22 and 22A are positioned such that when pin 28 is inserted therethrough the pin 28 is underneath hitch ball 40 as indicated in FIG. 4. This secures the ball 40 in the proper position. As shown in FIGS. 4 and 5, pin 28 rests below point 54 of ball 40. Point 54 is a point on the circumference of ball 40 on a plane perpendicular to the axis of the ball 40 and through about the center of the hitch ball. The material from which the trailer is made is preferably strong, high quality steel. In one trailer hitch I built the side guides 10 and 12 and the sides 18 and 16 and apex 20 of the hitch ball receiving compartment were made of three inch angle iron cut to obtain the wings members 36 and 36A. The hitch ball receiving compartment 20 was designed to receive a two inch diameter ball 40 with essentially very little tolerance; just enough so that it can move in and out of the compartment easily. The width of the bottom plate 26 inside of walls 16 and 18 was approximately one-half inch. The distance between the innermost portion of one edge 60 and inner edge 62 of bottom plate 26 is approximately one and one-quarter inches. The center of holes 22 and 22A are aligned with a line connecting the centers of holes 22 and 22A is approximately two inches from the center of apex of the hitch ball receiving compartment 14. With this arrangement I can accommodate either one and one-half inch ball a one and seven-eights ball or a two inches hitch ball. Thus, with this particular arrangement I can place the trailer hitch on a trailer and it can be used with whichever one of the three size balls which may be on the towing vehicle without changing out the hitch ball for another size such as is the case in other trailer hitches. Changing the hitch balls in the prior methods is not too big of a job unless you do not have the right size available then one would have problems. It is believed that by now the operation of connecting the trailer hitch to a hitch ball is apparent. However, a brief description using FIGS. 6 to 9 will assist in showing the advantages of this system. Shown in FIG. 6 is the trailer hitch ball. The trailer frame 52 is jacked up sufficiently so that the trailer hitch is at a higher elevation than the trailer hitch ball 40. While the trailer hitch is held in this elevated position the towing vehicles backs the hitch ball 40 in the direction of arrows 62. This continues until the hitch ball 40 is in the position shown in FIG. 7 where the hitch ball 40 is underneath the trailer hitch and in a lateral position so that it is directly under top plate 24, between side guide 10 and side guide 12. In FIG. 8 shows that the next step in which the trailer hitch is being lowered in the direction of arrows 64 until ball 40 is in the compartment between side guides 10 and 12 and just underneath top plate 24. At this point we have all the alignment maneuvering necessary to accomplish having the hitch ball connected to the trailer hitch. What is next done is to have the towing vehicle drive forward in the direction of arrow 66 as shown in FIG. 9. The hitch ball will be guided by the side guides 10 and 12 into the position shown in FIG. 9 where the hitch ball 40 is in its towing position within the hitch ball compartment of the trailer hitch. Neck 42 extends through the throat of bottom plate 26. At this time I insert pin 38 through holes 22 and 22A. I then insert the pin lock lever behind the lever lock 32 as shown in FIG. 2. I am now in a position to safely tow the trailer behind the towing vehicle. Although not essential to the operation of my trailer hitch I can provide, as shown in FIG. 6, a ball adjustment nut and bolt. Shown thereon is a bolt 70 having threads 72 which is threaded through nut 74 which is welded or otherwise secured to the trailer hitch. The bolt 60 extends through the wall of compartment 20 as indicated by dotted lines 76 to adjust the ball position. While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled.
A trailer hitch for connecting a trailer to a hitch ball on a towing vehicle. There are two converging sides arranged as a V which has an apex at the hitch ball receiving area. A top plate covers extends over most of the sides. There are a pair of holes in the sides which extend through the hitch ball receiving compartment. A pin with pin lock lever extends through the holes for securing the hitch ball in place.
1
FIELD OF THE INVENTION The present invention relates to the methods for production of polycrystalline silicon, in particular the method for production polycrystalline silicon by means of deposition from silicon-bearing gas mixtures on heated surfaces, for instance in Siemens process, is considered. BACKGROUND OF THE INVENTION WO2006110481 <<Production of polycrystalline silicon>> discloses the method wherein polysilicon is suggested to deposit onto hollow bodies. The hollow bodies replace slim rods in a conventional Siemens-type reactor and may be heated internally by resistance elements. The diameter of hollow bodies is selected to provide the deposition surface area much larger than that of silicon slim rods. However, the profitability of this method is reduced by use of the additional expensive equipment and complicated electrical systems. Besides, the productivity of this method cannot be considerably increased since the deposition occurs from the gas mixture, which is the same as that leaving the reactor. A method of polycrystalline silicon production from a gas phase is also known (U.S. Pat. No. 6,544,333, filling date Apr. 24, 2001, publication date Feb. 7, 2002 <<Chemical vapor deposition system for polycrystalline rod production>>), which comprises supply of a silicon-bearing gas through a system of pipes into the reactor, where silicon is deposited on surfaces heated by induction coils with production of output gases. Such method of rod heating allows increasing the rod surface temperature, final rod diameter, and, thereby, the productivity becomes higher. However, the required apparatus and its electrical system are extremely complicated and expensive. Both these methods have one common important disadvantage: the input gas is mixed with the products of silicon deposition reactions in the reactor vessel and silicon deposits from depleted mixture as compared with the supplied gas. Silicon grows from the mixture being the product of the process, and, hence, the reactor characteristics such as productivity, energy consumption, and gas-to-silicon conversion become worse. DISCLOSURE OF THE INVENTION Suggested method is aimed at creating highly efficient polycrystalline silicon production process via increasing the reactor productivity, silicon conversion from the feeding gas mixture, and reducing the energy consumption. In the proposed method a gas mixture containing silicon-bearing gas mixture is supplied into reactors through a pipe system. Silicon deposition occurs at the surface of heated bodies and is accompanied by formation of gas mixture containing reaction products in the reactor volume. At least two reactors are used simultaneously for silicon deposition: the reactors connected by a pipe system as one after another and the feeding gas mixture is transported through these reactors during the common production process. Order of the silicon-bearing gas transportation through the reactors is changed to the opposite one at least once during the process. Practically, polycrystalline silicon is produced at the plants equipped with numerous reactors and, hence, the suggested way of reactor connection is possible and expedient. DETAILED DESCRIPTION Feeding gas supply through pipe systems is aimed at increase of the turbulent flow intensity in the reactors, transportation of richer gas mixture to the growing surfaces, and, hence, results in an increase of the silicon deposition rate. At that, the supplied gas mixes with the gas being in the reactor and containing the products of silicon deposition. Gas mixing can also originate from the natural convection flow in the reactor. Under these conditions simultaneous process in at least two reactors, connected by a pipe system as one after another and transportation of the feeding gas mixture from the first to the last reactor provide conditions for silicon deposition from richer gas mixtures in all the reactors except for the last one than final output gas mixture. This effect is provided by the gradual depletion of the feeding gas mixture in the connected reactors. Silicon deposition in the last reactor occurs under the conditions similar to that in the reactors working in standalone mode, i.e. from the gas mixture having a composition like the output gas mixture. In the other reactors, silicon deposits from gas mixture containing more silicon. As the result, silicon productivity in the connected reactors increases. Since outlet of a previous reactor is connected by a pipe system with inlet of the next reactor, the output gas mixture from each reactor is supplied into the next reactor and the feeding mixture passes all the reactors one-by-one. The feeding gas mixture is depleted in several steps, number of which is the number of the reactors. So, increase of the productivity is achieved owing to the first reactors and gas-to-silicon conversion is increased owing to the last reactors. Outgoing gas mixture from the last reactor is the waste product of all the reactors in the suggested method. The advantages of the suggested method are seen already if two reactors are coupled. Use of a greater number of reactors can provide larger positive effect. But further increase of the number of connected reactors becomes senseless if the input and output gas compositions in each reactor become nearly the same due to the increase of the total gas flow rate. Besides, some negative effects, such as, for instance, dependence of all the reactors from a possible failure in one of the reactors, may arise as the number of reactors is increased very much. Choice of the number of the reactors to be connected depends on many factors and it should be made for specific plant conditions. If the silicon is deposited accordingly to the suggested method, intensity of the gas flow in the reactors increases owing to the pumping of the total feed gas mixture through each reactor. In this case, nearly the same gas depletion in the gas bulk and at the rod surfaces is provided due to the flow intensification and turbulization by increased flow rate. As the result, the process productivity increases additionally. Supply of increased gas flow rates into each reactor through larger number of inlets with the same velocity allows also producing more uniform gas flows in the reactors without flow intensity reduction. Both above factors of increased flow rate through each reactor may provide additional increase of productivity and gas-to-silicon conversion. It should be noted that the above advantages couldn't be obtained only by increasing the flow rate of the feeding gas through a stand-alone reactor. Enrichment of the gas mixture produced by the increase of the gas flow rate is accompanied inevitably by decrease of gas-to-silicon conversion from the input gas mixture in the stand-alone reactors. There is possibility to design a stand-alone reactor in which the input gas mixture passes the reactor without mixing with the gas in the reactor volume and is gradually depleted. Growth from a gas mixture being richer than that at the reactor outlet can occur in some sections of a stand-alone reactor. For this, a tube-like flow without gas circulation in the reactor chamber should be organized. But such a reactor is not effective since the gas mixture is depleted at the deposition surfaces because of the reaction of silicon deposition and tube-like flow cannot provide intensive species transport to the growing surface. Moreover, high non-uniformity of the growth conditions along the tube will also reduce the reactor efficiency. The suggested method allows providing both positive factors: intensive gas mixing in the reactor chamber and growth from a gas mixture, which is enriched as compared with output one. An additional possibility is to choose optimal growth conditions in each of the connected reactors working at differently depleted gas mixtures. More intensive gas movement in the suggested method leads to an increase of heating power in each of the connected reactors for maintaining the temperature of the growth surfaces. However, simultaneous increase of the productivity allows reducing the energy consumption per 1 kg of deposited silicon, which determines the energy usage efficiency. The highest productivity in the reactors is attained at the process end, when the deposition surface is maximal. So, the use of maximally uniform growth conditions in all the reactors is needed to provide maximal growth surfaces in all the reactors at the end of the joint deposition process. This could allow increasing the productivity and gas-to-silicon conversion additionally to the effect provided by the suggested reactor connection. Equalization of the growth conditions in connected identical reactors can be realized via periodic switches of gas pumping directions. To provide maximal deposition area at the process end, reactors characterized by different characteristic process time in stand-alone mode can also be connected to each other in turn of decrease the characteristic process times. Reactors of different designs or reactors working at different deposition temperatures may be used for this. The deposition temperatures in the connected reactors must be increased from first reactor towards the last reactor. Different reactor designs can have different density of bodies, on which silicon is deposited, maximal possible deposition surface area, and any possible design features defining the characteristic process time for this reactor. So, according to the above principles to get higher productivity, silicon conversion, and lower energy consumptions, an optimal reactor order can be chosen for any kind of reactors. Use of connected identical reactors with feeding gas being pumped only in one direction also results in an increase of productivity. As it will be shown by a further example, the productivity increase as compared with separate reactors in the case of non-changed pumping direction may be about 29%. If the flow rate of the feeding mixture supplied into first reactor is lower than ∑ 1 n ⁢ Q i , the suggested method allows increasing the gas-to-silicon conversion but does not allow considerably increasing the process productivity as compared with stand-alone reactors at input flow rates of Q i . This is due to extreme depletion of the gas mixture in the last reactors. On the other hand, if the flow rate of the feeding gas is larger than 1.5 ⁢ ∑ 1 n ⁢ Q i , gas-to-silicon conversion becomes lower than in the separate reactors at input flow rates of Q i . In each case, the optimal flow rate of the feeding gas required for all the connected reactors is determined accounting for the requirements of the whole production cycle and can be found experimentally. The use of the suggested method for chlorosilanes as silicon-bearing gases is expedient since there is wide production practice and, on the other hand, the silicon deposition rate from chlorosilanes strongly depends on the gas depletion. Trichlorosilane is one of the most suitable gases for polycrystalline silicon production. But this gas is characterized by low maximal conversion to silicon of nearly 20-30%. Mixing of the supplied gas with the reaction products in the reactor chamber leads to the situation, when the growth in conventional reactors occurs from the gas mixture depleted by about 10% compared to the input one. This essentially decreases the process productivity. Maximal gas-to-silicon conversion from the gas mixtures containing dichlorosilane is considerably higher, but its production cost is higher too. The use of the suggested method allows one to deposit silicon from richer gas mixtures or to replace a part of dichlorosilane by trichlorosilane in processes with dichlorosilane addition without the productivity reduction. Additionally, the efficiency can be increased owing to: (i) use of single common apparatus for producing the feeding gas mixture and (ii) organization of thermal insulation on the pipe system between the connected reactors. The process productivity is higher for larger deposition areas. For providing silicon deposition on increased surfaces, the use of hollow bodies or plates is useful in any kind of deposition reactors. In addition, the use of hollow bodies or plates has one more advantage for the suggested method. In this case the deposition area weakly changes during the process, remaining equal in all the connected reactors. Under these conditions, the change of the gas pumping direction is not required. So the use of hollow bodies or plates allows one to provide additional positive effect comparable with effect of change of gas pumping direction. The suggested method has considerably lower effect if the reactors with strongly different deposition area and productivity are coupled. If Q i <<Q 1 , . . . , Q i−1 , Q i+1 , . . . Q n , then additional connection of i- th reactor weakly changes total gas flow rate and gas velocity in the other connected reactors, while changes in i- th low-productive reactor result in small contribution to the total effect. PREFERRED EMBODIMENT OF THE INVENTION Invention is illustrated by examples, which, however, do not exhaust the possibilities of the method realization. Noticeable positive result was obtained even for coupled reactors. Two identical reactors were connected by pipe system for transportation of a feeding gas mixture from one to another. Surface of 48 silicon rods of 0.02 m in diameter was used as initial deposition surface. During the process, the diameter of the rods increased up to 0.14 m. The gas pressure was nearly equal in both reactors and it was 6×10 5 Pa. The flow rate of trichlorosilane and hydrogen mixture supplied into the first reactor was twice larger than the flow rate in the stand-alone mode for one reactor. The feeding mixture was supplied into first reactor, while the output gas mixture from first reactor was supplied into second reactor. The other operating conditions are presented in Tables 1-3. TABLE 1 Operating conditions of one stand-alone reactor Rod diameter M 0.02 0.05 0.08 0.11 0.14 SiCl 4 Flow rate Kmol/h 0 0 0 0 0 HCl Flow rate Kmol/h 0 0 0 0 0 SiHCl 3 Flow rate Kmol/h 2 7.1 11.4 14.3 20 SiH 2 Cl 2 Flow rate Kmol/h 0.2 0.71 1.14 1.43 2 H 2 Flow rate Kmol/h 13.2 23.43 35.11 40.9 52.8 Rod surface ° C. 1150 1080 1050 1040 1030 temperature TABLE 2 Operating conditions in the first of the coupled reactors Rod diameter M 0.02 0.05 0.08 0.11 0.14 SiCl 4 Flow rate Kmol/h 0 0 0 0 0 HCl Flow rate Kmol/h 0 0 0 0 0 SiHCl 3 Flow rate Kmol/h 4 14.2 22.8 28.6 40 SiH 2 Cl 2 Flow rate Kmol/h 0.4 1.42 2.28 2.86 4 H 2 Flow rate Kmol/h 26.4 46.9 70.2 81.8 105.6 Rod surface ° C. 1150 1080 1050 1040 1030 temperature TABLE 3 Operating conditions in the second of the coupled reactors Rod diameters M 0.02 0.05 0.08 0.11 0.14 SiCl 4 Flow Kmol/h 1.28 3.85 5.84 7.42 10.1 rate HCl Flow Kmol/h 0.163 0.229 0.334 0.463 0.617 rate SiHCl 3 Kmol/h 2.21 8.51 13.9 17.3 24.4 Flow rate SiH 2 Cl 2 Kmol/h 0.436 2.15 3.8 4.74 7.02 Flow rate H 2 Flow Kmol/h 27.2 48.9 73 85.3 110 rate Rod surface ° C. 1150 1080 1050 1040 1030 temperature Tables 1-3 show that the deposition processes were carried out at equal deposition temperatures for equal rod diameters both in coupled and separate reactors. The gas flow rate was increased with rod diameter increase. The output gas mixture containing deposition products HCl, SiCl 4 , and also SiH 2 Cl 2 , produced in the gas phase, was supplied into the second reactor. The direction of the gas pumping was changed several times, what results in nearly equal rod diameters in the coupled reactors. TABLE 4 Comparison of the reactor characteristics. The gas flow rate into the coupled reactors is equal to doubled gas flow rate for a stand-alone reactor. Rod diameters, m D = D = D = D = D = 0.02 0.05 0.08 0.11 0.14 First Productivity, kg/h 13.2 31.3 43.6 56.2 71.8 from coupled Energy 106 74.9 67.9 60.8 55.2 reactors consumptions kWh/kg Si conversion, % 11.1 7.1 6.2 6.4 5.8 Second Productivity, kg/h 9.3 23.2 33.1 42 54.2 from coupled Energy 152 97.9 83.9 75.1 64.3 reactors consumptions kWh/kg Si conversion, % 8.4 5.7 5.0 5.1 4.7 Average Productivity, kg/h 11.3 27.3 38.4 49.1 63 characteristics Energy 125.8 84.8 75.3 67.0 59.1 of coupled consumptions reactors kWh/kg Si conversion, % 18.6 12.4 10.9 11.2 10.2 Separate Productivity, kg/h 9.4 22.8 32 41.3 53.1 reactor Energy 136 90.9 78.7 69.8 60.6 consumptions kWh/kg Si conversion, % 15.2 10.4 9.1 9.3 8.6 Comparison Change of +20 +20 +20 +19 +19 of coupled productivity, % and separate Change of energy −7 −7 −4 −4 −2 reactors consumptions, % Change of Si +3.4 +2 +1.8 +1.9 +1.6 conversion, %, TABLE 5 Comparison of the reactor characteristics. The gas flow rate into the coupled reactors is equal to tripled gas flow rate for a stand-alone reactor. Thermal insulation of the gas directed into the second reactor is applied. Rod diameters, m D = D = D = D = D = 0.02 0.05 0.08 0.11 0.14 First Productivity, kg/h 15.5 36 49.6 64 81.1 from coupled Energy 94.7 69.8 64.9 58.7 54.4 reactors consumptions kWh/kg Si conversion, % 8.4 5.5 4.7 4.8 4.4 Second Productivity, kg/h 12 28.5 39.7 50.7 65.1 from coupled Energy 124 83.3 72.6 65 56.5 reactors consumptions kWh/kg Si conversion, % 7.05 4.6 3.9 4.0 3.7 Average Productivity, kg/h 13.8 32.3 44.7 57.4 73.1 characteristics Energy 107.6 75.7 68.3 61.5 55 of coupled consumptions reactors kWh/kg Si conversion, % 14.9 9.8 8.4 8.6 7.9 Separate Productivity, kg/h 9.4 22.8 32 41.3 53.1 reactor Energy 136 90.9 78.7 69.8 60.6 consumptions kWh/kg Si conversion, % 15.2 10.4 9.1 9.3 8.6 Comparison Change of +47 +42 +40 +39 +38 of coupled productivity, % and separate Change of energy −21 −17 −13 −12 −9 reactors consumptions, % Change of Si −0.3 −0.6 −0.7 −0.7 −0.7 conversion, %, TABLE 6 Comparison of the reactor characteristics. The gas flow rate into the coupled reactors equal to is tripled gas flow rate for a stand-alone reactor. Thermal insulation of the gas directed into the second reactor is not applied. Rod diameters, m D = D = D = D = D = 0.02 0.05 0.08 0.11 0.14 First from Productivity, kg/h 15.5 36 49.6 64 81.1 coupled Energy 94.7 69.8 64.9 58.7 54.4 reactors consumptions kWh/kg Si conversion, % 8.4 5.5 4.7 4.8 4.4 Second from Productivity, kg/h 11.7 28.5 41.1 50.9 65.9 coupled Energy 126 88 79.9 73.4 66.6 reactors consumptions kWh/kg Si conversion, % 6.9 4.6 4.0 4.0 3.7 Average Productivity, kg/h 13.6 32.3 44.9 57.5 73.5 characteristics Energy 108 77.8 71.7 65.2 59.9 of coupled consumptions reactors kWh/kg Si conversion, % 14.7 9.8 8.5 8.6 8.0 Separate Productivity, kg/h 9.4 22.8 32 41.3 53.1 reactor Energy 136 90.0 76.7 69.8 60.6 consumptions kWh/kg Si conversion, % 15.2 10.4 9.1 9.3 8.6 Comparison Change of +45 +42 +40 +39 +38 of coupled productivity, % and separate Change of energy −21 −14 −9 −7 −1 reactors consumptions, % Change of Si −0.5 −0.7 −0.6 −0.7 −0.6 conversion, %, Based on the data in Table 4, one can conclude that the use of coupled reactors as compared with a stand-alone reactor can result in considerable increase of productivity, gas-to-silicon conversion and decrease of energy consumption per 1 kg of deposited silicon. Table 5 shows that the gas flow rate increased by 1.5 times compared to the total flow rate required for operation of two reactors in stand-alone mode allows increasing productivity as compared with separate reactor nearly up to 40% and decrease of the energy consumptions by about 13%. At that, gas-to-silicon conversion becomes nearly the same as in stand-alone reactor. Effect of the change of the gas pumping direction can be estimated from the data in Tables 4 and 5. It is seen that growth rate in second reactor is lower than in first reactor by 20-30% at equal deposition areas. Then the rod diameter in second reactor in the process with non-changed pumping directions will be smaller than in first reactor maximally by 20-30%. The total amount of deposited silicon in two reactors at the process end is smaller by (0.75 2 +1)/2·100%=22%. The process time without the change of pumping direction is shorter by 25/2=12.5%. So the process productivity is 78%/0.875=89%, i.e. the productivity decreases by 11% in the processes without the change of the gas pumping direction as compared with the coupled reactors and changed pumping direction, where productivity increase is about 40%. Hence, productivity increase in coupled reactors without change of pumping direction as compared with separate reactor is about 40%−11%=29%. If hollow bodies or plates are used, the productivity increase of nearly 11% (similar to the change of pumping direction) is expected additionally to the effect of increase of initial deposition surfaces, which is observed in stand-alone mode as well. A decrease of rod surface temperature in first reactor also may provide equal deposition rates in coupled reactors. Negative profit resulting from some decrease of the growth rate in first reactor may be compensated by increase of polycrystalline silicon quality grown under lower temperatures. Tables 5 and 6 show that thermal insulation of the gas flow between the reactors reduces energy consumptions per 1 kg of silicon. The suggested method is recommended to use in production of polycrystalline silicon since it allows increasing the process profitability without serious reconstruction of the reactors.
The invention relates to a polycrystalline silicon production method. The inventive method involves supplying a gas mixture based on a silicon-containing gas to a reduction reactor via a tube system and precipitating silicon on heated surfaces in such a way that an effluent gas mixture is formed. The silicon precipitation process is simultaneously carried out in at least two reactors which are connected in series by the tube system for transporting the gas mixture. Then, the gas mixture used for the operation of all the reactors is supplied at entry into the first reactor and is continuously transmitted through all the connected in series reactors.
2
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention is directed to a motor vehicle propulsion system wherein kinetic energy is stored in a flywheel and is transferred on demand to accelerate and propel the vehicle. The flywheel is liquid-filled, and the transfer of energy is accomplished by the kinetic energy of the liquid. 2. Description of the Prior Art The conventional automobile has been in existence since approximately 1898. During the past 80 years, automobile design has led to increasing vehicle weight, larger engines, increasing comfort features, concern for engine emissions, and decreasing fuel economy. In the operation of an automobile, energy is required to accelerate the vehicle upon driver demand and, when stopping of the vehicle is required, the kinetic energy of the vehicle is converted to heat by way of the braking system. The powering of present-day automotive vehicles is a demand system where the engine is large enough to provide the power necessary for maximum acceleration while, for the majority of operating conditions, only a small amount of the maximum energy power is required. Present-day efforts at improving fuel economy have been directed toward improving power efficiency in the engine without addressing the basic problem of having an oversized engine. Improving fuel efficiency has been carried far forward so that any further improvement in motor vehicle propulsion efficiency must be directed to a basic system of greater potential than the elementary demand system described above. SUMMARY OF THE INVENTION In order to aid in the understanding of this invention, it can be stated in essentially summary form that it is directed to a motor vehicle propulsion system wherein a small engine drives a liquid-filled flywheel to store kinetic energy in the liquid. Power is transferred to the vehicle propulsion wheels on driver demand by releasing the liquid to a turbine which is connected to the drive wheels through a drive train. It is thus an object of this invention to provide a motor vehicle propulsion system wherein a small engine can be used to build up a significant amount of kinetic energy in a liquid filled flywheel, with the energy being coupleable to propel the vehicle through means of a driver demand controlled turbine. It is another object to provide a motor vehicle propulsion system wherein a small engine is capable of accelerating the motor vehicle by storing kinetic energy in a flywheel, with the flywheel being liquid-filled and hydraulically coupled to a turbine for rapid energy release. Another object is to provide a liquid-filled flywheel wherein kinetic energy is stored for propulsion usage, and the turbine mechanism coupled to propel the vehicle recovers kinetic energy from the vehicle and transfers it to the liquid-filled flywheel for deceleration of the vehicle, so that vehicle kinetic energy is recovered. The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may be best understood by reference to the following description, taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side-elevational view of the motor vehicle propulsion system of this invention, with an example of a motor vehicle with which it can be used shown in dashed lines. FIG. 2 is a plan view of the first preferred embodiment of the flywheel-turbine assembly of the propulsion system of this invention. FIG. 3 is an enlarged section taken generally along the line 3--3 of FIG. 2. FIG. 4 is a side-elevational view of a second preferred embodiment of the motor vehicle propulsion system of this invention. FIG. 5 is a plan view of the flywheel-turbine assembly of a third preferred embodiment of the motor vehicle propulsion system of this invention. FIG. 6 is a side-elevational view of the structure of FIG. 5. DESCRIPTION OF THE PREFERRED EMBODIMENTS Motor vehicle 10 is generally indicated in FIG. 1. It has a body 12 for housing of its propulsion system, for the carrying of its driver and load, and has support wheels for support, guidance and propulsion. In the motor vehicle 10 illustrated in FIG. 1, the motor vehicle is illustrated as having forward guidance wheels 16 and rear propulsion wheels 14, but any other arrangement is feasible with the propulsion system of this invention. The propulsion system of this invention comprises engine 18 which serves as a basic prime mover, liquid-containing flywheel 20 which is driven by engine 18, turbine 22 which can extract energy from and return energy to the liquid-containing flywheel, and drive train 24 interconnecting the turbine with the drive wheels 14. Engine 18 is the basic prime mover of the motor vehicle 10. It may be any prime mover, but it is particularly contemplated with respect to this invention that it be a combustion engine and particularly an internal combustion engine. It is contemplated that hydrocarbon fuel be the fuel employed with engine 18 in view of its convenience and simplicity of storage and combustion, but this invention is not limited to any particular prime mover. Engine 18 is sized to be able to propel the motor vehicle 10 and its load at a desired speed along a level highway, drive the auxiliaries of the motor vehicle, and may have a small amount of additional available power for supplying kinetic energy to flywheel 20. Engine 18 drives flywheel 20 through drive connection 26. Drive connection 26 may be any convenient drive connection, including direct coupling, shaft or chain drive. Furthermore, in view of the relatively small amount of power transmitted, some belt drives are also feasible. Flywheel 20 is a cylindrical structure having top wall 28, bottom wall 30 and cylindrical side wall 32 (see FIGS. 2 and 3). Flywheel 20 is mounted on central shaft 34 which is mounted for rotation in the body 12 of motor vehicle 10. For dynamic considerations discussed below, the flywheel 20 is preferably mounted near the longitudinal and transverse center of the motor vehicle. In view of that location, it is sometimes convenient to mount engine 18 elsewhere and drive it through drive connection 26. Otherwise, engine 18 can be directly mounted on top of flywheel 20. Flywheel 20 has liquid 36 therein. Liquid 36 is preferably water because of its weight and viscosity, inexpensive character and wide availability. When water is used, it may carry anti-rust and lubricity additives as well as anti-freeze additives for those cases where the motor vehicle may be used in a subfreezing ambient. With spinning of flywheel 20, liquid 36 is coupled thereto to spin with the flywheel. Internal vanes in the flywheel may be employed to increase coupling. Thus, engine 18 drives flywheel 20 and liquid 36 so that liquid 36 has a substantial amount of kinetic energy. A plurality of liquid nozzles are arranged around the flywheel in side wall 32 thereof. Nozzles 38, 40 and 42 are illustrated in FIG. 2, and nozzle 44 is illustrated in FIG. 3. A valve is positioned within each of the nozzles, and valve controller 46 is illustrated in FIGS. 2 and 3. In FIG. 2, the valve controllers are the radial connections which connect the valves to a central control. The central valve control system 48 is illustrated in FIGS. 1 and 3. In FIG. 1, it is illustrated as being under the direct control of the driver. Turbine 22 is a half torus 50 mounted on bottom plate 52 which serves as its support and rotational coupling. Vanes are positioned inside the torus, with vanes 54 and 56 illustrated in FIG. 2 and vane 58 illustrated in FIGS. 2 and 3. When flywheel 20 is rotating and its liquid 36 carries the rotational kinetic energy of the flywheel system, the opening of the valves in the nozzles permits the high kinetic energy liquid to discharge against the vanes. The kinetic energy is converted to torque and rotation of turbine 22. The rotational drive is transmitted through bottom plate 52 to the bottom of turbine where it is connected to drive train 24. The connection is in the form of bevel gear box 60 which may contain automatic torque and turns ratio conversion depending on vehicle speed. From bevel gear box 60 to the rear axle, drive train 24 is a conventional driveshaft with universal joints. It includes a differential on the rear axle. When the high kinetic energy liquid is discharged from the nozzles against the vanes in the turbine, it gives up its kinetic energy. The liquid falls to the bottom of the turbine and returns through channel 62 (see FIG. 3) to the center of the flywheel. Opening 64 (see FIG. 2) returns the liquid into the flywheel at a low kinetic energy location for continuous circulation of the liquid. Thus, the system is continuously liquid-filled, and the liquid circulates based on its kinetic energy. When the vehicle is moving and slowing down is desired, the valves are closed and the turbine 22 drives the liquid to increase its kinetic energy. Thus, kinetic energy is transferred from the vehicle into the liquid with consequent slowdown of the vehicle. In this way, kinetic energy is recovered from vehicle motion. Converting the kinetic energy of the moving vehicle into heat through braking is only necessary in panic stops. Because of the significantlysmaller engine, fuel economy is greatly improved. Furthermore, with the use of a small engine operating most of the time at its nominal maximum load, engine exhaust emissions can be more readily managed with a significant reduction in air pollution. Because the flywheel 20 is not only an energy-storing device but also a massive gyroscope, when it is rotating at speed, it provides gyroscopic stability to the motor vehicle 10. With this stability, a relatively light structure of the motor vehicle has the equivalent enhanced stability of a larger, heavier vehicle. The stability of vehicle 10 will be substantially better than other vehicles of the same size. Due to the gyroscopic stability, it would be impossible for the motor vehicle 10 to roll over around its longitudinal axis. The gyroscopic effect of the flywheel makes the apparent weight, and, therefore, the stability of the vehicle much greater than the actual weight of the motor vehicle 10. As a consequence of that, a significant reduction in the use of structural material is possible for the building of the vehicle. This not only conserves resources, but achieves a significant cost reduction. In view of the gyroscopic stability, precessional forces can be neutralized if they are determined to be a significant problem. FIG. 4 illustrates a pair of flywheels 66 and 68, each driven by its respective drive connection 70 and 72 from the engine similar to drive connection 26. The flywheels 66 and 68 rotate in opposite directions about the axis 74. Turbines 76 and 78 respectively surround flywheels 66 and 68 to form the same combination as the flywheel-turbine assembly 20-22. Nozzles are provided out of each of the flywheels 66 and 68 into turbines 76 and 78 together with valves to control them. In FIG. 4, the output drive trains 80 and 82 correspond to drive train 24. By contrarotation of the two flywheel-turbine assemblies, the precessional forces which would result from the vehicle being steered around a normal corner are balanced. FIGS.5 and 6 represent a flywheel-turbine assembly of a propulsion system in accordance with this invention which also equalizes the precessional forces but mounts the flywheels concentrically. Thus, inner flywheel 80 is an enclosed cylinder filled with liquid, and its only purpose is to provide gyroscopic stability and precession force balance. Outer flywheel 82 is concentric with inner flywheel 80 and has liquid 84 therein, the same as flywheel 20. Furthermore, it also has nozzles 86 which controllably release the liquid 84 with its high kinetic energy into turbine 88 to turn the turbine, the same as turbine 22. Inner flywheel 80 is driven in one direction by drive connection 90, while outer flywheel 82 is driven in the opposite direction by drive connection 92. Both of the drive connections are powered by the engine. Turbine 88 is connected through a suitable drive train to the rear wheels, similar to drive train 24. The construction of the flywheel-turbine illustrated in FIGS. 5 and 6 thus shows another embodiment wherein the motor vehicle propulsion system can have the benefits of gyroscopic stability and yet to overcome the problems of precessional forces by balancing the precession forces. Thus, with such a flywheel-turbine assembly, kinetic energy can be stored and recovered. This invention has been described in its presently contemplated best mode, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims.
Small constant power engine drives liquid filled flywheel to store large amounts of kinetic energy. When motor vehicle acceleration is desired, the flywheel liquid is coupled to a turbine which is connected through a drive train to drive the rear wheels. The transfer of liquid from the flywheel kinetic energy storage to the turbine controls vehicle acceleration.
1
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS This Patent Application is a Continuation of U.S. patent application Ser. No. 08/457,550, Jun. 1, 1995 now U.S. Pat. No. 5,543,963, which was a Divisional Patent Application of U.S. patent application Ser. No. 07/923,284, which was filed on Jul. 31, 1992, and which issued on Sep. 5, 1995, as U.S. Pat. No. 5,448,410. The present invention generally relates to a beam delivery system and more particularly relates to a beam delivery system for focusing a laser beam on a workpiece for making a range of cut sizes with varying magnification and energy densities for micro-machining operations. BACKGROUND OF THE INVENTION U.S. Pat. No. 4,757,354 issued Jul. 12, 1988 to Sato et al. for Projection Optical System discloses a projection optical system including refraction sub-system and a cata-dioptric subsystem optically connected to each other and is used for photolithography used in producing integrated circuits, large-scale circuits, or the like. U.S. Pat. No. 4,937,424 issued Jun. 26, 1990 to Yasui et al. for Laser Machining Apparatus discloses a laser machining apparatus including a laser resonator capable of producing a laser beam having a filled-in intensity distribution pattern and a condensing device for converting the beam into a suitable beam to perform an intended machining. SUMMARY OF THE INVENTION The present invention is an imaging system which shapes a raw laser beam and impinges it to an aperture, controls the divergence output from the laser through the aperture plane to imaging lenses to provide an optical train which accepts angular pointing errors of plus or minus three minutes of arc. The imaging system maintains color correction between two octaves of light, provides minimal aberrations, and further provides a magnification range of about 35× to about 105× within a constant total working distance to achieve a range of energy densities and cut sizes required for micro-machining with a minimal input laser power. A wide range of desired cut parameters is achieved with the minimum input power of 1-2 watts while maintaining optimum cut uniformity and edge definition. It is an object of the present Invention to provide a laser micro-machining apparatus which can accommodate lasers having different divergences. It is another object of the present invention to provide a laser imaging system which is color corrected such that various wavelengths are focused at the same point. It is another object of the present invention to provide a laser micro-machining apparatus which provides various energy densities and sizes of cuts. It is another object of the present invention to provide a laser micro-machining apparatus wherein the energy density of its cut size is a function of its aperture setting size and the demagnification of its lens system. The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of the preferred embodiment of the invention as illustrated in the drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagram of the laser imaging system of one embodiment of the present invention; FIG. 2 is a diagram of a beam shaping lens of the laser imaging system of FIG. 1; FIG. 3 is a table of the prescription of the beam shaping lens of FIG. 2; FIG. 4 is a diagram of a variable field lens of the laser imaging system of FIG. 1; FIG. 5 is a table of the prescription of the variable field lens of FIG. 4; FIG. 6 is a diagram of a Barlow lens of the laser imaging system of FIG. 1; FIG. 7 is a table of the prescription of the Barlow lens of FIG. 6; FIG. 8 is a diagram of zoom transfer lens of the laser imaging system of FIG. 1; FIG. 9 is a table of the prescription of the zoom transfer lens of FIG. 8; FIG. 10 is a diagram of a collimator of the laser imaging system of FIG. 1; FIG. 11 is a table of the prescription of the collimator of FIG. 10; FIG. 12 is a diagram of an objective lens of the laser imaging system of FIG. 1; FIG. 13 is a table of the prescription of the objective lens of FIG. 12; FIG. 14 is a table showing the magnification of the system resulting from various spacings of the lens groups of the laser imaging system of the embodiment of FIG. 1; FIG. 15 is a table showing the magnification of the system resulting from various spacings of the lens groups of another embodiment of the invention wherein the Barlow lens of FIG. 6 is omitted from the configuration shown in FIG. 1; FIGS. 16A-16D are graphs showing transverse ray aberrations of the present invention for tangential measurements taken on the optical axis, 2.50 mm off axis, 4.00 mm off axis, and 5.00 mm off axis, respectively, at a defocus of -0.01 mm; FIG. 17A-17C are graphs showing transverse ray aberrations of the present invention for sagittal measurements taken at 2.50 mm off axis, 4.00 mm off axis, and 5.00 mm off axis, respectively, at a defocus of -0.01 mm; FIG. 18A-18D are graphs showing the diffraction modulation transfer function of the present invention on the optical axis, and tangentially off axis at 2.50 mm, 4.00 mm, and 5.00 mm, respectively, at a defocus of -0.01 mm; and FIG. 19A-19C are graphs showing the diffraction modulation transfer function of the present invention for sagittal measurements taken at 2.50 mm off axis, 4.00 mm off axis, and 5.00 off axis, respectively, at a defocus of -0.01 mm. DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 is a diagram of the laser imaging system of the present invention. It will be understood that a laser, not shown, is located at the left of the laser imaging system of FIG. 1, and that a workpiece to be micro-machined is located on an image plane 114. The laser to be used with the present imaging system may be any number of known lasers, such as an Excimer laser, having an output in the order of 1-2 watts. The present imaging system Is designed to work with a variety of lasers having varying angles of divergence in the order of plus or minus 5 milliradians. The imaging system of the present invention is color corrected between two octaves of light, and is also corrected with minimum aberrations. These attributes allow the system to be used off the shelf lasers which produce beams of varying divergences. It will be understood that since the imaging system of the present invention is color corrected, light of different wavelengths will focus at the same spot. Therefore, light In the visible spectrum may be used to align the imaging system to the work piece at the image plane 114, and then light in an invisible spectrum (such as ultra violet) may be used to do the micro-machining on the work piece. Lasers usable with the present invention are well known by those skilled in the art, and will not be discussed further. The imaging system of FIG. 1 includes a beam shaping lens 100 which reduces the laser beam size by about two times to a partially collimated beam which impinges on an aperture 102 to define the beam. The design of the beam shaping lens 100 is shown in FIGS. 2 and 3. The lens 100 has three elements, element 210 having surfaces 201 and 202, element 211 having surfaces 203 and 204, and element 212 having surfaces 205 and 206. The thickness shown in FIG. 3 refers to the thickness in the material from the previous entry in the table of FIG. 3. For instance, the thickness of the glass between surfaces 201 and 202 is 5.0 mm, as shown in the entry in the table for the surface 202. The remaining tables are constructed in the same way. The aperture 102 may be motor driven by a stepper motor 103 to provide a defining member which is easily controlled between exact stops, as is well known. The distance between the beam shaping lens 100 and the aperture 102 is in the order of about 400 mm. Since the marginal rays outputted from the beam shaping lens 100 are partially collimated, the exact distance is not critical and may be varied to accommodate the linear distance available for the system. Next in the optical path of the system after the aperture 102 is a variable field lens 104. The design of the variable field lens 104 is shown in FIGS. 4 and 5, and has three lens elements 410, 411 and 412. As shown in the table of FIG. 5, the element 410 has surfaces 401 and 402, the element 411 has surfaces 403 and 404, and the element 412 has surfaces 405 and 406. The elements 411 and 412 are separated by 1.00 mm and are movable as a unit in relation to element 410. The distance between surfaces 402 and 403 of elements 410 and 411, respectively, may be from 1.0 mm to 20.0 mm, depending on the intrinsic output divergence of the laser used. Further details of the variable field lens are disclosed in copending patent application Ser. No. 07/923,207, filed on Jul. 31, 1992, entitled "Variable Focus Color corrected Field Lens, owned by the assignee of the present application. Next in the optical path of the system after the variable field lens 104, is a Barlow lens 106 whose design is shown in FIGS. 6 and 7. When the variable field lens 104 is set for a laser divergence of 0, the distance between the field lens 104 and the Barlow lens 106 is 73.81 mm. As shown in FIGS. 6 and 7, the Barlow lens 106 has two elements 610 and 611. The element 610 has surfaces 601 and 602, and the element 611 has surfaces 603 and 604. The Barlow lens 106 demagnifies the image of the aperture from the variable field lens 104 by 2×. A thin zoom transfer lens 108 is in the optical path of the system after the Barlow lens 106. The design of the transfer lens 108 is shown in FIGS. 8 and 9. The thin zoom transfer lens 108 provides the system with a range of magnification to enable production of various cut sizes and required energy densities. The transfer lens 108 meets all of the mechanical and optical requirements with CaF 2 glass elements reduced in thickness to ensure that the lens 108 will withstand greater energy. The thin zoom transfer lens lo has four elements, element 810 having surfaces 801 and 802, element 811 having surfaces 803 and 804, element 812 having surfaces 805 and 806, and element 813 having surfaces 807 and 808. Elements 811, 812 and 813 are movable as a unit with respect to element 810 such that the distance between surfaces 802 and 803 varies from between 0.40 mm to 2.50 mm, thereby changing the magnification of the transfer lens 108 from 6× to 8.9×, respectively. The first thickness entry in FIG. 9 (35.00 mm) is the distance from the entrance pupil of the lens 109. A telephoto type collimator 110 is In the optical path of the system after the transfer lens 108. The collimator 110 has a focal length of 320.12 mm. Its design is shown in FIGS. 10 and 11. The collimator 110 has two elements, element 1010 having surfaces 1001 and 1002, and element 1011 having surfaces 1003 and 1004. The collimator 110 picks up the intermediate image formed by the transfer lens 109 at its back focal point, collimating the beam. A ten element objective lens 112 is in the optical path of the system after the collimator 110. The design of the objective lens 112 is shown in FIGS. 12 and 13. In the objective lens 112, an element 1230 has surfaces 1201 and 1202, element 1231 has surfaces 1203 and 1204, element 1232 has surfaces 1205 and 1206, element 1233 has surfaces 1207 and 1208, element 1234 has surfaces 1209 and 1210, element 1235 has surfaces 1212 and 1213, element 1236 has surfaces 1214 and 1215, element 1237 has surfaces 1216 and 1217, element 1238 has surfaces 1218 and 1219, and element 1239 which is a plate has surfaces 1220 and 1221. An aperture 1240, which is listed as surface 1211 in FIG. 13, is located between the surfaces 1210 and 1212 of elements 1234 and 1235, respectively. The objective lens 112 has a long working distance to allow for fixturing and clearance of a workpiece on the image plane 114. The ten element objective lens 112 is further disclosed in copending patent application Ser. No. 07/923,283, filed on Jul. 31, 1992 entitled Superachromatic UV and Visible Focusing Objective Lens now U.S. Pat. No. 5,305,138, issued on Apr. 19, 1994, the disclosure of which is incorporated herein by reference, and which is owned by the assignee of the present invention. Where the workpiece is in a chamber (not shown) the thickness of the plate 1239 may vary in thickness, depending on the thickness of the chamber cover. Other objective lenses, such as the lens disclosed in IBM Technical Disclosure Bulletin, Vol. 33, No. 4, September 1990, Excimer laser Objective Lens, pages 206-207, may be used. Since the collimator 110 outputs a collimated beam, any infinite conjugate objective lens may be used to provide different magnification ranges with different numerical apertures from those disclosed herein. The distances D7 (without Barlow), D11 (with Barlow), D13, D19 and DTR of FIG. 1 are varied as shown in FIG. 14 and 15 to achieve various magnifications (demagnifications) to achieve various cut sizes and energy densities. It will be understood that if the aperture 102 is opened to a relatively large opening, and the resulting beam is demagnified to a cut size, the resulting energy density will be higher than if the aperture 102 is set to a relatively smaller opening and the resulting beam is demagnified by a smaller amount to the same cut size. The ability to increase the energy density of a cut size allows the micro-machining of harder materials or performing a deeper cut of the same cut size, as desired. The aperture 102 and the demagnification of the system may also be adjusted to give different cut sizes having the same energy density, if desired. FIG. 14 shows the distance settings for magnifications of from 34.7× to 47.89× for one embodiment of the system wherein the Barlow lens 106 of FIG. 6 is omitted, and FIG. 15 shows the distance settings for magnifications of from 76.56× to 106.50× for another embodiment of the system wherein the Barlow lens 106 is included. Each of the lenses of the system of FIG. 1 is color corrected such that the system is color corrected with minimal aberrations. The performance of the system is shown in FIGS. 16A through 19C for light having wavelengths of 308, 546 and 633 nanometers. While we have illustrated and described the preferred embodiment of our invention, it is to be understood that we do not limit ourselves to the precise construction herein disclosed, and the right is reserved to all changes and modifications coming within the scope of the invention as defined in the appended claims.
A train of air spaced optical mechanisms capable of taking a raw laser beam and focusing it on a workpiece for a range of cut sizes with varying magnifications and energy densities while controlling divergence and providing optimum uniformity. The lenses are diffraction limited for optimum uniformity and edge definition. The system uses variable down collimators to condense the beam to an aperture plane. The aperture is then imaged to the workpiece with Barlow, zoom transfer, collimator, and objective lenses. The components are color corrected to aid in alignment of an invisible beam and allow the aperture to be imaged to a workpiece in visible light.
1
FIELD OF THE INVENTION [0001] This invention relates to collapsible structural members or beams and more particularly to collapsible structural members which use substantially identical modules to form beam which are rigid in three dimensions. BACKGROUND OF THE INVENTION [0002] Various collapsible members have been used to form beams for collapsible structures such as temporary buildings and tents and also for work arms to position working tools in awkward locations. The collapsible structural members typically employ cables as tensioning members to bring separate segments or modules together to form a rigid structure. Such prior art structures usually rely on the cable itself to provide rigidity to the member or to separate pins or fasteners which must be installed to obtain rigidity and must be removed to permit collapse of the structure. Usually collapsible structural members require multiple parts and also require substantial time to form a structure and to collapse that structure. [0003] There is a need for a collapsible structural member which is simple to erect and to collapse and uses a minimum number of parts. It appears also that there is a need for a collapsible structural member which uses a tensioning member to bring the parts together but which locks them in a position so that they are not reliant on the tensioning member for rigidity or strength. [0004] An object of the invention is to provide a collapsible structural member which is simple and eliminates the need for many removable parts. [0005] Another object of the invention is to provide a collapsible structure member where a tensioning member is used to bring components, segments or modules of the structure together and into a position in which the components lock together frictionally and are maintained in the locked position without undue loading required on the tensioning member. [0006] A further object of the invention is to provide a collapsible beam structure which uses frictional locking principles similar to that used in Morse tapers for locking tapered drill bits and complementary tapered rotatable chucks to provide frictional locking between the drill and the chuck to transmit rotational torque. [0007] Still another object of the invention is to provide a collapsible beam structure having the ability of locking adjacent modules relative to each other using complementary spherical locking surfaces to provide a frictional lock required to hold the modules in a rigid position relative to each other whether the modules are aligned axially or at an angle to each and independently of the cable or tensioning member. SUMMARY OF THE INVENTION [0008] The objects of the invention are attained by a collapsible structural member utilizing a plurality of substantially identical adjacent modules with each of the modules including an elongated body with a pair of oppositely facing walls forming a head at one end and a skirt forming a socket at the other end to receive the head of an adjacent module. Each of the heads forms a pair of outwardly facing spherical concave locking surfaces facing away from each other and the skirts of each of the modules form concave complementary spherical locking surfaces facing each other. A passage is formed within the modules to extend longitudinally from the head and through the skirt to receive a tensioning member in the form of a cable. Upon application of the tension to the cable at the skirt of an end module of a number of modules on the cable to bring the pair of convex spherical locking surface of the head portions of each module into frictional locking engagement with a pair of concave locking surfaces of an adjacent one of the modules to form a lock between the adjacent modules of all of the modules. Stops are formed on each module to determine the angular relation of the modules so that the collapsible beam can be curved or straight and to form a rigid but collapsible structural member. The cable is used to maintain the position of the modules and upon release permits the cable to be collapsed. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 is a perspective view of a single module used to form a collapsible structural member. [0010] FIG. 2 is a front elevation of one of the modules; [0011] FIG. 3 is a side elevation of one of the modules; [0012] FIG. 4 is a top view of the modules seen in the preceding figures; [0013] FIG. 5 is a bottom view of the modules seen in FIGS. 1-3 ; [0014] FIG. 6 shows two adjacent modules in an aligned position just prior to locking; [0015] FIG. 7 shows three adjacent modules in their locked position; [0016] FIG. 8 is a cross sectional view of the modules seen in FIG. 7 showing the position of the tensioning cable within the modules; [0017] FIG. 9 is a cross sectional view taken on line 9 - 9 in FIG. 7 ; [0018] FIG. 10 is a modified version of the module of the collapsible structural member embodying the invention shown in FIG. 2 ; [0019] FIG. 11 is a view similar to FIG. 4 showing another modification of the module with the head portion of the module rotated slightly relative to the skirt portion for the purpose of changing the direction of curves in a collapsible structural member; [0020] FIG. 12 is a view similar to FIG. 3 showing a modified module with the head displaced relative to the skirt to form three-dimensional curved beam; [0021] FIG. 13 is a diagrammatic showing of a plurality modules of FIGS. 1 through 8 showing a collapsible structural member curved in a coil or in three dimensions; and [0022] FIG. 14 is a diagrammatic view of a collapsible structural member forming an arch to support a swimming pool cover. DESCRIPTION OF THE INVENTION [0023] The present invention utilizes a concept of spherical frictional locking surfaces. [0024] A common example of a frictional locking surface is the conical form found in the Morse taper invented by Steven A. Morse about 1864 and still in wide commercial use in drill presses and lathes. In such a locking arrangement the conical end of a shaft of a tool or drill bit has an included angle at the apex of about seven degrees (7°) or less. When the tool is inserted in a chuck having a complementary conical socket with the same included angle, friction alone maintains the tool in the socket. A small axial force applied to the tool to bring the tapered locking surfaces into engagement with each other is sufficient to frictionally lock the shank of the tool in torque transmitting relationship to the socket. A similar axial force in the opposite direction is applied to disconnect the tapered locking surfaces from each other. [0025] The locking surfaces employed in the present invention uses opposed complementary spherical locking surfaces to form a frictional locking angle of about seven degrees (7°) or less. The spherical surfaces are used to accommodate angled positions of modules relative to each other. [0026] A collapsible beam 10 of the present invention is made up of a plurality of modules or beads 12 . The modules 12 are substantially identical to each other when the beam 10 is to be straight and vary only slightly from each other if any portion of the beam is to be curved. The modules required for straight beams or those curved in a single plane will be discussed first. [0027] Each module 12 of the plurality of modules forming a collapsible beam 10 has a generally flat and elongated body portion 14 with a head 16 at one end and a skirt 18 at the other end forming a receiving socket 20 for the head 16 of an adjacent module 12 . [0028] Each module 12 is generally flat with front and back walls 22 which are identical to each other but facing in opposite directions from an imaginary longitudinal plane indicated at 24 in FIGS. 3 and 4 . Also, the modules 12 have opposite side walls 26 which face away from each other and are identical in shape. The side walls 26 are spaced equally to opposite sides of another imaginary plane 28 intersecting the first mentioned imaginary plane 24 at a right angle as seen in FIGS. 2 and 4 . All of the opposed wall surfaces 22 and 26 are symmetrical to a longitudinal axis 30 formed at the intersection of planes 24 and 28 as seen in FIG. 4 . The longitudinal axis 30 is coaxial with a passage 32 as best seen in FIGS. 2 and 3 . The position of the imaginary planes 24 and 28 as well as the longitudinal axis 30 are also indicated in FIGS. 4 . [0029] The side walls 26 of the head 16 are portions of the circumference of a circle with the center of radius 33 being located at the point 34 as seen in FIG. 2 with the diameter of the circular walls being slightly less than an opening 36 formed in end wall 37 as an entrance to socket 20 in skirt 18 as seen in FIG. 5 . [0030] Front and back walls 22 of head 16 have identical convex surfaces 38 which are formed by opposed segments of a sphere having a radius 39 centered at point 40 in FIG. 9 and extending to the opposite side of longitudinal plane 24 and disposed in a transverse plane 42 that passes through the center 34 of the radius for circular side walls 26 of head 16 as seen also in FIG. 2 . As seen in FIG. 9 , the two convex segments 38 of the sphere face in opposite directions and are relatively closely spaced to each other to form a relatively thin and flat head 16 . [0031] By making the radius approximately the length of the illustrated modules as illustrated in the drawings, the appropriate seven-degree (7°) or less included angle for frictional locking will be obtained. In the present case, if the overall length of the module is about three inches, the radius 39 could be approximately three inches and centered at 40 as seen in FIG. 9 to form one of the convex spherical frictional locking surfaces. The opposed convex spherical locking surfaces 38 forming the head 16 can be visualized by considering diametrically opposed equal segments of the sphere brought close together as seen in FIG. 9 for each of the modules. [0032] The sockets 20 in the skirts 18 of each of the modulesl 2 are provided with a pair of concave spherical locking surfaces 46 which face each other and are complementary to the spherical convex locking surfaces 38 on the head 16 of an adjacent module. [0033] The concave locking surface 46 in socket 20 are generated with a radius 45 substantially equal to radius 42 used to form the complementary spherical locking surface 38 with the convex shape. Referring to FIG. 9 and to the lower one of the modules 12 , transverse plane 42 coincides with the end wall 37 of the skirt 18 . The convex-concave matching frictional locking surfaces with the spherical shape are found to approximate the under seven-degree (7°) taper angle of Morse tapers common with conical connections. Also, the spherical frictional locking surfaces 38 and 46 are desirable to form curved collapsible beams since the taper locking surfaces are effective when adjacent modules 12 have their longitudinal axes 30 aligned or at an angle to each other. As seen in FIG. 2 the circular sides 49 of socket 20 defining the opposite edges of the concave locking surfaces 46 are defined by radius extending from point 37 A at the intersection of longitudinal axis 30 and end wall 37 of skirt 18 . Radius 37 A is substantially equal to radius 37 . The circular, concave side walls 49 of the socket 20 are complementary to the convex circular side walls 26 of the heads of adjacent modules. [0034] The passages 32 formed longitudinally of each module 12 serve to receive a cable or tensioning member 48 in which the modules or beads 12 are strung as best seen in FIG. 8 . The cable 48 serves to maintain the modules 12 aligned with each other when the beam 10 is in its collapsed condition. When tension is applied to the cable 48 , which can be to either end of a collapsible structural member 10 and as shown in FIG. 8 is anchored to the head 16 at a point indicated at 51 . Upon tightening the cable 48 at its opposite end, the head portions 16 are brought into locking engagement in the sockets 20 in adjacent modules of all of the modules on the cable 48 to form a rigid beam as will be described. It will be noted that the axial opening 32 is much wider than required for a single cable 48 . This is provided to accommodate additional cables to activate or apply tension to portions of a collapsible beam or to branch beam portions (not shown). [0035] The plurality of adjacent modules 12 in a collapsible beam 10 are maintained in line with each other by the cable or other tensioning member 48 extending in axial passage 32 in each of the modules 12 as best seen in FIG. 8 . The cable has been omitted in most of the other figures to simplify the drawings. The passages 32 and the cable 48 are so arranged that the modules 12 are in substantial alignment with each other in the collapsed condition of the structural members 10 with a portion of the head 16 in the socket 20 of an adjacent module as illustrated by the two modules in FIG. 6 . With cable 48 anchored to a first module, the application of tension to the cable 48 at another module 12 tends to bring adjacent modules 12 together to bring the convex locking surfaces 38 on the head 16 of each module 12 into locking engagement with the complementary and concave locking surfaces in the socket 20 in the adjacent module. The tension can be applied to the cable by a winch 56 shown diagrammatically in FIGS. 13 and 14 and operated either manually or by power. Thereafter, the loading of the cable 48 is such that only enough tension must be maintained to prevent the modules from changing position relative to each other. The strength or rigidity of the beam 10 is not dependent solely on the tension in the cable 48 which needs to be only high enough to maintain the adjacent modules in position relative to each other. [0036] The straight or angled position of adjacent modules 12 in their interlocked relation is determined by a pair of stop elements 50 formed on each of the front and back walls 22 of the head 16 of each of the modules 12 as seen in FIGS. 2 and 3 . The pairs of stop elements 50 are coaxial to each other as seen in FIGS. 3 and 4 and are disposed equally from opposite sides of plane 28 that intersects the longitudinal axis 30 and longitudinal plane 24 at a right angle. The stop elements 50 on front and back walls 22 of the modules are aligned with each other and are spaced equally from the longitudinal axis 30 of each head portion. Also, all four of the stop elements 50 can be regarded as disposed in the same plane 42 that also passes through radius center 40 for spherical locking surfaces 38 as seen in FIG. 9 . [0037] The four stop elements 50 are adapted to engage four stop recesses or notches 52 formed in the end wall 37 of the skirt 18 of an adjacent module 12 . The end walls 37 on skirts 18 coincide with the transverse plane 42 so that as seen in FIGS. 6 and 7 the stop elements 50 are engaged with the stop recess 52 and the top two adjacent modules 12 in FIGS. 7 and 8 are aligned with each other in a straight line. If the modules or beads 12 are to be at an angle with each other, the stop elements 50 are repositioned by moving them in an arc about radius center 34 out of reference plane 42 in FIG. 2 . By way of example, if the adjacent modules are to be at a fifteen-degree (15°) angle to each other, the stop elements 50 are moved from their original transverse position in FIG. 2 through an arc of fifteen degrees (15°) to the transverse plane 42 about the center 34 midway of stop elements 50 as illustrated also in FIG. 6 for the bottom module 12 . The axially aligned stop elements 50 at each side of head 16 are moved equally in opposite directions in an arc of fifteen degrees (15°) about radius center 34 from the original transverse position. [0038] In the preferred embodiment of the invention shown in FIGS. 1 through 9 maximum angle of adjacent modules is approximately twenty-two and one half degrees (22½°) to insure efficient operation of the cable or tension member 46 . [0039] The modules for any given size are molded of plastic material and the only differences between modules for straight beams and for curved beams is the position of the stop elements 50 . To create a collapsible structural member 10 only a few different modules are required namely those for straight beam portions and those for curved beam portions. Even here the inventory is simplified because modules for angled connection form an angle either to the left or to the right by simply turning the module one hundred eighty degrees (180°) about its longitudinal axis 26 . [0040] Thus far the modules 12 had been described as substantially identical except for the positioning of stop elements 50 to make curves in the collapsible structural member 10 . However, in FIG. 10 the module 12 A has been elongated by changing the distance between the head 16 and the socket 20 in skirt portion 18 which remain identical to the head 16 and socket 20 of the prior modules. Only the body member 14 has been changed by elongation as indicated by the bracket at 53 in FIG. 10 to space the head 16 at some greater selected distance from the socket 20 in skirt 18 . In all other respects the module 12 remains the same except for the possible positions of stop elements 50 . [0041] A further modification can be made to the modules 12 in the event a collapsible structural beam is to be curved in more than a single plane, that is a three-dimensional curve or for example such as that that would occur in a spiral on helix as illustrated diagrammatically in FIG. 13 . In that case, a module 12 B can be formed as a unitary module by rotating the head 16 relative to the skirt 18 and socket 20 about the longitudinal axis 30 of the module as seen in FIG. 11 . The angle of head 16 can be up to a full ninety degrees (90°) relative to skirt 18 , if desired, since it would not affect the operation of the tensioning member or cable 48 . [0042] Still another variation of modules 12 can be made by bending the head 16 relative to skirt 18 out of the longitudinal plane 24 as seen in FIG. 12 to form module 12 C. This variation of the module can also be used to form three-dimensional curved beams such as a helix shown diagrammatically in FIG. 13 . The tensioning members 48 should be in a path that avoids kinking of the cable and for that reason the angle of displacement of the head 16 relative to the skirt 18 should not exceed about fifteen degrees (15°). [0043] In all of the modifications of the basic module 12 seen in FIGS. 10, 11 and 12 the head 16 and socket 20 in skirt portions 18 remain unchanged. Only the body portion 14 between the head 16 and skirt 18 change by either stretching, as shown for module 12 A in FIG. 10 , by twisting, as shown for module 12 B in FIG. 11 , or by bending for module 12 C, as seen in FIG. 12 . In all of the modifications, the head and socket 20 in skirt 18 operate as in the first embodiment. Also, the stops 50 and recesses 52 operate in the same way for all versions of the modules. [0044] A three-dimension beam 60 is shown in FIG. 13 in a form of a spiral. The beam 60 would require not only the basic module 12 but a few of the modules 12 B or 12 C. [0045] A two dimensional beam 64 is illustrated in FIG. 14 and is made up and curved in a single plane using the basic modules 12 and elongated modules 12 A to form the support beam 64 for a flexible cover 66 for a swimming pool 68 . In such a cover arrangement to curved beam or beams 64 could be collapsed to permit the beams to be rolled up in the cover 66 to uncover the pool 68 . [0046] A collapsible beam structure has been providing a variety of straight or curved structural members of various sizes utilizing a basic module to be molded of plastic material. The basic module 12 is used to form straight beam structures and is modified slightly by repositioning stop elements 50 , which determine the angular position of adjacent modules relative to each other. The basic module 12 is further modified to twist the head 16 relative to the head receiving socket 20 as in module 1 2 B or to bend the head portion 16 relative to the socket portion 20 relative to the longitudinal transverse plane 28 of the modules 12 or to elongate the module as in module 12 A by separating the head 16 and socket 20 and stretching the skirt portion 18 of the module 12 with a greater distance than the basic module 12 . By selecting and arranging the basic module 12 and modified modules 12 A, 12 B and 12 C, regular and irregular configurations of structural beams can be constructed using only a few different modified modules to accomplish the end result. [0047] The beam structure of the present invention are rigid not only in a single plane or three planes but are rigid radially relative to the central axis of all of the modules. The structural strength comes from the frictional locking surfaces and the tensioning cable is required only to maintain the position of the modules.
A collapsible structural member has been provided in which substantially identical modules made up of metal or plastic are threaded on a tensioning member such as a cable and are movable relative to each other in the collapsed condition of the beam and are brought together into a condition where adjacent modules are locked together to form a rigid construction when the beam is in its erected operating condition. The beam is changed from its erected condition to its collapsed condition by relaxing the tensioning member or cable.
4
FIELD OF THE INVENTION The present invention relates to a process for producing 2-hydroxy-4-methylthiobutanoic acid useful as a feed additive and the like. In more particular, it relates to a method for separating ammonium sulfate and ammonium bisulfate from each other and a process for producing 2-hydroxy-4-methylthiobutanoic acid utilizing the method. BACKGROUND OF THE INVENTION Heretofore, 2-hydroxy-4-methylthiobutanoic acid has been produced by a process which comprises reacting 2-hydroxy-4-methylthiobutyronitrile with an equal molar or slight excess of sulfuric acid to hydrate and hydrolyze the nitrile compound, and separating the resulting reaction liquid into an aqueous layer and an oil layer containing 2-hydroxy-4-methylthiobutanoic acid. The aqueous layer, which contains ammonium bisulfate, is discarded without any after-treatment or discarded after neutralized with ammonia to form ammonium sulfate which is deposited and separated therefrom, see for example, U.S. Pat. No. 4,524,077 and U.S. Pat. No. 4,912,257. This process, however, is not an industrially recommendable process from the viewpoints of environmental friendliness as well as production cost, because it uses a large amount of sulfuric acid, forms a large amount of sulfates as by-products and moreover produces a large amount of sulfate-containing waste water. A known process devised for reducing the amount of sulfuric acid used in the above-mentioned prior art process comprises thermally decomposing the by-produced sulfates to evolve SO 3 and recovering the SO 3 as sulfuric acid, see U.S. Pat. No. 5,498,790. However, this process requires complicated equipment for recovering sulfuric acid and requires a heavy investment for construction of the equipment. SUMMARY AND OBJECTS OF THE INVENTION The present inventors have made extensive study with the object of providing a process for producing 2-hydroxy-4-methylthiobutanoic acid which permits a reduction of the amount of sulfuric acid used, a reduction of the sulfate-containing waste water produced and a reduction of production cost, and is therefore more environmental-friendly than before. As the result, it has been found that, in the process for producing 2-hydroxy-4-methylthiobutanoic acid by using sulfuric acid, (1) ammonium bisulfate contained in the aqueous layer, which has been discarded in the prior art process, has a capability to hydrate and hydrolyze 2-hydroxy-4-methylthiobutyronitrile, and combined use of ammonium bisulfate and sulfuric acid unexpectedly promotes the hydration and hydrolysis, (2) even when the aqueous layer contains ammonium bisulfate and ammonium sulfate in admixture, addition of a specific substance to the aqueous layer makes it possible to separate the two ammonium salts efficiently from each other and to recover ammonium bisulfate selectively, and (3) re-use of a part or all of the ammonium bisulfate-containing solution obtained after separating ammonium sulfate from the aqueous layer in the above-mentioned hydration and/or hydrolysis of 2-hydroxy-4-methylthiobutyronitrile provides a process for producing 2-hydroxy-4-methylthiobutanoic acid which permits the reduction of the amount of sulfuric acid used, the remarkable reduction of the amount of sulfate-containing waste water and the reduction of the production cost, and is therefore environmental-friendly. The present invention has been accomplished on the basis of the above findings. Thus, the present invention provides a method for separating ammonium sulfate and ammonium bisulfate from each other which comprises adding a water-miscible organic solvent to an aqueous solution containing ammonium sulfate and ammonium bisulfate to deposit the ammonium sulfate and separating the ammonium sulfate from the aqueous solution. The present invention further provides a method for producing 2-hydroxy-4-methylthiobutanoic acid which comprises conducting hydration and successive hydrolysis of 2-hydroxy-4-methylthiobutyronitrile in a reaction system containing 2-hydroxy-4-methylthiobutyronitrile and sulfuric acid, ammonium bisulfate being added to the reaction system while conducting the hydration and/or the hydrolysis. The present invention still further provides a process for producing 2-hydroxy-4-methylthiobutanoic acid which includes the above two methods. Specifically, the process includes: a process for producing 2-hydroxy-4-methylthiobutanoic acid which comprises the steps of: (A) conducting hydration and successive hydrolysis of 2-hydroxy-4-methylthiobutyronitrile in a reaction system containing 2-hydroxy-4-methylthiobutyronitrile and sulfuric acid, ammonium bisulfate being added to the reaction system while conducting the hydration and/or the hydrolysis, to obtain a solution containing 2-hydroxy-4-methylthiobutanoic acid, (B) separating the solution containing 2-hydroxy-4-methylthiobutanoic acid into an organic layer containing 2-hydroxy-4-methylthiobutanoic acid and an aqueous layer containing ammonium sulfate and ammonium bisulfate, (C) obtaining 2-hydroxy-4-methylthiobutanoic acid from the organic layer, and (D) adding a water-miscible organic solvent to the aqueous layer to deposit the ammonium sulfate and separating the ammonium sulfate from the aqueous layer; and more specifically, a process for producing 2-hydroxy-4-methylthiobutanoic acid which comprises the steps of: (A) conducting hydration and successive hydrolysis of 2-hydroxy-4-methylthiobutyronitrile in a reaction system containing 2-hydroxy-4-methylthiobutyronitrile and sulfuric acid, ammonium bisulfate being added to the reaction system while conducting the hydration and/or the hydrolysis, to obtain a solution containing 2-hydroxy-4-methylthiobutanoic acid, (B) separating the solution containing 2-hydroxy-4-methylthiobutanoic acid into an organic layer containing 2-hydroxy-4-methylthiobutanoic acid and an aqueous layer containing ammonium sulfate and ammonium bisulfate, (C) obtaining 2-hydroxy-4-methylthiobutanoic acid from the organic layer, (D1) adding a water-miscible organic solvent to the aqueous layer to deposit the ammonium sulfate and separating and recovering the ammonium sulfate from the aqueous layer, to obtain a solution containing ammonium bisulfate and the water-miscible organic solvent, (D2) removing the water-miscible organic solvent from the solution containing ammonium bisulfate and the water-miscible organic solvent, to obtain a solution containing ammonium bisulfate, and (D3) returning a part or all of the solution containing ammonium bisulfate to the step (A). BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a flow sheet showing one embodiment of the present invention as a block diagram wherein a solvent extraction method is used. FIG. 2 is a flow sheet showing another embodiment of the present invention as a block diagram wherein a layer separation method is used. DETAILED DESCRIPTION OF THE INVENTION In the present invention, in hydrating and hydrolyzing 2-hydroxy-4-methylthiobutyronitrile by using sulfuric acid, ammonium bisulfate is used together with the sulfuric acid at the time of the hydration and/or the hydrolysis to obtain 2-hydroxy-4-methylthiobutanoic acid. A part or all of the ammonium bisulfate used herein can be that by-produced in the above-mentioned series of reaction system. In the present invention, therefore, the part or all of ammonium bisulfate by-produced in the above-mentioned reaction system can be returned to the reaction system and can be used in combination with sulfuric acid for the hydration and/or the hydrolysis in the reaction system. 2-Hydroxy-4-methylthiobutyronitrile forms 2-hydroxy-4-methylthiobutanamide by hydration, which then forms 2-hydroxy-4-methylthiobutanoic acid by hydrolysis. In the present invention, ammonium bisulfate can be used either in the hydration or in the hydrolysis or in the both reactions. When ammonium bisulfate is used in the hydration and succeedingly the hydrolysis is initiated while the bisulfate is allowed to remain in the reaction system, the ammonium bisulfate added at the time of hydration contributes again to the hydrolysis since ammonium bisulfate is substantially kept unconsumed in the hydration, and hence there is no need to add ammonium bisulfate anew at the time of hydrolysis. Combined use of ammonium bisulfate and sulfuric acid in either the hydration or the hydrolysis or both permits a reduction of the required amount of sulfuric acid to be used as well as acceleration of overall reaction rate as compared with the use of sulfuric acid alone. The manner to carry out the process according to the present invention which comprises hydrating and hydrolyzing 2-hydroxy-4-methylthiobutyronitrile is not particularly limited so long as ammonium bisulfate is used in combination with sulfuric acid in either or both of the reactions. A preferred method of practicing the process is to add 2-hydroxy-4-methylthiobutyronitrile to sulfuric acid or a solution containing sulfuric acid to initiate the reactions. In the present invention, the amount of sulfuric acid used preferably falls within the approximate range of from 0.5 to 1 mole per mole of 2-hydroxy-4-methylthiobutyronitrile. When ammonium bisulfate is used at the time of hydration, it is preferable that the ammonium bisulfate is made to be present beforehand in a solution containing sulfuric acid, and thereafter 2-hydroxy-4-methylthiobutyronitrile is added thereto. The concentration of sulfuric acid in the solution before the addition of 2-hydroxy-4-methylthiobutyronitrile thereto preferably falls within the approximate range of from 60 to 75% by weight based on the solution without ammonium bisulfate. When the concentration of sulfuric acid in the solution after the addition of 2-hydroxy-4-methylthiobutyronitrile thereto does not fall within the range, it is preferably adjusted by adding additional sulfuric acid so as to fall within the range, i.e., 60 to 75% by weight based on the solution without both organic substances and ammonium bisulfate. The reaction temperature of hydration is preferably about 70° C. or below, more preferably about 40-60° C. The amount of ammonium bisulfate used in the hydration is not particularly restricted. It is preferably such an amount as not to cause the deposition of sulfates after the hydrolysis reaction. The molar amount of ammonium bisulfate may suitably be, as a guide, 1-3 times, preferably about 2 times the molar amount which is calculated by subtracting that of sulfuric acid (used in combination with ammonium bisulfate) from that of 2-hydroxy-4-methylthiobutyronitrile used. The reaction time of hydration varies depending on the each amount of sulfuric acid and ammonium bisulfate used. For example, in the case where the concentration of sulfuric acid in the solution after the addition of 2-hydroxy-4-methylthiobutyronitrile is about 60-75% by weight based on the solution without both organic substances and ammonium bisulfate, and about 0.5-1 mole of sulfuric acid and about 0.1-0.5 mole of ammonium bisulfate are used respectively per 1 mole of 2-hydroxy-4-methylthiobutyronitrile used, the reaction is allowed to continue for about 3 hours at the longest, usually for about 1-2 hours. In the hydrolysis, the concentration of sulfuric acid in the reaction mixture is preferably adjusted to 25-40% by weight based on the reaction mixture without both organic substances and ammonium bisulfate. In the case where ammonium bisulfate is added at the time of hydrolysis, a convenient method for adjusting the concentration is to prepare an aqueous solution of ammonium bisulfate as the source of the bisulfate and add the solution to a reaction mixture so that the concentration of sulfuric acid in the reaction mixture may fall in the range specified above. The amount of ammonium bisulfate is not particularly limited. It is preferably such an amount that may not cause deposition of sulfates after the hydrolysis reaction. The suitable molar amount of ammonium bisulfate to be used can be, as a guide, 1-3 times, preferably about 2 times the molar amount which is calculated by subtracting that of sulfuric acid (used in combination with ammonium bisulfate) from that of 2-hydroxy-4-methylthiobutyronitrile used. The higher the reaction temperature, the more repidly the reaction proceeds. Considering that the boiling point of the reaction system is about 115° C. at atmospheric pressure, the reaction is preferably conducted substantially in the neighborhood of that temperature. However, if the reaction is conducted at a higher temperature under applied pressure, the reaction proceeds more rapidly. The reaction time of hydrolysis varies depending on the each amount of sulfuric acid and ammonium bisulfate used. For example, in the case where the concentration of sulfuric acid in the reaction mixture is about 35-40% by weight based on the reaction mixture without both organic substances and ammonium bisulfate and where about 0.5-1 mole of sulfuric acid and about 0.2-1 mole of ammonium bisulfate are used respectively per 1 mole of the starting material used, i.e., 2-hydroxy-4-methylthiobutyronitrile used, the reaction is allowed to continue for about 5 hours at the most, usually for about 2-4 hours. After completion of the hydrolysis, the reaction mixture can be further kept in the neighborhood of reaction temperature while stirring for several ten minutes to 1 hour (this operation being hereinafter referred to as the aging treatment). After the hydrolysis, the reaction mixture obtained is separated into an aqueous layer and an oil layer of 2-hydroxy-4-methylthiobutanoic acid, so that the reaction product can be subjected, as it is, to a layer separation to isolate the objective product, 2-hydroxy-4-methylthiobutanoic acid. Alternatively, 2-hydroxy-4-methylthiobutanoic acid can be extracted from the reaction mixture by using a water-immiscible solvent. The latter method of a solvent extraction can be regarded as a more desirable method, because the aqueous layer left behind the solvent extraction substantially contains only ammonium bisulfate and ammonium sulfate. The water-immiscible solvents suitably used include various ketones and carboxylic acid alkyl esters. Specific examples thereof include methyl isobutyl ketone, methyl n-propyl ketone, methyl ethyl ketone, ethyl butyl ketone, isobutyl ketone, ethyl acetate, n-butyl acetate, n-propyl acetate and isopropyl acetate. The reaction mixture after the completion of the reactions contains a large amount of ammonium salts. To prevent the deposition of the ammonium salts, the reaction mixture is preferably kept at a temperature of 30° C. or above during the operation of the above-mentioned layer separation or solvent extraction. By conducting the above-mentioned layer separation or solvent extraction, an oil layer containing 2-hydroxy-4-methylthiobutanoic acid and an aqueous layer containing ammonium sulfate and ammonium bisulfate can be obtained from the reaction mixture after the hydrolysis. The above-mentioned aqueous layer obtained by separating 2-hydroxy-4-methylthiobutanoic acid from the reaction mixture after the hydrolysis is then subjected to a depositing operation by adding a water-miscible organic solvent thereto. By this operation, ammonium sulfate alone is deposited almost selectively from the aqueous layer. Consequently, the resulting mixture can be separated by a separating operation, for example, such a simple operation as filtration, into white crystalline ammonium sulfate and a solution containing ammonium bisulfate. When a part of the ammonium salts has happened to deposit in the reaction mixture before the depositing operation, it is preferable to add first a suitable amount of water and then a water-miscible organic solvent to the reaction mixture before initiating the deposition. The depositing operation is conducted preferably at room temperature or below, specifically at about 30° C. or below, more preferably at about 20° C. or below. The depositing operation at a high temperature exceeding about 30° C. is undesirable, because there is a potential risk of contamination of ammonium sulfate in the liquid layer. Water-miscible organic solvents used for the deposition include, for example, lower alcohols, e.g., methanol, ethanol, propanol, isopropanol and butanol, acetone and acetonitrile. The amount of the water-miscible organic solvent used for the deposition varies depending on the concentrations and the molar ratio of ammonium sulfate and ammonium bisulfate in the aqueous layer. For example, in the case where the deposition is applied to an aqueous layer containing 5-30% by weight of ammonium sulfate and 5-40% by weight of ammonium bisulfate at room temperature, the water-miscible organic solvent is added to the aqueous layer in an amount of preferably about 0.2-2 times, more preferably about 0.4-1.5 times that of the aqueous layer in weight basis. When the concentration of the ammonium salts in the aqueous layer is not definitely known or the concentration is outside the above-mentioned range, the water-miscible organic solvent can be added to the aqueous layer until white crystals cease to form in the layer. By conducting the separating operation subsequent to the depositing operation, white crystalline ammonium sulfate and a solution containing ammonium bisulfate are obtained. The ammonium sulfate obtained can be, if necessary and desired, subjected to a purifying operation, such as washing, to obtain a product with higher purity. The solution containing ammonium bisulfate is, after removal of the water-miscible organic solvent by a vacuum evaporation etc., returned to the step of hydration and/or hydrolysis of 2-hydroxy-4-methylthiobutyronitrile and used in combination with sulfuric acid. Thus, according to the present invention, substantially the whole amount of ammonium bisulfate formed as a by-product in the production of 2-hydroxy-4-methylthiobutanoic acid can be returned to and used in the course of the production process, specifically the step of hydration and/or hydrolysis of 2-hydroxy-4-methylthiobutyronitrile, whereby a process for producing 2-hydroxy-4-methylthiobutanoic acid substantially without producing waste water can be constituted. In the foregoing, the method for separating ammonium sulfate and ammonium bisulfate from each other according to the present invention was described with an example wherein the method was applied to the process for producing 2-hydroxy-4-methylthiobutanoic acid. However, the method for separating ammonium sulfate and ammonium bisulfate from each other according to the present invention can be applied not only to the process for producing 2-hydroxy-4-methylthiobutanoic acid but also to other processes in which sulfuric acid is used, for example, to the hydrolysis of acetone cyanhydrin, acrylonitrile, methacrylonitrile and the like; that is, the method can be similarly applied to an aqueous solution in which ammonium sulfate and ammonium bisulfate are present in admixture in such production processes. The conditions under which the method for the separation according to the present invention is to be applied are substantially the same as described in the above process for producing 2-hydroxy-4-methylthiobutanoic acid. In principle, no modification is needed depending on the process to which the method is applied. The method for separating ammonium sulfate and ammonium bisulfate from each other according to the present invention can also be applied to cases where ammonium sulfate and ammonium bisulfate are present as a mixture of powdery crystals. Specific methods to be used in such cases include, for example: a method which comprises adding a mixture containing ammonium sulfate and ammonium bisulfate to a mixed solution of water and a water-miscible organic solvent to dissolve ammonium bisulfate selectively and then subjecting the resulting mixture to a separating operation such as filtration, and a method which comprises first dissolving the mixture in water to form an aqueous solution of the two ammonium salts, then adding a water-miscible organic solvent to the solution to deposit ammonium sulfate selectively, and subjecting the resulting mixture to a separating operation, such as filtration. The former method is more preferably used than the latter method. Some embodiments of the present invention are described below with reference to accompanying drawings. FIGS. 1 and 2 are each a flow sheet showing one embodiment of the process for producing 2-hydroxy-4-methylthiobutanoic acid according to the present invention, as a block diagram. In FIG. 1, first a sulfuric acid solution is charged into a reaction vessel while stirring, then 2-hydroxy-4-methylthiobutyronitrile is added thereto, and the resulting mixture is aged for more than ten minutes to several hours while stirring, to cause hydration. To the resulting reaction mixture is then added a solution containing ammonium bisulfate obtained as described later, if necessary together with water, so that the concentration of the sulfuric acid initially charged may become about 25-40% by weight based on the reaction mixture excluding both organic substances and ammonium bisulfate, to cause hydrolysis. After completion of the hydrolysis, the reaction mixture may be kept at approximately the same temperature as the hydrolysis temperature for about more than ten minutes to several hours while stirring to conduct aging. Then the reaction mixture after hydrolysis is subjected to the next step of isolating the objective product, 2-hydroxy-4-methylthiobutanoic acid, from the reaction mixture. Specific examples of the method used in the step are the solvent extraction method shown in FIG. 1 and the layer separation method shown in FIG. 2. When the method of the solvent extraction is used, a water-immiscible solvent, such as methyl isobutyl ketone, is added to the reaction mixture to conduct the extraction and the resulting oil layer containing extracted 2-hydroxy-4-methylthiobutanoic acid, the objective product, and the resulting aqueous layer are separated from each other. The 2-hydroxy-4-methylthiobutanoic acid obtained by the extraction may be, according to necessity, purified by completely distilling off the water-immiscible solvent, such as methyl isobutyl ketone, by such operations as concentration under vacuum. The water-immiscible solvent, such as methyl isobutyl ketone, recovered by the distillation can be returned to the step of extracting 2-hydroxy-4-methylthiobutanoic acid. When the method of the layer separation is used, the reaction mixture after hydrolysis is, as such, separated into an oil layer containing 2-hydroxy-4-methylthiobutanoic acid and an aqueous layer. The 2-hydroxy-4-methylthiobutanoic acid may be purified by removing water from the oil layer containing 2-hydroxy-4-methylthiobutanoic acid obtained by the layer separation to concentrate the oil layer, and separating and removing thus deposited ammonium sulfate and ammonium bisulfate by such operation as filtration. In this case, when, in advance to concentrating the oil layer, ammonium bisulfate in the oil layer is converted to ammonium sulfate by adding ammonia to the oil layer, the above-mentioned separation and removal are facilitated. The ammonium sulfate and the ammonium bisulfate thus obtained can be mixed with the aqueous layer obtained by the layer separation after the hydrolysis as mentioned above and subjected, together with the aqueous layer, to a subsequent operation, e.g., a depositing operation by adding a water-miscible solvent. As described above, a water-miscible organic solvent is added to the aqueous layer obtained after separating 2-hydroxy-4-methylthiobutanoic acid from the hydrolysis reaction mixture by the solvent extraction method or the layer separation method, to deposit ammonium sulfate, which is then separated from the aqueous layer by such an operation as filtration. Then the water-miscible organic solvent is removed and recovered by such an operation as vacuum evaporation from the solution remaining after the separation of ammonium sulfate, to obtain a solution containing ammonium bisulfate. The ammonium bisulfate-containing solution thus obtained can be returned to the steps of the above-mentioned hydration and/or hydrolysis, and is used, together with sulfuric acid, for the hydration and/or hydrolysis in the steps. Although FIGS. 1 and 2 show examples wherein the recovered ammonium bisulfate-containing solution is returned to and is reused in the step of hydrolysis alone, the solution can also be returned to and be reused in the step of hydration alone or in both of the steps. Although the recovered ammonium bisulfate-containing solution is preferably entirely recycled and reused, it is not always necessary to recycle the whole amount and, if necessary from the operational balance, a part of the solution can be discarded as waste water. According to the process of the present invention set forth above, in the production of 2-hydroxy-4-methylthiobutanoic acid, ammonium bisulfate formed as a by-product is separated from ammonium sulfate and, without being discarded, is returned to and is reused in the reaction system of the production; resultantly the amount of sulfuric acid used can be reduced and the load of waste water can be greatly decreased. Thus, the invention is of great industrial value not only from the viewpoint of production cost reduction but also in environmental friendliness. The entire disclosure of Japanese Patent Application No. 9-49029 filed on Mar. 4, 1997 and Japanese Patent Application No. 9-248592 filed Sep. 12, 1997, both including specification, claims, drawings and summary, are incorporated herein by reference in their entirety. EXAMPLES The present invention is described in detail below with reference to Examples, but the invention is in no way limited thereto. The quantitative analyses of organic substances were made by liquid chromatography. The quantitative analyses of ammonium bisulfate and ammonium sulfate were made by neutralization titration with sodium hydroxide. Example 1 In 54.6 ml of water were dissolved 26.4 g (0.2 mole) of ammonium sulfate and 34.5 g (0.3 mole) of ammonium bisulfate. To the resulting solution (115.5 g) was added methanol at 20° C. in an amount of 30 g (a), 50 g (b), 70 g (C) or 100 g (d). Each of the resulting mixtures was stirred for 1 minute and white crystals thus formed were separated by filtration (samples (a) to (d)). As a Comparative Example, the above-mentioned solution was, without addition of methanol, concentrated by 30% under reduced pressure at 50° C., then cooled to room temperature and the deposit formed was separated by filtration (sample (e)). The respective deposits and filtrates thus obtained were analyzed for their composition. Table 1 shows the results. It reveals that use of a water-miscible organic solvent according to the method for separation of the present invention enables an effective separation of ammonium sulfate and ammonium bisulfate from each other. TABLE 1______________________________________ Ammonium AmmoniumAmount of sulfate bisulfatemethanol added (mole) (mole)______________________________________a) 30 g Deposit 0.1190 0.0078 Filtrate 0.0785 0.2855b) 50 g Deposit 0.1787 0.0117 Filtrate 0.0206 0.2867c) 70 g Deposit 0.1961 0.0086 Filtrate 0.0029 0.2929d) 100 g Deposit 0.1930 0.0110 Filtrate 0.0027 0.2861e) No Addition Deposit 0.1545 0.1857(comparative Filtrate 0.0391 0.1036Example)______________________________________ Example 2 Mixtures of ammonium bisulfate and ammonium sulfate with compositions shown in Table 2 were each dissolved in 34.5 ml of water. To each of the resulting aqueous solutions (64-65 g) was added 39 g of methanol at 20° C., the resulting mixture was stirred for about 1 minute and then the deposit thus formed was separated by filtration. The respective deposits and filtrates were analyzed for their composition, and the results are shown in Table 2. Table 2 reveals that, according to the method for separation of the present invention which uses a water-miscible organic solvent, ammonium sulfate and ammonium bisulfate can be efficiently separated from each other irrespective of the mixing ratio of ammonium sulfate to ammonium bisulfate. TABLE 2__________________________________________________________________________Composition of mixture used Ammonium bisulfate/ ammoniumAmmonium Ammonium sulfate Ammonium Ammoniumbisulfate sulfate (molar sulfate bisulfate(mole) (mole) ratio) (mole) (mole)__________________________________________________________________________0.2 0.05 4.0 Deposit 0.0483 0.0038 Filtrate 0.0 0.20520.15 0.1 1.5 Deposit 0.0920 0.0052 Filtrate 0.0007 0.14480.125 0.125 1.0 Deposit 0.1141 0.0046 Filtrate 0.0038 0.11410.1 0.15 0.67 Deposit 0.1383 0.0039 Filtrate 0.0052 0.0988__________________________________________________________________________ Example 3 48 Grams of methanol was respectively added to 80 g of an aqueous solution each containing 0.13 mole of ammonium sulfate and 0.165 mole of ammonium bisulfate while keeping the temperature of the solutions respectively at 30° C., 50° C. or 70° C. The resulting mixtures were stirred for about 30 seconds and then were rapidly filtered to separate the deposits formed. The respective deposits and filtrates were analyzed for their composition, and the results are shown in Table 3. Table 3 reveals that, according to the method for separation of the present invention which uses a water-miscible organic solvent, ammonium sulfate and ammonium bisulfate can be efficiently separated from each other irrespective of the temperature of separating treatment. TABLE 3______________________________________ Ammonium AmmoniumTreatment sulfate bisulfatetemperature (mole) (mole)______________________________________30° C. Deposit 0.115 0.007 Filtrate 0.013 0.15950° C. Deposit 0.102 0.006 Filtrate 0.025 0.15870° C. Deposit 0.094 0.005 Filtrate 0.035 0.159______________________________________ Example 4 To 50 g each of aqueous solutions each containing 0.07 mole of ammonium sulfate and 0.1 mole of ammonium bisulfate was respectively added 25 g of methanol, 50 g of methanol, 25 g of ethanol or 50 g of ethanol. The resulting mixture were stirred for about 1 minute and were respectively filtered to separate the deposits formed. The respective deposits and filtrates were analyzed for their composition, and the results are shown in Table 4. Table 4 reveals that, according to the method for separation of the present invention which uses a water-miscible organic solvent, ammonium sulfate and ammonium bisulfate can be efficiently separated from each other. TABLE 4______________________________________ Ammonium Ammonium sulfate bisulfate (mole) (mole)______________________________________Methanol Deposit 0.053 0.00325 g Filtrate 0.016 0.096Methanol Deposit 0.068 0.00350 g Filtrate 0.003 0.095Ethanol Deposit 0.037 0.00225 g Filtrate 0.034 0.098Ethanol Deposit 0.069 0.00450 g Filtrate 0.002 0.094______________________________________ Example 5 To a solution (a) consisting essentially of 35.5 g (0.25 mole) of 69 wt. % sulfuric acid and 11 g (0.1 mole) of ammonium bisulfate was added dropwise 65.5 g (0.5 mole) of 2-hydroxy-4-methylthiobutyronitrile over 1 hour, then the resulting solution was kept at 50° C. to cause hydration. The solution was sampled at time intervals to examine the change of the amount of 2-hydroxy-4-methylthiobutyronitrile remaining in the solution with the lapse of time. The results obtained are shown in Table 5. For comparison, an experiment was conducted in the same manner as described above except that a solution (b) consisting essentially of 35.5 g (0.25 mole) of 69 wt. % sulfuric acid was used in place of the solution (a) consisting essentially of 35.5 g (0.25 mole) of 69 wt. % sulfuric acid and 11 g (0.1 mole) of ammonium bisulfate. The results thus obtained are also shown in Table 5. Table 5 reveals that, according to the process of the present invention which uses sulfuric acid and ammonium bisulfate, 2-hydroxy-4-methylthiobutyronitrile is rapidly consumed and the hydration reaction proceeds rapidly. TABLE 5______________________________________Quantitative analysis of 2-hydroxy-4-methylthiobutyronitrileTime elapsedafterdropwiseaddition 0 hr 0.5 hr 1 hr 1.5 hr 2 hr 3 hr______________________________________Example 5 0.0654 0.0165 0.0062 0.0018 0.0007 0.0004(solution mole mole mole mole mole mole(a) wasused)Comparative 0.0880 0.0257 0.0102 0.0053 0.0025 0.0013Example mole mole mole mole mole mole(solution(b) wasused)______________________________________ Example 6 To a solution (a) consisting essentially of 94.7 g (0.25 mole) of 30 wt. % sulfuric acid and 28.8 g (0.25 mole) of ammonium bisulfate was added 75.1 g (0.5 mole) of 2-hydroxy-4-methylthiobutanamide to cause hydrolysis. The resulting solution was sampled at time intervals to examine the change of the amount of 2-hydroxy-4-methylthiobutanamide remaining in the solution with the lapse of time. The results thus obtained are shown in Table 6. For comparison an experiment was conducted in the same manner as described above except that a solution (b) consisting essentially of 98 g (0.3 mole) of 30 wt. % sulfuric acid was used in place of the solution (a) consisting essentially of 94.7 g (0.25 mole) of 30 wt. % sulfuric acid and 28.8 g (0.25 mole) of ammonium bisulfate. The results thus obtained are also shown in Table 6. Table 6 reveals that, according to the process of the present invention which uses sulfuric acid and ammonium bisulfate, 2-hydroxy-4-methylthiobutanamide is rapidly consumed and the hydrolysis reaction proceeds rapidly. TABLE 6______________________________________Quantitative analysis of 2-hydroxy-4-methylthiobutanamideTime elapsed 1 hr 2 hr 3 hr 4 hr______________________________________Example 6 0.0616 0.0200 0.0071 0.0031(Solution (a) mole mole mole molewas used)Comparative 0.0585 0.0331 0.0207 0.0123Example mole mole mole mole(Solution (b)was used)______________________________________ Example 7 To 90.5 g (0.6 mole) of 65 wt. % sulfuric acid was added dropwise 131.2 g (1.0 mole) of 2-hydroxy-4-methylthiobutyronitrile over 1 hour. During the dropwise addition and over a period of 2 hours after the addition, the temperature of the reaction mixture was adjusted to about 50° C. Thereafter 106 ml of an aqueous solution containing 46 g (0.4 mole) of ammonium bisulfate was added to the reaction mixture to adjust the concentration of sulfuric acid to 30% by weight based on the entire reaction mixture excluding both organic substances and ammonium bisulfate. The reaction mixture was then kept at a reaction temperature of 115° C. under reflux for 4 hours. The reaction mixture, while being kept at the high temperature, was subjected to an extracting operation using 160 g of methyl isobutyl ketone to obtain an oil layer containing 2-hydroxy-4-methylthiobutanoic acid and an aqueous layer. The aqueous layer obtained was subjected again to an extracting operation using 100 g of methyl isobutyl ketone. The oil layer thus obtained was combined with the oil layer obtained before. Methyl isobutyl ketone was distilled off from the combined oil layer to obtain 152 g of a liver brown liquid. It was confirmed by a liquid chromatographic analysis that an almost pure 2-hydroxy-4-methylthiobutanoic acid was obtained. Yield 94.5% (including the yield of dimer thereof). The above results reveal that, according to the process of the present invention which uses sulfuric acid and ammonium bisulfate, 2-hydroxy-4-methylthiobutanoic acid can be obtained in a high yield. Example 8 To 216 g of the aqueous layer obtained after two times of the extracting operations in Example 7 was added at room temperature 60% by weight, based on the aqueous layer, of methanol (130 g). Then 80 g of the deposit thus formed was removed by filtration to obtain 258 g of a filtrate. Methanol was distilled off from the filtrate under reduced pressure so as to give a total amount of the filtrate of 106 ml. The filtrate and the deposit were analyzed for their composition and the results are shown in Table 7. Table 7 reveals that, according to the method for separation of the present invention which uses a water-miscible organic solvent, ammonium sulfate and ammonium bisulfate can be efficiently separated from each other. TABLE 7______________________________________ Ammonium Ammonium bisulfate sulfate (mole) (mole)______________________________________Deposit 0.0524 0.4038Filtrate 0.4710 0______________________________________ Example 9 (1) To 90.5 g (0.6 mole) of 65 wt. % sulfuric acid was added dropwise 131.2 g (1.0 mole) of 2-hydroxy-4-methylthiobutyronitrile over 1 hour, and the mixture was allowed to react at 5° C. for 2 hours. (2) To the reaction mixture was added about 106 ml of a filtrate obtained in the same manner as in Example 8, and the resulting solution was kept at 115° C. under reflux for 4 hours. (3) Then the solution was subjected to an reacting operation by using 0.4 time by weight of methyl isobutyl ketone based on the solution to obtain an oil layer containing 2-hydroxy-4-methylthiobutanoic acid and an aqueous layer. The aqueous layer obtained was subjected to an extracting operation again by using 0.4 time by weight of methyl isobutyl ketone based on the aqueous layer, and the oil layer thus obtained was combined with the oil layer obtained before. The combined oil layer was washed with 50 ml of water, and then methyl isobutyl ketone was distilled off under reduced pressure from the oil layer to obtain 2-hydroxy-4-methylthiobutanoic acid. On the other hand, (4) the aqueous layer obtained after two times of the extracting operations was subjected to the same operation as in Example 8 to obtain 106 ml of a filtrate containing ammonium bisulfate as the main component and a deposit. (5) Then the procedures of (1) through (4) described above were repeated except that 106 ml of the filtrate obtained above was used in the procedure of (2), that is, the solution containing ammonium bisulfate as the main component was recycled and reused, to obtain 2-hydroxy-4-methylthiobutanoic acid. These procedures were repeated two times (that is, the procedures of (1) through (4) were conducted three times in all). The yield of 2-hydroxy-4-methylthiobutanoic acid obtained each time in the procedure (3) and the compositions of the filtrate and the deposit obtained each time in the procedure (4) are summarized in Table 8. Table 8 reveals that, according to the method for separation of the present invention which uses a water-miscible organic solvent, ammonium sulfate and ammonium bisulfate can be efficiently separated from an aqueous solution containing ammonium sulfate and ammonium bisulfate formed in the production of 2-hydroxy-4-methylthiobutanoic acid, and that the ammonium bisulfate obtained by the above-mentioned separation can be returned to and used in the production of 2-hydroxy-4-methylthiobutanoic acid without lowering the yield of the acid and without lowering the efficiency in separating ammonium sulfate and ammonium bisulfate from each other. TABLE 8__________________________________________________________________________2-Hydroxy-4- Deposit Filtratemethyl- Ammonium Ammonium Ammonium Ammoniumthiobutanoic bisulfate sulfate bisulfate sulfateacid yield *) (mole) (mole) (mole) (mole)__________________________________________________________________________1st Time92.1% 0.0570 0.4120 0.5252 02nd Time91.7% 0.0620 0.4066 0.6118 03rd Time91.8% 0.1398 0.4138 0.6270 0__________________________________________________________________________ Note: *) yield including that of dimer
A process for producing 2-hydroxy-4-methylthiobutanoic acid which includes conducting hydration and successive hydrolysis of 2-hydroxy-4-methylthiobutyronitrile in a reaction system containing 2-hydroxy-4-methylthiobutyronitrile and sulfuric acid, ammonium bisulfate being added to the reaction system at the time of the hydration and/or the hydrolysis, acquiring 2-hydroxy-4-methylthiobutanoic acid from the resulting organic layer, adding a water-miscible organic solvent to the by-produced aqueous layer to deposit ammonium sulfate, and separating and removing the ammonium sulfate from ammonium bisulfate, thereby permitting recycling and reusing of ammonium bisulfate, reduces the amount of sulfuric acid used, produces substantially no waste water containing sulfates and is of a low production cost and environmentally friendly.
2
[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 10/733,806 filed Dec. 10, 2003. FIELD OF THE INVENTION [0002] The present invention relates generally to golf mats, and more particularly to a golf mat having an artificial turf including a plurality of groups of fibers, each group including both non-linear fibers and substantially straight fibers sewn into a backing through a common opening, and having infill particles adhered to the non-linear fibers and lower portions of the straight fibers. DESCRIPTION OF THE PRIOR ART [0003] Golf mats for use as a practice playing surface are most effective if they simulate the feel of natural turf. A variety of mat constructions have been designed for this purpose. U.S. Pat. No. 6,156,396 uses a relatively thick base pad of resilient material (foam rubber), and an artificial grass-like carpet that is slidably positioned on the base so as to absorb club force, which is more like a natural turf than a rigidly mounted carpet. [0004] U.S. Pat. No. 5,830,080 by Reynolds discloses a turf simulating surface including a grass-like carpet layer placed over layers of material, each layer designed to simulate the shock absorbing nature of corresponding layers of soil. [0005] U.S. Pat. No. 4,497,853 by Tomarin, and U.S. Pat. No. 3,995,079 by Haas, Jr. also include layers of shock absorbing material beneath a grass simulating carpet. They also place granules, such as sand and/or rubber particles, covering/coating a lower portion of the grass-like carpet, giving support for the grass-like fibers and simulating the effect of soil. A disadvantage of the loose infill covering/coating in a golf mat is that it is displaced when impacted by a club head, which can result in undesirable variations in the infill depth, and air-born particles that can be irritating to the golfer. SUMMARY [0006] It is an advantage of this invention in that it provides a golf playing surface having an improved stability. [0007] It is a further advantage of this invention in that it provides a golf mat with improved durability. [0008] It is a still further advantage of this invention in providing a golf mat wherein a club stroke does not bottom out in the mat. [0009] It is another advantage of this invention in providing a golf mat with improved shock absorption when a club head strikes the mat. [0010] It is another advantage of this invention in that it provides a golf mat that will hold a golf ball tee without drilling a hole in the mat. [0011] In one embodiment of this invention, a golf mat includes artificial grass fibers attached to and extending upward from a backing material, which may be one or more layers. The artificial grass fibers include groups of at least two different kinds of fiber sewn through a common path in the backing material. One of the kinds of fibers in each group is shaped so as to appear like a blade of grass. The other kind of fiber in each group is pre-stressed/crimped so that the relaxed shape of the fiber is nonlinear, resembling a curlicued or articulated form having lateral excursions. The lateral excursions cause portions of one such pre-stressed fiber to overlap and interfere with another, forming a mesh. The height of the pre-stressed fibers in their relaxed state in the turf is less than the height of the relatively unstressed artificial grass fiber(s). The crimped fibers form a resilient mat with impact characteristics similar to natural turf. BRIEF DESCRIPTION OF THE DRAWINGS [0012] FIG. 1A illustrates a golf mat formed with artificial turf according to the present invention; [0013] FIG. 1B is an enlargened view of a portion of FIG. 1A configured for illustrating the construction of the mat of FIG. 1A ; [0014] FIG. 2 illustrates a golf tee held by the golf mat; [0015] FIG. 3 illustrates two fibers through one needle, and fiber tension; [0016] FIG. 4A shows one type of artificial grass fiber construction; and [0017] FIG. 4B shows the fiber of FIG. 4A rolled up. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0018] While the present invention will be described herein with reference to particular embodiments thereof, a latitude of modifications, various changes and substitutions are intended, and it will be appreciated that in some instances some features of the invention will be employed without a corresponding use of other features without departing from the spirit and scope of the invention as described with respect to the preferred embodiments set forth herein. [0019] A golf mat 10 of the present invention is shown in FIG. 1A , having artificial turf 11 . FIG. 1B is an enlargened view of a section “A” of the mat of FIG. 1A for illustrating the construction of the artificial turf 11 , and also showing alternative base layers 13 which can be of any number, thickness and resiliency. The artificial turf 11 includes a backing material 12 with two different kinds of fiber 14 and 16 sewn into it. Groups of fibers, each group including at least one grass-like fiber 14 and one non-linear fiber 16 pass through the same passages 18 through the backing 12 . Fiber 14 is an artificial grass blade that can be constructed in a number of ways to give the turf a grass-like appearance. Fiber 16 is pre-stressed into a non-linear shape. The tops 20 and 22 of the fibers are cut, forming cut ends, and thereby forming a “cut fiber” carpet/artificial turf, resulting in the fiber 14 appearing grass-like. The fibers 14 are relatively un-stressed and have only minor deviations from linearity, similar to a linear/straight grass blade appearance. Fibers 16 are pre-stressed prior to being sewn into the backing 12 , and upon being sewn into the backing 12 and released from the sewing machine, they return to a non-linear shape. The sewing machine applies tension to the fiber 16 , holding it in a linear shape as it is sewn. Once released by the sewing machine, the fibers 16 retract into their pre-stressed non-linear shape, causing them to form a mesh of fibers at a level below that of the straight fibers 14 as shown in FIG. 1 . In this way, the fiber mesh including a lower portion of the fibers 14 and the fibers 16 resembles grass thatch. The golf mat therefore provides a resistance that is similar to natural grass turf when a golf club head impacts the mat. The club head first impacts the taller, grass-like fiber portions that extend above the height of the non-linear fibers 16 . These portions provide resistance to the club head in a similar manner to natural grass. If the upper portion of grass-like fibers 14 does not stop the club head, the head then impacts the mesh, consisting of lower portions of the fibers 14 and the non-linear fibers 16 , which provides further resistance to the club head, similar to a club head hitting the thatch in natural turf. The non-linear fibers 16 have lateral excursions, for example as indicated by the letters “x” for one fiber 16 in FIG. 1B . FIG. 1B shows 10 groups, such as group 17 of fibers, with each group of fibers sewn through a common path 18 through the backing 12 . The fibers 16 and group spacing “S” are configured so that the lateral excursion of one such fiber 16 of one group overlaps the lateral excursion of a fiber 16 from an adjacent group, and forms a mesh of overlapping fibers 16 . For example, note that the excursion of fiber 16 A of one group overlaps the excursion of fiber 16 B from an adjacent group. The height of the installed non-linear fibers 16 is noted as “H 2 ” which is less than the height H 1 of the grass-like fibers. A preferred height H 1 is ⅞ inch, and a preferred range of H 1 is from ⅞″ to 3″ A preferred height of H 2 is ⅝ inch, and a preferred range of H 1 is from ⅝″ to 2½″ For the golf mat as disclosed, the fibers are preferably sewn with a stitch spacing S in the range of 0.350″ to 0.375″ with a preferred spacing of 0.350″, but other values of S are also included in the present invention. The combination of the grass-like fibers 14 and non-linear fibers 16 provides a shock absorbing and somewhat resilient layer, similar to that experienced on natural turf which generally has a layer of shock absorbent thatch. The tufted carpet/golf mat shown in FIGS. 1A and 1B as described includes the fibers 14 and 16 which are yarns/threads of synthetic material such as polypropylene, polyethylene, nylon or other synthetic yarns. The structure of FIGS. 1A and 1B is an improvement over the prior art in that it is more durable, is more grass-like in appearance and structure, and provides more cushion. Although two different yarns/fibers are shown sewn through common openings in the backing 12 , the present invention also includes other numbers of yarn/fibers sewn through common openings. The fibers/yarn can have different constructions, denier, twist, and crimp. The golf mat shown is rectangular, but it can be of any shape, including square, octagonal, rectangular, etc. The method of construction of the golf mat 10 differs from the prior art in that it is sewn with multiple yarns through a single needle eye. This will be illustrated more clearly in reference to FIG. 3 . [0020] The layer of height H 2 including the crimped/non-linear fibers 16 forms a cushion resembling natural grass thatch, and reduces shock and resists bottoming out of a golf club stroke. This reduced shock and resistance to bottoming out is a significant improvement over artificial turf having only fibers similar to the grass-like fibers 14 . [0021] Another useful feature/embodiment of the present invention is illustrated in FIG. 2 , wherein a golf mat 26 constructed as described above, has a lower, more dense portion 27 with fibers including both the straight 14 and crimped 16 fibers, that is sufficiently dense so as to hold a golf tee 28 erect with a golf ball 30 thereon as shown. A preferred height H 1 of the grass-like fibers is approximately ⅞ inch, with a preferred height range of ⅞″ to 3″. A preferred height range of H 2 of the crimped fibers is ⅝ inch, with a preferred range of ⅝″ to 2½″. A preferred weight of the mat, not including alternative layers 13 , is in the range of 60 to 90 ounces per square yard. The structure shown in FIG. 2 avoids the need for prior art structures such as drilling a hole in the mat for holding a golf tee, or using a vertical rubber tube for simulating a golf tee. [0022] During the sewing process, fibers 14 and 16 are both threaded together through the same sewing machine needle passages, and therefore pass through the same passages 18 through the backing through which the needle is inserted. Axial/longitudinal tension is provided on the fibers 14 and 16 by the sewing machine, which keeps both fibers 14 and 16 in a controlled/tensioned line, and most importantly, fibers 16 are held in an uncrimped, straight line. Upon being sewn into the backing 12 , the tension on fiber 16 is released and it returns to its pre-stressed/crimped condition, that could be described as curlicued. [0023] In one embodiment, the fibers 14 are constructed of polyethylene and fibers 16 of nylon. The polyethylene has a slick surface similar to a grass blade, which provides comparable resistance to a golf club head when the turf is in a golf mat. In a further embodiment of the present invention, the turf 11 can be a playing field such as a football field, and the slick surface helps avoid a player from twisting an ankle, which would more easily occur if the turf has a high coefficient of friction. The dimensions of the stitch spacing S and row spacing R, are preferably selected along with the design of the pre-stressed shape of the fiber 16 , so that lateral excursions of a fiber 16 from one passage 18 overlap the excursions of a fiber 16 from an adjacent passage 18 . In this way, in one embodiment an effective mesh of fiber 16 is formed to hold a golf tee. The density of fibers and fiber overlap can also can be configured so as to resemble natural turf. [0024] FIG. 3 is provided to illustrate the tension applied to the fibers 14 and 16 during the process of sewing. The initial ends 32 of the fibers 14 and 16 are secured during the process. The needle 34 is inserted through the backing 12 , taking both fibers 14 and 16 through a common passage 18 . A hook 36 grabs the loop of fibers and keeps the fibers from retracting back through the passage 18 as the needle 34 is retracted. The sewing machinery then inserts the needle 34 through the backing again at a stitch space “S” ( FIG. 1B ) from the first space 18 and the hook 36 grabs the material again. A cutting tool (not shown) follows along or is integrated with the hook apparatus 36 and cuts the loop ends 38 , at which time the tension on the cut fiber 16 is released and the fiber 16 returns to its curlicued/non-linear state as shown in FIG. 1B . [0025] In one embodiment, the fibers 14 are constructed of polyethylene, and extend upward from the backing a distance H 1 of approximately ⅞ inches. The retracted, rest state curlicued fibers 16 extend upward from the backing a distance H 2 of approximately ⅝ inches. Other dimensions are also included in the spirit of the present invention, as will be apparent to those skilled in the art. In general, the height H 2 of the curlicued fiber 16 must be shorter than the height of the relatively straight fiber 14 . [0026] As described above, the straight fiber 14 may be constructed from polyethylene, which provides a slippery surface similar to grass. Other materials that simulate the grass-like property of low resistance/friction are also included in the spirit of the present invention. The nylon fiber 16 is selected to be resilient. Other materials for fiber 16 are also included in the spirit of the present invention. [0027] The grass-like fibers 14 can be constructed in a variety of ways that will be apparent to those skilled in the art for use in the turf/mat of the present invention, and the present invention includes the use of these constructions in the turf structure as described in reference to the figures of the present disclosure. FIG. 4A illustrates the construction of one type of grass-like structure for use as an artificial grass blade. A length of polyethylene or other material of width “W” is sliced through in places 40 as indicated. The material is then rolled up, or pre-stressed to automatically roll up, as indicated in FIG. 4B , and when sewn into an artificial turf “backing”, it resembles a blade of grass. [0028] While the present invention has been described herein with reference to particular embodiments thereof, a latitude of modifications, various changes and substitutions are intended in the foregoing disclosure, and it will be appreciated that in some instances some features of the invention will be employed without a corresponding use of other features without departing from the spirit and scope of the invention as set forth in the appended claims.
A golf mat includes artificial grass fibers attached to and extending upward from a backing material, which may be one or more layers. The artificial grass fibers include groups of at least two different kinds of fiber sewn through a common path in the backing material. One of the kinds of fibers in each group is shaped so as to appear like a blade of grass. The other kind of fiber in each group is pre-stressed/crimped so that the relaxed shape of the fiber is nonlinear, resembling a curlicued or articulated form having lateral excursions. The lateral excursions cause portions of one such pre-stressed fiber to overlap and interfere with another, forming a mesh. The height of the pre-stressed fibers in their relaxed state in the turf is less than the height of the relatively unstressed artificial grass fiber(s). The crimped fibers form a resilient mat with impact characteristics similar to natural turf.
4
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/454,552 filed Mar. 14, 2003, which is incorporated herein in its entirety by this reference. FIELD OF THE INVENTION [0002] The invention resides in the field of nanoparticles, particularly triangular nanoframes that may be backfilled to form nanoprisms having nanopores. BACKGROUND OF THE INVENTION [0003] Metallic nanoparticles have generated significant scientific and technological interest due to their unusual optical properties, as well as their novel chemical and catalytic properties. Nonspherical particles, and in particular anisotropic particles, are of major interest because they allow investigation of how shape affects the physical and chemical properties of such structures. A variety of shapes, including stars, cubes, rods, discs, and prisms, have been fabricated, and their properties have been preliminarily characterized. Hollow nanoparticles are an interesting emerging class of materials that will help to better understand the structure-property relationship in nanoparticles. [0004] Although a significant amount of work has been done in developing synthetic methods for hollow spheres, cubes, and rods, little has been done with triangular nanostructures. In copending patent application (Publication No. 20030136223) the current inventors disclosed a novel process in which silver nanospheres were converted, via a photomediated reaction, to larger silver nanoprisms. Xia and coworkers have demonstrated the production of hollow forms of cubes and rods, but have not disclosed a method of making frames from nanoprisms. [0005] Thus, there remains a need for a method of generating triangular nanoframes. Preferably, the method would be operative on nanoprisms formed by known methods and applicable in a face-selective manner allowing the generation of triangular two-component nanostructures with filled or partially-filled cores. SUMMARY OF THE INVENTION [0006] The present invention provides a method of forming a triangular nanoframe including the step of etching a nanoprism with a salt to form a nanotriangle. The nanoprism may be silver and the salt may be a metal salt such as HAuCl 4 . Preferably, the triangular nanoprism is contacted with the salt in a suspension of nanoprisms to which the salt is added dropwise. [0007] The present invention also provides a method of narrowing or closing the pore in the triangular nanoframe by contacting the nanoframe with a reducing agent in the presence of the salt. Using this method, the walls of the nanoframe can be thickened to leave a narrow pore through the nanoframe. Typically, the pore has a diameter of less than about 35 nm and preferably between about 4 nm and about 14 nm. The thickness of the nanoframe is typically between about 10 nm and about 15 nm. The reducing agent is preferably a mild reducing agent such as ascorbic acid. The nanoframe may be repeatedly contacted with the salt to progressively thicken the walls of the nanoframe and reduce the diameter of the pore. If the contact with the reducing agent in the presence of a salt is repeated several times, the method of the present invention results in the reproduction of nanoprisms. [0008] The present invention also provides triangular nanoframes having an edge length of less than about 200 nm and a thickness of less than about 100 nm and a pore through the center of the nanoframe. The triangular nanoframes have an edge length between about 70 nm and about 80 nm, a thickness between about 5 nm and about 15 nm, and a pore size between about 5 nm and about 35 m. [0009] The present invention also provides triangular nanoframes made by the process of etching a nanoprism with a salt to form a nanotriangle. In this embodiment, the nanoprism is preferably a silver nanoprism and the salt is preferably HAuCl 4 . BRIEF DESCRIPTION OF THE DRAWINGS [0010] FIG. 1 shows a scheme of nanoframe synthesis. In step A, silver nanoprisms are etched with aqueous HAuCl 4 . Subsequent addition of L-ascorbic acid (step B) causes gold and silver ions in solution to crystallize primarily on the inner walls of the nanoframes, causing the central pore to shrink in size. This gold salt/L-ascorbic acid cycle (Steps A+B) can be repeated to progressively shrink the size of the central pore. [0011] FIG. 2 shows gold-silver nanoframes; A) UV-visible spectra of triangular nanoframes with varying Au:Ag ratios and B-D) tunneling electron microscope (TEM) images of gold-silver nanoframes; B: Au:Ag ration of 1:9; C: Au:Ag ratio of 1:5; D: Au:Ag ratio of 1:3. [0012] FIG. 3 shows UV-visible spectra and TEM images monitoring the back-filling process of silver and gold nanoframes having a Au:Ag ratio of 1:9. A,D) After addition of L-ascorbic acid to the triangular nanoframes. B,E) After 2 cycles of HAuCl 4 /L-ascorbic acid. C,F) After 3 cycles of HAuCl 4 /L-ascorbic acid. DETAILED DESCRIPTION OF THE INVENTION [0013] The methods of the present invention produce triangular nanoparticles with a hollow center resembling a nanotriangle. The methods of forming triangular nanoframes include etching a nanoprism with a salt to form a nanotriangle. The nanoframes may be exposed to a reducing agent in the presence of the salt causing backfilling of the hollow center of the nanoframe and thickening of the walls of the nanoframe. Repeated exposure to a reducing agent in the presence of a salt may progressively backfill the entire hollow cavity of the triangular nanoframe to form a solid triangular structure or reform a nanoprism. [0014] The methods of the present invention form a new class of nanostructures, metallic triangular nanoframes. Additionally, the etching is face-selective and the etching and novel back-filling process results in the formation of triangular nanoframes and prisms with different compositions. Also, in a preferred embodiment, these synthetic methods result in the conversion of silver nanoprisms to gold-silver alloy nanoprisms, which are otherwise not accessible via thermal and photochemical methods for making monometallic nanoprisms. [0015] The methods of the present invention take advantage of the large difference in reduction potential of the two reactants—the molecules forming the nanoprisms and the salt. Preferably, the nanoprisms are a metal such as silver and the salt is a metal such as gold. The disparity in the reduction potential of the Ag+/Ag pair (0.8 V, vs. SHE) and AuCl 4− /Au pair (0.99V, vs SHE), results in the oxidization and etching of the silver nanoprisms by gold ions in a type of nano-Galvanic cell reaction. Surprisingly, this method does not yield hollow nanoprisms, as would be expected using the techniques of the prior art, but rather generates triangular-shaped frames with solid walls and a hole in the center ( FIG. 1 , Step A). Triangles are formed because this etching approach is selective for the [ 111] faces of the silver nanoprism over the [ 110] crystal plane that makes up the edges. Without intending to be bound by any one theory, this may be due to the fact that the initial nanoprism particles have thickness of only about 10 nm or that the reaction conditions are milder than those of the prior art methodology. Additionally, these structures can be backfilled to generate nanoprisms incorporating the components of the nanoframe and the salt. In the instance of a silver nanoprism and a gold salt, the nanoframes can be backfilled with gold to generate gold-silver alloy nanoprisms. Notably, these etching processes of the present invention are not observed with all metal ions. For example silver nanoprisms are not etched in a H 2 PtCl 6 salt solution, possibly due to the relatively large lattice mismatch between platinum and silver (Pt=3.9231 Å, Ag=4.0862 Å). [0016] The nanoprisms which represent the starting materials for the methods of the present invention have an edge length of less than about 200 nm and preferably less than about 100 nm. More preferably, these nanoprisms have an edge length of less than about 80 nm and most preferably have an edge length of between about 70 nm and about 80 nm. These nanoprisms have a thickness of less than about 100 nm and preferably less than about 25 nm. More preferably, these nanoprisms have a thickness of less than about 20 nm and most preferably have a thickness of between about 5 nm and about 15 nm. The nanoprisms may be composed of any substance that is effectively etched by the salt. Typically, the nanoprism is a metal nanoprism and preferably the nanoprism is a Group VIII, IB or IIB metal and most preferably, the nanoprism is a silver nanoprism. The nanoprisms may be made by any suitable method and methods of making metal nanoprisms suitable for use in the methods of the present invention are known in the art (Jin et al. Science 294:1901 (2001); co-pending U.S. patent application 20030136223). [0017] The nanoprisms are preferably diluted in an aqueous solution to a concentration that will prevent agglomeration of the nanoframes formed in the methods of the present invention. Typically, the nanoprisms are suspended in water at a concentration between about 1 M and about 30M. Preferably, the nanoprisms are diluted to a concentration of between about 15 M and about 20 M prior to contact with the reducing agent. [0018] The nanoprisms are contacted with a salt to etch the nanoprism to form nanoframes. The salt may be any suitable salt with a greater reduction potential than the composition of the nanoframes. Typically, the salt is a metal salt, and preferably the salt is a Group VIII, IB or IIB metal salt and most preferably, the salt is a gold salt such as HAuCl 4 . This contact is best initiated by slow or dropwise addition of the salt to the nanoprism suspension, preferably with rapid stirring of the nanoprism suspension. The amount of salt to add to the suspension of nanoprisms should be calculated by the ratio of the reductant within the salt and the chemical composing the nanoframes. For example, in the embodiment of the present invention in which silver nanoprisms are etched with HAuCl 4 , the gold salt should be added to achieve a ratio of gold to silver (Au:Ag) between about 1:2 to about 1:10. Preferably, the Au:Ag is about 1:5. In many instances, the gold content of the suspension can be monitored by the color of the resulting suspension. For example, in the instance of silver nanoprisms etched with HAuCl 4 , as the gold salt is added, the turquoise-blue color of the silver nanoprism colloid gradually changes to purple and finally to blue or grey. Samples with low gold content (Au:Ag=1:9) form pale blue solutions and exhibit a low intensity, broad surface plasmon band around 775 nm. In contrast, colloids containing high gold concentrations (Au:Ag=1:5 to 1:3) are pale grey (essentially colorless) and display no strong surface plasmon bands in the UV-visible spectrum ( FIG. 2A ). [0019] Without intending to be bound by any one theory, it is believed that because nanoprisms possess well-defined crystal faces (instead of the highly faceted surfaces typical of “spherical” nanoparticles), the salt etches in a face-selective manner in which the prism face ([111] crystal plane) is selectively oxidized over the nanoprism edges ([110] planes). This explanation would account for the retention of the triangular shape of the initial silver nanoprisms while the gold salt etches the central silver matrix. Transmission electron microscopy (TEM) images after salt addition confirm that the resulting nanostructures are triangular in shape with hollow centers ( FIG. 2B -D). The wall width of the triangular nanoframes formed refers to the width of the nanoframe vertice (when viewed from above) whereas the thickness of the triangular nanoframes refers to the height of the particle (perpendicular to its longest dimension). The pore in the triangular nanoframes refers to the passage through the center of the nanoframe and the pore size refers to the diameter of that hole. The wall width of the nanoframe increases slightly with the increasing content of the salt in the suspension. The thickness of the nanoframes is similar to that of the nanoprisms from which they are derived. [0020] In another embodiment of the present invention, methods of filling the hollow center of the triangular nanoframes have been devised to change the size of the central pore ( FIG. 1 , Step B). In this embodiment, the nanoframes are contacted with a mild reducing agent. The reducing agent causes materials removed from the nanoprisms to be reduced and agglomerate once again to the nanoframe. This causes the walls of the nanoframes to thicken and reduces the size of the central pore. As shown in FIG. 3 , subsequent additions of the salt followed by the reducing agent ( FIG. 1 , Steps A and B), are performed to progressively reduce the size of the pore in the triangular nanoframes. Typically, the pore size is in the range between about 5 nm and about 35 nm. Referring to FIG. 3 , note how the pore size becomes gradually smaller with an increasing number of cycles. Part of the material added back to the nanoframe can include the salt originally used to etch the nanoprism. Any mild reducing agent is suitable for use in the present invention. Examples of suitable reducing agents include sodium formaldehyde sulfoxylate, 2-mercaptoethanol, cysteine hydrochloride, sodium thioglycolate, hydroquinone, p-aminophenol and ascorbic acid. An exemplary reducing agent is ascorbic acid as this chemical is a mild reducing agent, nontoxic, and inexpensive. The reducing agent is added in excess, preferably dropwise to the stirring suspension of nanoframes. For example, in the instance of silver nanoframes etched with HAuCl 4 , successive additions of ascorbic acid and HAuCl 4 results in a gold and silver alloy triangular nanoframe with a partially or completely filled pore. As the pore closing occurs, the metal ions (gold and silver) seem to primarily crystallize on the inner walls of the nanoframe. The faces and edges of the gold nanoprisms are rough in texture and their corners are truncated. The average edge length of the gold-silver alloy nanoprisms is between about 30 nm and about 80 nm. Typically, the average edge length of the gold-silver alloy nanoprisms is about 60 nm. [0021] The UV-visible spectrum of the filled nanoframes can be monitored to review the progress of the pore closing. In the case of silver nanoframes, the UV-visible spectrum is red-shifted and dampened with respect to the pure silver nanoprisms ( FIG. 3C ). This is the same phenomenon observed in spherical Au—Ag alloy nanoparticles in which the surface plasmon band of silver nanoparticles is redshifted and dampened with increasing amounts of gold. Hence, this UV-visible data confirms that Au—Ag alloy nanoprisms are formed. EXAMPLES Example 1 [0022] This example demonstrates the production of silver triangular nanoframes. Silver nanoprisms having an edge length of about 74 nm (σ=13%, N=200) and a thickness of about 9 nm (σ=27%, N=46) were prepared as described previously (U.S. patent application Publication No. 20030136223 incorporated herein by this reference). The silver nanoprism colloid was synthesized from a 0.1 mM AgNO 3 solution. The Au:Ag molar ratios were calculated assuming that the silver concentration was 0.1 mM. 10 mL of silver nanoprisms were diluted with pure water to one-fifth the starting concentration (18.2M). This was done to prevent aggregation of the resulting Ag/Au triangular nanoframes. Under ambient conditions, aqueous HAuCl 4 (5 mM) was added dropwise to the rapidly stirring colloid. As the gold salt was added, the turquoise-blue color of the colloid gradually changed to purple and finally to blue or gray. Samples with low gold content (Au:Ag=1:9) formed pale blue solutions and exhibited a low intensity, broad surface plasmon band around 775 nm. In contrast, colloids containing high gold concentrations (Au:Ag=1:5, 1:3) were pale gray (essentially colorless) and displayed no strong surface plasmon bands in the UV-visible spectrum ( FIG. 2A ). Transmission electron microscopy (TEM) images after gold addition showed that the resulting nanostructures were triangular in shape with hollow centers ( FIG. 1B -D). [0023] Both wall width and thickness were measured. The wall width of the nanoframes increased slightly with gold content; 7.7 nm (σ=11%, N=245) for Au:Ag=1:9 and 10.3 nm (σ=21%, N=230) for Au:Ag=1:3. The thickness of the gold-silver nanoframes (10 nm, σ=20%, N=24) was similar to that of the pure silver nanoprisms starting materials (9 nm). TEM analysis at high magnification (200,000×) revealed that the center of each nanoframe was indeed hollow, the amorphous carbon film of the TEM support grid could be clearly seen in the underlying area. Tapping mode atomic force microscopy (AFM) analysis (using a Nanoscope III AFM, Digital Instruments) also confirmed that these nanoframes were hollow structures. Example 2 [0024] This example demonstrates protocols that control the optical properties of the nanoframes, by changing the size of the central pore. A mild reducing agent, L-ascorbic acid, was used to reduce gold and silver ions in solution (generated from the first addition of gold salt) onto the triangular nanoframes of Example 1, causing the walls to thicken and the central pore to shrink ( FIG. 1 , Step B). Subsequent additions of HAuCl 4 followed by L-ascorbic acid ( FIG. 1 , Steps A and B), were performed to progressively reduce the size of the triangular nanoframe pore. [0025] In a typical experiment, an excess of L-ascorbic acid (1 mL, 5 mM) was added dropwise to a rapidly stirring colloid of two-component nanoframes (50 mL, Au:Ag=1:9 nanoframes). After addition of the reducing agent, the pale blue colloid gradually became turquoise, as evidenced by an increase in intensity accompanied by a blue-shift in the absorption band from 775 nm to 650 nm in the UV-visible spectrum of the solution ( FIG. 3A ). Growth of a second band centered at 463 nm was also observed. The observed change in the UV-visible spectrum is consistent with silver ions, generated from the initial etching process with gold, being reduced back onto the nanoframe. A second aliquot of HAuCl 4 (22 μL, 5 mM) was added dropwise, followed by more L-ascorbic acid (1 mL, 5 mM). The surface plasmon bands associated with the partially filled triangles, at 650 nm and 463 nm, red-shifted to 665 nm and 480 nm, respectively ( FIG. 3B ). The third and final addition of HAuCl 4 (22 μL, 5 mM) and L-ascorbic acid (1 mL, 5 mM) caused the most intense band at 665 nm to further red-shift to 693 nm ( FIG. 2C ). The shorter wavelength band also red-shifted to 508 nm but became a shoulder on the main surface plasmon band. The red-shift observed after the second and third HAuCl 4 /L-ascorbic acid additions was consistent with gold ions being reduced onto the nanoframe. Reduction of gold ions onto the nanoframe walls is responsible for the “backfilling” of the nanoframes to form alloy nanoprisms. The change in pore size of the triangular nanoframes as a function of Au deposition was monitored by TEM ( FIG. 3 D-F). After the first reduction, the pore size decreased from about 33 nm (σ=23%, N=286) to about 14 nm (σ=16%, N=695). The second addition of gold salt followed by reduction, generated triangular nanoframes with average pore sizes of about 7 nm (σ=14%, N=744). After the third gold/reduction cycle, many of the nanoframes were completely filled, and the remaining particles possessed average pore sizes of about 4 nm (σ=13%, N=659). After one cycle of HAuCl 4 /L-ascorbic acid, the thickness of the nanoframes increased from approximately 10 nm (σ=13%) to 12.4 nm (σ=11%, N=89). After three HAuCl 4 /L-ascorbic acid cycles, the thickness had increased to about 15.2 nm (σ=10%, N=8). The UV-vis spectrum of the filled nanoframes was red-shifted and dampened with respect to the pure silver nanoprisms ( FIG. 3C ). TEM-Energy Dispersive X-ray (EDX) analysis confirmed that the back-filled nanoprisms were gold-silver alloys. The average edge length of the gold-silver alloy nanoprisms is approximately 63 nm. [0026] The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and the skill or knowledge of the relevant art, are within the scope of the present invention. The embodiment described hereinabove is further intended to explain the best mode known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
The present invention provides nanoprisms etched to generate triangular framework structures. These triangular nanoframes possess no strong surface plasmon bands in the ultraviolet or visible regions of the optical spectrum. By adding a mild reducing agent, metal ions remaining in solution can be reduced, resulting in metal plating and reformation of nanoprisms. The extent of the backfilling process can be controlled, allowing the formation of novel nanoprisms with nanopores. This back-filling process is accompanied by a regeneration of the surface plasmon bands in the UV-visible spectrum.
1
BACKGROUND OF THE INVENTION This invention relates to prosthetic devices for mounting to bone tissue, and particularly to such devices useful in artificial dental implants. Prior U.S. Pat. No. 3,576,074 to Gault et al., discloses a dental implant which includes a root portion consisting of an open lattice cage containing a dowel receiving central tubular section. In accordance with the disclosure of Gault, the root portion is placed within the root cavity which remains after tooth extraction and is held in place until subsequent bone growth encapsulates the lattice cage to anchor the root portion to the surrounding bone. Following firm anchoring of the root portion, a crown portion may be attached. The Gault procedure calls for implantation and enclosure in the gum tissue of the root lattice until bone growth takes place. Following bone growth, the gum must be surgically reopened so that an intermediate piece and a crown portion can be fitted into position. Thus, two surgical procedures are necessary. It is an object of the present invention to provide a new and improved prosthetic device, useful for dental implants. It is a further object of the invention to provide such a device which is adaptable to different root cavities and resistant to biological rejection phenomena. SUMMARY OF THE INVENTION In accordance with the invention, a prosthetic device for mounting to bone tissue and provided with a bone growth receiving open structure is provided with a bone growth stimulating biochemical matrix in the open structure. The invention is usefully applied in a dental prosthetic device having a root portion which is adapted for receiving bone tissue growth. The root portion is shaped to the configuration and size of the root of the tooth to be replaced. Openings in the root portion communicate with its outer surface and the bone growth stimulating biochemical matrix is contained in the openings. A hollow cavity may be provided within the root portion to communicate with the root surface by the openings. The cavity may be completely filled with the matrix. A crown portion, which is separable from the root portion can be provided for attachment to the root portion after adherence to the surrounding bone. The crown portion may be provided with a protrusion for mating with a recess on the root portion. A temporary cover for the recess may be provided for protecting the recess prior to attachment of the crown portion. The prosthesis is preferably made from a material, such as polyethelene with a high molecular weight, for example about 1900. Such material is capable of being shaped to fit the root cavity by the use of dental tools. For a better understanding of the present invention, together with other and further objects, reference is made to the following description, taken in conjunction with the accompanying drawings, and its scope will be pointed out in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a dental prosthesis in accordance with the present invention. FIG. 2 is a longitudinal cross-section of the root portion of the FIG. 1 prosthesis. FIG. 3 is a transverse cross-section of the root portion of the FIG. 1 prosthesis. FIG. 4 is a cross-section of a jaw bone illustrating natural teeth. FIG. 5 is a cross-sectional of a jaw bone illustrating the use of the prosthesis of the present invention. FIG. 6 is a top view of a jaw bone illustrating a manner of securing the prosthesis in a root cavity. DESCRIPTION OF THE INVENTION The prosthetic device of the present invention is generally illustrated in the form of a dental prosthesis in FIGS. 1, 2, and 3. The prosthesis includes a crown portion 10 and a root portion 12. The root portion 12 is shaped to resemble the contours of a natural tooth root. In general, because of the varying shapes in which natural roots grow, it will be necessary to manufacture the root portion in different sizes and shapes, including multiple stem roots, for implantation following extraction of natural teeth of various shape. The root portion 12 is preferably made of a relatively hard, but pliable, biologically inert material, such as high molecular weight polyethelene. The material should be sufficiently strong to support the crown portion under the stress of use, but should also be capable of being shaped to closely fit a root cavity by the use of ordinary dental tools, such as drills. The crown portion 10 is preferably made from a similar, biological inert material, and should also be resistant to abrasion and wear encountered by contact with opposing teeth and dental materials. Suitable materials include polyethylene (high density molecular weight=1900), polyethylene-polystyrene mixture (80%-20% by weight) and high density polyethylene mixed with very high density polypropylene (50%-50% by weight). Selection of material is made according to the type of stress the tooth is likely to receive, i.e. cutting or grinding. The root portion 12 includes a solid upper section 22, a hollow middle section in which a relatively large cavity 20 is surrounded by root walls, and a solid lower section 14. The central portion is provided with openings 16 connecting cavity 20 to the outer root walls on the sides of the root portion. Openings 16 are preferably small pores, with diameters ranging up to 1.5 millimeters. The root portion may be conveniently formed by "blow molding" in a special mold having spine-like interior protections which form openings 16. The central cavity 20 and openings 16 contain, and are preferably filled with, a biochemical matrix 30. The biochemical matrix is a solidified mixture of active and bonding ingredients, which upon dissolving in body fluids, promotes and stimulates rapid growth of bone tissue into the openings and cavities of the root portion 12. The upper section 22 of root portion 12 is provided with a bore 24 which will receive a protrusion 26 on crown portion 10. Crown 10 is installed only after the root portion is firmly adhered to the surrounding bone by the growth of bone tissue. A temporary cover 28 may be provided to close and protect bore 24 during the time the implant is undergoing initial bone growth. FIGS. 4, 5, and 6 illustrate use of the dental prosthesis of FIGS. 1-3. FIG. 4 shows a cross-sectional view of a jaw bone 32 which is covered by gum tissue 34 and contains three natural teeth 36, 38, and 40. Tooth 38 is decayed beyond repair by normal dental techniques; extraction is required. Following extraction, there remains a root cavity in jaw bone 32 which previously held the root portion of tooth 38. The root cavity also contains the remnants of the periodontal membrane 42. The root portion 12 of the dental prosthesis is inserted into the root socket, preferably immediately after extraction. The root portion is selected to be approximately the same size and shape as the root of the extracted tooth, and may be additionally shaped with dental tools to fit snugly into the root cavity in the jaw bone. Following implantation of the root portion, preferably including protective cap 28, the root portion is secured in position by the use of sutures 44 as illustrated in FIG. 6. The root portion is left in position for a period of 8-10 weeks to enable bone growth to penetrate into the open portions of the root prosthesis and firmly anchor the root portion in position. After the root becomes anchored, temporary cap 38 may be removed to expose bore 24 and an appropriately selected and shaped crown portion 10 may be inserted onto the root portion and secured with a suitable bonding substance. Bone growth into openings 16 firmly anchors the root portion. End portion 14 is non-porous to facilitate extraction of the prosthesis if this becomes necessary. In accordance with the invention, the growth of bone tissue and suppression of implant rejection during the 8-10 week period is facilitated by the biochemical matrix provided in the openings of the root portion. A suitable biochemical matrix is as follows: ______________________________________ Approximate ProportionMaterial By Weight______________________________________(1) Phosphate of Calcium (Ca(H.sub.2 PO.sub.4).sub.2) 28% with ionic state calcium Ca.sup.+++(2) Phosphate of Potassium (K(H.sub.2 PO.sub.4).sub.2) 7%(3) Chondroitin Sulphate "C" 30%(4) Fibrinogen (at least 0.3g) 0.3%(5) Collagen (gel) 25%(6) Vitamin "D" (25 mg) 0.01%(7) Lactose (2% Strength Dried Lactose 0.01% Direct) (15 mg)(8) Bone Meal 1%(9) Casein 1%(10) Carboxymethylcellulose Filler as required to package above contents______________________________________ Those familiar with biochemical matrices of this type for stimulating growth will recognize that substantial variations and changes may be made in the contents of the mixture. It is important that the phosphate of calcium provide ionic calcium to stimulate bone growth. The other components are also selected for bone growth stimulation and are held together by the methylcellulose filler to form a waxy solid material which can be introduced into the root openings and maintained there during implantation. While there has been described what is believed to be the preferred embodiment of the present invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such embodiments as fall within the true scope of the invention.
A prosthetic device, particularly useful for artificial dental implants, includes a portion, such as a tooth root, adapted for mounting to a bone tissue. The bone mounting portion has an open structure in which a bone growth stimulating biochemical matrix is contained. The biochemical matrix stimulates the growth of bone tissue into the openings of the mounting portion for firm attachment of the device.
0
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates generally to internal combustion engines, and more particularly to such engines having rotary valves for controlling intake and exhaust communication with the power cylinders. 2. Description of the Prior Art The theoretical advantages offered by internal combustion engines having rotary valves, over engines having conventional reciprocal poppet-type valves, have long been recognized. Rotary valve engines enable a significant reduction in moving parts over their poppet-type valve counterparts, proving inherent increased engine reliability thereover, smoother and quieter engine operation and reduced maintenance requirements. While several design variations of such engines have appeared in the prior art, they have not been generally accepted by manufacturers or the purchasing public because of the practical problems associated with those designs, which problems have typically outweighed the theoretical advantages of such engines. Such practical problems have typically included sealing problems, distortion, lubrication, tooling, difficulty of repair and maintenance and the cost and facility of manufacture of such rotary valve engines. Internal combustion engines are well known in the art and generally comprise one or more compression chambers, each having intake and exhaust ports, a spark plug or other appropriate ignition element for igniting a combustible gaseous mixture within the chamber, a piston element for compressing the gaseous mixture within the compression cylinder and a crankshaft or other appropriate output drive means for transmitting the combustion energy into usable mechanical output energy. Combustible gaseous mixtures are provided from an intake manifold to the intake port of the cylinder and spent exhaust gases are expended from the exhaust port of the cylinder to an exhaust manifold by valve means which regulate and control the timed opening and closing of the intake and exhaust ports of the respective cylinders of the engine. "Rotary valve" embodiments of such valve means, to which this invention applies, include at least one rotatable member which selectively controls opening and closing of the intake and exhaust ports of the compression cylinder and selectively places the respective intake and exhaust ports of said cylinders in fluid communication with the intake and exhaust manifolds respectively of the engine. Prior art rotary valve engines can be generally classified, according to he basic operative structure of the rotating valve member portion of the engine, into two groups or types of valve structures: (1) those in which the rotating valve member defines a plurality of fluid flow passageways which extend diametrically through the rotating valve member, for directly transmitting intake and exhaust gases respectively between the intake and exhaust manifolds and the intake and exhaust ports of the compression cylinder portions of the engine; and (2) those in which the rotating valve member defines longitudinally extending internal fluid flow passageways therein which provide fluid flow communication through single strategically located openings in the outer shell portion of the rotating valve member between the intake and exhaust manifolds and the intake and exhaust ports respectively of the compression cylinders of the engine. U.S. Pat. No. 3,948,227 to Guenther, represents a rotary valve engine configuration of the first above-described type. A rotary valve of this type requires transfer (during the intake cycle) of the combustible fuel mixture from the intake manifold or carburation apparatus of the engine to the intake port of the compression cylinder -- all during that time interval in which the respective diametrically extending valve inlet passageways of the rotating valve member are in simultaneous "alignment" with the diametrically opposed intake manifold source and the respective intake ports of the cylinders. By their operative nature, such valve structures represent inefficiency in their transfer of intake gases to the cylinders, since the combustible intake mixture must travel through the full diameter of the rotating valve member during the short "alignment". The initial delay in the receipt of intake gases by a cylinder during the intake cycle is basically the rate of flow of the gas mixture through the rotating valve member times the length of the fluid passageway through the rotating valve member. Further, with such rotating valve structures, it is difficult to pressurize the gaseous mixture in the intake manifold so as to speed the intake procedure, for increasing the horsepower of the engine. While several such pressurization techniques have been attempted in the past, they have generally been difficult to implement and have not proved to be very efficient in operation. Further, most of such attempts have been directed more toward the concept of vaporization or atomizing the fuel within the carburetor than toward actual positive pressurization of the gaseous mixture to the combustion cylinders. U.S. Pat. Nos. 2,853,980 and 3,871,340 to Zimmerman, represent rotary valve engine configurations typical of the second above-described type. With this second type of rotary valve engine configuration, since the intake gases are always present within a longitudinal portion of the rotating valve member, there are virtually no delays associated with the transfer of combustible gases to the respective cylinders during the "intake" cycle. Upon alignment of the intake valve opening in the rotating valve member with the intake port of the respective compression cylinder, the combustible gases pass directly from the rotating valve member into the compression cylinder, with the only delay associated with the gas transfer therebetween being represented by the propagation delay of the gaseous mixture passing through the thickness of the outer wall of the rotating valve member. While rotary valve apparatus of the second type have generally proved to be more efficient than the first-described type of rotary valve apparatus with respect to their fluid transfer properties, their construction has generally been more complex and costly, and have presented more problems with the forming of reliable seals between various portions of the valve apparatus. In particular, mounting of the rotating valve member of the "second" type of valve assembly, within the engine head, has typically not enabled easy maintenance or replacement of the rotary valve portion of the apparatus or of associated internally disposed seal members. Further, with both of the above-described prior art structures, intake of the combustible mixture into the compression cylinder has depended only upon the suction or "draw" of the cylinder itself, caused by the partial vacuum created with the cylinder when the piston moves in the "downward" direction during the intake portion of the cycle. As the volume of available combustible intake mixture increases, for example with the second above-described type of apparatus, the practical effect of the "draw" is significantly reduced, basically leaving an inefficient gravity flow intake system. The present invention overcomes the above-mentioned problems associated with both the first and second basic embodiments of the rotary valve engine structures. While the structural operation of this invention is basically of the second above-described type, it is configured in a manner which offers a high degree of simplicity and ease of maintenance and repair and which maximizes efficiency and horsepower rating of the structure without sacrificing seal reliability between the various portions of the valve apparatus. While the present invention will be described with respect to the preferred embodiment of a rotary valve engine, it will be obvious to those skilled in the art in light of this disclosure, that other variations of the rotary valve member, the seal forming elements, the positive fluid-flow enhancing means, the exhaust feedback means and the material used herein, can be configured within the spirit and intent of this invention. SUMMARY OF THE INVENTION This invention provides an improved rotary valve assembly for an internal combustion engine. A cylindrical valve member is mounted by means of a plurality of bearing members within a stationary housing, for rotation about its longitudinal axis. This stationary housing is segmentable, along that portion of its length which houses the rotating valve member, for providing ease of removal and replacement of the rotating valve member. The rotary valve member and surrounding stationary housing, in combination define a first cavity therebetween. An intake exhaust manifold is connected to the stationary housing and provides a fluid flow path for intake gasseous mixtures from a carburetor to the first defined cavity. An exhaust manifold is also connected to the stationary housing and provides a fluid-flow for removal of exhaust gases from the first defined cavity. The intake and exhaust manifold openings into the first defined cavity are longitudinally spaced therealong to correspond with longitudinally spaced intake and exhaust portions of the rotating valve member. Rotatable friction seal mambers mounted within the first defined cavity between the rotary valve member and the stationary housing, and seal plug members inserted within the internal cavity of the rotary valve member, longitudinally separate and define intake and exhaust segments of the rotating valve/housing assembly, such that at least one such intake and one exhaust segment are available for servicing each combustion cylinder of the internal combustion engine with which the valve assembly is used. Circumferentially spaced passageways through the outer wall of the rotary valve member at both the intake and exhaust segments thereof, provide fluid flow communication between the first defined cavity and the respective intake and exhaust internal cavity portions of the rotating valve member. Blade or vane means mounted at the circumferentially spaced passageways provide a blower effect as the rotating valve member rotates, for positively directing gaseous fluid flow through the respective passageways. The longitudinally spaced intake and exhaust segments of the rotatable valve member further respectively have intake and exhaust valve access ports formed through the outer wall of the rotating valve member. Double plunger seal assemblies operatively connect the rotating valve member with the combustion cylinders, with one each of said plunger seal assemblies being operatively associated with each of said intake and exhaust valve access ports. The respective input and exhaust valve access ports which service a particular internal combustion cylinder are relatively angularly spaced on the rotatable valve member with respect to one another so as to respectively communicate with the plunger seal assemblies of the combustion cylinder being served thereby, in proper timed sequence as required by the particular combustion firing schedule of the combustion cylinder. Each plunger seal assembly includes reciprocably spring biased plunger elements which cooperate to slidably sealingly engage the rotating valve member at positions therealong which align with the respective intake and exhaust access openings of the rotating valve member, for providing a continuously sealed passageway between the internal valve cavity and the combustion chamber of the combustion cylinder when the respective intake and exhaust access openings are rotatably aligned with the plunger assembly. Spring biased equalizing lever means applies uniform sealing engagement pressure to the plunger elements, to insure a tight sliding seal of the plunger elements with the rotating valve member, even after the rotating valve member and plunger elements have experienced a high degree of wear. Impeller means mounted within the internal cavity of the rotating valve mmber, and positively driven by drive means responsive to the rotation of the valve member, atomize and pressurize intake fuel mixtures within the rotating valve member for positive injection thereof into the combustion cylinders during the intake stroke of the combustion cycle. Controlled exhaust feedback means, enable the controlled reburning of a portion of the exhaust gases ejected through the exhaust manifold during the combustion cycle. Spark arrester means within the exhaust feedback loop removes sparks and hot particulate particles from the exhaust gases prior to recycling thereof into the carburetor or intake manifold of the internal combustion engine. Timing drive means connected to the crank shaft of the internal combustion engine coordinate and control the timed rotation of the rotating valve member, for synchronous rotation thereof with respect to the particular steps of portions of the combustion cycle or sequence required for operation of the combustion cylinders of the internal combustion engine with which the rotary valve assembly is employed. While the present invention will be described with respect to a preferred embodiment thereof, which illustrates preferred structures and configurations of various portions thereof, it will be understood that numerous variations of the basic concepts and precepts disclosed in the preferred, can be configured within the spirit and broad scope of this invention. Further, while the preferred embodiment of the invention will be disclosed with respect to its applicable use with a four-cycle internal combustion engine, it will be understood that the invention applies equally well to other applicable uses thereof. Also, while a particular alternating intake/exhaust/intake/ . . . rotating valve configuration is disclosed in the preferred embodiment, it will be understood that other non-alternating configurations can be envisioned within the scope of this invention. Likewise while the invention is described with respect to its applicability to a single combustion cylinder, or to several in-line such combustion cylinders, those skilled in the art will recognize numerous alternate configurations of the basic valve assembly for use with internal combustion engines having varied cylinder configurations and arrangements. BRIEF DESCRIPTION OF THE DRAWING Referring to the Drawing, wherein like numerals represent like parts throughout the several views: FIG. 1 is a schematic block diagram of a portion of an internal combustion engine which employs the rotary valve assembly of the present invention; FIG. 2 is an enlarged perspective view, with portions thereof broken away, or the rotary valve assembly portion of the engine disclosed in FIG. 1; FIG. 3 is an exploded perspective view of the double plunger seal assembly portion of the rotary valve assembly disclosed in FIG. 2; FIG. 4 is a cross sectional view of the composite plunger seal assembly disclosed in FIG. 3; FIG. 5 is a cross sectional view of the rotating blade portion of the rotary valve assembly at an intake chamber portion thereof, generally taken along the Line 5--5 of FIG. 2; FIG. 6 is a perspective view, with portions thereof broken away, of a spark arrester assembly insertable within the exhaust feedback path to the carburetor, disclosed in FIG. 1; FIG. 7 is an enlarged fragmentary detail of a portion of the spark arrester assembly disclosed in FIG. 6; FIG. 8 is an enlarged view of one of the screen interface members of the spark arrester assembly disclosed in FIG. 7; FIG. 9 is an enlarged sectional view, with portions thereof broken away, of the impeller assembly portion of the rotary valve assembly disclosed in FIG. 2, at an intake chamber portion thereof; FIG. 10 is a perspective view, with portions thereof broken away, of a portion of the impeller assembly illustrated in FIG. 9; FIG. 11 is a sectional view illustrating the impeller assembly disclosed in FIG. 9, generally taken along the Line 11--11 of FIG. 9; FIG. 12 is an exploded perspective view of one of the two-part seal members disclosed in FIG. 2, illustrating the inner and outer relatively moveable portions thereof; FIG. 13 is a cross sectional view of the seal member disclosed in FIG. 12, illustrating the operative mounting of the seal within the rotary valve assembly of FIG. 2. FIG. 14 is a cross sectional view of the rotating valve member portion of the rotary valve assembly of FIG. 1, illustrating the relative angular spacing of the intake and exhaust valve access ports therethrough, generally as viewed along the Line 14--14 of FIG. 1; and FIG. 15 is an enlarged perspective view of a sealer plug portion of the rotary valve assembly disclosed in FIG. 1. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the figures, wherein like numerals represent like parts throughout the several views, there is generally illustrated at 20 in FIG. 1, a schematic block diagram representation of a portion of an internal combustion engine which employs the rotary valve assembly of this invention. Referring thereto, there is generally illustrated an internal combustion engine block 22 having one or more internal combustion cylinders 23. It will be appreciated that the engine 20 may include any suitable number of the combustion cylinders 23. The combustion cylinders 23 may be of any type well-known in the internal combustion engine art, and generally include a cylindrical wall 23a forming an internal cavity 23b between a first end 23a' of the cylindrical wall 23a, and a piston 23c, which longitudinally reciprocates within the cylindrical wall 23a. Sliding seal means are typically formed between the reciprocable piston 23c and the cylindrical wall 23a by means of a plurality of annular rings 23d, which are connected to and reciprocate with the piston 23c for preventing bypass of gaseous mixtures from the cavity 23b around the outer circumference of the piston 23c. A sparkplug 24 or other ignition element projects through the first end 23a' of the cylindrical wall 23a and into the internal cavity 23b of the cylinder 23, for selectively igniting combustible gases therein. An inlet or "intake" port 25 and an outlet or "exhaust" port 26 are also formed through the first end 23a' of the cylinder 23 and provide access to the internal cavity 23b by means of the rotary valve apparatus of this invention, hereinafter described. It will be understood that the sparkplug 24 is appropriately operatively connected to an electrical timing apparatus, which could be of a "distributor"-type (not illustrated), well-known in the art, for selectively energizing the sparkplug 24 in timed sequential relationship with the operative longitudinal position of the piston 23c within the respective combustion cylinder 23 with which the sparkplug is associated, and the operative position of the respective rotary valve apparatus (hereinafter described in more detail), which sequentially controls opening and closing of the inlet and outlet ports 25 and 26 to the respective cylinder 23. A crank shaft 28 is journaled (not illustrated) in the crank case or block 22 of the engine 20. One end of the crank shaft 28 is connected to a first timing gear 29, and the opposite end of the crank shaft 28 is connected in well-known fashion to a fly wheel (not illustrated). The respective crank portions 28a of the crank shaft 28 are operatively connected in well-known manner by means of a piston rod or connecting rod member 30 to the piston 23c, for controlling the reciprocal movement of the piston 23c within the cylinder 23. The intake and exhaust ports 25 and 26 of the respective cylinders 23 are operatively connected by means of generally cylindrical protective casing or tube members 32 to an outer stationary housing portion 42 of a rotary valve assembly, generally designated at 40. Since the details of construction of the tube members 32 which connect the intake and exhaust ports 25 and 26 respectively to the rotary valve assembly 40 are generally alike in construction, except for their respective functions with respect to operation of the engine 20, a further description of one such tube member and its internal plunger assembly (hereinafter described) will suffice to cover the application thereof for either an "intake" or an "exhaust" function. The rotary valve assembly 40 further has a primary rotating valve member 44 mounted for rotation (as hereinafter described) within the stationary housing 42 of the valve assembly 40. A second timing gear member 34 is mounted adjacent one end of the primary rotating valve member 44, for rotation therewith and is rotatably connected to the first timing gear member 29 by means of a drive chain 36. The first and second timing gear members 29 and 34 respectively are sized to provide a rotation ratio of 2:1 (i.e. the driving gear 29 rotates twice for each revolution of the driven gear 34). As will become apparent upon a more detailed description of the invention, however, it will be understood that any appropriate gear ratios and timed driving means for the primary rotating valve member 44 can be envisioned within the spirit and scope of this invention. An intake manifold 50 is illustrated in FIG. 1 as generally extending from a carburetor 52 into operative sealed connection with the stationary housing portion 42 of the valve assembly 40. As will become apparent upon a more detailed description of the preferred embodiment of the invention, the intake manifold 50 is illustrated as operatively connected to the stationary housing 42 at two longitudinally spaced positions therealong, corresponding to two combustion cylinders 23 of the engine 20. It will be understood that the intake manifold can be extended to service any number of combustion cylinders 23 of the engine 20. The intake manifold is configured to provide a passageway for combustible gaseous mixtures from the carburetor 52 to the internal chamber formed by the stationary housing 42, as hereinafter described. An exhaust manifold 54 is illustrated in FIG. 1 as extending from the stationary housing 42 of the rotary valve assembly 40, and provides an outlet or exhaust passageway therefrom, as hereinafter described in more detail, for spent or burned exhaust gases ejected from the underlying engine cylinder 23. While only one exhaust tube or passageway 54 of the exhaust manifold is illustrated in FIG. 1, it will be understood that at least one such tube is provided for each of the combustion cylinders 23, as will become apparent upon a more detailed description of the preferred embodiment. An exhaust gas feedback conduit 56 operatively extends between the exhaust tubes 54 of the exhaust manifold, back to the carburetor 52 for providing recycling or reburning of a portion of the exhaust gases. A spark arrester assembly 58 is operatively interposed within the exhaust feedback conduit 56, for removing sparks and highly combustible particles from the recycled exhaust gases, prior to introduction of the recycled exhaust gases into the carburetor 52. Valve means 59 are also provided within the exhaust recycling conduit 56 for controlling the rate of flow of recycled exhaust gases through the feedback conduit 56. While a specific example of an exhaust recycling and spark arrester configuration will be illustrated with respect to the preferred embodiment of this invention, it will be understood that numerous variations of these configurations can be envisioned within the spirit and scope of this invention. An enlarged perspective view of the rotary valve assembly portion 40 of the engine 20 is illustrated in FIG. 2. Referring thereto, it will be noted that the stationary housing 42, for ease of assembly and maintenance, comprises a two-part construction having an upper housing portion 42a and a lower housing portion 42b bolted together by appropriate bolt means 43 at appropriate locations along the longitudinal length of the housing 42 so as to define a cylindrical internal cavity, generally designated at 42c. As illustrated in FIG. 2, the inner wall of the housing 42, when operatively secured by the bolt means 43 as illustrated, defines annular race or groove portions 42d at axially spaced positions therealong, sized to matingly accept bearings 45. In the preferred embodiment of the invention illustrated in FIG. 2, there are two such bearings 45, one located at each side of the underlying combustion cylinder 23. It will be understood that while the invention will be described with respect to its application to a single combustion chamber, the principles of the rotating valve assembly can be extended to apply to the serving of any number of combustion cylinders 23, whether of an "in-line" type, the well-known "V-type" or any other type of combustion cylinder arrangement, by appropriate extension of the principles of this invention. For example, it will be understood that the housing 42 can be appropriately extended to service additional combustion chambers 23, in which case additional operative members such as the bearings 45 would be required at appropriate axially spaced positions along the housing 42. The bearings 45 rotatably support the primary rotating valve member 44 within the internal cavity 42c of the housing 42, and may be of any appropriate configuration, such as roller or ball bearings. In the preferred embodiment, the primary rotating valve member 44 comprises a cylindrical tube member defining an internal cylindrical cavity 44a and is rotatable by means of the second timing gear 34 in the clockwise direction, as viewed from the left end of the valve assembly 40 disclosed in FIG. 2. The materials used for constructing the housing 42 and the primary rotating valve member 44 may be any appropriate material suitable for withstanding the operative heat and wear conditions of the device, as hereinafter described. Referring to FIG. 2, that portion of the rotary valve assembly located between the axially spaced bearings 45 generally comprises the rotary valve structure for controlling the flow of intake and exhaust gases to and from respectively the intake and exhaust ports 25 and 26 respectively of the combustion cylinder 23 illustrated. The following discussion will specifically apply to the rotary valve structure 40 as applicable to controlling the intake and exhaust for the single illustrated combustion chamber 23; it being understood that the below-described principles can readily be extended to encompass the valve control apparatus for any number of such in-line combustion cylinders 23. The primary rotating valve member 44 has a plurality of "intake" passageways 44b formed through the cylindrical wall portion of the rotating valve member 44 and circumferentially spaced thereabout in an annular ring, enabling fluid communication between the internal cavity 44a of the valve member 44 and that portion of the internal cavity 42c which is disposed between the housing 42 and the outer surface of the rotating valve member 44. The intake passageways 44b through the rotating valve member 44 are radially disposed so as to generally underlie the entry position of the intake manifold 50 through the stationary housing member 42a, so as to form a fluid communication path from the carburetor 52, through the intake manifold 50 and to the internal cavity 44a of the rotating valve member 44. A plurality of vane or blade members 44c are mounted to or from a continuum with the rotating valve member 44 and are disposed across the intake passageways 44b thereof at angles relative to the outer cylindrical wall of the valve member 44 so as to enhance or "scope-in" intake gaseous mixtures from that cavity portion 42c surrounding the rotating valve member 44 and into the internal cavity 44a of the rotating valve member 44, as the valve member 44 rotates in the clockwise direction, as indicated in FIG. 2. This vane or blade assembly at the intake passageways 44b of the rotating blade member 44 simultaneously atomizes intake fuels for greater combustibility and provides for positive intake gas flow from the carburetor into the internal chamber or cavity 44a of the valve member 44, thus not depending upon normal gravity feed or transfer of the intake gases to the rotating valve assembly. An enlarged cross sectional view of the rotating vane or blade configuration above-described is illustrated in more detail in FIG. 5. Referring thereto, it becomes clearly apparent that intake gases flowing into the housing cavity 42c will be positively directed or "scooped" into the internal cavity 44a of the rotating valve member 44 by means of the blade or vane members 44c. Exhaust passageways 44d are formed through the cylindrical wall protion of the rotating valve member 44, in manner similar to the above-described intake passageways 44d, so as to enable fluid communication between the internal combustion cavity 44a of the valve member 44 and that portion of the internal cavity 42c which is disposed adjacent the exhaust tube or manifold 54. The exhaust passageways 44d enable fluid communication between the internal cavity 42a and the exhuast tube or manifold 54. A plurality of vane or blade members 44e are mounted to or form a continuum with the rotary valve member 44 and are disposed across the exhaust passageways 44d thereof, at angles relative to the outer cylindrical wall of the valve member 44 so as to enhance heat removal from the exhaust plunger assembly (hereinafter described), and to enhance extraction of exhaust gases from the internal cavity 44a of the rotating valve member 44 and into the exhaust tube or manifold 54. Referring to FIG. 2, it will be noted that the angle or pitch of the intake members 44c and the exhaust blade members 44e are exactly opposite to one another, so as to effect positive fluid flow transfer respectively to and from the internal cavity 44a of the rotating valve member 44 as the valve member 44 rotates. The internal cavity 44a of the rotating valve member 44 is axially separated into a plurality of adjacent chambers by disc-like barriers or plug-members 46, as illustrated in FIGS. 2 and 15. In the preferred embodiment, the plug barrier members comprise appropriate disc members which are press-fit into firm sealing engagement with the inner walls of the rotating valve member 44, to prevent leakage of gaseous materials between contiguous intake and exhaust portions of the internal cavity 44a. For ease of reference, the barrier elements 46 have been labeled as 46a-46d in FIG. 2. The barrier members 46a and 46b isolate the intake portion of the rotary valve member 44, defined therebetween from the exhaust portion of the rotary valve member which is defined between the barrier members 46b and 46c. The barrier members 46c and 46d, in combination, provided a dead air space within the internal cavity 44a defined therebetween, for isolating the exhaust portion of the rotary valve member of one combustion cylinder 23 from the intake portion of the rotary valve member 44 which services an adjacent combustion cylinder 23. The rotary valve member 44 further defines an intake valve access port 47 and an exhaust valve access port 48, each respectively providing fluid communication between the respective intake and exhaust portions of the internal cavity 44a and the surrounding internal cavity portion 42c of the stationary housing 42. The intake and exhaust access ports 47 and 48 are axially spaced along the rotating valve member 44 so as to generally matingly align with the casing or tube members 32, as hereinafter described in more detail. Further, the intake and exhaust access ports 47 and 48 are operatively relatively disposed and spaced apart from one another around the outer surface of the rotating valve member 44 such that only one of the valve access ports 47 or 48 can operatively address the corresponding intake and exhaust ports of the underlying combustion chamber 23 at a time during a complete cycle of an internal combustion engine with which the rotating valve assembly is used (as illustrated in FIG. 2). The circumferential lengths of the respective intake and exhaust valve access ports 47 and 48 are, in the preferred embodiment, approximately 30° to 40° and have a rotational or circumferential spacing therebetween of approximately 30° to 40° such that as the valve 44 rotates about its axis, the respective valve access ports 47 and 48 will maintain fluid communication between their respective intake and exhaust internal cavity portions 44a of the valve member 44 for somewhat less than 90° of angular rotation of the valve 44, see FIGS. 1 and 14. It will be understood by those skilled in the art that the respective "rotational or circumferential lengths" of the valve access ports 47 and 48 and the relative circumferential spacings therebetween will depend upon the dimensions of the cooperating plunger assemblies (hereinafter described). In the preferred embodiment, the valve assembly 40 is employed with a 4-cycle internal combustion engine, such that the relative sizes and positioning of the intake and exhaust valve access ports 47 and 48 respectively coincide with the "intake" and "exhaust" portions respectively of the well-known 4-cycle internal combustion sequence. A plurality of laminated seal members 49 (FIG. 2) are configured to provide a frictionless seal between the stationary housing 42 and the rotating valve member 44, so as to prevent the flow of gaseous mixtures therebetween through the internal cavity 42c. For convenience in describing relative positioning of the laminated seal members 49, these elements have been labeled as 49a-49h in FIG. 2. The seals 49a and 49b prevent the flow of intake gases out of the end of the housing 42. The seal members 49b and 49c isolate the intake portion of the rotary valve assembly which accepts gas mixtures from the intake manifold 50. The seal member 49d isolates the intake and exhaust portions of the internal cavity 42c which are in fluid communication with the internal cavity 42a of the rotary valve assembly by means of the intake and exhaust valve access ports 47 and 48 respectively. The seal members 49e and 49f isolate that portion of the internal cavity 42c which is in fluid communication with the exhaust tube or manifold 54. The seal members 49g and 49h isolate that portion of the internal cavity 42c which is in fluid communication with the intake manifold, for serving the second combustion chamber 23. The laminated seal members 49 are illustrated in more detail in FIGS. 12 and 13. Referring thereto, an inner seal sleeve member 49' having one or more external annular rings or bands 49x thereon is press-fit onto the outer circumference of the rotating valve member 44, as illustrated in FIG. 13. An outer, split-seal portion 49' having internal circumferentially disposed grooves or races 49y is configured to cooperatively mate in close non-touching tolerance the inner portion of the seal 49' so as to form a seal therewith. The outer seal portion 49' is split so as to enable ready installation thereof, and for ease of removal of the rotating valve 44 from the housing 42 in maintenance operations. Such laminated seals are well-known in the art and may be constructed of any appropriate materials suitable for simultaneously forming the maintenance free, friction-free seal. The frictionless property of the laminated seals 49 also prevent drag upon the rotation of the rotating valve member 44. Intake and exhaust gases are transmitted between the rotating valve member 44 and the combustion cylinder 23 by means of double plunger seal assemblies 60 mounted within the protective casing or tube connecting members 32. The double plunger seal assembly 60 is illustrated in more detail in FIG. 3 (exploded view) and FIG. 4 (cross sectional view). Referring thereto, the protective casing or tube members 32 generally comprises a cylindrical cylinder mounted near its bottom edge to the combustion cylinder 23 so as to overlie the appropriate intake or exhaust ports 25 or 26 respectively thereof, and is connected at its top end to the stationary housing 42b (see FIG. 2), to form a fluid passageway therebetween. A ring-like bottom support member 61 is threaded into the lower end of the outer casing 32 for easy installation and maintenance removal. The bottom support member 61 has a cross grid support structure 61a extending diametrically there across and tapered in a manner so as to minimize the restriction of gaseous flow there through. It will be noted, that the taper of the support grid portion 61a of the bottom support member 61 which is illustrated in FIGS. 3 and 4 conform to a double plunger seal assembly 60 which would be used at an "intake" port, since the direction of gaseous flow there through would be from "top" to "bottom" of the seal assembly 60, as viewed in FIG. 4. For a double plunger seal assembly 60 configured for use on an "exhaust" port, the apex of the tapered or beveled support grid portion 61a of the support member 61 would be reversed to that illustrated in FIG. 4, so as to minimize resistance to the gaseous flow through the plunger seal assembly 60 in the direction from the "bottom" to the "top" of the seal assembly 60. A mounting stud member 62 axially projects from the support grid portion 61a of the bottom support member 61 into the inner cavity of the casing member 32. A pair of equalizing levers 63 are pivotally mounted to the mounting stud member 62 by means of a pin 64 and are pivotally rotatable about the pin 64. The equalizing levers 63 each has a first lever arm 63a radially extending from the mounting stud member 62 in close proximity to but spaced apart from the inner wall of the external tube 32, and a second lever arm 63b diametrically opposed from the first lever arm 63a and terminating at a spring-retaining end configuration. An outer sealing plunger member 66 which is generally cylindrical in shape and is open at axially opposite ends thereof rests upon the first lever arm ends of the equalizing levers 63 and is sized for reciprocable axial movement within the outer casing 32. The upper end of the outer sealing plunger member 66 is contoured to matingly slidably engage the outer surface of the rotating valve member 44, and is mounted relative to the rotating valve member 44 so as to intercept the appropriate intake or exhaust valve access port 47 or 48 (depending upon the relative port with which the plunger assembly 60 is employed). The outer sealing plunger 66 has an annular groove 66a about its outer circumference, which holds a ring member 67 which slidably engages the inner cylindrical wall of the cylindrical casing 32 and forms a sliding seal therebetween. The outer sealing plunger 66 further has an alignment member 68 fixedly mounted therein. The alignment member 68 has an outer key member 68a which slides in a key way 32a axially formed within the inner cylindrical wall of the outer casing member 32 for maintaining the radial attitude (i.e. for preventing rotation thereof) of the outer sealing plunger member 66 relative to the outer casing 32. The alignment member 68 further has a second key member 68b projecting from its inner wall for maintaining the rotational attitude of an inner sealing plunger member (hereinafter described). An inner sealing plunger member 69, of generally cylindrical shape is coaxially mounted for reciprocal movement within the outer sealing plunger 66. The inner sealing plunger member 69 is configured adjacent its lower end to define a spring seat 69a, and is contoured at its upper end to matingly sliably engage the rotating valve member 44. A spring member 70 is compressively mounted between the spring seat 69a of the inner sealing plunger member 69 and the spring retaining portions of the second lever arm 63b of the equalizing lever 63 to maintain the inner sealing plunger member 69 in tight frictional engagement with the rotating valve member 44. In the preferred embodiment, the spring 70 is a coil spring construction, however, it will be understood that other appropriate biasing configurations can be employed within the spirit and intent of this invention. The inner sealing plunger member 69 further defines an annular groove 69b about its outer circumference into which is inserted a ring member 71 for forming a sliding seal between the inner and outer sealing plunging members 69 and 66 respectively. The inner sealing plunger member 69 further defines a key way 69c axially disposed along a portion of its outer circumference for matingly accepting the inwardly directed key portion 68b of the alignment member 68. The double plunger sealing assembly 60 is cooperatively installed with the rotating valve apparatus 44 so as to compress the spring 70 between the inner sealing plunger member 69 and the underlying equalizing levers 63. Once installed, the spring 70 maintains the inner sealing plunger member 69 into tight frictional sliding engagement with the rotating valve 44, and simultaneously transmits through the second and first lever arms 63b and 63a respectively of the equalizing lever 63, support forces to the outer sealing plunger 66 for maintaining a tight frictional sliding seal between the outer sealing plunger 66 and the rotating valve 44. The equalizing levers 63, in combination with the spring 70 equalize or maintain a balance of forces by the inner and outer sealing plunger members 69 and 66 respectively against the rotating valve member 44, regardless of wear of either the inner or outer sealing plunger members. Accordingly, a tight frictional seal between the rotating valve member and the plunger assembly is insured at all times by the spring biased equalizing assembly. Intake or exhaust gases from the rotating valve 44 pass through the respective intake or exhaust valve access ports 47 and 48 respectively through the internal cavity of the inner sealing plunger member, past the spring and equalizing lever assemblies and through the grid support structure of the bottom support member 61, into or out of the respective intake or exhaust ports of the compression cylinder as the case may be. The plunger assembly is constructed for ease of maintenance due to the fact that the bottom support member 61 is threaded into the outer casing 32 for ease of removal of the entire plunger assembly apparatus 60. The rotating valve member 44 is simply removed by releasing the bolt means 43 which secure the upper and lower portions of the stationary housing 42a and 42b respectively to one another (see FIG. 2). Positive intake feed pressure of intake gases from the "intake" portion of the internal cavity 44a of the rotating valve 44, to the combustion cylinder 23 by means of the plunger assembly 60, is provided by means of an impeller assembly 80. Detailed views of the impeller assembly 80 are illustrated in FIGS. 9, 10 and 11 of the Drawing. The impeller assembly 80 is used in the preferred embodiment, only with the intake portion of the rotary valve, and is mounted within the rotating valve member 44 between the intake passageways 44b and the intake valve access port 47 thereof (see FIG. 2). The impeller assembly 80 is mounted to a cylindrical casing member 81, which is closed at one end, and which is press fit in tight sealing engagement within the internal cavity 44a of the rotary valve member 44. The cylindrical casing member 81 has an elongate opening 81a formed through the cylindrical wall portion thereof, which matingly aligns with the intake access port 47 of the rotary valve member 44, for providing fluid communication between the internal cavity portion of the cylindrical casing member 81 and the intake passageway of the plunger seal assembly 60 (see FIG. 9). An impeller support ring and cross bracket holding apparatus 82 is press-fit mounted within the cylindrical casing member 81 and rotatably supports an impeller blade 83 for rotation about the axis of the rotary valve member 44. The impeller blade 83 is rotatably supported upon a shaft 84 which is coaxially connected for rotation with a first gear member 85. The first gear member 85 is operatively frictionally driven by a second gear member 86 which is rotatably mounted by a pin member 87 to the cylindrical casing member 81 which contains a slot 81b through the cylindrical wall thereof to allow free rotation of the second gear member 86. An annular gear ring 88 is fixedly mounted to the internal wall of the outer casing 42, and operatively engages by means of friction or intermeshing gears, the second gear member 86. The cross-arm portions of the impeller support structure 82 are tapered, as illustrated in FIG. 10, to minimize restriction to the flow of intake gaseous mixtures thereby, and the impeller blade structure is configured for "pushing" the intake gaseous mixture past the impeller apparatus from "left-to-right" as viewed in FIGS. 9 and 10. As the rotary valve member 44 rotates about its longitudinal axis, as driven by the crank shaft 28 by means of the gear and drive chain combination (29), (36) and (34), the second impeller gear drive member 86 operatively engages the annular gear 88 and imparts rotary motion to the impeller blade 83 by means of the first gear member 85. The net effect is that as the rotary valve member 44 rotates, the rotation of the impeller blade 83 positively directs, under pressure, the intake gaseous mixture from the intake manifold, through the rotary valve 44 and into the combustion chamber 23 via the plunger seal assembly 60 -- all resulting in an increase in efficiency and horsepower rating of the motor. It will be understood that the relative sizes of the gears 86 and 85 can be varied to regulate the rotary speed of the impeller blade 83. The rotary valve assembly 40 is lubricated through the intake gaseous mixture by means of the what is well-known in the art as an autolube impulse pump (not illustrated), that positively injects predetermined amounts of oil into the intake gas mixture. Oil lubrication ports illustrated in FIG. 2 at 90 are also provided for directly lubricating the internal gear assemblies of the rotary valve assembly 40. It will be understood that the oil lubrication ports 90 are connected to an appropriate oil source (not illustrated). Referring to FIGS. 9-11, oil lubrication passageways through the various support elements for the impeller support mechanisms are illustrated. Lubrication oil inserted through the external housing 42 through the oil lube ports 90 falls by gravity onto the rotating valve member 44. This lubrication oil also will splash upon and lubricate the annular gear 88 which in turn will lubricate the second gear member 86, which will lubricate the first gear member 85. An oil passageway generally designated at 92 in FIGS. 9-11, passes through the rotating valve member 44, through the cylindrical casing member 81 and through one of the cross-arms of the impeller support structure 82, to provide lubrication to the support shafts or pins 87 and 84 of the second gear member 86 and the impeller 83 respectively. While a specific mode of illustrating lubrication of the various moving gear portions of the preferred embodiment has been illustrated, it will be understood that many such lubrication variations can be envisioned within the spirit and intent of this invention. The present invention includes an exhaust feedback apparatus for partially recycling exhaust gases from the exhaust output port 26 of the combustion cylinder 23. The exhaust feedback structure is schematically illustrated in FIG. 1. A portion of the exhaust gases being ejected through the exhaust manifold 54 are recycled through the exhaust gas recycling conduit 56, and pass through the spark arrester assembly 58 for reuse by the carburetor 52. the screw valve 59 provides means for regulating the rate of flow of exhaust gases through the feedback conduit 56, which can be completely closed thereby if desired. A more detailed description of the spark arrester assembly 58 is illustrated in FIGS. 6-8. Referring thereto, the spark arrester assembly 58 generally includes an outer heat shield member 58a through which the exhaust recycling conduit 56 passes in serpentine-like manner. Within the serpentine-like configuration, the exhaust feedback conduit includes a plurality of screen interface members 58b which disperse and deenergize spark or hot particulate particles in the exhaust. An enlarged view of one typical interface member is illustrated in FIG. 8. Following each of the screen interface members 58b is a spark deflector member 58c which is mounted at an angle (as illustrated in FIG. 7) so as to deflect and remove hot spark or particulate particles from the exhaust flow. The exhaust feedback conduit member 56 is enlarged adjacent the free end of each of the spark deflector members 58b to force the exhaust gases around the spark deflector members 58c such that the larger particulate hot particles will remain entraped by the spark deflectors 58c, leaving the cleaner exhaust gases to pass there around. The spark arrester assembly 58 serves to remove burning particles from the exhaust gases and to cool the exhaust gases prior to allowing passage thereof into the carburetor, to prevent pre-combustion of intake gases either within the carburetor or the intake manifold, which could be caused by hot particulate or spark particles injected from the feedback exhaust gases. OPERATION OF THE PREFERRED EMBODIMENT From the foregoing description, operation of the rotary valve engine above-described in fairly self-evident. The crank shaft 28 turns the rotary valve member 44 by means of the timing and gear assembly comprising the gears 29 and 34 and the connecting drive chain 36. In the preferred embodiment, the combustion cylinder 23 operates on a well-known four-cycle combustion sequence. The intake and exhaust valve access ports 47 and 48 are disposed on the rotary valve member 44 in circumferential relationship to one another such that the intake access port 47 aligns with and provides fluid communication with the intake port of the combustion cylinder 23 during the "intake" quarter of the complete combustion cycle, and the exhaust valve port 48 aligns with the exhaust port of the combustion cylinder 23 during the "exhaust" stroke of the complete combustion cycle. As the intake and exhaust ports 47 and 48 respectively align with the plunger assemblies 60, direct fluid communication is provided between the respective intake or exhaust manifolds 50 and 54 respectively and the internal combustion chamber 23b of the combustion cylinder 23. As the rotary valve member 44 rotates in timed cooperative relationship with the crank shaft 28, the well-known four-cycle sequence is established: (1) piston moves down -- intake stroke; (2) piston moves up -- compression stroke; (3) spark ignition forcing piston down -- power stroke; and (4) piston moves up -- exhaust stroke. The blade or vane members 44c and 44e on the intake and exhaust passageways 44b and 44d respectively around the outer circumference of the rotary valve member 44, provide a blower effect for positively transferring the respective gaseous mixtures between the internal cavity portions 44a of the rotary valve member and the respective intake and exhaust manifolds 50 and 54 respectively. The impeller assembly 80 located adjacent the intake valve access port 47, further insures positive injection of the gaseous intake mixture to the combustion cylinder 23 on the "intake" stroke of the cycle. Since the internal cavity 44a of the rotary valve member 44, which lies adjacent the intake valve access port 47 is always filled with a pressurized combustible gaseous mixture, as soon as the intake valve access port 47 aligns with the double plunger seal assembly 60 during the intake stroke of the cycle, the gaseous intake mixture is immediately positively injected into the combustion cylinder 23, thus significantly increasing the efficiency and horsepower of the engine. The laminated seal members 49 mounted external of the rotary valve member 44 and the internal plug members 46 in cooperation with the closed-end cylindrical casing member 81 of the impeller assembly insure adequate fluid-flow preventing seals between the respective intake and exhaust portions of the rotary valve assembly, in a simple and easy repairable method. The cylindrical construction of the rotary valve member, coupled with the simplicity of construction of the various seals and bearing members operatively associated therewith, provides for rapid installation and easy maintenance of the valve assembly. The two-part outer housing 42 enable easy removal of the rotary valve assembly by simply removing the upper housing portion 42a thereof. The fail-safe double-acting plunger seal assembly 60 minimize the effects of wear on the valve portion of the engine, and insure tight sliding seals of the inner and outer sealing plunger members 69 and 66 respectively with the rotary valve member 44, even with significant wear of the respective plunger elements, by means of the equalizing lever 63 and biasing spring 70 combination. Accordingly, the wear and tear of the prior art poppet-type of valve are eliminated and the unique construction of the double plunger seal assembly 60 enables rapid replacement and maintenance of the plunger seal assemblies, if required. Reburning of exhaust gases is provided by the recycling conduit 56 and spark arrester assembly 58, to further increase efficiency of operation of the internal combustion engine assembly. Other modifications of the invention will be apparent to those skilled in the art in light of the foregoing description. This description is intended to provide concrete examples of individual embodiments clearly disclosing the present invention. Accordingly, the invention is not limited to any particular embodiment. All alternatives, modifications and variations of the present invention which fall within the spirit and broad scope of the appended claims are covered.
A reliable efficient rotary valve apparatus for internal combustion engines, configured for ease of installation and maintenance. Rotating valve apparatus controls transfer of intake and exhaust gases between intake and exhaust manifolds respectively of an internal combustion engine and the respective combustion cylinders thereof. Intake and exhaust portions of the rotary valve assembly are isolated by simple seal members. Activating means, responsive to rotation of the rotatable valve member, create positive fluid-flow transfer of gaseous currents through the rotating valve member. Spring biased, pressure equalizing plunger seal apparatus increases reliability and longevity of use of the rotary valve apparatus and maintains proper seals for fluid-flow passage between the rotating valve member and individual compression cylinders of the engine. Exhaust feedback apparatus with built-in spark arresters, enables controlled recycling of portions of the exhaust gases expended by the internal combustion engine during the combustion cycle.
5
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] None. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not Applicable. BACKGROUND OF THE INVENTION [0003] This invention relates to a method of increasing the strength of a paper mat of fibers produced in a papermaking process. Paper mat comprises water and solids and is commonly 4 to 8% water. The solid portion of the paper mat includes fibers (typically cellulose based fibers) and can also include filler. Increasing the strength of the paper mat would allow one to increase the proportion of the solids that is filler content. This is desirable because it reduces raw materials costs, reduces energy needed in the papermaking process, and increases the optical properties of the paper. Prior Art discloses paper mat having a solid portion of between 10% and 40% filler. The Prior Art however also discloses that increasing the filler content coincides with a loss in strength in the resulting paper. [0004] Fillers are mineral particles that are added to paper mat during the papermaking process to enhance the resulting paper's opacity and light reflecting properties. Some examples of fillers are described in U.S. Pat. No. 7,211,608. Fillers include inorganic and organic particles or pigments used to increase the opacity or brightness, or reduce the cost of the paper or paperboard sheet. Some examples of fillers include one or more of: kaolin clay, talc, titanium dioxide, alumina trihydrate, barium sulfate, magnesium hydroxide, pigments such as calcium carbonate, and the like. Previous attempts to increase the filler content in paper without losing paper strength are described in British Patent GB 2016498, and U.S. Pat. Nos. 4,710,270, 4,181,567, 2,037,525, 7,211,608, and 6,190,663. [0005] Calcium carbonate filler comes in two forms, GCC (ground calcium carbonate) and PCC (precipitated calcium carbonate). GCC is naturally occurring calcium carbonate rock and PCC is synthetically produced calcium carbonate. Because it has a greater specific surface area, PCC has greater light scattering abilities and provides better optical properties to the resulting paper. For the same reason however, PCC filled paper mat produces paper which is weaker than GCC filled paper. [0006] Paper strength is a function of the number and the strength of the bonds formed between interweaved fibers of the paper mat. Filler particles with greater surface area are more likely to become engaged to those fibers and interfere with the number and strength of those bonds. Because of its greater surface area, PCC filler interferes with those bonds more than GCC. [0007] As a result, papermakers are forced to make an undesirable tradeoff. They must either choose to select a paper with superior strength but inferior optical properties or they must select a paper with superior optical properties but inferior strength. Thus there is a clear need for a method of papermaking that facilitates a greater amount of filler in the paper, a paper that has a high opacity, and a filled paper that has a high degree of strength. BRIEF SUMMARY OF THE INVENTION [0008] At least one embodiment of the invention is directed towards a method of papermaking having an increased filler content. The method comprises the steps of adding a first flocculating agent to an aqueous dispersion in an amount sufficient to mix uniformly in the dispersion without causing significant flocculation of the filler particles, adding a second flocculating agent to the dispersion after adding the first flocculating agent in an amount sufficient to initiate flocculation of the filler particles in the presence of the first flocculating agent, the second flocculating agent being of opposite charge to the first flocculant, combining the filler particles with the paper fiber stock, treating the combination with at least one strength additive, and forming a paper mat from the combination. The paper fiber stock comprises a plurality of fibers and water, and the initiated flocculation enhances the performance of the strength additive in the paper mat. [0009] At least one embodiment of the invention is directed towards this method in which the strength of the paper made by the papermaking process is increased by an amount greater than the sum of: the strength enhancement provided by the preflocculation process using the first and second flocculating agents and the strength enhancement provided by the strength additive by itself. [0010] The filler may be selected from the group consisting of calcium carbonate, kaolin clay, talc, titanium dioxide, alumina trihydrate, barium sulfate, and magnesium hydroxide. The paper fiber may be cellulose fiber. The method may further comprise the step of shearing the dispersion to obtain a predetermined floc size. The filler flocs may have a median particle size of 10-100 μm. The first and second flocculating agents may have an RSV of at least 2 dL/g. The first flocculating agent may be anionic. The strength additive may be glyoxylated Acrylamide/DADMAC copolymer. The ratio of strength additive relative to the solid portion of the paper mat may be 0.3 to 5 kg of strength additive per ton of paper mat. The first flocculating agent may be a copolymer of acrylamide and sodium acrylate. The strength additive may be a cationic starch. The strength additive and the second flocculating agent may carry the same charge. [0011] The second flocculating agent may be selected from the list consisting of copolymers of acrylamide with DMAEM, DMAEA, DEAEA, DEAEM. The second flocculating agent may be in quaternary ammonium salt form made with a salt selected from the list consisting of dimethyl sulfate, methyl chloride, benzyl chloride, and any combination thereof. The filler may be anionically dispersed and a low molecular weight, cationic coagulant is added to the dispersion to at least partially neutralize its anionic charge prior to the addition of the first flocculating agent. The second flocculating agent may have a charge, which is opposite to the charge of the first flocculating agent. The filler flocs may have a median particle size of 10-100 μm. The filler may be selected from the group consisting of calcium carbonate, kaolin clay, talc, titanium dioxide, alumina trihydrate, barium sulfate and magnesium hydroxide. The low molecular weight composition may be a cationic coagulant, the first flocculating agent may be an anionic flocculent, the second flocculating agent may be a cationic flocculent, and both flocculants may have a molecular weight of at least 1,000,000 BRIEF DESCRIPTION OF THE DRAWINGS [0012] A detailed description of the invention is hereafter described with specific reference being made to the drawings in which: [0013] FIG. 1 is a graph showing the improved strength of paper made according to the invention. DETAILED DESCRIPTION OF THE INVENTION [0014] For purposes of this application the definition of these terms is as follows: [0015] “Coagulant” means a composition of matter having a higher charge density and lower molecular weight than a flocculant, which when added to a liquid containing finely divided suspended particles, destabilizes and aggregates the solids through the mechanism of ionic charge neutralization. [0016] “DMAEM” means dimethylaminoethylmethacrylate as described and defined in U.S. Pat. No. 5,338,816. [0017] “DMAEA” means dimethylaminoethylacrylate as described and defined in U.S. Pat. No. 5,338,816. [0018] “DEAEA” means diethylaminoethyl acrylate as described and defined in U.S. Pat. No. 6,733,674. [0019] “DEAEM” means diethylaminoethyl methacrylate as described and defined in U.S. Pat. No. 6,733,674. [0020] “Flocculant” means a composition of matter having a low charge density and a high molecular weight (in excess of 1,000,000) which when added to a liquid containing finely divided suspended particles, destabilizes and aggregates the solids through the mechanism of interparticle bridging. [0021] “Flocculating Agent” means composition of matter that when added to a liquid, destabilizes and aggregates colloidal and finely divided suspended particles in liquid into flocs. [0022] “GCC” means ground calcium carbonate, which is manufactured by grinding naturally occurring calcium carbonate rock [0023] “PCC” means precipitated calcium carbonate which is synthetically produced. [0024] “Preflocculation” means the modification of filler particles into agglomerates through treatment with a particular flocculating agent selected on the basis of the size distribution and stability of the floc that the flocculating agent will form. [0025] In the event that the above definitions or a definition stated elsewhere in this application is inconsistent with a meaning (explicit or implicit) which is commonly used, in a dictionary, or stated in a source incorporated by reference into this application, the application and the claim terms in particular are understood to be construed according to the definition in this application, and not according to the common definition, dictionary definition, or the definition that was incorporated by reference. [0026] At least one embodiment of the invention is a method of making paper, which is strong, has a high filler content, and has superior optical properties. In at least one embodiment of the invention the method of papermaking comprises the steps of: providing filler material, pre-treating at least some of the filler material by preflocculation leading to a decrease in the adsorption of a strength additive on the filler material, and adding both the preflocculated filler blend and the strength additive to the paper mat. [0027] Preflocculation is a process in which, material is treated by two flocculating agents in a manner that optimizes the size distribution and stability of the flocs under a particular shear force prior to its addition to the paper stock. The particular chemical environment and high fluid shear rates present in modem high-speed papermaking require filler flocs to be stable and shear resistant. The floc size distribution provided by a preflocculation treatment should minimize the reduction of sheet strength with increased filler content, minimize the loss of optical efficiency from the filler particles, and minimize negative impacts on sheet uniformity and printability. Furthermore, the entire system must be economically feasible. Examples of preflocculation methods applicable to this invention are described in US Published Application 2009/0065162 A1 and U.S. application Ser. No. 12/431,356. [0028] It has been known for some time that adding strength additives to paper mat increases the strength of the resulting paper. Some examples of strength additives are described in U.S. Pat. No. 4,605,702. Some examples of strength additives are cationic starches, which adhere to the cellulose fibers and tightly bind them together. [0029] Unfortunately it is not practical to add large amounts of strength additives to compensate for the weakness that results from using large amounts of filler in paper mat. One reason is because strength additives are expensive and using large amounts of additives would result in production costs that are commercially non-viable. In addition, adding too much strength additive negatively affects the process of papermaking and inhibits the operability of various forms of papermaking equipment. As an example, in the context of cationic starch strength additives, the cationic starch retards the drainage and dewatering process, which drastically slows down the papermaking process. [0030] Adding filler to the paper mat reduces the effectiveness of the strength additive. Because filler has a much higher specific surface area than fiber, most of the strength additives added into the papermaking slurry go to filler surfaces, and therefore there is less strength additive available to bind the cellulose fibers together. This effect is more acute with PCC compared to GCC because PCC has a much higher surface area and is able to adsorb more strength additive. One method of addressing this situation is by pre-treating the filler material with a coagulant as described in U.S. application Ser. No. 12/323,976. Another method involves using preflocculation instead of a coagulant. [0031] In at least one embodiment the filler content in the paper is increased by the following method: An aqueous dispersion of filler materials is formed and the filler materials are preflocculated before being added to a paper fiber stock. A first flocculating agent is added to the dispersion in an amount sufficient to mix uniformly in the dispersion without causing significant flocculation of the filler particles. A second flocculating agent is then added following the first flocculating agent, in an amount sufficient to initiate flocculation of the filler material in the presence of the first flocculating agent, the second flocculating agent being of opposite charge to the first flocculating agent. A paper mat is formed by combining the preflocculated filler material with the fiber stock and treating this combination with the strength additive. The preflocculation of the filler material enhances the performance of the strength additive. The fiber stock comprises fibers, fillers, and water. [0032] In at least one embodiment, the fibers are predominantly cellulose based. In at least one embodiment the flocculated dispersion is sheared to obtain a particularly desired particle size. [0033] While pre-treating filler particles is known in the art, prior art methods of pre-treating filler particles are not directed towards affecting the adhesion of the strength additive to the filler particles with two flocculants. In fact, many prior art pre-treatments increase the adhesion of the strength additive to the filler particles. For example, U.S. Pat. No. 7,211,608 describes a method of pre-treating filler particles with hydrophobic polymers. This pre-treatment however does nothing to the adhesion between the strength additive and the filler particles and merely repels water to counterbalance an excess of water absorbed by the strength additive. In contrast, the invention decreases the interactions between the strength additive and the filler particles and results in an unexpectedly huge increase in paper strength. This can best be appreciated by reference to FIG. 1 . [0034] FIG. 1 illustrates that a paper produced from a paper mat that includes PCC filler tends to become weaker as more PCC filler is added. When a large amount of PCC is added (over 25%), the addition of a strength additive adds little strength to the paper. Paper made from preflocculated PCC filler combined with a strength additive however increases the strength of the paper to a degree that it is stronger than paper having 10% less PCC that is not preflocculated. Even more surprising was the fact that paper containing preflocculated PCC without a strength additive was almost as strong as the paper with the strength additive. [0035] As a result, at least two conclusions can be reached, 1) the strength agent is more effective in increasing sheet strength with preflocculated filler than with untreated filler and 2) there is a synergistic effect from the combination of strength agent and filler preflocculation which makes it superior to the additive effects of the sum of the strength agent alone plus the filler preflocculation alone. As a result, preflocculation of the PCC filler material leads to the production of paper that is unexpectedly strong. [0036] At least some of the fillers encompassed by this invention are well known and commercially available. They include any inorganic or organic particle or pigment used to increase the opacity or brightness, reduce the porosity, or reduce the cost of the paper or paperboard sheet. The most common fillers are calcium carbonate and clay. However, talc, titanium dioxide, alumina trihydrate, barium sulfate, and magnesium hydroxide are also suitable fillers. Calcium carbonate includes ground calcium carbonate (GCC) in a dry or dispersed slurry form, chalk, precipitated calcium carbonate (PCC) of any morphology, and precipitated calcium carbonate in a dispersed slurry form. The dispersed slurry forms of GCC or PCC are typically produced using polyacrylic acid polymer dispersants or sodium polyphosphate dispersants. Each of these dispersants imparts a significant anionic charge to the calcium carbonate particles. Kaolin clay slurries also are dispersed using polyacrylic acid polymers or sodium polyphosphate. [0037] In at least one embodiment, the strength additive carries the same charge as the second flocculating agent. Strength additives encompassed by the invention include any one of the compositions of matter described in U.S. Pat. No. 4,605,702 and US Patent Application 2005/0161181 A1 and in particular the various glyoxylated Acrylamide/DADMAC copolymer compositions described therein. An example of a glyoxylated Acrylamide/DADMAC copolymer composition is product# Nalco 64170 (made by Nalco Company, Naperville, Ill.). [0038] In at least one embodiment, the fillers used are PCC, GCC, and/or kaolin clay. In at least one embodiment, the fillers used are FCC, GCC, and/or kaolin clay with polyacrylic acid polymer dispersants or their blends. The ratio of strength additive relative to solid paper mat can be 3 kg of additive per ton of paper mat. [0039] In at least one embodiment, the effectiveness of the synthetic strength additive is independent of or despite the presence of some, low amounts, or no amount of starch in the paper mat. In prior art disclosures, it is known that adding between 10 to 20 lbs of starch per ton of paper mat increases the strength of the resulting paper. The addition of materials in such large amounts however is cumbersome and less than ideal. The use of synthetic strength additives in contrast allows similar strength performance to be achieved while requiring the addition of far less strength additive material to the paper mat. In at least one embodiment the synthetic strength additive is cationic or anionic or contains both cationic and anionic functional groups. [0040] Unfortunately synthetic strength additives are known to be far more expensive than starch. In some processes the cost of using bulky large amounts of starch may be less expensive than smaller and more easily manageable amounts of synthetic strength additives. The combination of the strength adding effects of synthetic strength additives in low dosages combined with the preflocculation allows unexpected degrees of strength to be observed than would otherwise be expected with such low dosages of strength additives and in the absence of large amounts or any amount of starch. EXAMPLES [0041] The foregoing may be better understood by reference to the following example, which is presented for purposes of illustration and is not intended to limit the scope of the invention. [0042] A furnish was produced containing 25% pine softwood and 75% eucalyptus hardwood. Both the softwood and hardwood were reslushed from dry lap. The filler used was Albacar HO PCC obtained from Specialty Minerals Inc. The filler material preflocculation was performed with the dual flocculant approach described in example 14 of U.S. application Ser. No. 12/431,356. During the handsheet preparation, 6 lb/ton strength additive (Nalco 64114, a glyoxalated Acrylamide/DADMAC copolymer available from Nalco Company, Naperville, Ill., USA) was added. The results are displayed in FIG. 1 . [0043] While this invention may be embodied in many different forms, there are shown in the drawings and described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific papers, and any other referenced materials mentioned herein are incorporated by reference in their entirety. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments described herein and incorporated herein. [0044] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims. [0045] All ranges and parameters disclosed herein are understood to encompass any and all subranges subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, (e.g. 1 to 6.1), and ending with a maximum value of 10 or less, (e.g. 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range. [0046] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
The invention provides a method of producing paper with a higher proportion of mineral filler particles than is otherwise be possible without the expected loss in paper strength by preflocculating the filler particles. The method allows for the use of the greater amount of filler particles by coating at least some of the filler particles with a material that prevents the filler materials form adhering to a strength additive. The strength additive holds the paper fibers together tightly and is not wasted on the filler particles.
3
BACKGROUND OF THE INVENTION As set forth in 1980 in John J. Osborn's U.S. Pat. 4,197,858, entitled Sensing Liquid Trap for Respiratory Gas Analyzing Systems, he said, although reliable and rapid response carbon dioxide gas meters for respiratory measurements have been developed for more than twenty-five years, such meters have not been widely used for respiratory monitoring. Yet the continuous measurement of respiratory CO 2 concentration is very useful in the care of critical patients undergoing anesthesia, or on mechanical respirators. He further said the non use was based on the impracticability of any moisture or water traps in their collecting of water, before the water or moisture could reach the CO 2 gas analyzer, on a continuous basis and without degrading the signal capabilities of the CO 2 gas analyzer. He then illustrated and described his sensing, liquid trap made of plastic in an upright hollow cylindrical shape in which the patient's breaths enter downwardly, and after a flow directional change, to eliminate water, the drier breaths flow upwardly, enroute, via a shutoff valve, to the CO 2 gas analyzer. When Mr. Osborn's liquid trap, using the fluidic separation process, fills with water, a sensing circuit operates to shut off the valve, thereby protecting the CO 2 gas analyzer. Mr. Richard A. Cronenberg, in 1982, in his U.S. Dept. No. 4,327,718, entitled, Continuously draining Trap for Removal of Condensate From a Patient Breathing Circuit, illustrates how his trap and a trap, like Mr. Osborne's, are positioned between a patient and their respective breathing apparatus. As indicated by the disclosures of the water traps of Messrs. Osborn and Cronenberg, there remained a need for a very effective small water trap to be closely secured adjacent a respiration monitor, with both being very resistant to damage, when used together in critical areas of hospitals and for portable applications in harsh environments as found by paramedics, and during their use the excellent monitoring of the respiration of a critical patient would be successfully undertaken. SUMMARY OF THE INVENTION A very effective, relatively low cost, small water absorbing trap is compactly and protectively arranged for attachment to a rugged, shock resistant comparatively small infrared exhaled carbon dioxide apnea monitor. As so positioned adjacent the apnea monitor and then attached to an end of a sampling cannula, in turn positioned at the opposite end in the nares of a critical patient, this water absorbing trap has a hydrophyllic polymer arranged about a passageway of like diameter to the inside diameter of the cannula, to effectively absorb water or moisture from the passing breaths of the critical patient, so no moisture or water will enter the apnea monitor, and also the adequate analysis of the carbon dioxide of the breaths of the patients will not be impaired. In a preferred embodiment, within a surrounding molded and/or machined body or housing, a hydrophyllic polymer is placed, such as a high density polyethylene preexpanded to a porosity of 30 microns and pretreated to be hydrophyllic. This polymer has a 0.8" diameter, a 0.2" thickness along the passageway, and a 0.04" center hole serving to continue the overall passageway. After a relatively long operational time of absorbing water, if water is no longer being absorbed by this hydrophyllic polymer, then preferably a hydrophyllic pellet made of cross-linked polymer of polyvinyl pyrrolidone, spaced 0.05" away downstream, intercepts the unabsorbed water and quickly saturates sufficiently to expand and to thereby close its own 0.04" passageway originally matching the internal diameter of the sampling cannula. The water is then compltely stopped and kept from entering the apnea monitor, which thereafter quickly, by sound and sight indications alarms the doctos, nurses, and/or paramedics, in the same way such sound and sight indications would alarm them, when a critical patient had stopped breathing. A preferred embodiment of an expandable hydrophyllic pellet has a 0.2" diameter, a 0.1" thickness, and a 0.04" diameter passageway. The pellet is initially protected from moisture carried in vapors by a thin film, which does not, however, later protect it from water. DRAWINGS OF THE PREFERRED EMBODIMENTS A preferred embodiment of the water absorbing trap to protect an infrared absorption exhaled carbon dioxide apnea monitor of a critical patient's respiration is illustrated in the drawings, wherein: FIG. 1 is an isometric view illustrating the in use positioning of this water absorbing trap secured adjacent to the infrared exhaled carbon dioxide apnea monitor, and the sampling cannula extending from a nose adapter positioned at the nares of a critical patient to the a water absorbing trap, as the patient is receiving oxygen through another large diameter cannula; FIG. 2 is an enlarged isometric view of a nose adapter or nares fitting for an oxygen cannula of oxygen equipment, provided with extra fittings to receive a smaller cannula, which conducts the patient's exhaled breaths to the water trap and on to the apnea monitor; FIG. 3 is a cross section of a water absorbing trap, installed between the sampling cannula and the apnea monitor, utilizing both a hydrophyllic polymer to absorb the water and moisture from the breaths of the critical patient, and a downstream hydrophyllic pellet to quickly saturate with water and thereby to expand and shut off the passage of water to the apnea monitor if the hydrophyllic polymer completely fills with water; FIG. 4 is an exploded isometric view of the water absorbing trap previously shown assembled in FIG. 3, with its connections to the sample cannula and the apnea monitor; FIG. 5 is a cross section of another water absorbing trap similar to the water absorbing trap illustrated in FIGS. 3 and 4, not having however, the downstream hydrophyllic pellet; FIG. 6 is a cross section of another water absorbing trap having a larger water absorbing hydrophyllic polymer and a downstream hydrophyllic shutoff pellet; and FIG. 7 is a cross section of another absorbing trap having a larger water absorbing hydrophyllic polymer, but not having a downstream hydrophyllic shutoff pellet. DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred Positioning of the Water Absorbing Trap to Protect the Apnea Monitor Selected embodiments of a water absorbing trap 20, as illustrated in FIGS. 1 and 3 through 7, are particularly suitable for adjacent securement to an infrared exhaled carbon dioxide apnea monitor 22, making this overall combination 24 a very compact and strong respiration monitor assembly 24 for utilization in critical areas of a hospital and for portable applications in harsh environments found by paramedics. By using a cannula 26 conveniently extended from a nose adapter 27 positioned at the nares of a critical patient to the entry 28 of the water absorbing trap 20 located adjacent to the apnea monitor 22, the combination 24 of the water trap 20 and monitor 22, are readily and quickly placed in a convenient location nearby the critical patient during their necessary operating period. Constant Diameter of Exhaled Respiration Passageway In all embodiments the cross sectional area 30 of the exhaled respiration passageway 31, defined by the internal diameter of the sampling cannula 26, is maintained to keep the frequency response level of the apnea monitor 22 as high as possible. Therefore, as illustrated in FIGS. 2 and 4, the first embodiment 32 of the water absorbing trap 20, has a surrounding body or housing 34 which has a minimum internal diameter 36 equalling the internal diameter of the cannula 26, thereby maintaining the cross section area 30. Utilization of Standard Cannulae and Associated Standard Fittings Standard cannulae and associated standard fittings are used to make connections to and from the water absorbing trap 20 and on to the apnea monitor 22. These standard fittings are already used in other medical applications and they are known in reference to one of the sources as Luer fittings. At the entry end of all the embodiments of the water absorbing trap 20, the respective entries 28 are enlarged to receive a hollow insertable end 38 of a receiving adaptor 40. It is formed at its opposite end 42 to removably but firmly receive a standard end fitting 44 of cannula 26, by utilizing a central hollow insertable end 46 equipped with partial circular flange portions 48. They are threaded onto the threaded interior 49 of the standard end fitting 44. A Water Absorbing Polymer is Positioned and Protected Within the Housing of the Water Absorbing Trap Soon after entry into these embodiments of the water absorbing trap 20, such as the embodiment 32, a water absorbing polymer 50 is placed in an internal recess 52 of the body 34 and formed with a center passageway 54 maintaining the cross section area 30 of the exhaled respiration passageway 31. The surrounding hollow cylinder 56 of the water absorbing polymer 50 is selectively sized to absorb water and moisture from the exhaled breaths of the critical patient. Also in respect to such sizing the thickness of this hollow cylinder 56 must be large enough to create a sufficiently long enough passageway surface area 58 to initially and to continuously absorb all the moisture and water from the passing exhaled breaths during the specified operational times associated with the selected capacity of each water absorbing polymer 50. A Preferred Water Absorbing Polymer Material A high density polyethylene first expanded to a porosity of 30 microns and then treated to be hydrophyllic is a preferred water absorbing polymer material 50 for placement within the internal recess 52 of the body or housing 34 of this water absorbing trap 20. The Utilization of an Automatic Shutoff of the Flow of Exhaled Breaths Centering on the Use of a Second Polymer, Which Upon Contact with Water Swells to Close Up the Exhaled Respiration Passageway. As illustrated in FIGS. 3 and 4, in the first embodiment 32 of the water absorbing trap 20 or in the embodiment shown in FIG. 6, to provide for the time when the water absorbing shutoff of the flow of exhaled breaths will occur before they reach the apnea monitor 22, thereby avoiding the entry of moisture and water into its interior. Such unwanted entry of moisture and water tends to downgrade the signals produced, often cancelling them and completely disrupting the operation of the apnea optical infrared absorption sensing of the exhaled carbon dioxide contained in the critical patient's breaths. This automatic shutoff of the flow of exhaled breaths centers on the use of a second polymer 62, which upon contact with water swells, but does not dissolve, to close up the exhaled respiration passageway 31. As shown in FIGS. 3 and 6 the body or housing 34 has a second smaller internal recess 64 located immediately adjacent to the first internal recess 52, to receive and position this second polymer 62 at a slightly spaced distance downstream. The second polymer 62 is formed as a hollow cylinder 66 having a centered passageway 68 matching the cross section area 30 of the exhaled respiration passageway 31. It is sized to sufficiently expand and block off this passageway 31, thereby protecting the apnea monitor. However, until the water absorbing polymer 50 or 51 is completely filled, this spaced apart pellet shaped shutoff second polymer 62 will not activate, because sufficient water and moisture must reach it before it will expand and block the exhaled respiration passageway 31. A Preferred Elongating, Swelling or Expanding Polymer Material Activated by Water A cross linked pyrrolidone, after formation into a pellet 62, is covered with a coating of a humidity insensitive material, such as a film of 90% polyvinyl pyrrolidone, which is not cross linked, and a 10% aryl-sulfonamide formaldehyde resin. After the water absorbing polymer 50 is filled, and then water passes on to contact this shutoff pellet 62, this coating dissolves and the molecular chain of this polymer 62 elongates and the overall swelling action places sufficient portions of expanding pelletized polymer 62 across the cross section area 30 of the exhaled respiration passageway 31. The centered passageway 68 of the second polymer 62 is thereby self filled and there no longer is any open sampling conduit 31. In making this pellet 62 of polymer, the coating material selected reduces the sensitivity of the cross link polyvinyl pyrrolidone to humidity, but it does not hinder the swelling of this polymer when it is wetted. Moreover, although the pellet of polymer 62 expands upon being wetted it remains insoluble in water. Therefore, it is not pulled along the sampling conduit 31, thereby effectively maintaining the intended automatic blocking of the exhaled respiration passageway 31, so no moisture laden exhaled breath samples will reach the interior of the apnea monitor 22. Selected Sizes of the First and Second Polymers In the illustrated preferred embodiments the first water absorbing polymer shown in FIGS. 3, 4 and 5, in one specific embodiment, has a 0.8" diameter, 0.2" thickness, and a 0.04" diameter center passageway. This selected diameter is not critical but is sized in respect to the specified amount of water to be absorbed during the planned maximum operating periods and at a flow rate of 250 cc per minute. The selection of the 0.2" thickness is somewhat critical for this thickness dimension determines the internal surface area 58 of the water absorbing polymer 50 that is exposed to the exhaled breaths of the critical patient, sometimes referred to as the gas stream. This surface area 58 has to have sufficient path length to fully contact and absorb the water as it tries to pass by at this flow rate of 250 cc per minute. The 0.04" diameter of the center passageway 54, sometimes referred to as the hole 54, is the same diameter as the inside diameter of the cannula 26, sometimes referred to as the sample tube, sampling conduit, or exhaled respiration passageway 31. The second polymer 62 serving as the automatic shutoff pellet 62 has a 0.04" diameter hole to continue to ensure the integrity of the gas stream until the exhaled breaths are to be automatically or intentionally shut off. By having a 0.2" diameter and a 0.1" thickness sufficient crossed linked polymer is available in the shutoff pellet 62 to swell and thereby shut off the 0.04" diameter exhaled respiration passageway 31 and protect the apnea monitor 22. As noted previously the above selected sizes are based on a patient's breath flow rate of 250 cc per minute. As the thickness increases, the frequency response realized in the apnea monitor 22 decreases. Therefore generally, in respect to the lower breathing capacities of infants and small children, the first water absorbing polymer 62 has the smaller thickness as shown in FIGS. 3, 4 and 5, whereas in respect to the higher breathing capacities of adults, the polymer 63 has the larger thickness as shown in FIGS. 6 and 7. Current Sources of Polymers The water and moisture absorbing high density polyethylene selected to serve as the water absorbing polymer 50 after being treated to the hydrophyllic is preferred to be expanded to each a porosity of 30 microns. At this porosity the water collection is maximized while the diffusion of the carbon dioxide into this absorption media 50 is minimized. Moreover, the signals forthcoming from the apnea monitor 22, as the optical sensing of the exhaled carbon dioxide continues, based on infrared absorption closely compare with the signals that would be forthcoming if the water absorbing trap 20 were to be bypassed. As described previously the thickness of the polymers 62 or 63 effects frequency responses in the apnea monitor 22. Also the frequency response is effected in reference to the porosity of the polymers 62 or 63. As the porosity increases to 50 microns, the signal slightly becomes less effective. The same decrease is noted in stages as the porosity changes to 90 microns and 125 microns. However, as porosity increases the water capacity goes up, therefore a lowered frequency response could be selectedto provide a greater water absorbing capacity of the polymers 62 or 63. A current source of hydrophyllic treated polyethylene, is sold under the trademark of INTERFLO, by the Chromex Chemical Corporation of Brooklyn, N.Y. It is available in porosities ranging from 0.8 to 120 microns. Preferably, in reference to the water absorbing polymer 50 positioned in the water absorbing trap 20, the preferred porosities range from 25 to 50 microns. In this range, enough water and moisture absorption capacity is provided while at the same time the carbon dioxide signal is not substantially affected. The expandable hydrophyllic polymer serving as the second polymer or automatic shutoff pellet 62, is a cross linked polymer of polyvinyl pyrrolidone. Such an expandable polymer is sold under the trademark POLYPLASDONE XL, from G.A.F. Corporation. Other Embodiments of a Water Absorbing Trap Other ways, not shown, may be used to timely shut off the exhaled respiration passageway 31, when the water absorbing trap 20 is filled. If so, then other embodiments 72 and 73 of water absorbing traps 20 are provided, as illustrated in FIGS. 5 and 7. There is no second recess 64 because a shutoff pellet 62 is not used. In the embodiments shown in FIGS. 3, 4 and 5, the smaller water absorbing polymer 50 is illustrated, which although it fills with water in a shorter time period, the signals being monitored are better, especially when the patients are babies and small children. In the embodiments shown in FIGS. 6 and 7, the larger water absorbing polymer 51 is illustrated, which fills with water over a longer time period, however the signals being monitored may be somewhat less distinct. The water absorbing traps 20 in all embodiments will be produced at sufficiently lower costs, so they will be considered expendable. In some production procedures the water absorbing polymers 50 and 51 wll be inserted into the respective recesses 52 or 53 and thereafter an end encompassing disc 74 is fitted on the body 34 or 76. It is positioned by using its integral inserted portion 78. Also there is centered passageway 80 in this disc 74 to form the entry 28 which receives the insertable end 38 of the receiving adaptor 40. The Standard Luer Type Connections Used to Secure the Water Absorbing Trap to the Apnea Monitor In FIGS. 3 and 4 in a cross sectional view and in an exploded view, the water absorbing trap 20 is illustrated in respect to its connection to the apnea monitor 22. A receiving unit 84 is provided on the apnea monitor 22, centered about the entry 86 of the exhaled respiration passageway 31, as this passageway 31 continues into the apnea monitor 22. An interconnect unit 82 is threaded on the receiving unit 84. Thereafter the body 34 of the water absorbing trap 20 firmly interfits with this interconnect unit 82. When so arranged and connected, or similarly arranged and connected, with this apnea monitor 22, the water absorbing trap 20 is immune to the typical monitoring problems of motion artifact, cardiac activity artifact, electrode placement and sensitivity changes, otherwise known to be commonly associated with impedance pneumography monitoring. The overall assemblies are affordable, light weight, and reliable, to be efficiently and effectively utilized by doctors, nurses, paramedics, and others, who are providing excellent care to a critical patient.
A water trap is connected to a cannula which has a substantially constant internal diameter and which communicates moisture laden patient exhalations therethrough to an analyzer. The trap includes a body having a recess adapted for receiving a water absorbing compound which has an aperture therethrough for communicating dried exhalations to the analyzer. A second recess in the body is adapted for receiving another water adsorbing compound which similarly has an aperture of same diameter. When the first compound becomes substantially saturated and thereby permits moisture laden exhalations to pass therethrough, then the second compound absorbs those exhalations and swells for thereby closing its aperture and preventing communication of moisture laden exhalations to the analyzer.
8
BACKGROUND OF THE INVENTION [0001] The present invention relates to a connection device for connection of building members and a building comprising members thus connected. [0002] Buildings having a frame composed of building members such as columns, beams, or the like have been extensively built for a long time, and there have been increasing opportunities for using building members of concrete as well as wooden building members. Correspondingly, it has been desired to propose innovative measures in addition to conventional measures for mutual connection of building members. SUMMARY OF THE INVENTION [0003] In view of the above, the applicant of the present application has developed an epoch-making connection device of very high commercial value for connection of building members and a type of building comprising members thus connected. [0004] An explanation will be given to the gist of the invention with reference to the accompanying drawing. [0005] The gist of the invention resides in a connection device for connection of building members, such as vertical members 1 and horizontal members 2 , which constitute a building, and second connection portions 5 , to which are connected first connection portions 4 which are provided on building members such as the vertical members 1 and the horizontal members 2 , provided on the base body 3 , the first connection portion 4 and the second connection portion 5 being connected to each other by a first fitted annular body 6 to be fitted by opposing grooves onto an edge of both the first connection portion 4 and the second connection portion 5 , and a second fitted annular body 7 which is taper press fitted onto the first fitted annular body 6 . [0006] Also, the gist of the invention according to claim 1 resides in a connection device for connection of building members in which the second connection portions 5 are provided in two or more locations on the base body 3 . [0007] Also, the gist of the invention according to claim 1 or 2 resides in a connection device for connection of building members in which the base body 3 , second connection portions 5 , building members, and the first connection portions 4 are hollow members. [0008] Further, the invention relates to a building in which building members such as vertical members 1 and horizontal members 2 are connected together by the connection device according to any one of claims 1 to 3 to form a frame. [0009] Also, the invention relates to a connection device, in which the building members are hollow bodies having a square cross sectional shape in a direction perpendicular to a longitudinal direction. [0010] Further, inner holes of the building members are preferably circular in cross sectional shape in a direction perpendicular to a longitudinal direction. [0011] Further, the building members are preferably formed from concrete. [0012] In the invention, the first connection portion 4 provided on a building member such as vertical members 1 and horizontal members 2 , and the second connection portion 5 provided on the base body 3 are caused to approach each other and the first fitted annular body 6 is fitted onto the first connection portion 4 and the second connection portion 5 , so outer surfaces of the first connection portion 4 and the second connection portion 5 fit into an inner surface of the first fitted annular body 6 , and further the second fitted annular body 7 is taper press fitted onto the first fitted annular body 6 so that the first fitted annular body 6 is fixed, thus connecting the respective building members to the base body 3 . [0013] Accordingly, the building members are rigidly connected to the base body in a rapid and sure manner. [0014] As described above, the invention exhibits innovative function and effects which have not been found in the prior art. BRIEF DESCRIPTION OF THE DRAWINGS [0015] [0015]FIG. 1 is an exploded, perspective view showing a first embodiment; [0016] [0016]FIG. 2 is a cross sectional view showing an essential part of the first embodiment; [0017] [0017]FIG. 3 is a cross sectional view taken along the line A-A in FIG. 2; [0018] [0018]FIG. 4 is a view illustrating a state in which the first embodiment is used; and [0019] [0019]FIG. 5 is an exploded, perspective view showing a second embodiment. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0020] FIGS. 1 to 4 show a first embodiment of the invention, and FIG. 5 shows a second embodiment, which embodiments are described below. [0021] First, an explanation will be given to the first embodiment. [0022] The first embodiment serves to connect columns 1 and beams 2 which serve as vertical members and horizontal members constituting a building, using a base body 3 provided with second connection portions 5 which are connected to first connection portions 4 provided on building members such as the columns 1 and beams 2 , the first connection portions 4 and the second connection portions 5 being structured to be connected to each other by means of a first fitted annular body 6 , which is fitted onto an edge of the first connection portion 4 and an edge of the second connection portion 5 for groove fitting, and a second fitted annular body 7 which is further fitted onto the first fitted annular body 6 for taper fitting. [0023] An explanation will be given below in detail to respective parts according to an embodiment. [0024] The base body 3 is a suitable hollow, metallic member shown in FIGS. 1 and 2, four cylindrical portions 8 being formed on the peripheral surface projecting radially, and cylindrical holes 8 c of the cylindrical portions 8 and an inner hole 3 a of the base body 3 being structured to communicate with each other (In addition, while in the present embodiment the cylindrical portions 8 are shown as projecting from the base body 3 in six directions, configurations in which the cylindrical portions project in, for example, one direction, or two orthogonal directions, or three directions, are suitably adopted provided that a feature of the invention is displayed. [0025] The respective cylindrical portions 8 are formed to have a flange 8 b at their edges, the flange facing the base body formed with a groove 8 a. When this groove and flange are butted against a cylindrical portion 9 described later, the groove 8 a and the flange 8 b form the first connection portion 4 which together with a groove 9 a and a flange 9 b (the second connection portion 5 ) formed on an edge of the cylindrical portion 9 define a grooved portion 10 , which enables a part of the inner surface of the first fitted annular body 6 to be fitted onto both the first connection portion 4 and the second connection portion 5 . [0026] The cylindrical portion 9 is a suitable metallic member formed as shown in FIGS. 1 and 2, set to the same diameter as that of the cylindrical portions 8 of the base body 3 . [0027] Also, the cylindrical portion 9 is foxed at an edge with a flange 9 b , a groove 9 a being formed on the flange facing the base body. [0028] Also, the cylindrical portion 9 is formed at the base end thereof with a fixed attachment piece 9 c , which is to be secured to an end surface of building members such as the columns 1 , beams 2 , or the like, the fixed attachment piece 9 c being formed with a plurality of holes 9 c ′, each of which permits a length of steel threaded rod 11 exposed from an end surface of the building member and enables fixed attachment of the cylindrical portion 9 to the end surface of the building member by screwing a nut 13 onto the steel threaded rod 11 . [0029] The first fitted annular body 6 is a suitable metallic member formed to assume a C-shape as shown in FIGS. 1 to 3 , cut at one position and possessing elasticity affording slight opening. Accordingly, such elasticity is made use of to allow the first fitted annular body 6 to be fitted onto the grooved portion 10 defined by the first connection portion 4 associated with the cylindrical portion 9 and the second connection portion 5 associated with the base body 3 . [0030] Also, the first fitted annular body 6 is formed on its outer peripheral surface with an inclined surface, which is taper press fitted into an inner surface, described later, of the second fitted annular body 7 . [0031] Also, the first fitted annular body 6 is formed on an inner peripheral surface thereof with two ridges 6 a. [0032] The first fitted annular body 6 is structured to have its grooves fitted onto the grooved portion 10 to connect both the first connection portion 4 and the second connection portion 5 to each other when it is fitted onto the grooved portion 10 defined by the first connection portion 4 associated with the cylindrical portion 9 and the second connection portion 5 associated with the base body 3 . Concretely, the two ridges 6 a are fitted into the depression 9 a and the depression 8 a , and the flange 9 b and the flange 8 b are positioned between the two ridges 6 a. [0033] The second fitted annular body 7 is a suitable metallic member formed to assume an annular-shape as shown in FIGS. 1 to 3 , and structured to be preset to a diameter affording fitting the inner surface of the second fitted annular body 7 onto the outer peripheral surface of the first fitted annular body 6 by taper press fitting (a wedging action is generated). [0034] Also, in the embodiment, the building members such as the columns 1 , beams 2 , or the like are hollow bodies formed from concrete. [0035] Concretely, molding of the columns 1 and the beams 2 is carried out by means of a so-called hollow centrifugal molding technique. [0036] The so-called hollow centrifugal molding technique is one, in which a square-shaped form is rotated while concrete placing is performed, and when rotation of the form is stopped and the form is removed, inner circular holes 1 a, 2 a are formed centrally in the longitudinal direction of the form. A hollow body obtained by the hollow centrifugal molding technique is very rigid since centrifugal forces press the concrete. [0037] In the embodiment, the square-cylinder form is used to make the columns 1 and the beams 2 square in cross section in a direction perpendicular to the longitudinal direction, and the inner holes 1 a , 2 a are circular. [0038] Also, in the embodiment, the columns 1 and he beams 2 are formed to be of a PC concrete structure (prestressed concrete structure), in which steel wires 11 (piano wire, reinforcement, or the like) as tension members are introduced and tensioned, thus making rigid building members of high durability. [0039] With a building having a framed structure, in which the columns 1 and the beams 2 structured in the above manner are used and connected together by a connection device according to the embodiment as shown in FIG. 4, the respective hollow holes 1 a , 2 a , 3 a , 8 c , 9 d in the columns 1 , the beam 2 , the base body 3 and the cylindrical portion 9 can be also made use of as piping such as gas pipes, water service pipes and a space in which wiring such as electric wires and telephone wires can be placed. [0040] The reference numeral 12 denotes fire resistive covering materials. [0041] Since the embodiment is configured in the above manner, the first connection portion 4 provided on a building member, such as the column 1 and the beam 2 comprising a building, and the second connection portion 5 provided on the base body 3 are caused to approach each other and the first fitted annular body 6 is fitted onto the first connection portion 4 and the second connection portion 5 so that portions of the outer surfaces of the first connection portion 4 and the second connection portion 5 fit into the inner surface of the first fitted annular body 6 , and further the second fitted annular body 7 is taper press fitted onto the first fitted annular body 6 so that the first fitted annular body 6 is fixed, thus connecting the respective building members to the base body 3 . [0042] Accordingly, the building members are rigidly connected to the base body 3 in a rapid and sure manner. [0043] An explanation will be given below to a second embodiment. [0044] According to the second embodiment, a first fitted annular body 6 composed of a pair of half bodies 6 A, 6 B is adopted as shown in FIG. 5, and adapted to be fitted onto the grooved portion 10 defined by the first connection portion 4 associated with the cylindrical portion 9 and the second connection portion 5 associated with the base body 3 in such a manner that it sandwiches the grooved portion from right and left. [0045] The other features are the same as those of the first embodiment, and so an explanation therefor is omitted.
A connection device for connection of building members, and a building comprising members thus connected, exhibiting innovative function and effect which have not been found in the prior art. The connection device for connection of vertical members and horizontal members which comprise a building consists of a base body on which second connection portions are provided to be connected to first connection portions provided on building members such as vertical members, horizontal members, the first connection and the second connection being connected to each other by a first fitted annular body to be fitted by groove contact onto edges of both the first connection portion and the second connection portion, and a second fitted annular body adapted to be taper press fitted onto the first fitted annular body.
4
CROSS-REFERENCE TO RELATED APPLICATION This application is based upon and claims benefit of priority of Japanese Patent Application No. 2000-390855 filed on Dec. 22, 2000, the content of which is incorporated herein by reference. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a semiconductor sensor chip having a diaphragm for detecting pressure, acceleration or the like, the semiconductor chip being separated from a semiconductor wafer by dicing. 2. Description of Related Art It is generally known to form a thin diaphragm for detecting a pressure on a semiconductor sensor chip by making a cavity under an anisotropic etching process. There is a problem, however, that sharp corners are formed at bottom portions of the cavity if the cavity is etched out by the anisotropic etching. Since a stress is concentrated at the sharp corners, a mechanical strength of the thin diaphragm is reduced. JP-A-11-97413 proposes a method for rounding the sharp corners of the cavity by additionally performing electrochemical isotropic etching after the cavity is formed by the anisotropic etching process, thereby to reduce the stress imposed on sharp corners and to improve the mechanical strength of the diaphragm. Conductor lines have to be formed along column and row dicing lines on the semiconductor wafer to apply a voltage for the electrochemical isotropic etching. In the conventional method, however, it is highly possible that a part of a conductor material forming the conductor lines remains on individual chips after the sensor chip is separated by dicing. If the conductor remains on the semiconductor sensor chip, particles of the conductor adhere to diced-out sides of the sensor chip, and thereby a current leakage occurs on the side surfaces thereof. To prevent the leakage, it is proposed to use a protective diode connected between a sensor circuit and the conductor lines. However, the chip size has to be larger if such a diode is additionally used. SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problem, and an object of the present invention is to provide an improved semiconductor sensor chip having a diaphragm, in which current leakage is prevented without using a protecting diode. Another object of the present invention is to provide a method of manufacturing such an improved semiconductor sensor chip. A semiconductor wafer having an upper layer and a lower layer, both layers forming a P-N junction plane therebetween, is prepared. A plurality of sensor elements including strain gauges are formed on the upper layer of the wafer. Each sensor element is separated from one another by interstices running in column and row directions on the wafer. An impurity is diffused in the upper layer to form first diffused layer positioned along the interstices, and further the same impurity is diffused along the P-N junction plane to form second diffused layer positioned underneath the first diffused layers. The impurity density in the first and the second diffused layers is made higher than that of the semiconductor wafer. Then, conductor lines are formed on the upper layer to cover the first diffused layers. Portions of the lower layer are etched to form diaphragms, each positioned underneath each sensor element. The diaphragms are formed by first performing anisotropic etching and then performing isotropic etching by applying an electrical voltage to the lower layer through the conductor lines and the first and second diffused layers. Corners of cavities formed by the anisotropic etching are rounded by the isotropic etching, thereby to enhance mechanical strength of the diaphragms. Then, the semiconductor wafer is diced with a dicing blade along the conductor lines formed in the interstices to separate individual sensor chips. A width of the dicing blade is made wider than a width of the conductor lines, so that all of the conductor lines are removed by dicing. Preferably, a width of the first diffused layers formed underneath the conductor lines is made narrower than the width of the conductor lines to ensure all of the first diffused layers are removed by dicing when the conductor lines are all removed. Further, a width of the second diffused layers is made wider than that of the first diffused layers, so that the second diffused layers expose to sides of the semiconductor chips after they are diced out. Since the conductor lines and the first diffused layers are all removed by dicing, electrical leakage due to leftover particles is surely avoided. Further, the electrical voltage for the isotropic etching is effectively applied to the lower layer through the second diffused layers which are made wider than the first diffused layers. The second diffused layers exposed to the side surfaces of the sensor chip effectively separate the upper layer and the lower layer. Other objects and features of the present invention will become more readily apparent from a better understanding of the preferred embodiment described below with reference to the following drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view showing a semiconductor sensor chip diced out from a semiconductor wafer; FIGS. 2A -2D are cross-sectional views showing a sequence of a manufacturing process of the sensor chip according to the present invention, each showing a portion of a semiconductor wafer including an interstice along which individual sensor chips are separated by dicing; and FIG. 2E is a plan view showing a part of the wafer surface on which conductor lines are formed. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment of the present invention will be described with reference to accompanying drawings. FIG. 1 shows a semiconductor sensor chip diced out from a wafer that includes a plural sensor chips formed thereon. This sensor chip is used for detecting a pressure such as a fuel pressure in an automotive vehicle. A substrate of the sensor chip (a semiconductor wafer on which plural sensor chips are formed) is composed of a P − type silicon substrate 2 and an N − type epitaxial layer 3 formed the substrate 2 . The sensor chip is bonded to a glass substrate 1 . The P − type silicon substrate 2 is etched from its rear surface forming a cavity 2 c and a thin diaphragm 2 a . Upper corners 2 b of the cavity 2 c are rounded by isotropic electrochemical etching. P + type high density diffused layers 4 a are formed between the substrate and the epitaxial layer 3 . Strain gauges 6 are formed on the front surface of the N − epitaxial layer 3 and covered with a silicon oxide film 7 . The silicon oxide film 7 is further covered with a silicon nitride film 8 . Wires (not shown) connecting strain gauges 6 are also formed on the front surface of the N − type epitaxial layer 3 . A manufacturing process of the sensor chip will be described with reference to FIGS. 2A-2E. A plurality of sensor chips are formed on the semiconductor wafer, each separated from one another by column and row interstices 9 . Individual sensor chips are cut out form the wafer by dicing along the interstices 9 . As shown in FIG. 2A, the P + type high density diffused layer 4 a is first formed on the front surface of the P − type silicon substrate 2 , and then the N − type epitaxial layer 3 is formed thereon. Then, the strain gauges 6 and P + type high density diffused contact 4 b are formed on the front surface of the epitaxial layer 3 under known processes including oxidized film formation, photo-etching, ion-implantation, diffusion and so on. The P + type high density diffused contact 4 b is used as a contact for giving a potential to the silicon substrate 2 . The P + type high density diffused contact 4 b is formed to contact the P + type high density diffused layer 4 a . Other high density diffused layers (not shown) for insulating circuit elements are also formed at the same time. As shown in FIG. 2B, a conductor line 5 is formed on the front surface of the N − type epitaxial layer 3 at a position covering the P + type high density diffused contact 4 b . The conductor line 5 is formed in the same process forming wirings of the sensor circuit. The conductor line 5 is used for supplying voltage to the substrate 2 for isotropically etching the cavity 2 c (explained later). The conductor line 5 and the N − type epitaxial layer 3 are connected to each other by Schottky contact. Then, the silicon oxide film 7 and the silicon nitride film 8 are formed by patterning to cover the strain gauges 6 and associated circuits. The interstices 9 which run in the column and row directions on the wafer surface are provided to separate the sensor chips. Then, as shown in FIG. 2C, the P − type silicon substrate 2 is anisotropically etched using an aqueous solution such as KOH from the rear surface thereof. Portions of the substrate 2 are removed by the anisotropic etching, thereby forming the cavity 2 c and the diaphragm 2 a . Then, a voltage is supplied to the substrate 2 from the conductor line 5 through the P + type high density diffused contact 4 b and the P + type high density diffused layer 4 a . The voltage is supplied while dipping the substrate 2 in the aqueous solution such as KOH. By supplying the voltage, an anode-oxidized film covering the surface of the cavity 2 c is formed, and sharp corners 2 b formed at bottom corners of the cavity 2 c are rounded, as shown in FIG. 2D, by isotropically etching the anode-oxidized film. By rounding the cavity corners 2 b , the mechanical strength of the diaphragm 2 a are sufficiently improved. The process of rounding the cavity corners 2 b is carried out in the same manner as described in JP-A-11-97413 which is referred to in the background section above. Then, the glass substrate 1 is bonded to the rear surface of the substrate 2 , as shown in FIG. 1 . Then, the wafer is diced with a dicing blade along the conductor lines 5 formed in the interstices 9 . Thus, the wafer is separated into individual sensor chips. The width of the dicing blade W is wider than the width of the conductor line 5 and narrower than the width of the interstice 9 , as shown in FIGS. 2D and 2E. Since the width of the dicing blade W is wider than the width of the conductor line 5 , the conductor line 5 is entirely removed by the dicing process without leaving any part thereof. Therefore, particles of the conductor line 5 do not adhere to the diced-out side surface of the sensor chip. Thus, the current leakage due to the remaining conductor particles which occurred in the conventional process is eliminated in the process according to the present invention. Accordingly, it is not necessary to use a protective diode for preventing the leakage. The width of the P + type high density diffused contact 4 b is made smaller than the width of the conductor line 5 . Therefore, the contact 4 b is entirely removed in the course of the dicing process, and the leakage due to the particles of contact 4 b is also avoided. Further, it is guaranteed that the P + type high density diffused contact 4 b is entirely removed if it is confirmed that the conductor line 5 is removed by inspecting the sensor chip from outside. The width of the P + type high density diffused layer 4 a is made much wider than the width of the P + high density diffused contact 4 b , as shown in FIGS. 2A-2D. Therefore, the voltage for the isotropic etching is effectively applied to the silicon substrate 2 through the wide layer 4 a . Further, the layer 4 a exposes to the side surfaces of, the sensor chip at a position where the P − substrate 2 and the N − epitaxial layer 3 contact each other, when the sensor chip is cutout by dicing. Therefore, a leakage current between the P-N junction is prevented by the layer 4 a . The present invention is not limited to the embodiment described above, but it is applicable to other sensors. For example, it can be similarly applied to semiconductor dynamic sensors such as an acceleration sensor. Though the silicon substrate having a P-N junction is used in the embodiment described above, other semiconductor substrates may be used. While the present invention has been shown and described with reference to the foregoing preferred embodiment, it will be apparent to those skilled in the art that changes in form and detail may be made therein without departing from the scope of the invention as defined in the appended claims.
A plularity of sensor chips, each having strain gauges and a thin diaphragm, are formed on a semiconductor wafer having an upper layer and a lower layer forming a P-N junction plane therebetween. The sensor chips are separated into individual pieces by dicing along column and row interstices dividing the sensor chips. Conductor lines for supplying an electrical voltage for electrochemically etching the diaphragms are formed on and along the interstices. All of the conductor lines are removed by a dicing blade having a wider width than the conductor lines to avoid electrical leakage due to particles of conductor lines leftover on side surfaces of the diced out sensor chips.
6
CROSS REFERENCE TO RELATED APPLICATION This application is a continuation of copending International Application No. PCT/DE01/04089 filed Oct. 29, 2001, which designates the United States, and claims priority to German application number 10060939.2 filed Dec. 7, 2000, and German application number 10054182.8 filed Nov. 2, 2000. BACKGROUND OF THE INVENTION The present invention relates to a fluid dosing device for a pressurized liquid with a chamber arranged in a housing, which is supplied with pressurized fluid by means of a liquid supply line and with a valve needle, which is guided through the chamber, the first end section of said valve needle being able to be lifted outside the chamber and the second end section thereof forming a valve which is connected to the housing, in conjunction with a valve seat provided on the housing. Various sealing or leadthrough elements for fluid dosing devices are known in the prior art. In cases where pressurized fuel at a pressure of up to 300 bar for example and a working temperature of −40° C. to +150° C. is dosed, special requirements are set for mass-produced products. In particular exacting requirements must be complied with in respect of embrittlement, wear and reliability. The fatigue strength of the O-ring seals used up to now does not comply with the above requirements. Diaphragm seals such as for example metal beads, etc. can also be used in place of O-ring seals. When such diaphragms are used as the leadthrough element for a valve needle through a pressurized chamber however the requirements relating to high axial flexibility are not complied with when the compression strength is adequate. The valve needle can also continue to be effected by means of a clearance fit of the needle in a cylindrical hole in the housing as in diesel injectors. A disadvantage of this is the unavoidable leakage along the needle leadthrough. The higher level of hydraulic loss also reduces the overall efficiency of the motor. SUMMARY OF THE INVENTION The object of the present invention is to provide a tight leadthrough for the valve needle in a generic fluid dosing device in particular, which achieves the required fatigue strength. According to the invention this is achieved with a fluid dosing device for a pressurized fluid comprising a chamber located in a housing, to which the pressurized liquid is guided through a liquid supply line, a valve needle guided through the chamber, wherein a stroke can be applied to a first end section thereof outside of the chamber and the second end section thereof forming, in conjunction with a valve seat disposed on the housing, a valve which is connected to the chamber, and a flexible leadthrough element being provided for the first end section of the valve needle from the chamber outwards, which seals the chamber in said region in a tight manner, wherein at least one throttle point is provided circumferentially between the valve needle and the inner wall of the chamber in the section of the chamber between the leadthrough element and the mouth of the liquid supply line into the chamber, with a gap representing the throttle point being a few μm wide. The object can also be achieved by a fluid dosing device for a pressurized fluid comprising a chamber located in a housing, to which the pressurized liquid is guided through a liquid supply line, a valve needle guided through the chamber having a first end section outside of the chamber and a second end section which forms in conjunction with a valve seat disposed on the housing a valve which is connected to the chamber, and a flexible leadthrough element being provided for the first end section of the valve needle, which seals the chamber in said region in a tight manner, wherein at least one throttle point is provided circumferentially between the valve needle and the inner wall of the chamber in the section of the chamber between the leadthrough element and the mouth of the liquid supply line into the chamber, wherein the throttle point is formed by a gap having a width of a few μm. The fluid dosing device may further comprise bellows, in particular metal bellows, as the leadthrough element. The metal bellows may have a wall thickness of 25 to 500 μm. The leadthrough element may be attached to an assembly sleeve, in particular by means of a welded connection. The throttle point may be created in the chamber by the assembly sleeve. An upper valve needle guide can be provided and the throttle point can be created in the chamber by the upper valve needle guide. The free cross-section between the valve needle and the inner wall of the chamber can be changed abruptly in the region of the throttle point. The gap in the region of the throttle point may be a few μm wide. Fuel can be used as the liquid and the fuel pressure may be in the range of between 1 and 500 bar. The diameter of a clearance fit of the valve needle can correspond to a hydraulically effective diameter of the metal bellows. According to the invention, at least one throttle point is arranged circumferentially between the valve needle and the inner wall of the chamber in the chamber section between the leadthrough element and the mouth of the liquid supply line into the chamber. Measurements have shown that metal bellows designed as leadthrough elements for use in high pressure injection valves, for example in vehicle engineering, can withstand static pressure loads up to approx. 200 bar without any problems. A much higher compression resistance can also be achieved by increasing the wall thickness. Further tests on moving metal bellows seals also showed that metal bellows subjected to high pressure do not suffer degradation during execution of an axial movement of up to 50 μm with a frequency of 50 Hz typical of the injection valves. Using metal bellows thus means that the fuel chamber is hermetically sealed with adequate compression strength. It was however surprisingly established that the metal bellows fail after approx. 10 min when used operationally in a high-pressure injection valve at a static pressure load of 200 bar. The reason for this is that during the opening and closing of the injection valve or injector, pressure waves are triggered in the fuel chamber of the injector, which fluctuate about the basic pressure set with an amplitude of up to ±50% of the fuel pressure set and a frequency of approx. 500 Hz–10 Hz, typically in the range of approx. 500–800 Hz, depending on the opening and closing times of the injector. The occurrence of such pressure oscillations results in failure of the metal bellows seal when pressure waves are triggered. The throttle points provided according to the invention protect the metal bellows from the destructive effect of these pressure oscillations. To summarize, therefore, according to the invention adequate tightness of the fuel chamber is achieved by means of the metal bellows, with the metal bellows seal being protected from pressure waves occurring during operation, thereby achieving a typical fatigue strength for vehicle engineering of at least 10 9 load cycles (approx. 2000 operating hours). Advantageously the metal bellows have a wall thickness of 25 to 500 μm. These low wall strength levels have proven totally adequate at high pressures of for example 300 bar. Tests have shown that a configuration of the metal bellows in the form of semi-circular segments ranged adjacent to each other—visible in the longitudinal cross-section—offers particular advantages. These semi-circular segments can be supplemented by intermediate straight sections. According to a preferred embodiment the flexible leadthrough element is attached to an assembly sleeve, in particular by means of a welded connection. This is particularly favorable for manufacturing purposes, as metal bellows in particular can only be attached directly to the valve needle at relatively high cost. The assembly sleeve provides an element by means of which a precisely dimensioned throttle point can be achieved in the fuel chamber in a simple manner. In order to be able to create a suitable throttle point in the fuel chamber, an upper guide sleeve is configured as an alternative to or in addition to the appropriately dimensioned assembly sleeve, so that a narrow and as long as possible a clearance fit is achieved through this valve needle guide. As the upper valve needle guide is provided anyway in the fuel injector, additional components can be dispensed with. If both the assembly sleeve and upper valve needle guide throttle points are created at the same time in the fluid dosing device, the respective throttle gaps can be larger and/or shorter in the axial direction, without having a negative impact on the protective effect of the throttle points for the metal bellows. Also fitting errors are avoided, which may result in the valve needle jamming. However this also applies if the throttle point created by the assembly sleeves is dispensed with, with the throttle point created by the upper guide sleeve being designed accordingly. In order to prevent or significantly restrict propagation of the pressure waves in the fuel chamber in the direction of the metal bellows, the free cross-section between the valve needle and the inner wall of the chamber is changed abruptly in the region of the throttle point. This results in the required reflection of the pressure waves off the section of the inner wall of the chamber extending perpendicular to the direction of propagation of the pressure waves. The gap width of the throttle point is selected on the basis of the position of the throttle point in the fuel chamber and the length of the throttle gap taking into account the static and dynamic pressure conditions. A few μm have proved to be a typical value for the gap width of the throttle point in the fuel chamber of a high-pressure fuel injector. BRIEF DESCRIPTION OF THE DRAWINGS Four embodiments of the fluid dosing device according to the invention are described below using diagrammatic representations. These show: FIG. 1 a a longitudinal section of the first embodiment of the fluid dosing device, FIG. 1 b two cross-sectional representations along the lines A—A and B—B in FIG. 1 a, FIG. 2 a longitudinal section of the second embodiment, FIG. 3 a a longitudinal section of the third embodiment of the fluid dosing device and FIG. 3 b two cross-sectional representations along the lines A—A and B—B in FIG. 3 a. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The actuator unit generally known per se is not shown for the purposes of simplicity in an injection value 1 shown diagrammatically in FIGS. 1 a, b according to a first embodiment. The fuel injection valve 1 has a housing 3 with a central hole, in which a valve body 5 is mounted. A valve needle 9 is guided in an axially displaceable manner in a valve body hole 7 of the valve body. To this end a lower or front and upper or rear guide sleeve 11 , 13 is attached to the valve body 5 in the upper and lower end sections of the valve body hole 7 and these guide sleeves create corresponding valve needle guides. The resulting narrow points are designed so that they do not impede or throttle a flow of liquid when the valve 1 opens and closes. To this end the valve needle 9 has a circumferentially projecting, rounded square cross-section according to FIGS. 1 a, b (section A—A and section B—B) at both the level of the lower and upper guide sleeves 11 , 13 or the two valve needle guides. The valve needle 9 with the rounded edge areas 14 is inserted into the two guide sleeves 11 , 13 with a clearance of less than 2 μm. The free gap between the four side surfaces of the square of the valve needle 9 and the cylindrical inner wall of the guide sleeves 11 , 13 is configured so that it is significantly larger to avoid any throttle effect. In the basic state a valve disk 15 configured at the front end section of the valve needle 9 seals a valve seat 16 on the valve body 5 . A valve body fuel supply line 17 is provided in the valve body and this opens into the valve body hole 7 with a mouth 19 between the lower and upper guide sleeves 11 , 13 when viewed in the axial direction. A housing fuel supply line 21 is also correspondingly provided in the valve housing 3 . At the upper end section of the valve needle 9 a spring plate 23 is attached to this. A nozzle spring 25 presses against this and is braced on the housing side, thereby tensioning the valve needle 9 in the closing direction. Above the upper guide sleeve 13 an outer assembly sleeve 27 is attached in the central hole of the valve housing 3 . The outer assembly sleeve 27 has a sleeve collar 44 at its lower end and this rests on a ring-shaped contact surface 45 on the housing 3 . The sleeve collar has an outer surface 46 , which is assigned to an inner wall 47 of the housing 3 . A sealing element 48 in the form of a sealing ring is inserted between the outer surface 46 and the inner wall 47 . The sleeve collar 44 is welded tightly to the inner wall 47 with a ring-shaped circumferential weld seam 49 . This creates a needle leadthrough through an opening in a sleeve base 29 , the leadthrough being sealed as described below. In a partial section of the outer assembly sleeve 27 restricted in the axial direction its inner wall forms a narrow point described in more detail below with the outer wall of an inner assembly sleeve 31 , which is in turn attached to the valve needle 9 . Cylindrical metal bellows 33 are welded to the outer and inner assembly sleeves 27 , 31 , the valve needle 9 being guided outwards by said bellows. The metal bellows 33 serve to seal the fuel chamber 35 off hermetically from an unpressurized, air-filled intermediate space 36 . The metal bellows 33 are preferably in the region of the opening on the sleeve base 29 and attached to a surface of the inner assembly sleeve 31 , which is turned towards the sleeve base 29 . Using the metal bellows 33 in the needle leadthrough allows the high-pressure area in the chamber 35 of the injection valve 1 to be sealed off totally, permanently and reliably from the intermediate space 36 with the drive area (not shown). Despite a low level of wall thickness of for example 50 to 500 μm the metal bellows 33 can withstand very high pressures due to their very high level of radial rigidity, without suffering irreversible deformation. The metal bellows 33 can also be designed so that high mechanical flexibility, i.e. a small spring constant in the direction of movement of the valve needle or the axial direction, is achieved. This means that deflection of the valve needle 9 is not impaired and that the forces induced in the valve needle due to length changes in the needle leadthrough caused by temperature are kept as small as possible. Furthermore the use of the metal bellows 33 in the needle leadthrough means that fuel leakage can be prevented with a high level of reliability. The needle leadthrough sealed with the metal bellows in the outer assembly sleeve 27 can also be configured so that the forces caused by pressure and acting on the valve needle 9 mutually offset each other. This means that the valve needle 9 is generally kept pressure-free. For this the hydraulically effective diameter of the metal bellows is selected so that it corresponds exactly to the diameter of the valve seat 16 (not shown). As a result the pressure force triggered by the pressurized fuel acting on the valve needle 9 and the valve disk 15 and the force induced due to pressure by the metal bellows 33 in the valve needle mutually offset each other. This means there is no pressure force component acting on the valve needle 9 as a result. This ensures that the injection valve 1 exhibits a switching response which is almost completely independent of the fuel pressure, as the opening and closing forces are only determined by the actuator element, for example by piezo-actuators pretensioned in a spring tube, and the force of the pretensioned nozzle spring 25 . The metal bellows 33 also have a broad operating temperature range with the same level of functionality due to their metal material. Even thermal length changes in the metal bellows 33 only result in negligibly small changes of force at the valve needle 9 in the axial direction due to the low level of axial spring constant of the metal bellows. The metal bellows can also partially or wholly replace the nozzle spring 25 due to their mechanical spring effect in the axial direction. The outer sleeve housing 27 is configured according to FIG. 1 a so that it creates a narrow and as long as possible a clearance fit with the inner assembly sleeve 31 . The clearance here is only a few μm. The throttle effect of this long cylindrical fit means that rapid pressure changes in the fuel chamber 35 are kept away from the metal bellows 33 , while static pressures can act unhindered on the bellows wall. Also the pressure waves in the region of the cross-section change of the first throttle point 37 are reflected off the chamber wall section perpendicular to the axial direction or the front face of the sleeve, so that only a pressure wave with a greatly reduced pressure amplitude continues into the ring-shaped gap created by the first throttle point 37 . With a fuel injection valve 1 according to the second embodiment only one modification is made in FIG. 2 in the region of the first throttle point 37 compared with the valve 1 according to the first embodiment, to the effect that the free internal diameter of the sleeve collar 44 of the outer assembly sleeve 27 is reduced for the same throttle gap dimensions in favor of the external diameter of the inner assembly sleeve 31 . As in the valve according to the first embodiment the throttle gap between inner and outer assembly sleeves 27 , 31 is selected to be so small and long that an adequate throttle effect is achieved. The pressure waves triggered during the opening and closing of the valve 1 in the fuel chamber 35 cannot or can only slightly impact on the metal bellows 33 due to the short distance between the inner and outer assembly sleeves 27 , 31 . A fuel injection valve 1 according to the third embodiment shown in FIGS. 3 a, b has a second throttle point 39 in the region of the upper valve needle guide or the upper guide sleeve 13 as an alternative in place of the first throttle point according to the first two embodiments. As the fuel supply line 17 opens below the upper valve needle guide 13 into the space between the valve needle 9 and the valve body 5 or the fuel chamber 35 , the fuel to be injected into this does not have to pass the upper valve needle guide 13 . Therefore the upper valve needle guide can even be configured as a narrow, long cylindrical clearance fit of the valve needle 9 in the upper guide sleeve 13 , as shown in section B—B in FIG. 3 b . Unlike the lower valve needle guide (section A—A) the valve needle 9 here is not configured as a square but is cylindrical (section B—B). The pressure waves triggered during opening and closing processes are reflected off this second throttle point 39 and a dynamic volume exchange is throttled significantly in the direction of the metal bellows 33 . Integration of the throttle point 39 in the valve needle guide means that multifits can be avoided. The throttle effect of the upper valve needle guide 13 splits the fuel chamber 35 into two sub-volumes, namely a first and a second chamber sub-volume 41 , 43 . Although dynamic pressure changes of great amplitude are generated in the lower first sub-volume 41 of the fuel chamber 35 by the opening and closing of the injection nozzle, the action of these in the upper second sub-volume 43 of the fuel chamber 35 , where the metal bellows needle leadthrough is located, can be greatly reduced by the dynamic sealing effect of the second throttle point 39 . The metal bellows 33 are protected from dynamic pressure changes as a result. According to the fourth embodiment of a fuel injection valve (not shown) the throttle points 37 , 39 shown in FIGS. 1 or 2 and 3 are combined in one valve. The first throttle point 37 is created by the inner and outer assembly sleeves 27 , 31 and the second throttle point 39 is created by the upper guide sleeve 13 or the upper valve needle guide. In the embodiments disclosed bellows in the form of a metal bellows were disclosed as a flexible leadthrough element. The invention is however not limited to this type of flexible leadthrough element but can also be used with other types of flexible leadthrough elements such as for example a diaphragm or a flexible plastic or rubber sleeve. The diaphragm is preferably made of metal. The diaphragm and the sleeve are stuck or welded in the same way as the disclosed metal bellows to the inner and outer assembly sleeve 27 , 31 . In general the pressure in the second chamber sub-volume 43 can be adjusted by appropriate selection of the diameter of the clearance fit of the valve needle 9 in relation to the hydraulically effective diameter of the metal bellows 33 . Adjusting the diameter of the clearance fit to be bigger (or smaller) than the hydraulically effective diameter of the metal bellows 33 means that the pressure in the second chamber sub-volume 43 drops (or increases) when the injection valve is opened. It is particularly advantageous if the diameter of the clearance fit corresponds to the hydraulically effective diameter of the metal bellows 33 , because in this way the pressure in the second chamber sub-volume 43 remains essentially constant when the injection valve is opened; the metal bellows 33 are then only exposed to a constant pressure load in all operating states.
A fluid dosing device for a pressurized liquid is disclosed, which comprises a chamber ( 35 ) which is supplied with pressurized liquid by means of a liquid supply line ( 17, 19 ); a valve needle ( 9 ) which is guided through the chamber ( 35 ), the first end section of said valve needle being able to be lifted and the second end section thereof forming a valve in conjunction with a valve seat disposed on the housing ( 3 ). Metal bellows ( 33 ) are provided as a leadthrough element for the first end section of the valve needle ( 9 ). The metal bellows seal the chamber in said region in a tight manner. A throttle point ( 37, 39 ) is provided between the valve needle ( 9 ) and the inner wall of the chamber between the metal bellows ( 33 ) and the mouth ( 18 ) of the liquid supply line ( 17 ) leading into the chamber.
5
FIELD The invention concerns a bottom rail for Venetian blinds comprising means for fastening raising cords and ladder cords. The invention furthermore concerns the use of such fastening means. BACKGROUND Venetian blinds of the type that have freely suspended slats without side guides may be manufactured to precise measurements, i.e. with a pre-defined slat length and height of the Venetian blind, or else only the width and slat length are pre-defined by the width of a window, and the height of the Venetian blind must then be adjusted on location, so that the Venetian blind may be adjusted during use without any part rubbing against the window sill or the similar. A Venetian blind consists of a number of ladder cords that carry and adjust the angle of the slats, and raising cords or draw cords that pass through cut-outs in the slats and are fastened to the bottom rail. The adjustment of the angle is usually carried out by lifting one part of the ladder while lowering the other, and raising occurs by lifting the bottom rail by means of the raising cords, so that one slat after the other comes to rest on a pack of slats that increases in thickness. The bottom rail must have a certain stiffness so that the pack of slats may remain flat and not sag between the points of attachment of the raising cords. The ladder cords may either be adjusted by means of an operation that is separate from the raising function or else it is performed by reversing the direction of rotation of the same actuating device that also performs the raising. In the last instance the raising cords are wound around drums in the top rail. The strings have to be fastened securely to the bottom rail, and various methods to obtain this are known, comprising threading them through holes that are provided for the purpose. A known solution uses holes in the upper side of a hollow bottom rail, through which the strings are threaded, whereupon a knot is tied or a lock is provided on the inside. This bottom rail is split lengthwise in two, and during the assembly the ladders are pinched at the outer edges. Thereby the bottom rail is made into a hollow profile with the desired stiffness. However, this solution suffers from the disadvantage that the adjustment is changed by the very clipping together of the two parts of the bottom rail. SUMMARY Systems are known using clips that may retain a C-shaped bottom rail for the raising cord and ladder tapes (an older solution for Venetian blinds), and which use the lowermost slat as a lid for the bottom rail, e.g. U.S. Pat. No. 2,627,917, but they have the disadvantage that special tools are required to cut the edges of the bottom rail to make room for the ladder tapes. These disadvantages are avoided in a construction according to the invention which is particular in that the bottom rail is disposed as an essentially C-shaped profile, in which the inwards facing parts are suitable as recipients of hook-like fingers fitted onto clips that may pushed from above to engage the inwards facing parts and subsequently be shifted along the length of the profile, in that the clips have on their upper side hooks that are suited for gripping a slat for a Venetian blind on either side of a ladder cord and in that the clips each have a hole for fixing a raising cord. During installation a ladder may be be cut just below a rung that carries the lowermost Venetian blind slat, the raising cord may be pulled through the hole and provided with a thickening on the lower side, each clip may be clipped to the lowermost slat and finally be clipped into the C-shaped profile. A fine adjustment may be performed of the position of the clips in the bottom rail, and the installation may be finalized by fitting a cap at each end of the profile. Hereby the lowermost slat creates a lid for the bottom rail, where the thickness of the clip creates a small slit that provides character to the bottom rail by its shadow effect. Furthermore a last possibility for adjustment is achieved, even after installation, because the clips may be slid sideways out of the bottom rail, the height may be finally adjusted, and the clips may be clicked in place again. Furthermore the ladder is attached to the bottom rail in that the lowermost slat is fitted to the bottom rail, i.e. a completely normal placement of a ladder with respect to a slat. An advantageous embodiment is particular in that a slider that is fitted between the hook-like fingers has means for gripping the end of a raising cord and may be displaced in the clip, lengthwise with respect to the bottom rail, for individual tightening of the raising cord. Hereby it is obtained in the manufacture of that type of Venetian blinds in which the raising cords are wound upon drums in the top rail, that the length of the raising cords, including a thickened end, may be decided at the time of manufacture. Fine adjustment occurs by equalizing the lifting forces in the individual raising cords, because the raising cords are adjusted individually by means of the slider until they participate equally in the raising. A further advantageous embodiment is particular in that means have been provided to create friction, such as barbs, between the slider and the clip to maintain the slider in the final position. This embodiment is particularly advantageous when a tall Venetian blind is considered, in which the pulling force in a raising cord may be considerable. BRIEF DESCRIPTION OF THE DRAWINGS The invention furthermore comprises the use of a clip as defined in the claims. The invention will be described further in the following, where FIG. 1 shows a known solution for fixing of cords in a bottom rail, FIG. 2 shows a longitudinal section of the bottom rail according to the invention, FIG. 3 shows a first cross section along the section I-I of the bottom rail according to the invention FIG. 4 shows a second cross section along the section II-II of the bottom rail according to the invention FIG. 5 shows a third cross section along the section III-III of the bottom rail according to the invention, FIGS. 6 a and 6 b show a clip according to the invention, FIG. 7 shows a slider that may adjust the length of a raising cord, and FIG. 8 shows a clip mounted on a bottom rail. DETAILED DESCRIPTION In FIG. 1 is seen a known bottom rail that consists of two parts 1 and 2 that are clipped together to create a closed profile. The ladder cords 3 and 3 ′ are held firmly between the two profiles 1 and 2 , and the raising cord 4 has been pulled through a hole in the upper part 1 , and a thickening, such as a knot, has been provided for the cord 4 . Furthermore, the lowermost slat 5 is shown. In FIG. 2 is shown a longitudinal section of a bottom rail 6 according to the invention, along one of the lengthwise inside edges 6 ′, with a fitted clip 7 . Furthermore, the lowermost slat 5 and the next-lowermost slat 5 ′ are shown. By I-I is indicated the location of a first cross section through the bottom rail 6 , the clip 7 , and hooks 8 , 8 ′, and by II-II is shown the location of a second cross section through the bottom rail 6 , the clip 7 , and the raising cord 4 . By III-III is shown a third cross section through the hook-like fingers 7 ′ on the clip 7 . In FIG. 3 is shown the cross section I-I. It will be seen that the lowermost slat 5 is held by the hooks 8 , 8 ′, and that it has a small distance to the bottom rail 6 . In FIG. 4 is shown the cross section II-II. It will be seen that the ladder cords 3 , 3 ′ have been pulled under the clip 7 and brought between the clip and the bottom rail 6 until the space between the edges 6 ′ and 6 ″, where they are joined by means of a rivet or the like. The raising cord 4 is pulled through a hole 9 in the clip 7 , and a tubular rivet 4 ′ or the like is fitted to prevent its being pulled out. In FIG. 5 is shown the cross section HI-III. It will be seen that the clip 7 has oppositely directed hook-like fingers 7 ′ and 7 ″ that may engage below the edges 6 ′ and 6 ″ so that the bottom rail is fixed and may be lifted by pulling upwards on the clip 7 . In FIGS. 6 a and 6 b is shown a spatial representation of a clip according to the invention, in which a number of the features identified above may be seen. In FIG. 7 is shown a slider for tightening the raising cord. It is shown how one end 11 is shaped to grip a raising cord 4 . This will pass vertically through the hole 9 in the clip 7 , through the oblong slit S in the slider 10 and horizontally along the lower side of the slider 10 , until the thickening 4 ′ provides its end in the gripping means 11 . There is furthermore shown a pinion-like corrugation 12 ′ in the shape of a number of parallel barbs that cooperate with similar elements 12 on the clip 7 . This serves to retain the slider in the position, in which a tightening of the raising cord has been obtained. During installation a set of ladder cords 3 , 3 ′ may be cut just below a rung that carries the lowermost Venetian blind slat 5 , the raising cord may be pulled through the slat and through the hole 9 in the clip 7 and be provided with a thickening, such as a rivet, on the lower side. Each clip 7 may be clipped to the lowermost Venetian blind slat by means of the hooks 8 , 8 ′, and may finally be clipped into the C-shaped profile 6 . Fine adjustment of the position of the clips along the bottom rail 6 may be performed, and the installation may be finalized by means of a cap at each end of the profile. Thereby the lowermost slat 5 becomes a lid for the bottom rail 8 , where the thickness of the rail creates a small slit that provides character for the bottom rail by its shadow effect. Furthermore the ladder cords 3 , 3 ′ are fixed to the bottom rail, because the lowermost slat is fitted to the bottom rail, i.e. a completely normal placement of a ladder with respect to a slat. The distance between the next-lowermost slat and the lowermost slat/bottom rail hence becomes quite habitual. If there is a large discrepancy between the lengths of the raising cords, the clips may be slid lengthwise out of the bottom rail, so that the hook-like fingers 7 , 7 ″ are liberated, and the thickening 4 ′ may be fitted correctly to the raising cord 4 . The clips 7 may be clipped back in place in order that the hook-like fingers 7 , 7 ″ engage the inwards facing parts 6 ′, 6 ″ on the bottom rail 6 . There is furthermore a possibility of adjustment even after the installation by the use of the slider 10 , in that the lifting force or the height may be finally adjusted by displacement of the slider 10 . This requires that the means 11 are brought in engagement with the thickening 4 ′ of the raising cord 4 . The means 11 may be fork-shaped or guide in a V-shape towards a hole that pinches the raising cord 4 . The established correct position of the slider 10 is maintained by the barbs 12 ′ that are established in the slider 10 for cooperation with a similar structure 12 on the clip 7 . In case an unforeseen stretching or shrinking of a raising cord should occur immediately subsequent to installation or after it has seen some use, a post-adjustment may be made by freeing the lowermost slat from the hooks 8 on each clip 7 , the raising cord in question may be adjusted by displacing the slider 10 in the gap between the two parts 6 ′, 6 ″ in the bottom rail, and the lowermost slat 5 is again clipped on.
Known bottom rails fulfill the requirements stiffness and adjustability at the time of installation, but a noted inequality in the load on the individual raising cord cannot be corrected without a complex dismantling of the bottom rail. According to the invention the bottom rail is suspended in clips ( 7 ) that on the one hand holds the lowermost slat ( 5 ) and the raising cords ( 4 ), on the other hand has means ( 10 ) so that the tightening of the raising cords may be adjusted individually.
4
BACKGROUND OF THE INVENTION The present invention relates generally to improvements in blast furnace operations, and more specifically to methods and materials for improving the quality of blast furnace coke. Investigations of blast furnaces that produce less hot metal than expected has shown that coke at the level of the furnace tuyeres was smaller in size, less permeable to air flow, more readilly abraided, higher in alkali content, and more reactive with CO 2 than the coke fed into the blast furnace. In coke CO 2 reactivity tests that were conducted, the "tuyere" coke resulted in more coke fines than production coke. These poor quality characteristics result from the catalytic effect of the higher amounts of alkali contained in "tuyere" coke on increasing the coke reactivity, promoting coke degradation, and subsequently increasing the resistance to air passage. Alkalis, mainly, sodium and potassium, are carried into the blast furnace stack as constituents in the iron burden, the flux and the coke. For example, the burden may contribute up to 28% or more of the inputed K 2 O and from 60 to 76% or more of the inputed Na 2 O, and the coke may contribute from 64 to 73% of the K 2 O and from 19 to 32% of the Na 2 O. Depending upon the slag basicity and high temperature, part of these alkalis are removed with the slag, primarily as alkali silicates. Because of the reducing and high temperature conditions existing in the bosh region of the furnace, the remainder of the alkalis are vaporized as oxides or as metal vapors and are carried with the ascending bosh gases to the upper stack where a portion of the vaporized alkalis are condensed on the relatively cool descending materials, including the coke, charged into the furnace. It has been shown that the alkalis that deposit on the descending coke charge appreciably accelerate the solution loss reaction on the coke-carbon reaction (C + CO 2 = 2CO). It has also been demonstrated that, in direct relation to increased coke reaction, the reacted coke exhibits an increased tendency to degrade into fines that tend to plug the void spaces in the bosh zone so as to impede the flow of ascending hot reducing gases and descending liquids, i.e. slag and hot metal. This reduces the furnace productivity and causes a tendency for the furnace to hang. SUMMARY OF THE INVENTION The purpose of the present invention is to improve the quality of blast furnace coke by retarding its degradation during oxidation in an alkali environment and thereby improve the performance of blast furnace operations. It has been discovered that the deleterious effect of condensed alkali vapors on a coke charge in a blast furnace can be minimized by enriching the coke with a finely dispersed addition of silica, such as silica flour, fire clay, quartzite or the like. The siliceous material in or on the coke reacts with the condensed alkalis to form alkali silicates which do not catalyze the carbon-CO 2 reaction. In addition, the silicates will be removed from the furnace via the slag, thus minimizing the vaporization, refluxing, and accumulation of alkalis in the furnace. The reduction of the alkalis in the furnace also minimizes the formation of scabs on the furnace walls. In accordance with the foregoing, the present invention provides an impovement in the process of operating a blast furnace by charging ore, coke and flux into the furnace and reducing the ore by oxidation of the coke characterized by the steps of employing coke enriched with at least 1% by weight of a finely dispersed silica addition as the coke charge, and allowing the silica to react with condensed alkalis on the coke to form alkali silicates and thereby retard coke degradation. According to another aspect of the invention, there is provided a silica enriched coke especially adapted for blast furnace operations containing added silica in an amount of at least 1% by weight. Still another aspect of the invention is the provision of a method of making silica enriched coke comprising the steps of coking coal containing an addition of finely disbursed silica in an amount of at least 0.7% by weight of the coal. In more preferred embodiments of the invention, the silica addition is in a range of from about 1.4 to about 2.8% by weight of the coal or from about 2 to about 4% by weight of the coke and has a size no greater than about 75% by weight minus 100 mesh (Tyler). As hereinafter discussed in more detail, results of tests show that coked blends enriched with a minimum of about 1% by weight of added silica, and more preferably a minimum of about 2% by weight of added silica having a size no greater than about 75% minus 100 mesh, is effective to retard significantly coke degradation resulting from an alkali environment. Tests have also shown that the stability factor of coked blends, as determined by a standard ASTM Tumble Test, is not significantly changed by silica additions up to at least 4% by weight of the coked blend. As used herein, the term "enriched" refers to coke to which silica has been added, such as by dispersing and blending the silica in the coal prior to coking or by coating the coke in any suitable manner with a siliceous material. The term "silica" encompasses ground silica or silica flour which is substantially 100% silica and siliceous materials such as fire clay, quartzite and the like which may contain ingredients in addition to silica, such as alumina, as well as fluxing impurities. Further advantages and a fuller understanding of the invention will become apparent from the following detailed description of the preferred embodiments. DESCRIPTION OF PREFERRED EMBODIMENTS The effect of added silica on reducing coke breakdown or degradation was demonstrated by CO 2 reactivity tests conducted on coked blends which contained different amounts and size fractions of the added silica. In carrying out these tests, the silica was blended with coals used to produce production coke known to exhibit appreciable degradation in the presence of alkali. The blends were coked in a 500 pound movable wall oven, and samples of the coked blends were crushed and screened to obtain a minus 11/2 inch; plus 1 inch size fraction that was used for the tests. A portion of the sized coke was impregnated with alkali (1.5 parts by weight sodium as Na 2 CO 3 per 100 parts by weight coke). The procedure for impregnating the coke comprised the steps of placing a weighed amount of the 11/2 inch by 1 inch size in a stainless steel basket and preheating it in an oven at 300° F. for about 1/2 hour. The stainless steel basket containing the heated coke was immersed in a hot Na 2 CO 3 solution and allowed to remain in the solution until bubbling stopped. The coke was then removed from the solution, drained, and dried in an oven for about 2 hours at 320° F. The alkali impregnated coke and the unimpregnated coke was tested for CO 2 reactivity and coke degradation. The coke reactivity was determined by measuring the weight loss of coke resulting from the reaction of carbon dioxide with coke carbon to form carbon monoxide for a 2 hour period at a temperature of about 1800° F. The coke reactivity value was then expressed as a weight percent of the original coke lost as a result of the reaction. The specific procedure used for measuring CO 2 reactivity involved placing a weighed amount of the 11/2 inch by 1 inch size coke in a reactor vessel. The reactor was positioned in an electric furnace and balanced by counterweights. The atmosphere within the reactor was continually purged with nitrogen during heating and cool down. After reaching a coke bed temperature of about 1800° F., carbon dioxide was metered into the reactor at a rate of 11 cubic feet per hour for two hours. Throughout the test, the coke bed temperature was maintained at 1800° F. The loss in coke weight was noted at 10 minute intervals. After two hours, the carbon dioxide flow was shut off, the reactor removed from the furnace and allowed to cool to room temperature. After cool down, the reacted coke was removed from the reactor, weighed and the percent of coke weight loss calculated. Coke degradation was determined by screening the reacted coke using 1, 3/4 and 3/8 inch screen sizes. The percent of plus 1, minus 1, plus 3/4, and minus 3/8 inch coke was determined from the coke fraction weights. Since the coke charged for the reactivity test was sized to 100% plus 1 inch screen size, the percentage of plus 1 inch coke and the percentage of minus 3/8 inch coke fines after the reaction represents a measure of coke degradation during reaction. As a further measure of coke quality, the coked blends with and without added silica were subjected to a standard ASTM Tumble Test and a stability factor index was determined. The testing procedure involved screening the coke blend to obtain a minus 3 inch plus 2 inch screen size fraction. The 3 by 2 inch coke was tumble tested according to ASTM designation D-29-50, and a stability factor for each blend representing the weight percent of plus 1 inch coke after tumbling was calculated. The reactivity test results of the coked blends containing the different percentages of sized silica are reported in Tables I, II and III below. Included in these tables are the percentages of alkali added to the coke, the reactivity values, the size consists of the reacted coke, and the stability factors of the coked blends. TABLE I__________________________________________________________________________COKE REACTIVITY TEST -- COKED BLEND WITH20 × 50 MESH SILICA SAND (QUARTZITE) ADDITIONSilica Added toCoal Blend, % by wt. Reacted Coke, % by wt. Alkali (Na) Reactivity Stability FactorTest RunCoal Coke Added, % by wt. Value, % by wt. +1 in. +3/4 in. -3/8 in. % by wt. +1__________________________________________________________________________ in.2365-73none none 5.6 90.1 8.5 1.2 52.91907-261.4, 20×50 mesh, 2.0 none 4.2 95.1 4.4 0.5 51.92365-54none 1.5 16.1 78.0 15.5 5.2 52.91907-301.4, 20×50 mesh, 2.0 1.5 15.3 83.3 13.2 3.2 51.9__________________________________________________________________________ The adverse effect of alkali (Na) on reactivity and degradation will be apparent by comparing Run 2365-73 (no alkali) to Run 2365-54 (1.5% alkali). The presence of the alkali increased the reactivity value from 5.6 to 16.1 and decreased the amount of plus 1 inch size reacted coke from 90.1 to 78. The amount of minus 3/8 inch coke fines was increased from 1.2% to 5.2%. At the 1.5% alkali level, the coked sample containing 2% of minus 20 plus 50 mesh size quartzite (Run 1907-30) showed a slight lowering in the reactivity value, a somewhat greater percent of plus 1 inch reacted coke, and a lower percent of minus 3/8 inch size than the coked sample without quartzite (Run 2365-54). This increase in the plus 1 inch size reacted coke from 78.0% for Run 2365-54 to 83.3% for Run 1907-30 along with a decrease in minus 3/8 inch fines from 5.2% (Run 2365-54) to 3.2% (Run 1907-30) represents an improvement affected by added silica on deterring alkali induced coke degradation. TABLE II__________________________________________________________________________COKE REACTIVITY TEST -- COKED BLENDCONTAINING PERCENTAGES OF 100 × 0 MESH GROUND SILICASilica Added toBlend, % by wt. Reacted Coke, % by wt. Alkali (Na) Reactivity Stability FactorTest RunCoal Coke Added, % by wt. Value, % by wt. +1 in. +3/4 in. -3/8 in. % by wt. +1__________________________________________________________________________ in.1907-40none none 5.9 96.3 2.9 0.6 53.11907-44none 1.5 17.5 79.2 14.9 4.2 53.11907-821.4, 100 mesh, 2.0 1.5 15.9 87.7 7.5 4.2 53.61907-832.1, 100 mesh, 3.0 1.5 16.6 93.4 3.2 2.8 52.11907-462.8, 100 mesh, 4.0 1.5 11.8 96.2 2.3 1.2 51.2__________________________________________________________________________ Silica sand ground to minus 100 mesh (Tyler) was blended in the coal blend prior to coking in 1.4%, 2.1% and 2.8% amounts. Results of the testing at these levels of added silica are reported in Table II. These results show that the coked blend (Run 1907-44) with alkali but without added silica resulted in a 79.2% plus 1 inch size reacted coke and a 4.2% minus 3/8 inch size fraction. When tested in the same alkali environment, the coked blend containing 2%, 3% and 4% silica resulted in 87.7%, 93.4% and 96.2% plus 1 inch and 4.2%, 2.8% and 1.2% minus 3/8 inch size reacted coke for Runs 1907-82, 83 and 46, respectively. Since the percent of plus 1 inch size reacted coke is a measure of the amount of coke degradation, these results demonstrate that the addition of increased amounts of silica is increasingly effective in lowering coke degradation. TABLE III__________________________________________________________________________COKE REACTIVITY TEST -- COKED BLEND CONTAININGPERCENTAGES OF SILICA SANDSilica Addedto Blend, % Reacted Coke, % by wt. Alkali (Na) Reactivity Stability FactorTest RunCoal Coke Added, % by wt. Value, % by wt. +1 in. +3/4 in. -3/8 in. % by wt. +1__________________________________________________________________________ in.2427-23none none 6.4 92.2 6.8 0.9 51.72427-11none 1.5 17.0 73.7 20.7 3.7 51.72427-120.7, 100 mesh, 1.0 1.5 18.5 76.9 18.4 3.6 53.52427-160.7, 200 mesh, 1.0 1.5 15.2 77.3 19.3 3.0 54.22427-81.4, 100 mesh, 2.0 1.5 17.2 84.0 11.9 3.3 51.72427-221.4, 120 mesh, 2.0 1.5 15.4 85.8 11.3 2.4 52.32427-72.1, 100 mesh, 3.0 1.5 14.9 87.0 9.2 2.9 52.22427-242.1, 120 mesh, 3.0 1.5 14.8 92.5 5.5 1.9 53.4__________________________________________________________________________ NOTE: 100 mesh silica sand, 47.5% passing 100 mesh screen. 120 mesh silica sand, 77.5% passing 100 mesh screen. 200 mesh silica sand, 96.0% passing 200 mesh screen. Samples of various size grades of silica sand were obtained from a commercial source and different percentages of the sand were blended with the tested coal blends. The reactivity test results are presented in Table III. These results show a progressive increase in the percent of plus 1 inch size reacted coke and a decrease in the percent of minus 3/8 inch coke fines as the percent of added silica was increased to about 3% of the coke blend. The 3% addition in the coked blend (2.1% addition to the coal blend) of 120 mesh silica sand (Run 2427-24) was the most effective of the silica additions in minimizing coke degradation. The coked blend resulted in 92.5% plus 1 inch size reacted coke and 1.9% minus 3/8 inch coke size as compared to 92.2% plus 1 inch size reacted coke and 0.9% minus 3/8 inch size without added alkali (Run 2427-23) and to 73.7% plus 1 inch size reacted coke and 3.7% minus 3/8 inch coke size with alkali without added silica (Run 2427-11). The results reported in Table III also show that the finer 120 mesh silica sand at each percentage level gave a higher percentage of plus 1 inch reacted coke than the coarser 100 mesh silica addition. The effectiveness of the finer silica in lowering coke degradation is demonstrated by comparing the 85.8% plus 1 inch size reacted coke and 2.4% minus 3/8 inch coke fines for the coke containing the 2% addition of 120 mesh silica (Run 2427-22) with the 87.0% plus 1 inch size reacted coke and 2.9% minus 3/8 inch coke size for coke containing the 3% addition of 100 mesh silica (Run 2427-7). The preferred 120 mesh silica had the following Tyler screen analysis and chemistry: ______________________________________Sieve Analysis Percent Passing______________________________________100 Mesh 77.5140 Mesh 62.5200 Mesh 51.5325 Mesh 35.0Chemistry Percent -SiO.sub.2 99.00Fe.sub.2 O.sub.3 0.18Al.sub.2 O.sub.3 0.60TiO.sub.2 0.03LOI 0.17______________________________________ In each of the tables discussed above, the stability factors for the coked blends tested with and without added silica are listed. Comparison of the data at the different silica levels shows that the stability factor of the tested coked blend was not significantly affected by silica additions up to 4% contained in the coke. In summary of the foregoing, results of the tests show that added silica, preferably a silica flour having a size no larger than about 75% minus 100 mesh, in a minimum amount of about 0.7% by weight of the coal blend which corresponds to about 1% by weight of the coked blend is effective to significantly retard coke degradation resulting from an alkali environment, and that the most pronounced improvements are obtained when the silica is added in a minimum amount of about 1.4% of the coal or about 2% by weight of the coke. The improvements in coke degradation are progressively increased by increased amounts of added silica in the coked blend up to at least 2.8% by weight of the coal or about 4% by weight of the coke. The tests further show that the CO 2 reactivity of coked blends in an alkali environment is decreased by added silica. Various modifications and variations of the invention will be apparent to those skilled in the art in the light of the foregoing detailed disclosure. Therefore, it is to be understood that, within the scope of the appended claims, the invention can be practiced otherwise than as specifically described.
A process of operating a blast furnace characterized by the steps of employing silica enriched coke as the coke charge, and allowing the silica to react with condensed alkalies in the furnace to form alkali silicates and thereby minimize degradation of the coke during oxidation. A silica enriched coke especially adapted for blast furnace operations containing added silica in a minimum amount of about 1% by weight, and a method of making the same by dispersing and blending the silica in the coal in a minimum amount of about 0.7% by weight before coking.
2
[0001] This application claims the benefit of priority of U.S. provisional application Ser. No. 61/983,622, filed Apr. 24, 2014, entitled “System and Method for Injecting Oil into an Air Conditioning System,” the entire disclosure of which is incorporated herein by reference in its entirety. TECHNICAL FIELD [0002] This disclosure relates generally to refrigeration systems, and more particularly to refrigerant recovery systems for refrigeration systems. BACKGROUND [0003] Air conditioning systems include a mechanical compressor that compresses refrigerant flowing through the air conditioning system. The compressor requires oil to function properly and efficiently. During normal operation of the air conditioning system, a portion of the compressor oil is entrained in the refrigerant and circulated through the air conditioning system. When the air conditioning system is serviced, the refrigerant, along with the oil entrained therein, is typically removed from the air conditioning system. Additionally, the air conditioning system may require replacement of parts within the circuit, which can also remove compressor oil within the replaced parts. As such, new compressor oil must be injected into the system to replace oil removed from the system during maintenance and service operations. For this reason, most air conditioning service (“ACS”) machines include a circuit for injecting oil into the air conditioning circuit prior to recharging refrigerant into the air conditioning system. [0004] Measuring the oil injected into the air conditioning circuit is important to ensure the proper quantity of compressor oil is in the air conditioning circuit. Excess or insufficient oil in the compressor reduces the overall operational efficiency of the air conditioning circuit. One commonly used method of measuring oil injected into the air conditioning circuit is visual identification. Some conventional ACS machines include a bottle of oil having graduated markings that indicate the amount of oil in the bottle. To measure the quantity of oil injected into the circuit, the user monitors the oil level in the bottle with reference to the graduated markings as the ACS machine injects the oil, and terminates the injection operation when the desired quantity of oil appears to have been injected. This method has the lowest cost, but relies entirely on the user to monitor the bottle and inject the correct amount. As a result, the visual identification method suffers from issues, including operator error and inaccuracy of the markings or in reading the markings that can cause deviation from the desired quantity of oil injected into the air conditioning circuit. [0005] Some conventional ACS machines include a load cell associated with the oil bottle to measure the weight of the oil bottle. The ACS system is configured with a controller that subtracts the weight of the bottle during the injection process from the initial weight of the bottle to determine the amount of oil injected. Once the controller determines that the desired quantity of oil has been injected into the circuit, the controller operates the oil injection valve to close. However, load cells are expensive and delicate, and, as a result, ACS machines having a load cell for the oil bottle are costly to manufacture and maintain, and may malfunction if handled incorrectly. [0006] Other typical ACS machines estimate the quantity of oil injected into the air conditioning system based on the time the oil injection solenoid valve is open. The oil flow rate is assumed, and a length of time that the oil injection solenoid valve needs to be open in order to inject the desired quantity of oil is estimated from the assumed oil flow rate. For example, in some ACS machines, the oil flow rate is assumed to be 2 ml per second. A user inputs the amount of oil for the system to inject, for example 10 ml. The ACS controller then calculates the time the system should be open, which, in this example, is 5 seconds. [0007] One issue with such an oil injection method is that the oil flow rate is not a constant. The flow rate varies depending on the oil viscosity and the temperature of the oil, which is typically approximately the ambient temperature of the ACS machine. Some ACS machines that include time-based oil injection also include a way for the user to input a correction factor to correct the injected quantity or the time the valve is open based on variations in the flow rate due to the current conditions. One problem with this is that the user may not have accurate information to determine the proper correction factor. Another issue is that the user may be required to perform baseline tests or calculations in order to determine the correction factor, and errors in these tests or calculations can result in an incorrect correction factor being input to the machine. As a result, the time injection method fails to provide adequate accuracy due to the required user intervention and system variables. [0008] For all of the above reasons, it would be desirable to provide an ACS machine that improves the precision of the quantity of oil injected into an air conditioning system at a low cost. Additionally, it would be desirable to provide an ACS machine that accurately injects a desired quantity of oil into the air conditioning system with minimal user intervention. SUMMARY [0009] In one embodiment, an air conditioning service system comprises an oil receptacle configured to store oil, a coupling port in fluid communication with the oil receptacle through an oil injection line, a first solenoid valve configured to selectively allow the oil to flow from the oil receptacle into the oil injection line, a memory including program instructions stored therein, and a controller operably connected to the first solenoid valve and the memory. The controller is configured to execute the program instructions to obtain at least one viscosity signal associated with a viscosity of the oil, obtain a volume signal indicative of an amount of oil to be charged, determine a first time period based upon the obtained at least one viscosity signal and the obtained volume signal, control the first solenoid valve to an open condition, and control the first solenoid valve to a closed condition after the determined first time period has passed since opening of the first solenoid valve. Determining the time period over which the oil is injected from the oil receptacle based upon the viscosity signal enables quick and accurate injection of the oil without the need for expensive equipment, such as a load cell. [0010] In an embodiment of the air conditioning service system, the at least one viscosity signal comprises a first temperature signal indicative of a temperature of one of the oil receptacle and ambient surroundings of the air conditioning service system. In a further embodiment, the air conditioning service system includes a temperature sensor configured to generate the first temperature signal. [0011] In another embodiment, the at least one viscosity signal comprises a first oil type signal associated with a type of the oil. [0012] In some embodiments, the air conditioning service system further comprises a vacuum pump configured to generate a vacuum in the oil injection line, and the controller is operably connected to the vacuum pump and further configured to execute the program instructions to control the vacuum pump to generate a vacuum in the oil injection line prior to controlling the first solenoid valve to the open condition. [0013] In one embodiment, the air conditioning service system further comprises a second solenoid valve configured to selectively isolate the oil receptacle from the oil injection line, a chamber having an inlet in fluid communication with the first solenoid valve and an outlet in fluid communication with the second solenoid valve, and a pressure sensor configured to generate pressure signals associated with pressures of the chamber. The controller is further operably connected to the second solenoid valve and the pressure sensor and configured to execute the program instructions to generate the at least one viscosity signal during a viscosity determining procedure using the generated pressure signals. [0014] In a further embodiment, the controller is configured to execute the program instructions to perform the viscosity determining procedure. The viscosity determining procedure comprises controlling the first solenoid valve to a closed position, generating a vacuum in the chamber, controlling the first solenoid valve to an open position thereby placing the chamber in fluid communication with the oil receptacle, obtaining a first of the generated pressure signals after controlling the first solenoid valve to the open position, and generating the at least one viscosity signal based upon the obtained first of the generated pressure signals and a second time period between controlling the first solenoid valve to the open position and obtaining the first of the generated pressure signals. [0015] In yet another embodiment, the viscosity determining procedure further comprises controlling the second solenoid valve to an open position before generating the vacuum in the chamber, generating the vacuum in the chamber through the second solenoid valve, and controlling the second solenoid valve to a closed position after the vacuum has been generated. [0016] In some embodiments, the viscosity determining procedure further comprises obtaining a second of the generated pressure signals after controlling the second solenoid valve to a closed position and prior to controlling the first solenoid valve to the open position, and generating the at least one viscosity signal based upon the obtained second of the generated pressure signals. [0017] Some embodiments of the air conditioning system include a vacuum pump configured to generate the vacuum in the chamber. The controller is operably connected to the vacuum pump and further configured to execute the program instructions to control the vacuum pump to generate the vacuum in the chamber. [0018] In another embodiment, a method of injecting oil into an oil injection line of an air conditioning service system, comprises obtaining with a controller at least one viscosity signal associated with a viscosity of the oil, obtaining with the controller a volume signal indicative of an amount of oil to be charged, and determining a first time period based upon the obtained at least one viscosity signal and the obtained volume signal by executing with the controller program instructions stored in a memory. The method further includes placing an oil injection line in fluid communication with an oil receptacle by controlling the first solenoid valve to an open condition with the controller, flowing oil from the oil receptacle into the oil injection line through the open first solenoid valve, and controlling the first solenoid valve to a closed condition with the controller after the determined first time period has passed since opening of the first solenoid valve. [0019] In another embodiment of the method, the obtaining of the at least one viscosity signal comprises obtaining a first temperature signal indicative of a temperature of one of the oil receptacle and ambient surroundings of the air conditioning service system. In some embodiments, the obtaining of the first temperature signal comprises obtaining the temperature signal with a temperature sensor. [0020] In a further embodiment, the obtaining of the at least one viscosity signal comprises obtaining a first oil type signal associated with a type of the oil. [0021] In yet another embodiment, the method further comprises generating, with a vacuum pump operably connected to the controller, a vacuum in the oil injection line prior to controlling the first solenoid valve to the open condition. [0022] In some embodiments, the method further comprises obtaining with a pressure sensor pressure signals associated with pressures of a chamber having an inlet in fluid communication with the first solenoid valve and an outlet in fluid communication with a second solenoid valve that is configured to selectively isolate the oil receptacle from the oil injection line, and generating the at least one viscosity signal during a viscosity determining procedure using the generated pressure signals. [0023] In one embodiment of the method, the viscosity determining procedure comprises controlling the first solenoid valve to a closed position, generating a vacuum in the chamber, and controlling the first solenoid valve to an open position thereby placing the chamber in fluid communication with the oil receptacle. The viscosity determining procedure further includes obtaining a first of the obtained pressure signals after controlling the first solenoid valve to the open position and generating the at least one viscosity signal based upon the obtained first of the generated pressure signals and a second time period between controlling the first solenoid valve to the open position and obtaining the first of the generated pressure signals. [0024] In another embodiment, the viscosity determining procedure further comprises controlling the second solenoid valve to an open position before generating the vacuum in the chamber, generating the vacuum in the chamber through the second solenoid valve, and controlling the second solenoid valve to a closed position after the vacuum has been generated. [0025] In a further embodiment, the viscosity determining procedure further comprises obtaining a second of the generated pressure signals after controlling the second solenoid valve to a closed position and prior to controlling the first solenoid valve to the open position, and generating the at least one viscosity signal based upon the obtained second of the generated pressure signals. [0026] In another embodiment of the method, the generating of the vacuum in the chamber comprises operating a vacuum pump operably connected to the controller to generate the vacuum in the chamber. BRIEF DESCRIPTION OF THE DRAWINGS [0027] FIG. 1 is a partial cutaway front view of a refrigerant service system. [0028] FIG. 2 is side perspective view of the refrigerant service system of FIG. 1 connected to a vehicle. [0029] FIG. 3 is a schematic view of the refrigerant service system of FIG. 1 . [0030] FIG. 4 is a schematic view of the control components of the refrigerant service system of FIG. 1 . [0031] FIG. 5 is a process diagram of a method of operating a refrigerant service system to inject oil into an air conditioning system. [0032] FIG. 6 is a schematic view of an oil injection system for a refrigerant service system according to the disclosure. [0033] FIG. 7 is a schematic view of the control components of the oil injection system of FIG. 6 . [0034] FIG. 8 is a process diagram of another method of operating a refrigerant service system to inject oil into an air conditioning system. [0035] FIG. 9 is a graph of oil absolute viscosity as a function of temperature for a variety of different oils. DETAILED DESCRIPTION [0036] For the purposes of promoting an understanding of the principles of the embodiments described herein, reference is now made to the drawings and descriptions in the following written specification. No limitation to the scope of the subject matter is intended by the references. This disclosure also includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the described embodiments as would normally occur to one skilled in the art to which this document pertains. [0037] FIG. 1 is an illustration of an air conditioning service (“ACS”) system 10 according to the disclosure. The ACS system 10 includes a refrigerant container or internal storage vessel (“ISV”) 14 , a manifold block 16 , a compressor 18 , a control module 20 , and a housing 22 . The exterior of the control module 20 includes an input/output unit or user input interface 26 for input of control commands by a user and output of information to the user. Hose connections 30 , 32 (only one is shown in FIG. 1 ), which are also referred to herein as coupling ports, protrude from the housing 22 to connect to service hoses that connect to an air conditioning (“A/C”) system (also referred to herein as an “air conditioning circuit”) and facilitate transfer of refrigerant between the ACS system 10 and the A/C system. [0038] The ISV 14 is configured to store refrigerant for the ACS system 10 . No limitations are placed on the kind of refrigerant that may be used in the ACS system 10 . As such, the ISV 14 is configured to accommodate any refrigerant that is desired to be charged to the A/C system. In some embodiments, the ISV 14 is particularly configured to accommodate one or more refrigerants that are commonly used in the A/C systems of vehicles (e.g., cars, trucks, boats, planes, etc.), for example R-134a, CO 2 , or R1234yf. In some embodiments, the ACS unit has multiple ISV tanks configured to store different refrigerants. [0039] The manifold block 16 is fluidly connected to the ISV 14 , the compressor 18 , and the hose connections 30 , 32 through a series of valves, hoses, and tubes. The manifold block 16 includes valves and components configured to filter and purify refrigerant recovered from a vehicle during a refrigerant recovery operation prior to the refrigerant being stored in the ISV 14 , and to recharge the refrigerant back into the air conditioning circuit from the ISV 14 . [0040] FIG. 2 is an illustration of a portion of the ACS system 10 illustrated in FIG. 1 connected to a vehicle 50 . Service hoses 34 , 36 include coupling connectors 38 , 40 ( FIG. 3 ) configured to connect an inlet and/or outlet port of the air conditioning circuit of the vehicle 50 to the hose connections 30 (shown in FIGS. 1 and 3 ) of the ACS unit 10 . [0041] FIG. 3 illustrates a schematic diagram of the ACS system 10 . The ACS system 10 includes a bulkhead manifold 104 , a vacuum pump 108 , a recovery manifold 112 , the ISV 14 , and a controller 120 . In some embodiments, one or both of the bulkhead manifold 104 and the recovery manifold 112 are at least partially integrated within the manifold block 16 , while in other embodiments the bulkhead manifold 104 and the recovery manifold are separate from the manifold block 16 . [0042] The high-side service hose 34 and the low-side service hose 36 connect to the coupling ports 30 , 32 of the bulkhead manifold 104 at one end, and the hose couplers 38 , 40 at the other end of the service hoses 34 , 36 are configured to attach to the high-side and low-side, respectively, of the air conditioning circuit of the vehicle 50 . The bulkhead manifold 104 includes a high-side line 140 and a low-side line 144 fluidly connecting the coupling ports 30 , 32 , respectively, to a vacuum line 148 , a recovery line 152 , and an ISV charge line 156 through a high-side solenoid valve 160 and a low-side solenoid valve 164 , respectively. [0043] The vacuum pump 108 and a vacuum solenoid valve 168 are disposed in the vacuum line 148 . A recovery solenoid valve 172 is located in the recovery line 152 , which fluidly connects the recovery manifold 112 to the high-side and low-side lines 140 , 144 . The recovery manifold 112 includes components, for example a compressor, oil separators, a heat exchanger, and filters and dryer units, configured to remove oil entrained in refrigerant and purify the refrigerant when the refrigerant is recovered from an air conditioning circuit. The purified refrigerant is then stored in the ISV 14 . The ISV charge line 156 connects the ISV 14 to the high-side and low-side lines 140 , 144 through a charge solenoid valve 176 to enable recharging refrigerant from the ISV 14 to the air conditioning circuit. [0044] A first oil receptacle 180 , a second oil receptacle 184 , and a dye receptacle 188 are fluidly connected to a first oil supply line 192 , a second oil supply line 196 , and a dye supply line 200 , respectively. A first oil injection check valve 204 and a first oil injection solenoid valve 208 are fluidly connected to the first oil supply line 192 , a second oil injection check valve 212 and a second oil injection solenoid valve 216 are fluidly connected to the second oil supply line 196 , and a dye injection check valve 220 and a dye injection solenoid valve 224 are fluidly connected to the dye supply line 200 . The solenoid valves 208 , 216 , 224 are fluidly connected to the high-side line 140 via a first oil injection line 226 , a second oil injection line 228 , and a dye injection line 230 , respectively. In some embodiments, the solenoid valves 208 , 216 , 224 are directly connected to the high-side line 140 such that the high-side line 140 is the oil injection line. [0045] Each of the first and second oil receptacles 180 , 184 is configured to store a type of oil. In some embodiments, the oil stored in the first oil receptacle 180 has a different viscosity and different thermal properties than the oil stored in the second oil receptacle 184 to enable use of the ACS system 10 with a wider variety of air conditioning circuits. The dye receptacle 188 stores dye, which can be injected into the air conditioning circuit to aid a user in diagnostic operations, for example locating a leak in the air conditioning circuit. In some embodiments, one or both of the oil receptacles 180 , 184 are connected to the recovery manifold 112 by a system oil return line (not shown) to transfer oil separated from recovered refrigerant back into the oil receptacle 180 , 184 for subsequent reuse. [0046] The injection check valves 204 , 212 , 220 and solenoid valves 208 , 216 , 224 are all disposed in the bulkhead manifold 104 in the embodiment of FIG. 3 , though in other embodiments the valves 204 , 208 , 212 , 216 , 220 , 224 may be in another manifold or installed individually within the ACS machine 10 . In the embodiment of FIG. 3 , the ACS machine 10 includes two oil receptacles 180 , 184 and one dye bottle 188 . In some embodiments, the ACS machine includes only one oil receptacle or more than two oil receptacles. In other embodiments, the ACS machine does not include a dye receptacle or the associated valves and lines, or the ACS machine may include more than one dye bottle to store different types of dye. [0047] FIG. 4 illustrates a schematic diagram of a control system 236 for the ACS machine 10 . The control system 236 includes the controller 120 , which is operably connected to a user input interface 26 . The controller 120 is configured to receive inputs from the user input interface 26 , and, in some embodiments, display information for a user on the user input interface 26 . The controller 120 is also operably connected to an ambient temperature sensor 244 , which is configured to sense the ambient temperature of the ACS unit 10 and generate electronic signals corresponding to the ambient temperature. In some embodiments, an oil receptacle temperature sensor, which senses the temperature of the oil in the oil receptacle, is used in place of the ambient temperature 244 . [0048] The controller 120 is operably connected to a memory 252 to store data received from the user input interface 26 and the temperature sensor 244 . The controller 120 and the memory 252 may be integrated in the control module 20 of the ACS system 10 . In some embodiments, in addition to or as an alternative to storing the data in the memory 252 , the data is stored outside the ACS machine 10 . In one embodiment, the data is transmitted via a wired or wireless internet connection to a “cloud” storage location. In another embodiment, the data is transmitted to a memory device such as a hard disk drive, a USB drive, a solid state drive, a network attached storage (NAS) device, or the like. The controller 120 is also operably connected to the solenoid valves 160 , 164 , 168 , 172 , 176 , 208 , 216 , 224 and to the vacuum pump 108 . The controller 120 is configured to transmit electronic signals to operate the solenoid valves 160 , 164 , 168 , 172 , 176 , 208 , 216 , 224 to an open or closed condition and to operate the vacuum pump 108 to activate and deactivate. [0049] Operation and control of the various components and functions of the ACS machine 10 are performed with the aid of the controller 120 . The controller 120 is implemented with general or specialized programmable processors that execute programmed instructions. The instructions and data required to perform the programmed functions are stored in the memory unit 252 associated with the controller 120 , or in a memory unit (not shown) integrated in the controller 120 . The processors, memory, and interface circuitry configure the controller 120 to perform the functions described above and the processes described below. These components can be provided on a printed circuit card or provided as a circuit in an application specific integrated circuit (ASIC). Each of the circuits can be implemented with a separate processor or multiple circuits can be implemented on the same processor. Alternatively, the circuits can be implemented with discrete components or circuits provided in VLSI circuits. Also, the circuits described herein can be implemented with a combination of processors, ASICs, discrete components, or VLSI circuits. [0050] In operation, the high-side and low-side hose couplers 38 , 40 are connected to the high-side and low-side connection ports of an air conditioning circuit, for example an air conditioning system of vehicle 50 of FIG. 2 . To perform a recovery operation, the recovery solenoid 172 and one or both of the high-side and low-side solenoids 160 , 164 are opened. Compressed refrigerant within the air conditioning system flows to the recovery manifold 112 , where system oil entrained in the refrigerant is separated from the refrigerant and the refrigerant is purified for storage in the ISV 14 . [0051] It is often necessary during normal maintenance of an air conditioning circuit to replace the system oil entrained in the refrigerant removed from the air conditioning system so that the air conditioning system continues to perform optimally. As such, an oil injection operation is performed after the refrigerant recovery operation, during which the refrigerant is recovered from the air conditioning circuit, and prior to a refrigerant recharge operation, during which refrigerant is recharged into the air conditioning circuit. Once the recovery operation is complete, the recovery solenoid 172 is closed, the vacuum solenoid 168 is opened, and the vacuum pump 108 is activated. The vacuum pump 108 produces a negative pressure in the high-side and low-side lines 140 , 144 , pulling any remaining refrigerant from the air conditioning circuit and reducing the pressure in the air conditioning circuit below atmospheric pressure. The high-side and low-side solenoid valves 160 , 164 are then closed and the vacuum pump 108 is deactivated to close off the air conditioning system and retain the air conditioning system at the vacuum pressure. [0052] The controller 120 then controls one of the oil injection solenoids 208 , 216 to open. In some embodiments, the controller 120 is programmed to automatically select the appropriate solenoid valve 208 , 216 to open, while in other embodiments a user instructs the controller 120 which oil injection solenoid valve 208 , 216 to open via the user input interface 26 , an external electronic device operably connected to the controller 120 , or a combination thereof. Opening one of the oil injection solenoids 208 , 216 fluidly connects the associated oil receptacle 180 , 184 to the respective check valve 204 , 212 , which opens due to the negative pressure in the air conditioning system and the high-side line 140 . As such, the respective oil receptacle 180 , 184 is fluidly connected to the air conditioning circuit via the high-side line 140 . [0053] The flow rate of the oil through the solenoid valve 208 , 216 into the air conditioning circuit is dependent on the absolute viscosity of the oil, which is a function of the temperature and viscosity rating, or oil type, of the oil. As discussed in further detail below, the controller 120 is therefore configured to determine the absolute viscosity of the oil based on the current ambient temperature and the viscosity rating or oil type of the oil, and to calculate the flow rate based upon the absolute viscosity of the oil. The controller 120 is further configured to calculate the length of time the respective solenoid valve 208 , 216 is to be open based on the quantity of oil desired to be injected into the air conditioning system and the calculated flow rate. The controller 120 then controls the respective oil injection solenoid valve 208 , 216 to open for the calculated length of time to inject the desired amount of oil into the high-side line 140 and the air conditioning system. [0054] Once the oil has been injected, the controller 120 controls the respective oil injection solenoid valve 208 , 216 to close and performs a recharge operation. During the recharge operation, the charge solenoid valve 176 and the high-side solenoid valve 160 are opened. Refrigerant in the ISV 14 flows from the ISV 14 through the high-side line 140 into the air conditioning circuit. Any residual oil remaining in the high-side line 140 from the oil injection operation is entrained in the refrigerant and transferred to the air conditioning circuit. In some embodiments, the low-side solenoid valve 164 is also opened during the recharge operation such that refrigerant flows from the ISV 14 through both the high and low side lines 140 , 144 into the air conditioning circuit. [0055] FIG. 5 is a process diagram of a method 300 of injecting oil into an air conditioning circuit. The controller 120 of the refrigerant service system 10 includes a processor configured to execute programmed instructions stored in a memory associated with the controller to implement the method 300 . [0056] The method 300 begins with the controller 120 obtaining the rated viscosity of the oil and the ambient temperature (block 304 ). In one embodiment, the rated viscosity of the oil, or the type of oil, and the ambient temperature are input by the user via a user input interface, such as the user input interface 26 of the embodiment of FIGS. 3 and 4 . In another embodiment, the user inputs the rated viscosity of the oil or the oil type, and the controller obtains the ambient temperature from the temperature sensor 244 . In a further embodiment, the rated viscosity or the oil types of the oils stored in the oil receptacles are stored in the memory 252 when one of the oil receptacles is filled or changed or the rated viscosity is programmed into the memory 252 during manufacture of the ACS machine 10 , and the rated viscosity is obtained by the controller 120 from the memory. [0057] The controller 120 then determines the absolute viscosity of the oil and the corresponding flow rate of the oil at the ambient temperature (block 308 ). In one embodiment, tables or charts of oil absolute viscosity for various different oil types or rated viscosities at various temperatures are stored in the memory 252 . One example of a chart of oil absolute viscosity as a function of temperature for a variety of oil grades is shown in FIG. 9 . The controller 120 recalls the absolute viscosity of the oil from the table or chart based on the ambient temperature and the rated viscosity of the oil. [0058] The flow rate of the oil is dependent primarily on the size of the tubes and openings connecting the oil receptacle and the air conditioning system (for example oil supply and injection lines 192 , 196 , 226 , 228 check valves 204 , 212 , and solenoid valves 208 , 216 ), the length of the lines, the pressure difference between the oil receptacle and the air conditioning circuit, and the absolute viscosity of the oil. The size and length of the oil path are constants, and may be programmed into the memory 252 of the ACS system 10 . In some embodiments, the pressure difference is calculated based on a pressure signal received from a pressure transducer configured to determine the pressure in the air conditioning circuit. In other embodiments the pressure is assumed based upon a known vacuum condition in the air conditioning circuit and the ambient pressure, which is either measured or assumed. The controller is then configured to determine the flow rate of the oil at the determined absolute viscosity. In another embodiment, the system includes a viscosity sensor configured to sense the viscosity of the oil, which the controller uses to calculate the flow rate of the oil. [0059] Next, the controller 120 calculates the length of time to open the oil injection solenoid valve (block 312 ). For simplicity of description, the remainder of the method 300 will be described with reference to oil being transferred from the oil receptacle 180 through solenoid valve 208 and oil injection line 226 , through the reader should appreciate that the oil may be transferred from the second oil receptacle 184 in a similar manner. In one embodiment, the user inputs an amount of oil to inject into the air conditioning system into the user input interface 24 , which transmits a volume signal to the controller 120 . In another embodiment, the user inputs a vehicle type, air conditioning circuit model, or air conditioning circuit refrigerant capacity to the user input 24 of the ACS machine 10 and the controller 120 recalls a volume signal representing the amount of oil to inject from the memory 252 based upon the value input by the user. In a further embodiment, the ACS machine 10 determines the quantity of oil removed from the air conditioning circuit during the recovery operation and stores the quantity of oil removed in the memory 252 , and the controller 120 recalls a volume signal corresponding to the removed quantity to determine the amount of oil to inject into the air conditioning circuit. The controller 120 then determines the length of time the oil injection solenoid valve 208 is open based on the amount of oil to inject and the oil flow rate. [0060] The controller 120 controls the vacuum pump 108 to generate a vacuum pressure in the air conditioning circuit, the high-side line 140 , and the oil injection line 226 (block 316 ). The reader should appreciate that the generation of the vacuum pressure may be performed before, during, or after the determination of the oil viscosity and the valve open time. In one embodiment, the controller controls the high-side solenoid valve 160 , the vacuum solenoid valve 168 , and the vacuum pump 108 to generate the vacuum, closing the valves 160 , 168 to retain the air conditioning circuit, the high-side line 140 , and the oil injection line 226 at the vacuum pressure. [0061] Once the air conditioning circuit is at vacuum pressure and the opening time for the oil injection solenoid valve 208 has been calculated, the controller controls the oil injection solenoid valves 208 to open for the calculated time (block 320 ), such that the amount of oil flows through the solenoid valve 208 into the oil injection line 226 , the high-side line 140 , and the air conditioning circuit. After the valve 208 is open for the calculated length of time, the controller 120 controls the valve 208 to close. Refrigerant is then charged into the air conditioning circuit by, for example, opening the charge solenoid valve 176 and the high-side solenoid valve 160 to open a path from the ISV 14 to the air conditioning circuit (block 324 ). Refrigerant flows from the ISV 14 into the air conditioning circuit, capturing any oil remaining in the oil injection line 226 and the high-side line 140 and transferring the oil into the air conditioning circuit. [0062] FIG. 6 illustrates another oil injection system 400 for a refrigerant service system, which can be used in place of the oil injection system of the refrigerant service system 10 depicted in FIG. 3 . The oil injection system 400 is disposed in a bulkhead manifold 404 , and includes an oil supply line 408 , a check valve 412 , a first solenoid valve 416 , a chamber 420 , a second solenoid valve 424 , an oil supply line 428 , and a pressure transducer 432 . [0063] The oil injection line 408 fluidly connects the oil receptacle 180 to the check valve 412 , which is fluidly connected to the first solenoid valve 416 . The chamber 420 includes an inlet 434 , which is fluidly connected to the first solenoid valve 416 , and an outlet 436 , which is fluidly connected to the second solenoid valve 424 . In some embodiments, the inlet 434 and the outlet 436 are combined into a single combination inlet/outlet line or port used to both receive and discharge oil. In some embodiments, the chamber 424 is connected to a separate line that is connected to the line between the first and second solenoid valves 416 , 424 , instead of being directly positioned between the first and second valves 416 , 424 . [0064] The second solenoid valve 424 is fluidly connected to the oil injection line 428 , which discharges oil into the high-side line 140 . As described above with regard to FIG. 1 , the high-side line 140 is fluidly connected to a high-side hose 34 and high-side hose coupler 38 via the coupling port 30 . [0065] The chamber 420 is configured to hold a predetermined volume of oil, which, in one embodiment, is approximately 5 mL. The pressure transducer 432 is configured to sense the pressure within the predefined volume of the chamber 420 and generate an electronic signal corresponding to the pressure within the chamber 420 . [0066] FIG. 7 illustrates the control system 438 of the oil injection system 400 of FIG. 6 . A controller 440 is operably connected to the user input interface 26 and a memory 252 , both of which are configured substantially the same as described above with regard to the embodiment of FIGS. 3 and 4 and may be integrated within the control module 20 of the ACS system 10 . The controller 440 is also operably connected to the chamber pressure transducer 432 to receive the signal corresponding to the pressure in the chamber 420 . The controller 120 is operably connected to the first and second oil injection valves 416 , 424 and configured to transmit electronic signals to control the solenoid valves 416 , 424 to open and close. [0067] Operation and control of the various components and functions of the oil injection system 400 are performed with the aid of the controller 440 . The controller 440 is implemented with general or specialized programmable processors that execute programmed instructions. The instructions and data required to perform the programmed functions are stored in the memory unit 252 associated with the controller 440 . The processors, memory, and interface circuitry configure the controller 440 to perform the functions described above and the processes described below. These components can be provided on a printed circuit card or provided as a circuit in an application specific integrated circuit (ASIC). Each of the circuits can be implemented with a separate processor or multiple circuits can be implemented on the same processor. Alternatively, the circuits can be implemented with discrete components or circuits provided in VLSI circuits. Also, the circuits described herein can be implemented with a combination of processors, ASICs, discrete components, or VLSI circuits. [0068] In operation, the controller 440 is configured to initiate an oil injection operation after a refrigerant recovery operation and before a refrigerant recharge operation. The oil injection operation begins with execution of a viscosity determining procedure. The viscosity determining procedure beings with the controller activating a vacuum pump (not shown in FIG. 6 or 7 ) to produce a vacuum in the high-side line 140 , the high-side hose 34 , the oil injection line 428 , and the air conditioning circuit. The controller 440 then controls the second oil injection solenoid 424 to open, such that the vacuum pressure is transferred to the chamber 420 . The controller 440 controls the second oil injection solenoid 424 to close, deactivates the vacuum pump, and opens the first oil injection solenoid 416 . The negative pressure in the chamber 420 opens the check valve 412 , drawing oil from the oil receptacle 180 through the oil supply line 408 and into the chamber 420 . [0069] The controller 440 monitors the signal produced by the pressure transducer 432 as the oil travels into the chamber 420 . Once the controller 440 identifies that the pressure in the chamber 420 is equal to or greater than a predetermined threshold, which, in one embodiment, is atmospheric pressure, the controller 440 calculates the flow rate of the oil from the oil receptacle 180 . The amount of time required for the chamber 420 and the known volume of the chamber 420 is representative of the viscosity of the oil. The controller 120 then generates a viscosity signal that enables the controller 440 to calculate the flow rate of the oil being transferred from the oil receptacle 180 , and the viscosity determining procedure is completed. [0070] Once the oil injection flow rate is calculated, the controller calculates the amount of time the valves 416 , 420 are opened such that the desired quantity of oil is injected into the air conditioning circuit. The controller 440 then controls the second solenoid valve 424 to open, so that both valves 416 , 424 are open. Oil travels from the oil receptacle 180 through the oil supply line 408 and the chamber 420 , through the oil injection line 428 , the high-side line 140 , the high-side hose 34 , and into the air conditioning circuit of the vehicle. After the calculated amount time has elapsed, the solenoid valves 416 , 424 are closed and the air conditioning circuit is charged with refrigerant, capturing any remaining oil in the lines 428 , 140 , and the hose 34 and transporting the oil into the air conditioning circuit of the vehicle. [0071] FIG. 8 illustrates a process diagram of a method 500 of injecting oil into an air conditioning circuit. The controller 440 of the refrigerant service system 10 includes a processor configured to execute programmed instructions stored in a memory associated with the controller to implement the method 500 . [0072] The method 500 begins with the controller 440 opening the outer solenoid valve 424 (block 504 ) to fluidly connect the chamber 420 to the oil injection line 428 , the high-side line 140 , and the air conditioning circuit. The controller 440 then controls the vacuum pump to generate a vacuum in the air conditioning circuit, the high-side line 140 , the oil injection line 428 , and the chamber 420 (block 508 ). The outer valve 424 is closed (block 512 ), isolating the chamber 420 from the air conditioning circuit, and an inner solenoid valve 416 is opened (block 516 ), connecting the oil receptacle 180 to the chamber 420 . The controller 440 obtains the pressure signal produced by the pressure transducer 432 (block 520 ) and compares the pressure in the chamber 420 with a predetermined pressure threshold (block 524 ). [0073] If the pressure is less than the threshold, the process continues at block 520 by obtaining the signal corresponding to the pressure inside the chamber 420 again. If the pressure is equal to or greater than the threshold, the controller 440 determines the average oil flow rate into the chamber 420 , which is equal to the chamber volume divided by the amount of time required after opening the inner solenoid valve 416 for the pressure to reach the threshold, indicating that the chamber 420 is full (block 528 ). In some embodiments, the controller 440 corrects the determined average flow rate by a correction factor based upon temperature, ACS machine specifications, or other environmental or system variables. The execution of blocks 504 through 528 are referred to collectively as the viscosity determining procedure. [0074] Based on the determined average flow rate, the controller calculates the solenoid open time (block 532 ), which is equal to the amount of oil desired to be injected into the air conditioning circuit divided by the determined average oil flow rate. The outer solenoid valve 424 is then opened (block 536 ), fluidly connecting the oil receptacle 180 to the air conditioning circuit of the vehicle. The controller 440 waits for the calculated period of time to elapse (block 540 ), and then controls both the inner and outer solenoid valves 416 , 424 to close (block 544 ). The controller 440 then controls the components in the ACS system 10 to charge the air conditioning circuit with refrigerant (block 548 ). [0075] It will be appreciated that variants of the above-described and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the foregoing disclosure.
An air conditioning service system includes an oil receptacle, a coupling port in fluid communication with the oil receptacle through an oil injection line, a solenoid valve configured to selectively allow the oil to flow from the oil receptacle into the oil injection line, a memory including program instructions stored therein, and a controller operably connected to the solenoid valve and the memory. The controller is configured to execute the program instructions to obtain at least one viscosity signal associated with a viscosity of the oil, obtain a volume signal indicative of an amount of oil to be charged, determine a time period based upon the obtained at least one viscosity signal and the obtained volume signal, control the solenoid valve to an open condition, and control the solenoid valve to a closed condition after the determined time period has passed since opening of the solenoid valve.
5
FIELD OF THE INVENTION [0001] This invention relates generally to assembly methods for thermoplastic components and more particularly to methods and apparatus for manufacturing window and door frames using vibration welding techniques. BACKGROUND OF THE INVENTION [0002] At present, plastic window and door frames are typically assembled from polyvinyl chloride (PVC) extruded profiles using hot plate welding technology. Typically, the corner welding process involves pressing the mitered cut ends of two profiles against a Teflon-coated heated metal plate. After the thermoplastic PVC material has melted, the heated metal plate is removed and the two ends are then pressured against each other forming a hermetically sealed welded bond. [0003] Typically, in manufacturing a four sided frame assembly either one-head, two-head or four-head welding equipment is used. For four-head welding equipment, the complete frame is assembled in one operation and, taking into account the time required for frame set-up, profile loading, corner welding, cool down and frame unloading, the total cycle time is about two minutes. [0004] As well as being a comparatively slow process, a further drawback of hot plate welding is that a large quantity of plastic flash is created at the weld line and this plastic flash has to be mechanically removed through a process that can involve cutting, shaving and routing operations. Generally, the equipment required for flash removal is complex and expensive and the process can also damage any surface coatings applied to the extruded profiles. In addition because the plastic flash material is contaminated during the welding process, the removed waste material cannot be recycled and the contaminated material can also effect the final weld strength. Finally to order consistently achieve a square right angled square corner, the equipment incorporates elaborate and complex mechanical support systems. [0005] Vibration welding is one commonly used method for welding together the flat surfaced end walls of two thermoplastic components. As described in U.S. Pat. No. 4,352,711, the typical vibration welding process involves one component being held firmly in place in a stationary bottom fixture while a second component is firmly held in place in a moveable top fixture. By applying pressure and moving the top fixture very rapidly, heat is generated through surface friction, in a very short period of time, that melts the two contact surfaces of components that are to be welded together and thus in addition to a short cycle time, a further key advantage of vibration welding is that minimum flash is generated so that the need for mechanical flash removal can be substantially reduced. Generally, the two plastic component parts are injection molded and this allows for flash dams and other features to be incorporated into the components. As a result, even with the limited flash that is generated, its movement and location is controlled so that it is not visually obtrusive or unsightly. [0006] Various efforts have been made in the past to use vibration welding techniques for plastic frame assembly but without commercial success. In U.S. Pat. No. 5,902,657, issued to Hanson et al, two alternative processes are described that are specifically developed for manufacturing window and door frames. One technique uses an apparatus similar to a conventional hot plate welder where a vibratory metal plate rapidly moves back forth between the ends of two profiles. To create a welded joint, the metal plate is then removed and the two profiles are pressed against each other. As described, there are some technical issues with this process because unlike conventional hot plate welding, only a thin surface layer is heated and as a result, when the vibratory metal plate is moved away, the small amount of surface plastic material that has been melted is either removed and / or rapidly cools down so that when the two profiles are finally pressed together the welded bond formed between the two profiles is poor. [0007] There are also some technical concerns with the second alternative process described in U.S. Pat. No. 5,902,657. With this method for a four-sided frame, two opposite sides are held fixed in position while the other two sides are moveable. The moveable sides are held in fixtures that are connected to four vibratory heads that are located at profile corner ends when directly welding together two hollow thin wall profiles. Because the vibratory head moves back and forth very rapidly, it is very difficult to accurately control the final position of the vibratory head and so consequently the thin profile walls are not correctly aligned and this results in reduced corner weld strength as well as an uneven joint line which is visually noticeable. [0008] With vibration welding, there is typically a minimum zone of disturbance at the weld line. However, for glass fiber re-enforced plastics as described in U.S. Pat. No. 5,874,146 by Kagan et al, higher structural strengths can be achieved with a wide weld zone that allows for some of the glass fibers to orient away from the flow direction and to cross the weld interface. SUMMARY OF THE INVENTION [0009] The invention provides a method for forming a vibratory welded connection between first and second members and a junction piece where said members and said junction piece are composed at least in part of thermoplastic resin material, said method comprising providing a vibratory head; engaging said junction piece in a fixture connected to said vibratory head; mounting said first and second members in fixtures that are independent of said vibratory head; creating an engagement force between each of said first and second members with a respective opposite side of said junction piece; maintaining said engagement forces while vibrating said junction piece by means of said vibratory head at a frequency of from 50 to 500 Hz to create friction generated heat to melt material on the ends of said members and on each respective opposite side of said junction piece, such melted material upon cooling forming a weld between said junction piece and said members; and where said engagement forces between said first and second framing members and said junction piece are applied separately from the operation of the vibratory head. [0010] Preferably the engagement forces provide even pressure on each side of the junction piece. The engagement forces desirably are varied in the duration of the welding step such that after the desired degree of melting of the materials of the engaging faces has been achieved, each engagement force is reduced to a level wherein the melted material remains molten in position between the ends of the members and the junction piece. [0011] Preferably the junction piece has a planar flange that extends at an angle with respect to each of the members, the junction piece incorporating a removable tab that is an extension of the planar flange. The tab is held in the fixture connected to the vibratory head, and after the welding step has been completed it is removed. The tab preferably has a geometric shape that is held in the fixture in an insert hole with a similar geometric shape, e.g. T-shaped, the junction piece being held firmly in position by means of metal spring attachments or the like. Alternatively, the junction piece can incorporate insert holes for engagement by insert pins on the fixture to secure the junction piece in position. [0012] For a particular application, the vibratory corner welding process is controlled by adjusting the duration of the operation of the vibratory head for a specified amplitude, frequency, and engagement force. [0013] From another aspect the invention provides Apparatus for forming a vibratory welded connection between end faces of first and second frame members and a junction piece, and where said frame members and said junction piece are composed at least in part of a thermoplastic material, said apparatus comprising: [0014] a) a vibratory head including a drive for vibrating said head in a predetermined plane at an amplitude or at least 0.4 mm and at a frequency of from 50 to 500 Hz; [0015] b) opposed first and second fixtures each having clamping structure for securing thereon a respective one of said first and second frame members and where said first and second fixtures support said first and second frame members for movement independently of said vibratory head; [0016] c) a third fixture for holding the junction piece in a balanced way and typically in a central location on said vibratory head, said junction piece having a planar part that is aligned perpendicularly to said predetermined plane; [0017] d) guide structure for guiding relative movement between said frame members and said junction piece in directions parallel to said predetermined plane and perpendicular to said planar part and to said end faces to facilitate engagement between opposite sides of said junction piece and said first and second frame members respectively; [0018] e) pressure actuators coupled to first and second fixtures to provide an engagement force between opposite sides of said junction piece and said first and second members; and [0019] f) a control system to regulate the operation of the vibration corner welding apparatus. [0020] Preferably there are adjustment mechanisms associated with each pressure actuator whereby the engagement force provided by each pressure actuator is independently adjustable. In this way, a variable force of engagement can be provided through the duration of the welding step. [0021] The third fixture which holds the junction piece is preferably located so that the planar flange of the junction piece is balanced and positioned typically in a central location, with the first and second fixtures being movable independently of this third fixture. [0022] The invention also contemplates a system for interconnecting a series of elongate frame members to form a closed frame. In this system adjacent ends of adjoining frame members are engaged by use of the aforesaid apparatus. The frame member can be a rectangular frame, a set of apparatuses aforesaid being provided at each of the four corners of the frame. [0023] The framing members need not be assembled at right angles, but can in fact be connected at any selected angle in the range 90° to 15°. The angles of adjoining frame members with respect to the junction piece can also be different. Nor is it essential that the framing members be straight, but on the contrary, one or more of the framing members may be longitudinally curved. [0024] The system for interconnecting the frame members can be used to assemble those members around an inner panel prior to the frame members being welded together to form a complete assembly with the panel. The panel can be of any desired composition such as a sheet of glass or rigid plastics material, an insulating glazing unit, a multi-cavity sheet extrusion, or the like. [0025] The invention further provides a frame comprising a plurality of elongate frame members, adjacent ends of pairs of said members being interconnected through an interposed junction piece, wherein said frame members and said junction piece are each composed at least in part of a thermoplastic resin, wherein each said junction piece is secured to a pair of adjacent frame members by vibratory welded bonds on opposite sides of said junction piece, and wherein said junction piece has a planar flange that extends at an angle with respect to each said frame member. [0026] Preferably each hollow profile has a peripheral wall that provides a surface for welding to the planar flange. The hollow profile of the frame members can be subdivided into two or more cavities. [0027] Preferably the planar flange has a thickness in the range of 2 mm to 12 mm and preferably 3 mm to 6 mm. [0028] The flat surfaces of the planar flange may incorporate a textured surface finish to improve the build-up of friction generated heat. [0029] The frame members are preferably composed of glass fiber reinforced thermoplastic material, such as polyvinyl chloride. The frame members can have decorative coatings or finishes incorporated on their outer surfaces. [0030] The junction piece may preferably carry integral legs that extend from opposite sides of the planar flange, the legs being sized to engage longitudinally within the hollow interiors of the adjacent frame members. The integral legs of the junction piece may incorporate each an integral spring centering device. Furthermore the hollow frame profile members can be fixed to the legs of the junction pieces by ultrasonic spot welding at locations spaced from the planar flange. [0031] Preferably the ends of the framing profiles are miter cut to provide the desired corner angle of the frame, e.g. a miter cut at 45° to provide a 90° corner. The miter cut ends of the framing profiles may be formed with a so-called dado cut (open sided groove) and a pressure plate can be applied on the miter cut ends of the front face of the framing profile during the welding process to prevent the appearance of this front face being marred by any welding flash. [0032] The junction piece can incorporate devices such as traps, grooves or welding beads for locating or receiving plastic flash generated during the vibratory welding process. [0033] There are three preferred applications for the vibration corner welding process, namely: (i) where frame members are assembled around an insulating glass unit and where silicone sealant is applied in gaps between the assembled frame and the insulating glass unit; (ii) where glazing sheets are directly adhered to the sides of a frame assembly using silicone sealant, and (iii) where an assembled frame is located between spaced glazing sheets. BRIEF DESCRIPTION OF THE DRAWINGS [0034] The following is a description by way of example of certain embodiments of the present invention, reference being made to the accompanying drawings, in which: [0035] [0035]FIGS. 1A and 1B are elevation views of a frame corner assembly fabricated from square profile, glass fiber filled PVC extrusions and welded at the corner using conventional hot plate welding technology. [0036] [0036]FIG. 2 is a vertical cross section taken on -the line 1 - 1 in FIG. 1 through a corner assembly. [0037] [0037]FIG. 3 is an elevation view of the test fixture for the thermoplastic corner test as specified in the North American Fenestration Standard (NAFS-1). [0038] [0038]FIG. 4 is an exploded perspective detail of a frame corner assembly incorporating a removable tab on the outer side edge where the thermoplastic extrusions are vibration welded at the corners to a diagonal corner web [0039] [0039]FIG. 5 is a horizontal cross section of a frame corner assembly where the thermoplastic extrusions are vibration welded to a diagonal planar flange junction piece incorporating a removable tab on the outer side edge. [0040] [0040]FIG. 6A is a perspective view of a single corner vibration welding apparatus. [0041] [0041]FIG. 6B is a schematic diagram of the control system for a single corner friction welding apparatus. [0042] [0042]FIG. 7A is a plan view of a single corner, vibration welding apparatus with the extrusions installed in the fixtures prior to the welding process. [0043] [0043]FIG. 7B is a view similar to FIG. 7A showing the single corner vibration welding apparatus during the welding process. [0044] [0044]FIG. 8A is an exploded perspective view and FIG. 8B is a perspective view of a vibration welded corner frame assembly incorporating a junction piece with a planar flange and a removable tab on the bottom edge. [0045] [0045]FIG. 9A is a cross section detail of a planar flange web incorporating flash traps. [0046] [0046]FIG. 9B is a cross section detail of a planar flange web incorporating welding beads. [0047] [0047]FIG. 10 is a cross section detail of the moveable fixtures that hold the framing profiles in position during the vibration welding process. [0048] [0048]FIG. 11 is a perspective view of a junction piece with a planar flange and a removable T-shaped tab on the outer side edge. [0049] [0049]FIG. 12A is a perspective detail of a junction piece with a planar flange and incorporating a removable tab with a double set of L-shaped slots on the back edge. [0050] [0050]FIG. 12B is an exploded top elevation view of a junction piece holding fixture and a planar flange junction piece web as shown in FIG. 12A. [0051] [0051]FIG. 12C is a vertical cross section of the junction piece holding fixture with a planar flange junction piece as shown in FIG. 12B. [0052] [0052]FIG. 13 is a perspective view of a corner web with a removable tab on the bottom edge. [0053] [0053]FIG. 14A is a top plan view of a junction piece fixture incorporating a separate pressure strip device. [0054] [0054]FIG. 14B is a vertical cross section detail of a corner web fixture incorporating a separate pressure strip device. [0055] [0055]FIG. 15A is a cross section plan view detail of a frame corner assembly where the thermoplastic plastic extrusions are vibration welded at the corner using a corner key with a diagonal web and integral legs. [0056] [0056]FIG. 15B is a cross section detail of the frame corner assembly as shown in FIG. 15A where the plastic framing profile is ultrasonically spot welded to the integral legs of the corner key. [0057] [0057]FIG. 15C is a cross section and elevation detail of the plastic framing profile and corner key as shown in FIG. 15A. [0058] [0058]FIG. 16 is a fragmentary plan view of vibration welding apparatus showing that the framing profiles can be assembled at varying angles to the planar flange junction piece. [0059] [0059]FIG. 17A is an elevation view of a round top window frame. [0060] [0060]FIG. 17B is a cross section detail of a butt joint assembly between a straight and curved framing profile. [0061] [0061]FIG. 18 is an exploded perspective view of a vibration welded corner frame assembly incorporating a junction piece with a planar flange and a top held removable tab. [0062] [0062]FIG. 19A and 19B are elevation views of a vertical four head vibration welding apparatus featuring two stage frame assembly. [0063] [0063]FIG. 20 is an elevation view of a vertical four head vibration welding apparatus where all four corners are simultaneously welded. [0064] [0064]FIG. 21A is an elevation view of a composite channel sash window panel with the thermoplastic framing profiles assembled using vibration corner welding. [0065] [0065]FIG. 21 B is a vertical cross section detail taken on a line 21 A- 21 A in FIG. 21A of a composite channel window panel incorporating a double glazed insulating unit. [0066] [0066]FIG. 22 is an exploded perspective view of a composite channel frame being assembled around an insulating glass unit using vibration corner welding. [0067] [0067]FIG. 23B is a perspective view of a corner assembly of a composite channel window incorporating different size framing profiles and assembled using vibration corner welding. [0068] [0068]FIG. 24A is a perspective view of a vibration welded composite channel frame assembly where the framing profiles incorporate a single I-shaped cavity and thin solid frame profile walls for supporting the insulating glass unit. [0069] [0069]FIG. 24B is an exploded top view of the corner frame assembly shown in FIG. 24A. [0070] [0070]FIG. 25A is an elevation view of an insulating glass panel with a rigid thermoplastic spacer frame assembled using vibration corner welding. [0071] [0071]FIG. 25B is a vertical cross section detail taken on a line 25 A- 25 A in FIG. 25A of the insulating glass panel incorporating a rigid thermoplastic spacer frame. [0072] [0072]FIG. 26A is an elevation view of a sealed frame window panel where the outer glazing sheets are directly adhered to the frame assembly. [0073] [0073]FIG. 26B is a vertical cross section detail taken on a line 26 A- 26 A in FIG. 26A of a sealed frame window panel as shown in FIG. 26A. [0074] [0074]FIGS. 27A and 27B are front and side elevation views of a corner end of a framing profile specifically fabricated for friction corner welding of sealed frame panels. [0075] [0075]FIG. 28 is an exploded perspective detail of a corner frame assembly for a sealed frame window panel as shown in FIG. 26A. [0076] [0076]FIGS. 29A to 29 E are details of the production steps involved in the sealed frame corner assembly using a combination of friction welding and ultrasonic spot welding techniques. [0077] [0077]FIG. 30 is a perspective view of a junction piece with a removable tab incorporating insert holes for engagement by insert pins that form part of the junction piece holding fixture. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0078] Referring to the drawings FIGS. 1A and 1B show side and front elevations of a frame corner assembly 31 fabricated from square hollow profile, glass fiber filled PVC extrusions 32 and 33 . The miter cut corner ends 34 of the frame members 32 and 33 are welded together using conventional hot plate equipment. One major drawback of hot plate welding is that a large quantity of plastic flash 35 is created at the weld line 36 . This plastic flash 35 has to be mechanically removed and this process often involves removing a shallow groove at the weld line 36 . As a result of this mechanical removal process, the structural performance of the corner weld can be quite significantly reduced. [0079] [0079]FIG. 2 shows a vertical cross section on a line 1 B- 1 B through he frame corner assembly 31 where the miter cut ends 34 of the frame members 32 and 33 are welded together at the perimeter wall edge. As previously described this process creates plastic flash 35 that has to be mechanically removed from the profile exterior. [0080] In North America, the structural performance of thermoplastic corner welds are evaluated according to the North American Fenestration Standard (NAFS-1) test procedure. As shown in FIG. 3, the test procedure involves attaching a welded frame corner assembly 31 to a support 39 with clamps 40 and 41 . The bottom clamp 41 is located 100 mm above the top edge 42 of the lower frame profile 33 . A point load L 44 is gradually applied to the lower frame profile 33 with this load 44 being located at a distance of 360 mm from the front side edge 45 of the upper profile 32 . The pass/fail test criterion is that when loaded to failure, the break shall not extend along the entire weld line 36 . [0081] Using conventional hot plate welding technology, corner weld test samples as shown in FIG. 2 were fabricated from 30 per cent glass fiber filled PVC extrusions. The samples were tested according to NAFS-1 procedure and the samples failed with the break extending fully along the weld line 36 . The main reason that the fiber filled material failed the NAFS test procedure is that the weld strength is typically no higher than the base matrix polymer and as a result, because the 30 per cent glass fiber filled profiles are stronger and stiffer, the joint is the weak link in the frame assembly. [0082] As described in detail with reference to FIGS. 4 - 30 , one of the main purpose of this invention is to provide a corner frame assembly method where the test samples fabricated from 30 per cent glass fiber filled PVC extrusions, consistently pass the NAFS-1 Thermoplastic Corner Weld test procedure. [0083] [0083]FIG. 4 shows an exploded perspective view of corner frame assembly where the miter cut ends 34 of thermoplastic framing member 32 and 33 are vibration welded to opposite sides of a junction piece 47 incorporating a planar flange 48 and a removable tab 49 . The junction piece 47 is made from the same base polymer as the thermoplastic framing members 32 and 33 . The planar flange 48 incorporates a rough or textured surface and because this surface treatment accelerates the generation of friction heat, the weld cycle time is substantially reduced. The wall thickness of the planar flange 48 can vary between 2 mm to 12 mm with the preferred range being 3 to 5 mm. The removable tab 49 is thicker than the planar flange 48 and this provides for increased strength and stiffness. After the welding process is complete, the removable tab 49 is cut off using a shear press or similar device. Because the vibration welding does not contaminate the plastic weld material, this removable tab can be recycled and the plastic resin reused. [0084] [0084]FIG. 5 shows a horizontal cross section through the fabricated corner frame assembly from hollow plastic profiles 32 and 33 . Because the framing members 32 and 33 are vibration welded to either side of the junction piece 47 , the structural loads at each of the two welds is reduced accordingly. In addition, the planar flange 48 provides for diagonal corner bracing, further increasing the structural performance of the frame assembly. [0085] A removable tab 49 that forms an extension of the planar flange 48 is located on the outer side back of the junction piece 47 . During the vibration welding process, this tab 49 is firmly held in a holding fixture 50 linked to the vibratory head 52 of the special vibration welding apparatus 51 as described in FIGS. 6A, 6B and 7 A, 7 B. [0086] A corner test sample was fabricated using the same hollow square profile PVC extrusions with 30 per cent glass content as the samples that had been previously made using conventional hot plate welding equipment. The profile samples were welded to the planar flange using the special vibration welding techniques but unlike the hot plate welded test samples, these vibration welded test samples passed the NAFS-1 Thermoplastic Corner Weld test procedure. [0087] As shown in FIG. 5, the vibration welding process generally results in the plastic framing profiles 32 and 33 being embedded in the planar flange 48 . Although it is desirable that the planar flange is made from the same resin-based material as the framing profiles, one option is for the junction piece to be made from a stiffer plastic material (e.g. glass fiber filled material) so that the profiles are not excessively embedded within the planar flange. [0088] [0088]FIG. 6A shows a top perspective view of a prototype single corner vibration welding apparatus 51 . The apparatus consists of five main components: [0089] 1. Vibratory Head [0090] A linear vibratory head 52 that incorporates a top plate 53 which vibrates back and forth very rapidly in a predetermined plane. [0091] 2. Junction Piece Holding Fixture [0092] A junction piece holding fixture 50 is directly attached to the top plate 53 and firmly holds the planar flange junction piece 48 in position. [0093] 3. Moveable Framing Fixtures [0094] Two moveable framing fixtures 55 and 56 incorporate clamping devices 60 that firmly hold the framing profiles in position. The movement of the framing fixtures 55 and 56 is operated through a variety of means including: electrical servo motors, pneumatic and hydraulic devices. [0095] 4. Control Systems [0096] A control system 46 that regulates the various operating parameters of the vibration welding apparatus including: weld time, hold time, joint pressure, amplitude, frequency and voltage. The control system is located in a protective housing and is linked to an operator interface 64 . [0097] 5. Machine Frame [0098] A machine frame 65 provides the structure that supports the other components. [0099] The vibratory head 53 can move in either a linear or orbital manner. With linear vibration welding, the vibratory head moves back and forth very rapidly in a predetermined plane. While with orbital vibration, the vibratory head continuously rotates in a circular operation. As a continuous process, orbital vibration offers some major advantages including: reduced time, less energy, less weld amplitude, reduced clearance and better flash control. At present, orbital vibration is somewhat less reliable because the continuous circular motion is driven by an electrical motor and so only linear vibration welding is illustrated in the following figures. However, it can be appreciated by those skilled-in-the-art that orbital vibration welding can also be substituted for many of these corner welding applications and specifically, the process offers advantages where a planar flange junction piece is used. [0100] [0100]FIG. 7A shows a plan view of a single corner, vibration welding apparatus 51 in an open position. The linear vibration welding apparatus 51 features a vibratory head 52 that linearly moves back and forth in a pre-determined plane. The vibratory head 52 is similar to the vibratory heads used on commercially available linear vibration welders such as the Branson Mini Welder, but unlike these commercially available products, the vibratory head is turned upside down as this allows for more flexible and easy positioning of the framing members 32 and 33 during the frame assembly process. A flat plate 53 is bolted to the top surface of the vibratory head 52 . As with standard vibration welders, the vibratory head is bolted to a separate heavy cast iron support (not shown) and isolated from the cast iron support structure (not shown) using rubber mounts. This cast iron support structure is in turn bolted to a machine frame 65 that positions the vibratory head 52 at a convenient working height. [0101] Flat plate metal sheets 54 are bolted to the top surface of the machine frame 65 but this top working surface is separated apart from the vibratory head 52 so that a minimum of vibratory movement is transferred to the machine frame 65 . Moveable profile fixtures 55 and 56 are supported on guide rails 57 directly attached to the top table plate 54 and these fixtures hold the framing profiles extrusions 32 and 33 in position. The moveable profile fixtures 55 and 56 move over the vibratory head 52 but there is no direct contact except where the framing profiles 32 and 33 contact the junction piece 47 . The moveable fixtures also allow for the miter cut ends 34 of the framing profiles 32 and 33 to be positioned parallel to the planar flange 48 of the junction piece 47 . [0102] Each moveable profile fixture 55 and 56 consists of a horizontal flat plate 58 , a support member 59 that is attached to the horizontal plate 58 and a clamping fixture 60 that firmly holds the profiles 32 and 33 against the support member 59 . A front clamp 60 is positioned adjacent to the side edge 61 of the flat plate 58 and to ensure that the profile 33 is firmly held in position, the miter cut profiles 32 and 33 only extend 2 or 3 mm beyond the side edge 61 . It is also important that both the profiles extend the same distance from the two clamping fixtures. [0103] To provide for a right angled joint connection (i.e. 90°), the vertical support members 59 are positioned at a 45° angle to side edge 61 . However for special framing shapes, the angular position a of the support member 59 can be adjusted as required by means of a pivot point 62 and an attachment device 63 . A fixed holding fixture 50 for the junction piece 47 is located so that the planar flange of the junction piece is in a balanced central position. The holding fixture 50 which is directly attached to the top plate 53 of the vibratory head 52 , firmly holds the removable tab 49 of the junction piece 47 in position. [0104] [0104]FIG. 7B shows a plan view of the vibration welding equipment in operation. The miter cut ends 34 of the profile extrusions 32 and 33 are pressured against the planar flange 48 of the junction piece 47 . As required, the angular displacement of the profile fixtures 55 and 56 can be adjusted so that all four joint surfaces are parallel with each other. [0105] In operation, friction heat is generated at the two joint interfaces between the parallel surfaces of the miter cut ends 34 of the framing profiles 32 and 33 and the planar flange 48 of the junction piece 47 . By vibrating the junction piece 47 back and forth and by simultaneously pressuring the framing profiles 31 and 32 against the planar flange 48 of the junction piece 47 , friction heat is generated at the two joint interfaces. When a molten state is reached at the two joint interfaces 66 and 67 , the vibration is stopped and the perpendicular pressure P is then maintained briefly while the molten plastic solidifies to form two welded joints 66 and 67 on either side of the planar flange 48 . In order to provide for even weld strength, essentially the same perpendicular engagement force has to be simultaneously applied to each side of the junction piece 47 [0106] In the vibration welding process, if excessive pressure is applied after the surface plastic has been melted, the melted plastic can be pushed away from the joint line resulting in a poor structural bond. By carefully controlling the engagement force or pressure of the framing profiles on the junction piece, this joint bond problem can be avoided. After the desired degree. of melting of the materials at the joint line has been achieved, the engagement force is reduced to a level where the melted material remains molten in position between the ends of the framing profiles. [0107] In friction welding glass fiber filled profiles, one of the reasons for reduced weld strength is that the glass fibers align along the weld line, perpendicular to the applied engagement force or pressure. This weld zone is typically very narrow varying from 40 to 100 microns. By carefully controlling and optimizing the welding parameters and particularly the applied pressure, a wide weld zone can be created so that some of the glass fibers are oriented away from the weld line and cross the weld interface. As a result, higher weld strengths can be achieved for the glass-fiber filled profiles. [0108] Using the prototype corner welding apparatus, a series of experiments have been carried out and these experiments have shown that satisfactory structural welds can be achieved by optimizing the different welding parameters through quite a wide range of different parameter values. For example, maximum applied pressure can be reduced if amplitude is increased, or both maximum applied pressure and amplitude can be reduced if weld-time is increased. Particularly to reduce the amount of plastic flash that is produced, our experiments have also shown that is preferable to use a higher frequency and a lower amplitude. Generally, the different welding parameters can be varied through the following values although for each application, there is a need to establish a particular set of welding parameters. Maximum applied pressure 6 kN Weld time 2-12 seconds Weld amplitude 0.4 mm to 3 mm Weld frequency 50 to 500 Hz [0109] Generally for a particular application, the vibratory corner welding process is controlled by the weld time that is determined for a specified weld amplitude, frequency and maximum applied pressure or engagement force. It should be noted that weld time is defined as the duration of the operation of the vibratory head. [0110] [0110]FIG. 6B is a schematic diagram of the control system 46 for the single corner vibration welding apparatus 51 . The control system 46 consists of a central controller 84 which is protected within metal housing and linked to an operating interface 45 . The controller 84 controls the operation of five main components: (i) vibratory head 55 , (ii) clamping mechanism 239 and (iii) pressuring mechanism 240 of the first moveable profile fixture 55 and (iv) the clamping mechanism 241 and (v) pressuring mechanism 242 of the second moveable profile fixture 56 . Through an input / output information feed, the operations of these five components can be coordinated and controlled. [0111] Using the prototype single corner vibration corner equipment as described in FIGS. 6A, 6B, 7 A and 7 B, corner frame profile assemblies have been successfully produced from a wide variety of different plastic materials, including: polyvinyl chloride (PVC); composite glass fiber filled PVC; cellular foam PVC; composite wood fiber filled PVC and thermoplastic pultrusions. For all assemblies, it is desirable that the planar flange junction piece is made from essentially the same base resin as the framing profiles. A series of alternative designs for the corner web have also been tested and our experiments have shown that satisfactory welds can be produced even with a planar flange thickness of less than 1.5 mm. [0112] [0112]FIGS. 8A and 8B show an exploded perspective view of a vibration welded corner frame assembly 31 incorporating a junction piece 47 with a planar flange 48 incorporating a removable tab 49 on the bottom edge. In contrast to the side held junction piece, one advantage of the tab on the bottom edge is that the junction pieces are easier to load into the holding fixture. [0113] For simple corner web designs, the junction pieces can be die cut from plastic sheet material. Alternatively, the junction pieces can be injected molded and this has the advantage that various design features can be incorporated into the junction piece that essentially eliminate the need for plastic flash removal. FIGS. 9A and 9B show two alternative joint designs that essentially eliminate the need for mechanical flash removal. In FIG. 9A, two hollow-thermoplastic profiles 32 and 33 are longitudinally joined together using a junction piece 47 incorporating a planar flange 48 . The junction piece 47 incorporates flash traps or melt recesses 69 on either side of a central bead 70 . [0114] During the vibration welding process, plastic flows into the flash traps 69 creating double parting lines 71 . [0115] As shown in FIG. 9B, where the aesthetic requirements are more demanding, the plastic profiles ends 72 can incorporate a dato cut 73 . The flat cut ends 75 of the profiles 32 and 33 overlap the planar flange 48 that incorporates welding beads 74 . During the vibration welding process, plastic flows inwards around the ends of the junction piece 47 and the two flat cut ends 75 almost touch, creating a single thin parting line. As previously noted, the main advantages of using flash traps and welding beads is that the plastic flash is contained during the welding process and does not have to be mechanically removed from the surface of the plastic extrusions. As a result, it is feasible for decorative surface finishes 76 to be incorporated on the plastic extrusions 32 and 33 because there is no mechanical flash removal, these surface finishes 76 are not damaged during the welding process. A further advantage of weld beads and flash traps is that by not having to remove melted plastic flash material, joint weld strength can also be increased. Although as shown in FIG. 9B, a dato cut is incorporated into the framing profile, it can be appreciated by those skilled-in-the-art, that welding beads can be incorporated into the joint design without the need for dato cuts. [0116] For the vibration welding equipment shown in FIGS. 6A, 6B and 7 A, 7 B, the framing profiles are held firmly in position by means of a front clamp 60 . For more complex profile shapes, special custom fixtures have to be used and where there is a need for different framing profiles to be welded on the same production line, it is necessary for these custom clamps to be changed over. As a result, there can be production slow downs and delays which means that the productivity advantages of vibration corner welding may not be realized. [0117] To eliminate this need for special custom fixtures, FIG. 10 shows a cross section detail of an adjustable clamp 60 for holding the plastic framing profile 77 firmly in position. A vertical support member 59 is attached to the moveable horizontal plate 58 . The framing profile 77 is held firmly in position by means of a double set of flat metal strips 78 and 79 with each strip 81 incorporating a special gripping tip 82 . The first set of strips 78 slide into position and assume the general profile shape of the front face 80 of the framing profile 77 so that the profile 77 is held against the vertical support member 59 . The second set of flat strips 79 then slide into position and assume the general profile shape of the side face 83 of the framing profile 77 so that the framing profile 77 is held also against the horizontal plate 58 . Each set of strips incorporate a locking system (not shown) that locks the strips into position. [0118] [0118]FIG. 11 shows a perspective detail of the junction piece holding fixture 50 for the single corner vibration welding equipment 51 . The junction piece holding fixture 50 is mechanically attached to the top plate 53 of the vibratory head 52 (not shown). Because the junction piece holding fixture 50 is vibrated back and forth very rapidly, the stresses or shock level on the fixture are very high and it has been estimated that these stresses are in excess of 100 G-forces. As a result, mechanical pressure devices to hold the corner key in position are not suitable as these pressure devices can not withstand the continual vibration. [0119] As shown in FIG. 11, one way of eliminating mechanical pressure devices is for the removable tab 49 of the junction piece 47 to incorporate a T-shaped profile 85 and for the holding fixture 50 to also incorporate a complementary T-shaped insert hole 86 . The junction piece 47 is slid into position and the T-shaped profile 85 is held firmly in position by means of metal spring attachments (not shown). [0120] [0120]FIG. 12 illustrates an alternative corner key holding system that also incorporates no moving parts. [0121] [0121]FIG. 12A shows a perspective detail of junction piece 47 incorporate a planar flange 48 and a removable tab 49 . The back edge 87 of the removable tab 49 incorporates a double set of L-shaped slots 88 . [0122] [0122]FIG. 12B shows a top view of a junction piece holding fixture 50 and a planar flange junction piece 47 prior to installation of the junction piece within the holding fixture. The junction piece holding fixture 50 incorporates a narrow slot 89 and the width of this slot 89 is marginally larger than the width of the removable tab 49 . Two circular metal pegs 90 span across the narrow slot 89 . [0123] [0123]FIG. 12C shows a cross section view of the junction piece holding fixture 50 prior to installation of the junction piece. In the corner frame assembly process, the junction piece 47 is first moved horizontally across so that the two circular pegs 90 are engaged within the double set of L-shaped slots 88 . The junction piece is then dropped down into its final position where the circular pegs 90 are contained within the circular shaped toe 91 of the L-shaped slots 88 . Compared to the T-shaped junction piece shown in FIG. 11, the main advantage of the double L-shaped slots is that the junction pieces use less material and so can be manufactured at a lower cost. [0124] [0124]FIG. 13 shows an exploded perspective view of a junction piece 47 with a planar flange 48 and a removable tab 49 on the bottom edge. The removable tab 49 incorporates double vertical slots 92 that correspond to double circular pegs incorporated into junction piece fixture (not shown). Compared to the side held holding system shown in FIG. 12, the main advantage is that the junction pieces are easier to load into the bottom held holding system. [0125] [0125]FIG. 30 shows a second alternative junction piece holding system that also incorporates no moving parts. The junction piece 47 incorporates a planar flange 48 and a removable tab 49 . Two insert holes 96 and 97 are incorporated into the removable tab 49 of the junction piece 47 . Complementary insert pins 98 and 99 are incorporated into junction piece holding fixture 50 that is attached to the top plate 53 of the vibratory head. When the two pins 98 and 99 are inserted into the two holes 96 and 97 , the junction piece is held firmly in position during the vibration welding process. [0126] Rather than incorporating flash traps and welding beads, an alternative method for controlling plastic flash as shown in FIG. 14 is to apply a pressure strip device to the weld joint during the vibration welding process. [0127] [0127]FIG. 14A shows a top plan detail of the corner web fixture incorporating a separate pressure strip device 95 featuring a non-stick coating such as Teflon on the contact surface of the pressure strip 95 . The profile extrusions 32 and 33 are held in position by the moveable framing fixtures 55 and 56 . A pressure strip device 95 is attached to a separate support structure 96 and this support structure is isolated from the, vibratory head 52 . [0128] [0128]FIG. 14B shows a vertical cross section detail of the single corner vibration welding equipment 51 incorporating a separate pressure strip device 95 and a bottom-held planar flange junction piece 48 . During the vibration welding process, downward pressure is directed on the weld line between the framing profiles 32 and 33 and as a result, the plastic flow generated during the welding process is directed inwards and away from the weld line between the two profiles. [0129] As shown in previous figures, the junction piece 47 consists of a planar flange 48 with a removable tab 49 . For certain framing applications, this planar flange configuration does not provide for sufficient structural support and there is a need for additional corner re-enforcement. As shown in FIG. 15, this can be achieved by the junction piece or corner key 100 incorporating integral legs 101 . [0130] [0130]FIGS. 15A and 15B show a cut out cross section plan view of a corner frame assembly 31 fabricated from square profile glass fiber filled PVC profile extrusions 32 and 33 and where the profiles 32 and 33 are welded at using a junction piece or L-shaped corner key 100 incorporating integral legs 101 . [0131] As shown in FIG. 15A, the integral legs 101 of the corner key 100 incorporates an integral spring centering device 102 that simplifies frame assembly. The planar flange 48 of the corner key 100 is first vibration welded to 15 the miter cut ends of the profiles 32 and 33 . Because of the need to accommodate the vibration movement back and forth, the legs 101 only loosely fit within the profile. [0132] As shown in FIG. 15B in order to provide for additional support, the plastic framing extrusions are ultrasonically spot welded to the legs of the corner key 100 . A double tip welding head is typically used creating spot welds 106 and 107 . Because the legs only loosely fit within the profile, the ultrasonic welding process allows the plastic to flow in the gap between the corner key legs and the profile extrusions creating an extra strong welded spot bond and reduced material flow on the exterior surface. Because of their complex profile shape, the corner keys 100 are typically injected molded and have to be manufactured from essentially the same base resin material as the extruded profiles 32 and 33 . [0133] One of the main advantages of using ultrasonic spot welding is that it is an assembly technique that joins two similar thermoplastic components at localized points with no preformed hole or energy director. In operation, the spot 30 welding tips pass through the frame profile wall and the molten plastic displaced is shaped by a raised cavity in the tip (not shown) forming a neat, raised ring on the surface. Simultaneously, energy is released at the interface producing frictional heat. The tip then penetrates the corner key, displacing molten plastic material between the two surfaces and after the plastic has solidified, this forms a permanent structural bond between the framing profiles and the corner key legs. [0134] [0134]FIG. 15C shows a vertical cross-section through the hollow profile 33 . The integral legs 101 of the corner key 100 consist of a rigid flat bar 103 with a central positioning fin 104 . The profile extrusion 33 incorporates a half circular indentation and this allows the positioning fin 104 to be centrally located. [0135] [0135]FIG. 16 shows a fragmentary plan of vibratory head 52 of the single corner friction corner welding apparatus 51 showing framing angle options. A junction piece 47 is centrally located and extruded profiles 32 and 33 are positioned against the vertical support members (not shown) and the angular displacement D of these support members can be varied from 90° to 15° and this allows for special shape frames to be manufactured. [0136] [0136]FIG. 17A shows an elevation view of a round top window frame 108 . The straight framing profiles 109 , 110 , 111 are miter cut and vibration welded at the bottom corners 113 and 114 using planar flange junction pieces 48 . At the butt joints 115 and 116 between straight framing profiles 109 and 111 and the round top profile 112 , the profiles are straight cut and vibration welded together using special junction pieces 117 . [0137] [0137]FIG. 17B shows a cross section detail of the butt joint 115 between the straight framing profile 111 and round top or curved framing profile 112 . The junction piece 117 incorporates legs that feature an integral spring centering device that simplifies the assembly of the window frame. [0138] [0138]FIG. 18 shows an exploded perspective view of a corner frame assembly where two framing profiles 32 and 33 are vibration welded to a junction piece 47 incorporating a planar flange and with a removable tab located on the top edge 119 of the planar flange 48 . To provide for simplified handling at the framing profiles, the junction piece corner key fixture is typically attached to a flat plate located on the top surface of the vibratory head. However, the position of the vibratory head can be reversed so that the junction piece 47 is held from above and particularly for frame-and-panel assemblies, this reversed head position offers the advantage that both the panel and the final assembled unit can be more easily moved in-and-out of the vibration welding apparatus. [0139] Although frame assemblies can be manufactured using a single corner welder, it is more productive if two or more corners are welded simultaneously. FIG. 19A shows a front elevation view of a vertical four head vibration welder equipment 120 . As with conventional hot plate welding equipment, the four head welding equipment 120 consists of a rectangular structural frame 121 with leg supports 122 and 123 . The four welding heads 130 , 131 , 132 and 134 are attached to two vertical bridge supports 124 and 125 that span between the top beam 126 and bottom beam 127 of the structural frame 121 . The first vertical bridge support 124 is fixed in position while the second bridge support 125 is moveable and is driven by a servo motor on a cog track located on the bottom beam 127 of the structural frame 121 . The top end 129 of the moveable bridge 125 is supported by a guide rail 128 located on the top beam 126 of the structural frame 121 . [0140] A first set of vibration welding heads 130 and 133 are attached to the first bridge support 124 that is fixed in position and a second set of vibration welding heads 131 and 132 are attached to the second moveable bridge support 125 . Each set of vibration welders are operated by a electro servo motor driven ball screw that in combination with special control devices allow the vertical position of each head to be individually controlled so that in operation, all four heads can move up and down either simultaneously or independently towards a central horizontal datum line 154 . After the four heads 130 , 131 . 132 and 133 have moved to their initial start location, the four framing profiles 134 , 135 , 136 and 137 are loaded into position as well as the four junction pieces 138 , 139 , 140 and 141 . [0141] In contrast to a conventional four point welder where all four corners are welded simultaneously, the preferred operating strategy for friction welding is a two stage process. As shown in FIG. 19A, two diagonally opposite corners 150 and 152 are first welded together. For each corner weld, the process is essentially the same as with a single corner vibration welder. Both sets of framing profiles 134 , 137 and 135 , 136 are independently pressurized against the two diagonally opposite corner keys 138 and 140 . In addition, only the moveable frame clamping devices, immediately adjacent to the corner keys 138 and 140 are in operation. After the welding process is complete, the corner keys 138 and 140 have to be released and by incorporating as part of the vibratory welding head a tab removal shear press or a similar device (not shown), this allows for this release process to be carried out very efficiently. [0142] As shown in FIG. 19B, the next step is for the other set of diagonally opposite corners to be welded together. The bottom head 133 on the first vertical beam is fixed in position while both the top two heads 130 and 131 move downwards while simultaneously the second bridge support 125 moves sideways. During this second stage process, only the moveable frame clamping devices immediately adjacent to the corner keys 139 and 141 are in operation. After the second set of diagonally opposite corners 151 and 153 are welded, the assembled frame is then unloaded. [0143] Because the friction welding process is so fast ( 3 to 6 seconds), this two stage process does not significantly increase cycle time and compared with simultaneously welding all four corners, the key advantage is that the required movement and control of the heads is greatly simplified. For the four head welder, the controllers for the individual heads form part of a coordinated control system (not shown) that controls all four heads as well as the operation of the other mechanized components of the automated four point welder. [0144] For a conventional four head, hot plate welder, the overall cycle time is about 2 minutes and this overall cycle time includes: profile loading, corner welding, cool down and frame unloading. In comparison, the estimated overall cycle time for the two-stage vibration welding process is less than 30 seconds and so this represents a significant increase in productivity. To further improve productivity, one option is to incorporate an automated mechanical feed (not shown) for installing the junction pieces in the corner holding fixtures. [0145] As shown in FIG. 20, it is technically feasible to simultaneously weld all four corners 150 , 151 , 152 and 153 in one operation. All four vibration welding heads 130 , 132 , 133 and 134 incorporate an additional servo motor 156 that allows each head to move fractionally as the plastic material is melted during the vibration welding process. As a result, the position of the heads can be fractionally adjusted in varying directions so that at four all corners, perpendicular pressure is simultaneously applied by the four framing profiles 134 , 135 , 136 and 137 to the four corner keys 150 , 151 , 152 and 153 . However because the head movements involved are so small and so complex, the control system for this simultaneous four headed welding operation is complex and requires very sophisticated software. Although FIGS. 18, 19 and 20 show vertical four head vibration corner welder, it can be appreciated by those skilled-in-the-art that the bridge supports can span horizontally on a table support. [0146] Although vibration corner can generally be used to join together extruded plastic profile extrusions, the improved assembly method offers particular advantages for fenestration applications. In addition to the production of conventional windows and doors, the improved assembly method provides for the development of new types of fenestration products. To illustrate the performance advantages of vibration corner welding, FIGS. 21 to 31 show three examples of these new types of fenestration products, namely: 1. composite channel window panels, 2. glass panel units and 3. sealed frame window panels. [0147] Compared to the simple rectangular frame assemblies illustrated in previous figures, these new types of fenestration products incorporate complex profile shapes, but it should be noted that the basic component joint design does not change and the planar flange junction piece can be configured to correspond to the miter joint contour of these more complex profiles shapes. [0148] [0148]FIG. 21A shows an elevation view of a composite channel window panel 158 consisting of a conventional sealed double glazed unit 159 and a rectangular sash frame 160 that is assembled around the sealed glazing unit 159 using vibration corner welding. [0149] [0149]FIG. 21B shows a cross section detail on a line 21 A- 21 A of the composite channel window panel 158 . The sealed double glazing unit 159 consists of two glazing sheets 161 and 162 and incorporates a conventional perimeter seal 163 with the specific example shown being an inner barrier seal 164 of desiccant filled polyisobutylene (TPS) and an outer structural seal 165 of polysulphide sealant. The sealed glazing unit 159 is supported on conventional hard rubber glazing blocks 166 and the glazing channel 167 is conventionally drained. After the multi-cavity hollow plastic frame has been assembled and welded at the corners, two silicone sealant beads 169 and 170 are applied in the gaps between the glazing unit 159 and the channel frame profile 168 . Preferably, the window frame profile is made from glass fiber filled PVC and this has the advantage that because of the combined stiffness of glass-and-frame assembly, the overall frame profile size can be reduced when compared to conventional PVC window profiles. [0150] [0150]FIG. 22 shows an exploded perspective corner detail of a composite channel window panel 158 . The channel-shaped framing profiles 171 and 172 are assembled around the insulating glazing unit 159 and the framing profiles 171 and 172 are then joined and sealed at the corners using vibration corner welding. One key feature is that the junction piece 47 incorporates a removable plastic web 49 that is located on the outer side of the frame and is held in the corner web holding fixture attached to the vibratory head of the friction welding equipment. This has the advantage that the frame can be assembled around the insulating glass unit and the corners then welded and sealed. As a result, by eliminating the need to separately install the insulating glass unit 169 , there are significant material and labor cost savings. [0151] With conventional hot plate welding, in order for the thin wall profile walls to be welded together at the corners, the framing profiles have to be essentially the same size and shape. However with vibration corner welding, by using a common corner web, different profile sizes and shapes can be structurally joined together. For example as shown in FIG. 23, the bottom framing profile 173 is larger and incorporates a deep hardware channel 175 while the side framing profile 174 is smaller and there is no hardware channel. In addition, with conventional hot plate welding, only 45° miter cut corners can be used, while with a friction welding and a corner key web, it is feasible to join together framing profiles with different miter cut angled corners (i.e. 60° and 30°). [0152] It should be noted that when joining together different size profiles using friction corner welding, it is necessary for the two moveable framing fixtures to apply different engagement forces so that when taking into account the different profile sizes, essentially the same pressure is being applied on either side of the web. [0153] Although the examples given in FIGS. 21 to 24 show examples of a window framing profile being assembled around an insulating glass unit, it can be appreciated by those skilled-in-the-art that the same production process can also be used to fabricate a wide range of frame-and-panel products including: picture frames; mirrors; partitions; shower doors and cupboard doors. [0154] [0154]FIGS. 24A and 24B show a perspective and top plan view of a welded composite channel frame assembly where the framing profiles 176 and 177 incorporate a single I-shaped cavity 178 and where the thin supporting profile walls 179 for the insulating glass unit are solid. The main advantage of this narrow composite channel profile is that the overall width of the framing profile is reduced and as a result, there are material and cost savings. One drawback of this narrow channel profile is that with a full section corner web, it is difficult to achieve a consistent corner weld because the legs of the channel-shaped corner web are so thin. [0155] One option is for the corner web to only extend to the top profile wall 181 of the I-shaped cavity 178 and to incorporate a notch 182 in the miter cut corners of the framing profiles 176 and 177 . As a result, while the bottom part of the profiles 183 is sealed and welded at the corners, the miter cut solid profile walls 184 only butt together. However because the vibration welding process can be closely controlled, the open gap 185 between the two miter cut profiles 176 and 177 can be kept to a minimum. [0156] [0156]FIG. 25A shows an elevation view of a sealed double glazed panel 159 incorporating a rigid thermoplastic spacer frame 186 that is welded and sealed at the corners using vibration corner welding. [0157] [0157]FIG. 25B shows a cross section detail on a line 25 A- 25 A of the perimeter edge of the double glazed panel. The spacer frame 186 is made from an open channel, rigid thermoplastic framing profiles 187 that are vibration welded at the corners to planar flange junction pieces 47 made from essentially the same thermoplastic resin as the spacer profile. To minimize differential expansion between the glazing sheets 161 and 162 and the spacer frame 186 , the thermoplastic spacer profiles are made from glass fiber re-enforced thermoplastic extrusions or continuous glass fiber re-enforced pultrusions. After the spacer frame 186 has been assembled, desiccant-filled polyisobutylene sealant is applied to the inner surface 188 of the spacer frame 186 creating a continuous barrier seal. After the panel has been assembled, double beads 190 and 191 of structural thermosetting sealant are applied between the spacer frame 186 and the two glazing sheets 161 and 162 . [0158] For insulating glass panels, the main advantage of using vibration corner welding is that there is a continuous, single wall barrier seal made from rigid thermoplastic material. As a result, the back face 192 of the spacer frame can incorporate a variety of profile features including attachment devices. In addition without damaging the integrity of the barrier seal, other thermoplastic parts (e.g. gas fill patches) can also be welded to the back face 192 of the spacer frame 186 . [0159] [0159]FIG. 26A shows an elevation view of a sealed frame, triple glazed sash window panel incorporating a perimeter sash frame 194 with vibration welded corners. [0160] [0160]FIG. 26B shows a cross section detail on a line 26 A and 26 A of a triple glazed, sealed frame window panel 193 . The panel consists of two glazing outer sheets 161 and 162 that overlap the perimeter sash frame 194 and are adhered to the frame with thermosetting structural sealant 195 . The inner center glazing sheet 196 is supported by the perimeter frame 194 . [0161] The perimeter frame 194 is assembled from glass-fiber filled, hollow thermoplastic profiles 197 which are joined and sealed at the corners using vibration corner welding. The thermoplastic profiles incorporate glass fiber fill and as previously noted this provides for increased strength and rigidity as well as reduced thermal expansion. Compared to conventional window assembly, the main advantage of sealed frame glazing unit is that through composite structural action, the required size of the sash profiles 197 can be significantly reduced resulting in improved energy efficiency and material cost reductions. [0162] With composite structural action, the sealed frame panel performs in a similar manner to a stressed skin sandwich panel where the perimeter edges of the two glazing sheets 161 and 162 are respectively in compression and tension and so instead of the panel performing as two independent glazing sheets, the two sheets 161 , 162 act together as a structural unit. [0163] The glazing sheets 161 and 162 are structurally adhered to the plastic frame profiles 197 with structural thermosetting sealant 195 and for long term durability, silicone sealant is the preferred material. For enhanced composite structural performance, a high modulus silicone sealant is required with the thickness of sealant being preferably less than 3 mm. To provide for increased panel stiffness, both the bottom edges 198 and perimeter side edges 199 of the glazing sheets 161 and 162 are adhered to L-shaped seats 200 on either side of the perimeter frame profiles 197 . To allow glazing sheets 161 and 162 to bow in and out with changes in temperature and pressure, the side edge contact length is kept to a minimum with 10 mm being the typical length required. [0164] A third center glazing sheet 196 is located between the two outer glazing sheets 161 and 162 and this glazing sheet is similar in shape but smaller in size than the outer two glazing sheets. For improved thermal performance, the width of the cavity spaces 201 and 202 between the glazing sheets 161 , 196 and 162 is typically between 9 and 18 mm. For improved energy efficiency, a low-e coating 203 can also be applied to one or more of the glass cavity surfaces of the window panel 193 . In addition, the cavity spaces 161 and 162 can incorporate a low conductive gas such as argon or krypton. [0165] To provide for long term gas retention as well as maintaining the integrity of the perimeter edge seal, there is a need for a continuous perimeter edge seal between the outer glazing sheets. Various edge seal configuration sand sealant materials can be used to provide this continuous barrier seal. One option as shown in FIG. 26B is to apply low permeable sealant material 204 to the front face 205 and front side edges 206 of the perimeter frame 194 . To accommodate glass bowing and movement, the sealant material must be flexible and because of its low temperature performance, polyisobutylene is the preferred material. To remove moisture vapor from the glazing cavity spaces 201 and 202 , the low permeable sealant incorporates desiccant fill material with the preferred material combination being 85 per cent 3A molecular sieve and 15 per cent silica gel. [0166] The rigid frame profiles 197 can be made from many alternative plastic materials produced using various processes. One preferred material is glass fiber-filled polyvinyl chloride (PVC) that is extruded to the required profile shape. One suitable product is Fiberloc 80530 that features a 30 per cent glass fiber fill and is produced by PolyOne Inc. of Cleveland Ohio. The co-efficient of thermal expansion of the 30 per cent, glass fiber filled material is 18×10 −6 cm/cm/° C. and this compares to the thermal coefficient of glass which is 9×10 −6 cm/cm/° C. For very large panel sizes, the thermal expansion of the plastic profiles can be further reduced by reinforcing the frame profile walls 207 and 208 adjacent to the outer glass sheets 161 and 162 with continuous unidirectional glass fiber strips (not shown). [0167] Instead of fiber glass reinforced PVC, the frame profiles 197 can be made from various other alternative plastic materials, including: thermoplastic fiber glass pultrusions, glass fiber reinforced engineering structural plastic foam extrusions and high draw oriented thermoplastic extrusions. Because the plastic profiles are firmly bonded to the glazing sheets and expand outwards from the mid points of the perimeter frame, maximum stress due to the differential expansion between the plastic profiles and the glass sheets occurs at the corners. Particularly with glass fiber filled profiles, because the corner welds are typically only as strong as the un-reinforced plastic, the corner welds can be a potential weak point in the frame assembly. To provide for increased strength and rigidity and to also reduce stress on the corner welds, the preferred assembly method is to join the plastic profiles together at the corners using a combination of friction corner welding and ultrasonic spot bonding and this production method has previously been described in FIGS. 15A and 15B. [0168] [0168]FIGS. 27A and 27B show a front elevation (FIG. 27A) and a side elevation (FIG. 27B) view of the diagonal cut end 209 of the framing profile for a triple glazed sealed sash window panel. By removing the frame profile material, a 3 to 4 mm deep channel 210 is formed in the diagonal cut end of the profile 209 creating plastic side ribs 211 and 212 . The dotted line 212 l on the side elevation of the diagonal cut end indicates the depth of the channel 210 . [0169] [0169]FIG. 28 shows an exploded perspective detail of the corner frame assembly for a triple glazed, sealed frame window panel 193 . The two framing profiles 213 and 214 are joined together by means of special corner keys incorporating a planar flange web 215 and integral legs 216 . To provide for simplified frame assembly, the integral legs incorporate a self centering spring device. [0170] As previously shown in FIGS. 27A and 27B, by removing the frame profile material, a channel can be formed in the miter cut ends 217 and 218 of the framing profiles 213 and 214 so that the top side rib surfaces 220 and 221 overlap the diagonal center flange 215 of the corner key 217 . During the friction welding process, the profile ends except for the top side ribs 220 and 221 are pressured against the center flange 215 . Because plastic flash is only generated at the interface between the profiles ends 222 and 223 and the corner key flange 215 , a clean parting line is created between the two top side ribs 220 and 221 of the framing profiles 213 and 214 . [0171] [0171]FIGS. 29A to 29 E show the production steps involved in manufacturing a single, vibration-welded, sealed-frame corner assembly. [0172] As shown in FIG. 29A, the sealed frame corner assembly consists of two framing profiles 213 and 214 and a special L-shaped corner key 219 with a diagonal center flange 215 and a removable tab 224 . A channel is formed in the miter cut ends of the framing profiles 213 and 214 so that the top side ribs 220 and 221 of the framing profiles overlap the diagonal center flange 215 of the corner key 219 . [0173] As shown in FIGS. 29B and 29C, the two legs 225 and 226 of the L-shaped corner key 219 are loosely fitted into the two framing profiles and the corner assembly is placed in the vibration corner welding apparatus. The removable tab 224 incorporates a special arrow-head profile 227 that fits into a complementary shaped insert hole 228 within the corner key fixture 229 . The framing profiles 213 and 214 are held firmly in position by means of front clamping devices 230 and 231 that are attached to the moveable framing fixtures 232 and 233 of the vibration welding apparatus (not shown). [0174] As shown in FIGS. 29C and 29D, the two profiles are pressured using perpendicular force against the contact surfaces of 234 and 235 of the corner key 219 and friction is created by rapidly moving the corner key 219 back and forth. During the friction welding process, as the two profiles 213 and 214 are pressured against the corner key flange 215 , plastic flash flows to either side of the contact surface. Because relatively limited flash is produced, the flash does not extend into joint line between the two diagonal cut ends 236 of the framing profiles and so as a result, a clean parting line 237 is created between the framing profiles. [0175] After the friction welding process is complete and as shown in FIG. 29E, the tab 224 is mechanically removed from the L-shaped corner key 219 . The final step in the production process is to bond the interior profile walls to the L-shaped corner keys using ultrasonic spot welding 238 .
Vibratory welded connections are formed between first and second members ( 32, 33 ) of thermoplastic material by interposing a junction piece ( 47 ) of similar material and vibrating the junction piece ( 47 ) at high speed while pressing the first and second members ( 32,33 ) in a controlled manner against opposite sides of the junction piece ( 47 ). Friction created by the vibration generates heat which melts a small amount of material at the engaging surfaces which upon cooling provides a strong welded joint having minimal flash. Entire frame systems such as window-frames can be fabricated by an apparatus system ( 120 ) which forms a friction welded joint between adjacent ends of the frame members ( 134, 135, 136, 137 ). Furthermore the frame can be fabricated around a panel such as a glazing panel. The welded connections formed by the system do not mar the finish of the frame members and produce no unsightly flash bead requiring subsequent machining steps for its removal.
1
This application is a continuation of application Ser. No. 07/671,680, filed on Mar. 19, 1991, which is now abandoned and which was a continuation of application Ser. No. 07/439,597, filed Nov. 20, 1989, also abandoned. BACKGROUND OF THE INVENTION The present invention broadly relates to an insect trap and more, specifically, a trap for flying insects within enclosed spaces such as restaurants, homes and stables. The invention further includes a method of trapping insects; dispensing means for the insect trap; and a process for the preparation of the insect trap. Previously known methods for catching insects are largely based in the application of glue to a carrier, such as a paper strip covered with resinous glue which is then hung vertically in areas where insects are to be caught. The paper strip, having at least one adhesive surface, is stored in a cardboard cover and upon use is drawn out into the formation of a helix to expose the adhesive surface area for catching insects. Other known adhesive-type insect traps utilize large paper sheets which are generally covered on both sides with glue and optionally an attractant such as euginol. These large sheets are then suspended vertically in barns and stables or other insect infested areas. It has been found that the known insect catching devices have a number of drawbacks. For example, they quickly become covered by dirt, dust, and other airborne contaminants and thereby lose their adhesive property; they obstruct activities around them; they are troublesome to hang up and take down, and with regard to the large surface area traps, i.e. about 0.5 m 2 , they disrupt ventilation, which in barns and stables is important for the well-being of the animals. Furthermore, the larger insect-catching devices have even been known to catch small birds, which, of course, is undesirable. Finally, none of the known adhesive-type insect-catching devices is particularly aesthetically pleasing in restaurants, confectioner's shops, and other similar locations where food is sold or dispersed. Nevertheless there is a general demand for the elimination of flies and other flying insects, since they are known carriers of disease and their bites can be irritating and painful. Since the use of poisons, particularly in enclosed environments, for the elimination of insects is not a preferred alternative, the need for a safe, effective, easy and attractive means for eliminating such insects continues to be of importance. SUMMARY OF THE INVENTION The object of the present invention is to provide a method and apparatus capable of catching insects, particularly in-door insects, such as flies, mosquitoes, wasps and plant pests. The insect trap is suitable for use in homes, restaurants, stables, barns, and other enclosed spaces. It has been found that the present invention eliminates most, if not all of the aforementioned drawbacks of the known adhesive-type insect traps and moreover, unexpectedly results in an increase in the number of insects trapped over a fixed period of time as compared with the known prior art adhesive insect traps. In tests carried out where the present invention was compared with a vertically hanging paper sheets containing the same adhesive material and using the same amount of an attractant, the present invention caught more than ten (10) times the number of flies trapped by the paper means on an area one third as large as the paper trap. The invention specifically comprises an adhesive-covered cord optionally covered with an attractant. The cord has a relatively small surface area, i.e. diameter, as compared to prior art adhesive traps and preferably, is positioned horizontally in an area where insects are to be caught. DESCRIPTION OF THE PREFERRED EMBODIMENT In accordance with the present invention, the cord used can be of any type and material as long as it has sufficient mechanical strength and does not exude a repelling agent, such as sisal and hemp which are known to repel flies. An inert white polypropylene cord, a polypropylene reinforced cord of cotton, or a pure cord of natural fiber such as cotton are all suitable for use. The diameter of the cord, prior to being coated with a suitable adhesive, is from about 2.5 to 4.0 mm, preferably 3.0 to 3.5 mm. After coating with an adhesive material, the diameter ranges from about 3.0 to 5.0 mm and preferably from about 3.5 to 4.3 mm. A cord with the diameter of 3.2, after being coated with a sufficient amount of an adhesive, generally has a diameter of about 4.0 mm and it has been found that this dimension is optimal. Suitable glues or adhesives are styrene based adhesives, NR-based adhesives, and resin based glues, (i.e. such glues/adhesives which are normally used in insect catching devices). The consistency of the glue should be adapted so as to be effectively adhesive at a temperature of from about 18 to 22° C. The consistency of the adhesive must also be effective with regard to the humidity present in the environment in which the insect trap is to be used. If the glue/adhesive is sensitive to UV light, such as sytrene based adhesives, they should not be exposed to a direct radiation from the sun. Of course, the adhesives may also contain a suitable unprotecting agent, provided that it does not diminish the effectiveness of the adhesive and does not act to repel insects. The cord can also be impregnated or coated with a suitable attractant, such as euginol, eutanol, or ethanol for flies, and other known attractants for other insects, such as for mosquitoes or wasps. However, the attractant used should not diminish the effectiveness and preferably should cause the glue/adhesive to act as a plasticizer for the adhesive. In accordance with the present invention, the cord may be stretched horizontally, or hung or stretched vertically form a suitable supporting surface. Thus, both high and low placements can be used, depending on the type of insect or even the specie within an insect family to be caught. Particularly in stables, barns and green houses the cord is preferably stretched horizontally from suitable support members, such as rafters or beams. The adhesive coated cord may be dispensed from a roll arranged on a supply drum, which is drawn underneath a ceiling or along a wall, optionally via one or more pulleys to a collecting drum, whereby a suitable length of new cord can be fed by means of a hand crank or by motor. In the latter case, the motor can be controlled in different ways, e.g. by a time relay, so that a predetermined length of cord per 24 hours, as required, can be released. When a drum has become full, it is easily disposed of and a new drum with a fresh cord is installed. If the drums are treated with a silicon oil the glue will not adhere to the drum surfaces. The cord trap can also be designed in different ways to be adapted to different environments and surroundings. Thus, it can be cut into small lengths and used in flower pots and flower boxes to eliminate plant insects and flies. It can be fashioned into decorative designs and shapes such as a rosette on a stick to be placed among plants in a window. In restaurants and confectioners shops, the cord trap can be hidden behind a curtain rod, if so desired and the cord and or adhesive may be colored. EXAMPLE 300 m of a polypropylene cord (split fibre) with a diameter of 3.2 mm were impregnated with euginol in an amount of 2.5 g per 300 m. The cord was then coated with an elastomer based melting glue (styrene based, viscosity: 2800 mPas at 80° C.; softening point: 52° C. according to the ring-ball method; Hernimelt 8693, Hernia International AB, SE) by dragging the cord through a container containing the glue up to a diameter of 4.0 mm. 0.84 kg of styrene based glue were used. (The impregnation of the cord by an attractant can be accomplished in different ways, such as a gaseous method, dissolving the attractant in the glue, or spraying the attractant onto the cord using an atomized attractant.) TEST 1 22 m of the cord according to the Example above were stretched horizontally in a barn. A paper sheet covered with the same glue and the same attractant, and having an area 0.88 m 2 was arranged vertically under the same conditions. The area of the cord was 0.28 m 2 /22 m. The cord caught 200 flies during 1 minute, while the paper sheet caught 17 flies during the same time period. The cord thus caught about 30 times more flies per area unit during 1 minute than did the paper sheet. TEST 2 The same cord as produced according to the Example above was stretched horizontally as well as vertically in a barn. 1 m long cord segments were hung vertically down from the horizontal cord on each running meter. The amount of vertical cord was thus equal to the length of horizontal cord. The horizontal cord caught 72 flies in 1 minute compared with 30 flies in 1 minute for the vertical cords. The horizontal cord thus caught twice as many flies. Compared with Test 1 above, however, the vertical cords caught more flies per time unit and area unit than the paper sheet did. TEST 3 In a kitchen, a cord prepared according to the Example above was hung horizontally. A conventional paper strip (5×100 cm) was also hung in the kitchen. While the cord caught 12 flies, the paper strip had caught only 1 fly during the past period. The glue and the attractant were the same in both cases. TEST 4 In order to determine the difference between a cord with glue and attractant, and a cord with glue only, two such cords were stretched horizontally in a barn under the same conditions. No significant difference in the amount of flies caught could be determined. The presence of an attractant is thus not necessary for the present invention. The trapping ability is substantially related to the cord shape, and unexpectedly when it is stretched horizontally, as opposed to vertically. TEST 5 In a further test, a cord according to the present invention was compared with a paper strip, both types being arranged horizontally. The length of the cord was 1000 mm and its diameter was 3.2 mm, uncoated. The length of the paper strip was 1000 mm as well, and its width was 50 mm. The two catching devices were coated with the same glue and attractant. The cord and the strip, respectively, were arranged horizontally under the same outer conditions. Each cord and strip were replaced after each 24 hour period. The results are given in the Table below. Fly: Musca domestica. As shown in the table, the cord of the present invention caught significantly more flies than did the conventional paper strip. TABLE______________________________________ Number of flies caughtDay Cord Strip______________________________________1 12 12 6 03 24 64 18 45 36 86 12 27 66 138 36 79 72 2610 111 3211 96 3112 42 813 21 614 118 2915 42 7______________________________________ While the foregoing describes and provides examples of the present invention and preferred embodiments, methods of use and dispensing means, it will be apparent in those of ordinary skill in the art, that changes and modifications may be made without departing from the invention in its broad aspect.
The present invention relates to a method and apparatus for catching insects using a glue trap, wherein a cord is coated with glue and optionally an attractant, and placed horizontally in an area where insects are to be caught. The present invention further comprises a device for distributing the apparatus.
0
BACKGROUND OF THE INVENTION This invention relates to a roll for the pressure treatment of a web of material which includes an hollow outer roll and crosspiece extending therethrough with a longitudinal chamber filled with pressure fluid formed between the cross piece and hollow roll, in general and more particularly to apparatus for maintaining a constant temperature in the pressure fluid in such a roll. A roll for the pressure treatment of webs of material which includes a hollow roll forming the working roll circumference, a cross piece which goes through the hollow roll lengthwise and leaves radial spacing all around from the inside circumference of the hollow roll and protrudes in the lengthwise direction from the hollow roll at the ends, longitudinal seals arranged at the cross piece and extending over a substantial part of the length of the hollow roll and defining a longitudinal chamber located between the inside circumference of the hollow roll and the cross piece in the action plane of the roll, a feed line and a discharge line for pressure liquid which open into the longitudinal chamber, and a temperature setting device for the pressure liquid is described in German Pat. No. 10 26 609. The longitudinal chamber lies on the side of the rolling gap and supports the hollow roll from the inside on a pressurized liquid cushion as if floating. The support is not purely hydrostatic. Rather, an hydrodynamic equilibrium is maintained, in which pressurized liquid is fed to the longitudinal chamber at the feed line and is removed again from the longitudinal chamber at the discharge line. In many cases not only is a longitudinal chamber formed on the side of the rolling gap filled with pressurized liquid, but the opposite longitudinal chamber which accounts for the remainder of the space between the inside circumference of the hollow roll and the cross piece is also filled. The resulting forces which form the line pressure at the rolling gap are then obtained from the difference of the pressures, taking the effective area of the longitudinal chambers into consideration. It is also known in such rolls to influence the temperature of the working roll circumference via appropriate temperature control of the pressurized liquid. The feeding and discharging of liquid in such cases is done at opposite ends of the roll so that a flow over its entire extent is obtained. If the requirements as to constant temperature transversely to the web of material or along the roll are stringent, problems arise, however, because a temperature change always occurs along the flow path. Practice has shown that, for instance, in the case of heated rolls, a temperature difference of up to 10° C. can prevail between the ends of the roll if the flow is only in one direction; for many applications of interest, this temperature difference is too high. In a roll of the type of German Pat. No 10 26 609, it is, therefore, known already to have heated pressurized liquid flowing through the longitudinal chamber located on the side of the rolling gap from one end of the roll to the other in one direction and through the opposite longitudinal chamber in the other direction. The effect on the hollow roll is made up of the effects of the two longitudinal chambers together, and in this manner an equalization of the temperature gradients and a rather good temperature constancy along the roll is obtained. The prerequisite therefor, however, is a roll with two longitudinal chambers through which liquid can flow along the entire length of the roll. This condition, however, is not always met. A first example where this condition is not met is the case where the opposite, so-called, leakage chamber is not filled. This is the case, for instance, in what is known as an easy-running roll according to German Pat. No. 27 44 524, in which special precautions are taken in order to avoid hydrodynamic resistances at high operating speed. This includes insuring that no pressurized liquid accumulates in the leakage chamber. Another example occurs when the longitudinal chamber which is primarily responsible for the generation of the line pressure is located on the side of the rolling gap, but is not continuous over the entire length of the roll. Rather, it is subdivided in the transverse direction so that it forms, for instance, three zones, of which two narrower ones are located at the ends of the roll and the larger one in the center. This can be necessary for influencing the line pressure. Because a continuous flow over the entire length of the roll cannot be generated, special problems as to the uniformity of the temperature arise here. It is an object of the invention to reduce or compensate for the temperature gradient even in these cases. SUMMARY OF THE INVENTION The present invention accomplishes this by providing at least one longitudinal subdivision in the longitudinal chamber forming two partial longitudinal chambers, and insuring that the flow of the pressure liquid in the two partial longitudinal chambers is in opposite directions. The action of this design is such that the temperature gradient caused by the customary one-sided flow is equalized, at least partially, by maintaining a counterflow in one and the same longitudinal chamber which is formed between two longitudinal seals which are adjacent to each other in the circumferential direction and are sealed against the pressurized liquid. The temperature gradient in the one partial longitudinal chamber is opposed by a temperature gradient of opposite direction in the other partial longitudinal chamber so that, as a result, every point of the hollow roll is subjected to the same mean temperature. Generating the counterflow in one and the same longitudinal chamber is advantageous also in another aspect. When the pressurized liquid passes, in the circulation known from the roll according to German Pat. No. 10 26 609, through the so-called pressure chamber located on the side of the rolling gap, it is at a pressure higher than the pressurized liquid returning to the so-called leakage chamber facing away from the rolling gap. This can be accomplished in a closed loop only if the pressurized liquid passes a choking point. The pressurized liquid must, therefore, be pumped through the pressure chamber against this resistance. If the throughput quantity and thereby, the flow velocity are to be increased, considerable pumping power is required which increases the cost. In addition, however, a pressure gradient occurs along the pressure chamber if the flow resistance along the pressure chamber is increased; this imperils the uniformity of the line pressure so that possibly, nonuniformity of the line pressure must be tolerated for a somewhat more uniform temperature and accelerated pumping of the pressurized liquid. If, however, the counterflow is maintained in one and the same longitudinal chamber in the manner according to the present invention, the flow takes place at one and the the same pressure level and no resistance in the form of a choking point of the flow need to be overcome, so that the circulating amount can be increased without excessive power. Any pressure drop which may occur along the flow path is compensated by the opposite pressure drop on the return. The outgoing and return flow need to take place only in one and the same longitudinal chamber, i.e., at the substantially same pressure level, in contrast to the known design. It is possible in principle to provide a separate feed line and a separate discharge line for each partial longitudinal chamber and to provide the feed and discharge line of adjacent partial longitudinal chambers at different ends thereof. The alternative is to let the pressurized liquid at the end of the roll which is opposite the first feed line pass into an adjacent partial longitudinal chamber and to let it flow back in that chamber in a direction opposite the first direction. It is further understood that the invention can find application for any kind of roll temperature influenced via the hydraulic liquid, i.e., to cooled as well as heated rolls. The invention is realized already if the customary longitudinal chamber is divided only once, so that only two partial longitudinal chambers are provided. However, it is also possible to provide several longitudinal subdivisions and to let the pressurized liquid run in meander-fashion. In all such cases the pressurized liquid passes in and out at one end. The subdivision need not be a seal. It is not important that the adjacent partial longitudinal chambers are hermetically sealed against each other in the circumferential direction. The pressure in partial longitudinal chambers adjacent in the circumferential direction is substantially the same, as compared to the longitudinal seals forming the chamber which must essentially seal against the actual pressure in the longitudinal chamber toward the outside. The lengthwise subdivisions rather need to be only pure flow dividers. A first embodiment includes a radially movable element which may be a strip radially guided in a slot of the cross piece or a strip which can follow the changes of the distance between the cross piece and the inside circumference of the hollow roll, maintaining its divider action. Such changes occur if the cross piece is bent relative to the hollow roll under the action of the line pressure. The distance changes can be quite considerable in large rolls with a length of, for instance, 8 to 10 meters and can amount to about 25 mm. Resilient contact can be maintained by a backing spring or liquid pressure. Another embodiment is one in which the longitudinal subdivision is no longer arranged radially, i.e., it is symmetrical but is inclined and follows the changes of the distance between the cross piece and the inside circumference of the hollow roll by changing the inclination of the setting. It should be pointed out that the term "longitudinal chamber" can mean a longitudinal chamber located on that side of the rolling gap in which the high pressure for generating the line pressure prevails, as well as a longitudinal chamber which is located on the opposite side and can likewise be filled with pressure liquid and then also has a feed line and a discharge line. If, for instance, the pressure chamber is subdivided, the leakage chamber is provide with the lengthwise subdivision; if the leakage chamber remains empty it must, of course, be the pressure chamber which is subdivided. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross section through a roll according to the present invention. FIG. 2 is a longitudinal section through the plane II--II in FIG. 1. FIG. 3 is a longitudinal section through the plane III--III in FIG. 1. FIG. 4 is a longitudinal section corresponding to FIG. 2 through another embodiment of the invention. FIG. 5 is a partial section in the region of the lengthwise subdivision in a modified embodiment. DETAILED DESCRIPTION The roll 10 in FIG. 1, comprises a revolving outer hollow roll 1, through which a cross piece 2 extends lengthwise protruding from the hollow roll 1 as can be seen from FIGS. 2 to 4. The ends of cross piece 2 are supported in a roll stand or acted upon by force exertion members such as hydraulic cylinders or the like. The hollow roll 1 can be fixedly supported at its ends on the cross piece 2 or be capable of being positioned in the radial direction relative to the cross piece 2 on its entire length by a suitable gate guidance. In the space 4 between the cross piece 2 and the inside circumference 3 of the hollow roll 1, longitudinal seals 5 and transverse end seals 6, which are fastened at the cross piece 2 and rest against the entire circumference 3 of the hollow roll 1 divide off a longitudinal chamber 7. This longitudinal chamber 7 can be fed pressurized liquid via a feed line 8 with the liquid discharged again at a discharge line 9. A steady-state hydrodynamic state is, therefore, established and the pressure of the pressurized liquid in the longitudinal chamber 7 acts from the inside against the hollow roll and exerts a force which is uniform over the length of the longitudinal chamber 7. The counterforce is supplied by the bending of the cross piece 2. The seals 5 and 6 are designed so that they can follow the changes in spacing which occur between the cross piece 2 and the hollow roll 1, while maintaining the sealing action. In the embodiment of FIGS. 1 to 3, the rolling gap is at the top according to FIGS. 1 and 2, and the longitudinal chamber 7 is located on the side of this rolling gap. In the longitudinal chamber 7 a lengthwise subdivision 11 is provided which is realized by a plastic or sheet metal strip guided in a longitudinal slot 12 on the top side of the cross piece 2. The lengthwise subdivision 11 subdivides the longitudinal chamber 7 into two partial longitudinal chambers 7' and 7". In the illustrated embodiment, the longitudinal subdivision 11 is not continuous up to the transverse end seal 6 at the right in FIG. 2, but ends shortly before and leaves a transition 13, at which point the pressurized liquid, which flows in at the end located at the left in FIGS. 2 and 3 from the feed line 8 and which flows on from left to right in the sense of the arrows 20' through the partial longitudinal chamber 7', flows into the partial longitudinal chamber 7" and then flows back, according to FIGS. 2 and 3, from the right to the left in the sense of the arrow 20", until it is discharged again at the end of the partial longitudinal chamber 7" located at the left according to FIGS. 2 and 3. The temperature at the outer circumference of the hollow roll 1 is to be influenced via the pressurized liquid. If a temperature increase is involved, the pressurized liquid is brought up to temperature, after it is brought up to the pressure by the pump 14, by a temperature setting device in the form of a heat exchanger 15 schematically indicated in FIG. 3 to the left and is supplied to the feed line 8 under pressure and elevated temperature. There, the hot pressure liquid enters the partial longitudinal chamber 7'. The temperature drops from left to right according to FIGS. 2 and 3. In the right-hand region, the temperatures in the partial longitudinal chamber 7' and 7" differ only little. In the partial longitudinal chamber 7", the temperature drops further, however, and specifically from right to left so that, in the left-hand region, hot pressure liquid in the partial longitudinal chamber 7' confronts the heavily cooled-down pressure liquid in the partial longitudinal chamber 7", and thus, an equlization is obtained which leads to the condition that the temperatures at the left and right ends of the hollow roll 1 differ only by a small amount. In the embodiment of FIGS. 1 to 3, the lengthwise subdivision 11 is provided in a longitudinal chamber 7 which is located on the side of the rolling gap and, therefore, contributes substantially to the formation of the line pressure. The opposite longitudinal chamber which occupies the rest of the circumference, is not empty but contains the leakage oil which passes at the longitudinal seals 5 and is continuously drained therefrom. In some cases, a certain amount of pressure is intentionally maintained in this longitudinal chamber disposed opposite the longitudinal chamber 7 so that the effective pressure is obtained from the pressure difference. When the opposite chamber contains fluid under pressure, the longitudinal subdivision 11 does not have to be provided on the side of the rolling gap. In the case of the roll 10' shown in FIG. 4, the transverse end seals 6' extend over the entire circumference and, by means of additional semiannular transverse seals 6" there are formed, on the side of the rolling gap, three chambers 16, 17 and 18 each of which have separate feed and discharge lines only indicated in FIG. 4 and in which different pressures can be maintained if required. A counterflow continuous over the entire length, thus, cannot be realized here. In this case the lengthwise subdivision is provided instead on the opposite side in the longitudinal chamber 19 which is supplied for this purpose with temperature controlled pressure liquid. Also in this case, the lengthwise subdivision 11 leaves a passage 13, through which the pressure liquid passes into the partial longitudinal chamber which is located behind the plane of the drawing and is adjacent in the circumferential direction, and flows back there according to FIG. 4, from right to left toward the left end of the hollow roll 1 where it is drained off. It is not necessary that the longitudinal seals 5 be arranged exactly opposite each other in the meridian plane of the cross piece. The invention can also be used for longitudinal seals 5 which are placed closer together in the circumferential direction and form the narrow longitudinal chamber 7. Also, the longitudinal subdivision 11 need not leave the passage 13. The same effect is also obtained if each partial longitudinal chamber 7 and 7' has a feed line of its own at one end and a discharge line of its own at the other end. Important is only that the flows in partial longitudinal chambers adjacent in the circumferential direction are in opposite directions. The longitudinal subdivision 11 can be designed, in the manner indicated in FIG. 1, as a straight strip which is disposed in a slot 12 and holds contact at the inner circumference 3 of the hollow roll 1 by hydraulic pressure acting against it from below or by springs. However, it is also possible to use the embodiment which is indicated in FIG. 5. To the outside circumference of the cross piece 2, a longitudinal subdivision 21 in the form of an inclined strip of metal or plastic is fastened by means of screws 24. The screws 24 are provided along a lengthwise edge of the strip while it rests against the inside circumference 3 of the hollow roll 1 with its lengthwise edge 22. The lengthwise subdivision 21 which is substantially planar and is resilient in spring fashion encloses, with the tangential plane at the fastening line given by the screws 24, an acute angle 23. Changes of the distance between the cross piece 2 and the hollow roll 1 are followed by the lengthwise subdivision 21 through a change in the angle 23. The seal between the partial longitudinal chambers 7' and 7" need not be hermetic. It is only necessary to provide a flow division which makes the counterflow possible.
A roll for treating a web of material includes a hollow roll supported for rotation about a stationary cross piece. Between the inside circumference of the hollow roll and the cross piece, a longitudinal chamber filled with temperature-controlled pressure liquid is provided, in which a lengthwise subdivision is arranged so that the flow of the pressure liquid in the two partial longitudinal chambers is in opposite directions in order to obtain a uniform temperature distribution along the roll.
3
FIELD OF THE INVENTION This present invention relates to food dispensing machines such as those found in bulk food stores or candy shops. In particular, the present invention relates to an improved racking, storage and delivery system of simple, modular construction, that is suitable for operation with a wide variety of candies and other products including hardware such as nuts and low aspect ratio screws or bolts. BACKGROUND OF THE INVENTION Food dispensing machines have long been known. They range from coin operated devices, such as bubble gum machines, to simple open topped bins that are commonly found in bulk food stores. These bulk food bins are often prone to contamination. A scoop is usually provided in these existing systems to allow customers to scoop out a desired quantity of product. The handling of food products in this way makes bulk foods a ready ground for undesired contamination. The containers themselves may not be cleaned very frequently. Existing bulk food bins are also cumbersome to use. Most often, the units require the user to hold open a lid or door while scooping out product from the storage area, only to have the lid shut closed while the user empties the contents of the scoop into a bag or other container. Bulk vending systems in which the lid remains in an open position create another problem--often the consumer forgets to close the lid when he or she is finished scooping out product. This enables dust, dirt and vermin access to the contents of the dispenser creating a contaminated environment. Product may also be wasted by the consumer resulting in the loss of profitability to the merchant as the consumer may often drop product on the floor due to overfilling or mishandling of the scoop. Conventional rack systems for bulk dispensers for displaying and dispensing candy and the like are usually made in the form of a solid shelved structures. Often, such structures are placed on a table top or counter top. These structures occupy a relatively large amount of space which leaves a relatively limited area for placement of the dispensing units. Also, due to the limited open area that a conventional solid rack system provides, the candy within the containers cannot be seen very well by consumers, especially when the amount of candy left in the dispenser is low, and thus, the display function of the rack system is reduced. Finally, dispensers on existing rack systems are awkward to refill. Usually a merchant must remove each individual dispenser from the rack to refill it on a table or on the floor. Additionally, a merchant must have a designated area to warehouse product refills. There remains a need for a simple, bulk food dispensing apparatus and rack system that is easy to clean, not easily prone to contamination, easily refillable, and allows a user to easily dispense any amount of the product so desired. SUMMARY OF THE INVENTION It is an object of the present invention to provide a rack system for holding a plurality of dispensing units for displaying and dispensing candy and the like therefrom. It is another object of the present invention to provide a rack system for holding a plurality of dispensing units that can be easily refilled and maintained. It is still a further object of the present invention to provide a bulk vending system in which food product is dispensed in a hygienic manner. It is still another object of the present invention to provide a bulk vending system for allowing a consumer to easily dispense product. It is yet another object of the present invention to provide a bulk vending system which virtually eliminates wasted product due to consumer mishandling. A still another object of the present invention is to provide a bulk vending system for displaying and dispensing a plurality of bulk dispensers in a minimum amount of floor space. In one aspect of the present invention, a bulk vending apparatus for dispensing a user-determined amount of product stored in bulk is provided that includes a rack unit having a plurality of support structures capable of extending out from the rack unit and a plurality of dispensing units each containing a product for dispensing. The dispensing units are arranged on each of the support structures. Finally, the rack unit also includes a restraining means to restrain all but a first support structure of the plurality of support structures when a first support structure is extended from the rack unit. In another aspect of the present invention, a vending apparatus for dispensing a user-determined amount of product stored in bulk is provided which includes a storage portion for storing loose product, and a dispensing barrel located at the bottom of the storage portion. The dispensing barrel includes a product inlet and outlet. Finally the bulk vending apparatus also includes an auger having a major diameter located within the dispensing barrel, and a brush member for brushing away excess product from the major diameter. The auger is rotatable to dispense a metered quantity of the product. These and other features, aspects, and advantages of the present invention will become much more apparent by reference to the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front perspective view of a rack system according to the present invention, on which a plurality of candy dispensers are mounted. FIG. 2 is a rear sectional perspective view of a rack system illustrating a restraining system according to the present invention. FIG. 3 is a side sectional view of a rack system illustrating a restraining system according to the present invention. FIG. 4 is a perspective view of a candy dispenser unit according to the present invention. FIG. 5 is an exploded view of a dispenser portion for a candy dispenser according to the present invention. FIG. 6 is a sectional view of a dispenser portion of a candy dispenser according to the present invention. FIG. 7 is a sectional view of a refill opening and door for a candy dispenser according to the present invention. FIG. 8 is a rear view of a dispenser portion for a candy dispenser according to the present invention. FIG. 9 is a sectional view of a dispenser portion illustrating a baffle member for a candy dispenser according to the present invention. FIG. 10 is a sectional view of a middle portion of a dispenser portion for a candy dispenser according to the present invention. FIG. 11 is a sectional view of a spout member of a dispenser portion for a candy dispenser according to the present invention. FIG. 12 is a sectional view of a front portion of a dispenser portion of a candy dispenser illustrating a ratchet mechanism according to the present invention. FIG. 13 is a top view of a locking knob for the dispenser portion of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS. 1-3, a structurally sound rack system 300 is shown having a framework 320, a plurality of bulk product dispensers 310, and a facade 380. The framework 320 supports shelving support members (trays) 330, 332 and 334 for supporting the bulk product dispensers 310, and a storage area 390 having doors (sliding, swinging, or in the alternative removable covers) 392 and 394. Although the current embodiment of the present invention contains three shelving support members in a horizontal position, the rack system according to the present invention may include any number of shelving support members in vertical positions also. The framework 332, shelving support members, and facade 380 can be made from any one of a number of different materials including wood, plastic, steel, or combination thereof. The framework and shelving members are designed to be structurally rigid for their intended function. Anchored to the framework 320 and to each shelving support member are shelving slides 370, which provide extension capability to each shelving support member. These slides enable a shelving support member to be pulled forward, away from the rack unit. In addition, the rack system includes a novel restraining system that allows only a single shelving unit at a time to be extended out from the rack system. The restraining system includes three cables, 360, 361 and 362, whose ends are attached to the rear of each shelving support member. Each cable connects one shelf member with another as well as anchoring the shelves to the racking system. As shown in FIGS. 2 and 3, cable 360 connects shelving unit 332 with 334, passing through rear wall anchors 350 and 351; cable 361 connects shelving unit 330 with 332, passing through rear wall anchors 352 and 353; and finally, cable 362 connects shelving support member 330 with 334, and passes through rear wall anchors 350, 351, 352 and 353. The cables may be made of steel, or an equivalent material having similar material properties. The diameter of the steel cables is determined by the cable material and the tensile load required for a cable based on the force necessary to move, and restrain the shelving support members. The anchors located on the rear wall of the racking system may be an eye type anchor, or any type of anchor that allows a cable to be threaded through therein. Whereas the anchors affixed to the rear of each shelving support members can be any type of anchor which allows an end of a cable to be affixed thereon. These anchors can include hook and eye anchors, in which case the end of the cables must have a means of attachment thereto. Such means can include clips, hooks, and the like. As an alternative, the ends of the cable can be attached to the shelving unit anchors by welding or adhesive. Each cable is made to a predetermined length, which allows only one shelving support member to be opened at a time. Thus, when all the shelving support members are in the closed position, cables 360, 361 and 362 have slack, which hangs freely within the backside of the rack system. However, when shelving support member 334 is in an open position, for example (i.e., is pulled out away from the rack unit 300 (and away from the back wall 310; see FIG. 3), the slack in cables 360 and 362 is taken up and the cables are placed under tension (i.e., being extended to their full predetermined length). The length of the cables allow the shelving support member 334 to be pulled out up to a specific distance. This distance is preferably approximately equal to the width of the shelving support member, although the ultimate length of cables 360 and 362 can be designed to handle any distance that may be required to access the bulk dispensing units for refilling or maintenance. When cables 360 and 362 are under tension, as a result of shelving support member 334 being pulled out, the remaining shelving support members 330 and 332 remain locked in place due to the tension in cables 360 and 362. The restraining system works similarly when either shelving support member 330 or 332 is open. The purpose behind this system is to provide an easy and effective manner to refill the bulk dispensing units 310 as well as to ensure that the rack unit 300 will not tip over in the event of having too many shelving members in the open position. Accordingly, the rack unit 300 is designed so that the unit will remain stable in all conditions of operation. For example, in a worst case scenario when, say, the bulk dispensing units 310 arranged on the upper most shelving member 334 are full, and the remainder of the bulk dispensing units 210 arranged on the other shelving support members are empty, and shelving member 334 is placed in the open position, the unit will not topple forward, even with additional weight from a merchant leaning on the shelving support member 334 when refilling the upper units. When an open shelving support member is returned into the rack unit 300, then another of the shelving members may be opened, albeit, only one at a time. Although the present invention includes the currently described novel restraining system, this does not limit the invention to this restraining system. Other restraining systems familiar to one skilled in the art may also be used. Such systems may include similar systems using elastic cords and springs, or a series locking levers that keep remaining shelving support members locked in a closed position when one of the shelving support members is open. In addition, electrical means and methods for ensuring that only a single draw is open are not beyond the scope of the present invention. FIGS. 4-12 illustrate a type of bulk dispensing unit 210 that may be used with rack system 300. Specifically, FIG. 4 shows a perspective view of bulk dispenser 210 illustrating overall housing 219. The housing 219 may be made from any number of materials including wood or steel, but preferably plastic, and may be manufactured as a single molded product, or multiple piece assembly. The bulk dispenser unit also includes refill opening 225 having a refill door 230. The sides of the bulk dispenser housing 219 include notched areas 215 and 217 which provide an area for receiving a shelving support member, so that the dispenser unit 310 may be locked into the shelving support member for stable operation. As shown in FIG. 4, the front wall 214 of the dispenser unit 210 is preferably comprised of a transparent material. This allows one to view the material contents of the dispenser unit 210, without having to open refill door 230 and peer into the dispenser unit 210 through refill opening 225. In addition, as shown in FIGS. 6 and 7, an internal wall located behind the existing front wall 214 of the housing 219 creates an internal space 213 for containing loose product. This creates a display "window" giving an "always full" view for the bulk dispensing unit 310 illustrating the product for dispensing. Finally, the dispenser unit 210 includes dispensing barrel assembly 200 which dispenses the loose product contained within the housing 219 to the consumer. As shown in FIGS. 5 and 6, the dispensing barrel assembly 200 includes dispensing tube 133, having a product receiving area 135 for receiving product from the product stored in the housing 219. In the front of dispensing barrel assembly 200 is a barrel cap 90, which includes the front half of a spout 130. The back half of spout 130 is integral with dispensing barrel 133. The main component included within the dispensing barrel assembly 200 is an auger 100, which is comprised of a plurality of individual flights 102 which are centrally assembled side by side over a shaft 110, through a central opening in each flight 102. The central opening in each flight is designed to conform to the shape of the shaft 110, so as to be radially locked onto the shaft 110. As shown in FIG. 5, the shaft 110 is in the form of a square, but can be of any shape. In addition, the auger, or auger and shaft may be manufactured as a single one-piece unit. The auger may be exchanged with another auger-shaft assembly having a different pitch, major diameter, minor diameter, and pitch diameter of the flights. This may be done in order to compensate for different size product to be dispensed. These dimensions are limited, however, by the overall diameter of the dispensing barrel 133 and spout diameter. Preferably, the size of the flights for the present invention will be of a size for accepting a wide variety of small loose product including candy, nuts, coffee beans and the like. At the product exit end of the auger 100 is an end cap 101 that slides over the end of shaft 110, terminating the flights 102. At the opposite end is a rear bushing 120, which is received by an opening 137 in the rear of the dispensing barrel 133, in the back wall adjacent the product receiving area 135. The dispenser barrel 133 is capped by barrel cap 90. Immediately adjacent and located within the barrel cap 90 is a ratchet gear 70 and a ratchet spring 80. The ratchet gear 70 slides over the center shaft 110 through a conforming center portion. The ratchet allows one-way only rotation of the auger within the dispensing barrel 130. It is noted that the one-way rotation of auger 100 can also be accomplished in any number of ways including both electrical and other mechanical means. A cap cover 60, also with central portion conforming to the shape of shaft 110, covers the ratcheting mechanism. A knob 35 including rear portion 50 and front portion 40, slides over the end of shaft 110. The knob portion is then completed with color or product designating chip 20, inserted within front knob portion 40, and sealed with transparent cover 10 to allow a consumer to view a specific characteristic (color, name, shape, size) of the product contained within the bulk dispensing unit. The entire dispensing barrel assembly 200 is held together by front and rear fasteners. At the rear of dispensing barrel 130, a machine screw 150 locks a locking bushing 160 and rear bushing 120 onto the center of the rear end of shaft 110. As shown in FIG. 13, the central portion of locking knob 170, having an equivalent shape of locking bushing 160, also contains an inner hub 171 and a post 172. When the locking knob 170 is slid over the locking bushing 160, a clockwise twist of the locking knob 170 moves an end of locking bushing 160 up the inner hub 171 terminating the end at post 172. A front machine screw 30 locks the knob halves 40 and 50, the ratchet gear 70, the ratchet spring 80 and barrel cap 90 into the front end of the shaft 110. The front machine screw is hidden from view by product designating chip 20 and transparent cover 10. The completed dispensing barrel 200 is then slid into the lower portion of the housing 210. There it is secured in place by a tab 142 and secured by a set screw 140, threaded into sonic insert 146. Finally, a brush assembly 175 including a brush 190 secured to a brush holder 180, is located within the dispensing area of the lower portion of the housing 219 directly above the product receiving area 135. The brush assembly insures that the material to be dispensed does not jam the auger at the front edge of the product receiving area 135, by "brushing" excess product away from the intersection of the auger and product receiving area 135. The excess material brushed away is swept back into the preceding flight. The operation of the dispenser unit 210 is as follows. As shown in FIG. 6, product 5 fills the storage area of the housing 219, and is funneled down into the product receiving area 132 of dispensing barrel 133 by a sloped floor 7 and the brush assembly 175. As a consumer turns knob 35 clockwise, the auger 100 also rotates clockwise. The primary function of the rachet assembly is to keep the auger from rotating in the opposite direction, i.e., counter clockwise. In addition, the speed of the auger can be limited somewhat by the pressure of the ratchet spring 80 on the ratchet gear 70. This creates a "clicking" sound as one rotates the handle. Due to gravity, product 5 fills the voids in each of the exposed individual flight of auger 100. The product is carried down the auger 100 by the clockwise rotation of knob 35. As the product 5 passes the individual flights located directly below brush 190, excess product located above the top part of the screw thread is brushed back to be funneled into the preceding flights of auger 100 located toward the rear of the product receiving area 135. Product is moved along the length of auger 100 where it exits the dispensing barrel at the flights 102 located above exit spout 130. The assembly allows the user to obtain as much or as little product as desired by rotating the auger a large or small amount, respectively. In addition, the speed of the product exiting the dispensing barrel 200, although somewhat limited by the ratcheting mechanism, can be user-determined by rotating the knob 35 in a fast or slow fashion. When the amount of product has been exhausted in the storage area of the dispensing unit housing 219, the unit may be refilled with more product. However, prior to refilling, the dispensing barrel may be removed for cleaning and maintenance by removing retaining screw 140 and tab 142 and sliding the unit out from the base of the housing. When no more product appears after repeated rotations of the knob 35, the unit requires refilling. As shown in FIGS. 3 and 7, the storage area of the dispensing unit 210 is refilled by sliding the appropriate shelving support member to the open position, and lifting lid 230 to expose the opening 225 located above the storage area. The merchant can then place product into the storage area through the opening 225, and, depending upon the popularity of the product, fill the storage area to a desired level. The lid 230 is then closed or replaced and the shelving support member returned to the closed position.
A bulk vending apparatus for dispensing a user-determined amount of product stored in bulk includes a storage portion for storing loose product and a removable dispensing barrel located within the bottom of the storage portion. The dispensing barrel includes an inlet positioned adjacent a first end of the barrel and an outlet positioned adjacent a second end of the barrel opposite the first end. The first end of the barrel is removably fastened to the storage portion. The apparatus also includes an auger located within the dispensing barrel having a major diameter and a first end removably fastened to the first end of the dispensing barrel, and a brush member positioned adjacent the auger for brushing excess product away from the major diameter.
4
CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation in part of prior U.S. application, Ser. No. 08/784,244, Filed Jan. 15, 1997, and entitled Hydraulically Controlled Riding Trowel, now U.S. Pat. No. 5,890,833, issued Apr. 6, 1999. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates generally to motorized riding trowels for finishing concrete surfaces of the type classified in United States Patent Class 404, Subclass 112. More particularly, our invention relates to multiple-rotor, hydraulically driven riding trowels. 2. Description of the Prior Art It is well established in the concrete finishing arts that freshly placed concrete must be appropriately finished to achieve the desired smoothness and flatness. As freshly poured concrete "sets", it soon becomes hard enough to support the weight of motorized riding trowels, that are particularly effective for finishing concrete. Motorized riding trowels are ideal for finishing large areas of plastic concrete quickly and efficiently, and a variety of riding trowels are known in the art. Typical riding trowels employ multiple, downwardly projecting rotors that contact the concrete surface and support the weight of the trowel. A typical rotor comprises a plurality of radially spaced apart finishing blades that revolve in frictional contact with the concrete surface. The blades may be coupled to circular finishing pans for treating green concrete. When the rotors are tilted, steering and propulsion forces are frictionally developed by the blades (or pans) against the concrete surface. Riding trowels finish large surface areas of wet concrete more efficiently than older "walk behind" trowels. Significant savings are experienced by the contractor using such equipment, as time constraints and labor expenses are reduced. Preferably, the finishing process starts with panning while the concrete is still "green", within one to several hours after pouring depending upon the concrete mixture involved. The advent of more stringent concrete surface finish specifications using "F" numbers to specify flatness (ff) and levelness (fl), dictates the use of pans on a widespread basis. Both "super-flat" and "super-smooth" floors can be achieved by panning with motorized trowels. Pan finishing is normally followed by medium speed blade finishing, after the pans are removed from the rotors. A developing technique is the use of "combo blades" during the intermediate "fuzz stage" as the concrete continues to harden. So-called "combo-blades" are a compromise between pans and normal finishing blades. They present more surface area to the concrete than normal finishing blades, and attack at a less acute angle. The rotors are preferably turned between 100 to 135 RPM at this time. Finishing blades are then used, and they are rotated between 120 to 150 RPM. Finally, the pitch of the blades is changed to a relatively high contact angle, and burnishing begins. Rotor speeds of between 135 and 165 RPM are recommended in the final trowel finishing stage. Holz, in U.S. Pat. No. 4,046,484 shows a pioneer, twin rotor, self-propelled riding trowel wherein the rotors are tilted to generate steering forces. U.S. Pat. No. 3,936,212, also issued to Holz, shows a three rotor riding trowel powered by a single motor. Although the designs depicted in the latter two Holz patents were pioneers in the riding trowel arts, the devices were difficult to steer and control. Prior U.S. Pat. No. 5,108,220 owned by Allen Engineering Corporation, the same assignee as in this case, relates to an improved, fast steering system for riding trowels. Its steering system enhances riding trowel maneuverability and control. The latter fast steering riding trowel is also the subject of U.S. Des. Pat. No. 323,510 owned by Allen Engineering Corporation. U.S. Pat. No. 5,613,801, issued Mar. 25, 1997 to Allen Engineering Corporation discloses a power-riding trowel equipped with separate motors for each rotor. Steering is accomplished with structure similar to that depicted in U.S. Pat. No. 5,108,220 previously discussed. Allen Engineering Corporation U.S. Pat. No. 5,480,258 discloses a multiple engine riding trowel. The twin rotor design depicted therein associates a separate engine with each rotor. As the engines are disposed directly over each revolving rotor assembly, horsepower is more efficiently transferred to the revolving blades. Besides resulting in a faster and more efficient trowel, the design is easier to steer. Again, manually activated steering linkages are used. Allen Engineering Corporation U.S. Pat. No. 5,685,667 discloses a twin engine riding trowel using "contra rotation." Many trowel users prefer the steering characteristics that result when the trowel rotors are forced to rotate in a direction opposite from that normally expected in the art. While modern, high power riding trowels are noted for their speed and efficiency, extreme demands are placed upon the relatively small, internal combustion motors that power such machines. Adequate horsepower must be available at all times for the rotors, that must operate under varying conditions of speed, drag, rotor tilt-angle, blade pitch, and concrete hardness. Demands upon drive motors can vary widely when switching between panning and blade-finishing modes. Generally speaking, the more powerful the trowel, the faster finishing operations can be completed. However, optimum engine speed (i.e., for rated torque and horsepower) is limited to a relatively small RPM range. On the other hand, a variety of blade speeds are required for modern finishing, and as explained earlier, load conditions vary widely as well. Engine RPM is usually the key variable related to output power. Typical riding trowel engines are coupled through belts and pulleys to gear boxes connected to the rotor shafts. The output shaft speed (i.e., rotor speed) is geared down, with a ratio of 20:1 being common. While it is recognized that effective motor output characteristics are RPM related, the use of fixed ratio reduction gearing often results in a mismatch between the desired blade speed, the frictional load, and the available motor horsepower at a given RPM. If engine speed increases too much, excessive power may be developed, and the finishing mechanism may rotate too fast. For example, the initial panning stage requires relatively high power because of the viscous character of green concrete, but relatively low rotor speeds are desired. Since the rotors are driven through a fixed ratio established by the gearbox, belts and drive pulleys, optimum engine power often cannot be obtained during panning without risking excessive rotor speeds. It is thus desirable to provide a riding trowel wherein the engine and gear boxes can operate at ideal speeds over a wide range of finishing conditions. One solution pioneered by Allen Engineering Corporation, is the subject of pending U.S. patent application Ser. No. 09/008,355, filed Jan. 16, 1998, and entitled "Riding Trowel with Variable Ratio Transmission." The object is to vary the overall drive gear ratio during different panning and blade finishing stages so that motors may operate within optimum RPM ranges as much as possible. In the Allen design, the effective drive ratio established between the motor output pulleys and the drive pulleys splined to the gearbox input shaft can be dynamically varied. However, since the rotor gearbox reduction ratio is still fixed, the range of adjustment of the overall drive train gear ratio (i.e., the ratio between motor RPM and rotor RPM) is limited. What appears necessary is a variable ratio "drive gear" for revolving the rotors that allows the motors to maintain a relatively constant speed over a variety of working conditions and loads. Although hydraulic motors would seem logical, their practicality has hitherto been limited by the steering and handling characteristics of motorized trowels, and the available engine horsepower. Many early riding trowels use manually operated levers for steering. The steering levers project upwardly from the frame and are grasped and manipulated by the operator to direct the machine. The steering levers deflect linkages below the trowel frame to tilt the rotors. Often a vigorous physical effort is required. Where separate engines are used with each rotor assembly, additional physical effort is required to tilt the rotors for steering, or to vary blade pitch. It has now been established that modern, state-of-the art riding trowels require power steering for maximum performance. Hydraulic steering systems for multiple engine trowels previously proposed by Allen Engineering Corporation have proven desirable. For example, copending Allen Engineering Corporation patent application Ser. No. 08/784,244, filed Jan. 15, 1997, entitled "Hydraulically Controlled Riding Trowel" discloses a powered steering system for riding trowels. Quick, responsive handling optimizes trowel efficiency, and preserves operator safety and comfort. At the same time, power steering requires added hydraulic motors and accessories that increase the demand for motor horsepower. Hydraulic steering devices consume energy, further aggravating the need for power and optimal motor control. In other words, internal combustion engine drive speed should be maintained within an optimal RPM range to supply adequate horsepower. But, as explained earlier, the overall drive train gear ratio limits motor performance. By using hydraulic motors to drive trowel rotors, the internal combustion motors may operate continuously within ideal RPM ranges. The resultant horsepower increase more than offsets losses caused by hydraulic inefficiencies. Concomitantly, the added weight resulting from hydraulic drive motors and required accessories further burdens the steering system. The heavier and more powerful the trowel, the more important it is to establish responsive steering and fast, effective handling. Hence we have designed a multiple-rotor, hydraulically driven trowel. In the best mode the hydraulic drive system is employed with an optimized steering control system. SUMMARY OF THE INVENTION The preferred trowel comprises a plurality of spaced apart rotors gimbaled to the frame. One or more internal combustion motors power suitable hydraulic pumps for energizing hydraulic accessories. The rotors are powered and directly driven hydraulically, so mechanical gearboxes are avoided. In the best mode an "electric-over-hydraulic" system effectuates steering and maneuvering. The preferably gasoline or diesel powered internal combustion motors operate over an optimized RPM range. Joysticks, conveniently placed near the operator, initially activate the electrical circuitry that, in turn, activates hydraulic components to tilt the rotors for steering and maneuvering the trowel, and for changing blade pitch. The enhanced steering system and the hydraulic drive system compliment one another, as the hydraulic drive system allows the internal combustion motors to run at an optimum speed, making horsepower readily available. The extra horsepower adequately powers the energy demands of the hydraulic accessories. The increased weight and horsepower of the system demands an improved steering design, and our preferred hydraulic steering system readily delivers the enhanced functional characteristics that make hydraulic drive practicable. Thus a fundamental object of our invention is provide a workable hydraulic direct drive system for riding trowels. Another fundamental object of our invention is provide a hydraulic direct drive system adapted for multiple engine riding trowels. Another important object is to provide power steering and power blade pitch control for use with hydraulic, direct drive riding trowels. A further object is to provide an electrical-over-hydraulic steering and control system for riding trowels that is lever or joystick controlled. Another important object is to simplify the operation of high power, dual or triple rotor trowels. A related object is to reduce the physical effort required to safely drive a twin-rotor or triple-rotor riding trowel. Another basic object is to provide a direct drive system and a complimentary power steering system for high power riding trowels characterized by multiple rotor assemblies. It is also an object to provide hydraulic power steering and direct hydraulic drive for twin-engine and triple engine riding trowels. Similarly, it is an object to provide hydraulic steering and hydraulic direct drive systems that are effective over a wide variety of operating conditions. A further object is to provide a multiple rotor riding trowel characterized by direct hydraulic drive and hydraulic steering that readily handles conventional blades, combo-blades, or finishing pans. A still further object is to provide a hydraulic control circuit of the character described that will function on a variety of riding trowels, including diesel or gasoline powered trowels with either one or two motors. Another object is to provide a high power riding trowel that overcomes power-draining vacuum effects that occur when panning wet concrete. Another fundamental object is to independently, hydraulically control each of the rotors in a twin-rotor trowel. A related object is to provide an electrical control system for actuating the hydraulic system in a twin-rotor trowel. It is a feature of this invention that "joystick steering" is employed for ultimate trowel ride control in conjunction with the hydraulics. Another basic object is to provide a hydraulic direct drive system for multiple rotor riding trowels that performs with either standard rotation or contra rotation. Another basic object is to provide a functional, hydraulic drive system for riding trowels that enables directional and variable speed control, while applying relatively constant torque under varying speed conditions. A still further object is to provide a direct drive hydraulic system of the character described that enables the trowel internal combustion motor to run constantly within an optimum RPM and horsepower range. Yet another object is to provide a power steering riding trowel wherein the rotors flatten the concrete surface sufficiently to attain the high "F-numbers" (i.e., flatness characteristics) that are established by ACI regulations. Another object is to provide a multiple-rotor, high power riding trowel that is inherently stable and easy to maneuver. A related object is to provide multiple-rotor riding trowels that are ideal for pan finishing and quick curing concrete jobs. These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections. BRIEF DESCRIPTION OF THE DRAWINGS In the following drawings, which form a part of the specification and are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout in the various views wherever possible: FIG. 1 is a partially fragmentary, front elevational view of a Hydraulically Driven, Multiple Rotor Riding Trowel, with portions thereof omitted or broken away for clarity; FIG. 2 is a fragmentary, top plan view of a trowel with portions thereof broken away or shown in section for clarity; FIG. 3 is an enlarged, fragmentary, isometric exploded view showing preferred hydraulic drive motor components, steering linkages, and associated hydraulic controls; FIG. 4 is an enlarged, fragmentary, isometric view showing a steering system for a twin-rotor trowel; FIG. 5 is a schematic diagram of the preferred hydraulic steering circuit; FIG. 6 is an electrical schematic diagram of the preferred right hand joystick control circuit; FIG. 7 is an electrical schematic diagram of the preferred left hand joystick control circuit. FIG. 8 is a schematic diagram of the preferred hydraulic motor control circuit; and, FIGS. 9 and 10 are schematic diagrams that supplement FIG. 8 and show possible twin-rotor and triple-rotor hydraulic motor arrangements; FIG. 11 is a front, environmental, perspective view of a high speed, triple rotor trowel with hydraulic direct drive and hydraulic steering, showing the best mode of the invention known at this time; FIG. 12 is a fragmentary top plan view of the trowel of FIG. 11 with portions thereof omitted or broken away for clarity; FIG. 13 is a fragmentary, bottom plan view of the trowel of FIG. 11 with portions omitted for clarity; FIG. 14 is an enlarged, fragmentary, top plan view of circled portion 14 of FIG. 12, with portions thereof broken away for clarity or omitted for brevity; and, FIG. 15 is an enlarged, fragmentary top plan view of circled portion 15 in FIG. 12, with portions broken away for clarity or omitted for brevity. DETAILED DESCRIPTION With initial reference now directed to FIGS. 1-4 of the accompanying drawings, a multiple rotor riding trowel 20 broadly designated by the reference numeral 20 features a new hydraulic drive system (FIG. 3) and a complimentary hydraulic steering system (FIG. 4). Substantial structural details of pertinent riding trowels are set forth in prior U.S. Pat. Nos. 5,108,220, 5,613,801, 5,480,257, and 5,685,667 which, for disclosure purposes, are hereby incorporated by reference herein. Riding trowel 20 comprises a metal frame 25 (FIGS. 1, 4) surrounded by a guard cage 30 (FIGS. 1, 2) defining its periphery. A pair of spaced apart rotor assemblies 50, 55 are gimbaled to the frame and project downwardly into contact with concrete surface 23. Several radially spaced apart blades 60 extend outwardly from each of the rotors 50, 55. The blades 60 frictionally contact the concrete surface 23 to be finished and support the trowel 20 and the operator. An operator station 65 mounts at the top of the frame. At least one internal combustion engine 40 secured to the frame beneath the operator station 65 is employed for powering left and right hydraulic drive motors 45, 46 respectively that control rotor assemblies 50, 55. In the best mode the rotors use contra-rotation, as described in U.S. Pat. No. 5,685,667 which is incorporated by reference herein. However, it will be appreciated that the hydraulic steering and drive systems of the present invention may be used with riding trowels, with either normal or contra rotation, and with one or more gasoline, diesel powered, or alternative engines. The controls are easily reached by a seated operator at station 65. In the best mode the operator steers trowel 20 with joysticks 70, 75 (FIG. 1). Left joystick 75 and right joystick 70 (i.e., from the point of view of a seated operator) respectively control steering apparatus associated with left rotor 50 and right rotor 55 respectively. Left joystick 75 and right joystick 70 are secured to control housings 75A and 70A respectively. As described later, the two-way left joystick 75 operates electric circuit 400 seen in FIG. 7; the four-way right joystick 70 operates the electric circuit 300 of FIG. 6. Right joystick 70 can be pushed forwardly or pulled rearwardly to move the trowel frontward or backwards; it may be moved to the operator's left and right for maneuvering, turning or crabbing. In the best mode known to us at this time left joystick 75 (FIG. 1) need only move forwards or backwards. Electrical circuits 300 and 400 (FIGS. 6, 7) operate hydraulic steering system 220 (FIG. 5) to tilt the hydraulic motors 45, 46 to control machine steering and maneuvering. System 220 also controls blade pitch by operating blade pitch forks 176 (FIG. 1). The gimbal mounting systems 90, 95 respectively mount left and right hydraulic rotor-drive motors 45, 46 (FIG. 4). The gimbal system controls the angle or degree of tilt of the rotors 50, 55 to generate steering and propulsion forces as is known in the art. The frame 25 comprises an upper deck 100 (FIG. 1) that provides a mounting surface for station 65. A seat 106 on station 65 permits the operator to ride the trowel. Conventional engine controls and gauges (not shown) are conveniently mounted adjacent the seat 106 within or upon housings 70A, 75A. Two gas tanks 108 and 109 are mounted on opposite frame ends. A forward subframe 120 projecting from the frame 25 mounts a throttle pedal 122. The throttle peddle 122 controls the flow of fuel from the gas tanks 108, 109 to the internal combustion engine 40 to ensure that the rotors 50, 55 (FIG. 1) rotate substantially uniformly at a high power RPM setting. With joint reference to FIGS. 3 and 4, gimbal systems 90 and 95 are similar. Preferably, both gimbal systems 90, 95 tilt left and right in a plane parallel with the biaxial plane (i.e., the hypothetical plane established by the axis of rotation of both rotors). Additionally, right gimbal system 95 tilts front to back (and back to front) in a plane perpendicular to the biaxial plane. When deflected by cylinders 150 or 150B, the elongated torque rods 187 or 186 (FIG. 4) respectively extending from gimbal systems 95, 90 tilt the rotors in a plane parallel with the biaxial plane. The torque rods 186, 187, that function as the preferred levers, are generally aligned and extend along the bottom of gussets 188, 189. The rods 186, 187 are also forwardly offset from the axis of rotation 140 (FIG. 4) of the gimbal systems. Gimbal system 95 can be tilted in a plane perpendicular to the biaxial plane with hydraulic cylinder 150A that lifts or lowers rocking plate 96 through linkage 151 (FIG. 4). Cylinder 150A is preferably oriented horizontally for clearance purposes (FIG. 4). It is secured between braces 161 by pivot 161A. Ran 163 terminates in a clevis 163A pivoted to arm 162A that is welded to sleeve 162. Housing 167 suspended from depending tab 167A (FIGS. 3, 4) rotatably captivates sleeve 162. Horizontally extending arm 162B emanating from sleeve 162 is radially deflectable. It drives a Heim joint 164 coupled to rocking plate 96. Cylinder 150A thus rocks plate 96 to tilt the right side gimbal system in a plane perpendicular to the biaxial plane. Alternatively, cylinder 150A could be oriented vertically, obviating the need for linkage 151. Cylinders 150 and 150B (FIG. 4) lift the torque rods 187 or 186 to forcibly rock the rotors 55, 50 respectively in a plane parallel with the biaxial plane. The latter cylinders are preferably mounted vertically. The terminal clevis 166 on ram 165, for example, is directly pivoted to the end of torque rod 187. Thus a rocking movement in the direction of arrows 169A, 169B (FIG. 4) is established. Blade pitch control cylinders 200, 200A are also mounted vertically. These change blade pitch by moving the forks 176, producing displacements as illustrated by arrows 178 (FIG. 4). Trowel blade pitch control is thoroughly discussed in the previously cited patent documents. With emphasis now on FIG. 3, a preferred gimbal mounting system 95 comprises a generally rectangular subframe 141 whose sides are provided with bearing orifices 141A, 141B, 141C, and 141D. Subframe 141 is pivotally suspended below the frame between spaced apart bracket pairs 142A, 142B that mount aligned bearing orifices 144A, 144B. Subframe bearing orifices 141A and 141B register with bearing orifices 144A, 144B and, when pinned with a suitable axle 140 (FIG. 4), jointly establish an axis of rotation (i.e. about axle 140) that enables the right rotor (and right hydraulic motor 46) to pivot in a plane generally perpendicular to the biaxial plane. A subframe in left gimbal system 90 similar to subframe 141 mounts left hydraulic motor 45, but it can be welded to corresponding bracket pairs 142C and 142D (FIG. 4) as it need not pivot in a plane perpendicular to the biaxial plane. The right hydraulic motor 46 comprises a rigid, peripheral mounting flange 46A (FIG. 3) enabling it to be mounted to rocking plate 96 by suitable bolts 145. The motor output shaft 46B projects concentrically through clearance orifice 146 in rocking plate 96 and is attached to the blade assembly to control blades 60 (FIG. 1). Apertured mounting tabs 147A and 147B projecting downwardly from rocking plate 96 register with subframe orifices 141C and 141D (FIG. 3) and pivotally mount the rocking plate over the subframe 141. An axis of rotation established by the pivot through subframe orifices 141C, 141D facilitates rocking of the right hydraulic motor 46 in a plane parallel with the biaxial plane. Such pivoting is caused by hydraulic cylinder 150 acting through torque rod 187 whose gusset tab portion 189A is secured beneath rocking plate 96 to downwardly projecting flanges 147E. Left hydraulic drive motor 45 is similarly gimbaled for pivoting in a plane parallel with the biaxial plane. Referring now to FIG. 5, hydraulic tilting circuit 220 is responsible for rotor tilting for steering and maneuvering, and for blade pitch control. Hydraulic pump 223 driven by the internal combustion motor 40 on trowel 20 circulates fluid stored in reservoir 255, suctioning as indicated by arrowhead 224. Pump output reaches T-fitting 190 coupled to variable bypass needle valve 192 via passage 190A. Valve 192 is adjustable, and it is preferably mechanically located on the top of the trowel on cabinet 75A adjacent the driver so he can adjust his steering response speed. Valve 192 drains through line 192A to the hydraulic return 253. Valve 192 is preferably connected forwardly of the flow divider 232, as illustrated in FIG. 5. The hydraulic flow rate and load experienced by the trowel depends upon numerous factors including the type of blade or pans chosen, the weight of the operator, and the hardness of the concrete being treated. Valve 192 provides a convenient means for the driver to quickly adapt flow rates to his operating conditions. It is preferred that this bypass valve be plumbed in immediately after the pump and before the flow dividers. The main solenoid control valves are arranged in a manifold identified schematically by the reference numeral 225 that comprises steering valve bank 226 and blade pitch valve bank 226B (FIG. 5). Steering bank 226 is pressured through line 241 outputted from T-fitting 190 and lines 243A, 243B and 243C from the flow divider 232. Bank 226B, responsible for blade pitch, is connected to the "T" port of valve 229 on line 230. The pitch control solenoid valves 240 and 240A in bank 226B are interconnected by flow lines 230 and 230A. Steering valve bank 226 (FIG. 5) preferably comprises a plurality of four way, three position, solenoid-actuated hydraulic valves 227, 228, and 229. The "T" ports of valves 227 and 228 are tied together. Valves 227, 228 are respectively connected to tilting cylinders 150, 150A that control right rotor tilting (FIG. 4). Valve 229 controls left rotor cylinder 150B, that rocks it in a plane parallel with the biaxial plane. Ports A1 and B1 of valve 227 control cylinder 150. Ports A2 and B2 of valve 228 control cylinder 150A, and ports A3 and B3 of valve 229 control cylinder 150B. Pitch control bank 226B comprises solenoid activated hydraulic valves 240 and 240A. These respectively actuate right pitch control cylinder 200 and left pitch control cylinder 200A (i.e., FIGS. 4, 5). Ports A4 and B4 of valve 240, for example, control right pitch control cylinder 200 that controls blade pitch by hydraulically deflecting the pitch control fork. Ports A5 and B5 of valve 240A similarly control left pitch control cylinder 200A. The hydraulic steering 223 (FIG. 5) transmits through line 241 to flow divider 232 that divides the hydraulic output into three equal flows. Flow from section one of divider 232 appears on line 243A and reaches cartridge relief valve 244A and port P1 of the four way valve 227 via line 245. Solenoid 227A establishes normal flow; solenoid 227B reverses the flow across ports A1 and B1. Similarly, the flow from sections two and three of divider 232 outputted on lines 243B and 243C respectively reaches cartridge relief valves 244B, 244C and solenoid valves 228, 229. Relief valves 244A-244C are set to 450 P.S.I. in the best mode. Valves 228 and 229 have similar solenoids that are electrically energized to reverse flow across their output ports A2, B2 and A3, B3 respectively. The double acting cylinders 150, 150A, 150B are thus extended or retracted. Each valve 227-229 has a pair of flexible lines 247A, 247B, 247C respectively interconnecting its output ports to the tilting cylinders 150, 150A, and 150B respectively. Right side steering is primarily established by valve 228 and cylinder 150A; right side forward/reverse control is primarily established by valve 227 that activates cylinders 150. Left rotor forward/reverse control is primarily established by valve 229 that tilts cylinder 150B (FIG. 4). The hydraulic circuit return is completed by lines 250, 251 and 253 (FIG. 5). The main relief valve 254 is coupled across the circuit by line 242; in the best mode it is set at 550 P.S.I. Return to reservoir 255 is indicated by arrowhead 255A. Reservoir 255 is vented by breather 256. Electrical control will be detailed hereinafter. Valves 227, 228, and 229 operate similarly. The absence of solenoid control signals establishes a neutral steering position; cylinder deflection to a neutral position occurs because of the weight borne by the rotor assemblies. The pitch control bank 226B is powered through the third section of flow divider 232 and the T port of valve 229 on lines 230 and 230A. Valves 240 and 240A control right pitch control cylinder 200 and left pitch control cylinder 200A respectively via their respective A and B ports. These valves have solenoids similar to solenoids 227A and 227B previously discussed. Pilot-operated check valves 260A and 260B hold the cylinders in position without drift. Circuit 300 (FIG. 6) is operated by the right hand joystick 70 (FIG. 1). The right hand joystick 70 can be deflected between forward-neutral-reverse positions and left-neutral-right positions. The particular mechanical movement was selected for backwards compatibility with older twin rotor trowels; the joystick motions correspond generally with the mechanical hand-lever movements necessary for steering older twin rotor trowels. In circuit 300 power (i.e., nominally 12 or 24 volts D.C.) is applied across lines 301 and 302. When the right joystick is moved forwardly switch contacts 303 close, activating solenoid field 305 that energizes solenoid 227A (FIG. 5) to pressure port A1 of valve 227 for forward steering. Moving the right joystick 70 rearwardly activates contacts 304 to energize solenoid field 306 and solenoid 227B (on valve 227), activating port B1 and reversing cylinder 150. Movement of the right joystick to the right activates solenoid field 308 through contacts 309 to activate port A2 on valve 228 for steering right (by tilting the right rotor assembly perpendicularly to the biaxial plane with cylinder 150A). Similarly, movement of the right hand joystick to the left activates solenoid field 310 through contacts 311 for steering left; at this time port B2 on valve 228 is pressured. Push button switch 314 (FIG. 6) operates relay 315 and LED indicator 316; relay 315 closes switch contacts 318 to energize the running lights 320. Other electrical accessories can be powered in this fashion. The left, single-axis joystick 75 can be deflected between forward, neutral, and reverse selections. Again, the particular mechanical movement establishes backwards compatibility with older riding trowels. Blade pitch control switches are incorporated in the handle; there is a toggle control switch for pitch control of each rotor. The left hand joystick 75 (FIG. 1) operates circuit 400 (FIG. 7). In circuit 400 source voltage is applied across lines 401, 402 (FIG. 7). When the left joystick is pushed forwardly (i.e., concurrently with the right joystick) to move the trowel forwardly, contacts 404 are closed to energize solenoid field 406. This activates port A3 of valve 229 (FIG. 5) and cylinder 150B (FIG. 6). Pulling the left hand joystick rearwardly closes contacts 407 to energize solenoid field 408; this activates port B3 of valve 229 and retracts cylinder 150B, rocking the left rotor in the biaxial plane. To control blade pitch it is preferred to use an electrical pitch control circuit generally designated by the reference numeral 403 (FIG. 7). A plurality of single pole double throw toggle switches 411 are preferred. When, for example, switch contacts 411B (FIG. 7) are closed to energize solenoid field 414, port A5 of valve 240A (FIG. 5) is activated to change blade pitch on the left rotor pitch control cylinder 200A (FIG. 4). Solenoid fields 415, 416, and 417 are similarly energized by the contacts and movements illustrated in FIG. 7. The respective solenoid valve "A" and "B" ports indicated in FIG. 5 correspond to the labeled ports in FIG. 7. Switch contacts 420 activate relay field 421 to close relay contacts 422, energizing an optional spray pump motor 424. Referencing FIG. 8, the preferred hydraulic motor control circuit for powering a direct drive rotor motor 45, 46 has been designated by the reference numeral 500. It appears to us at this time that duplicate circuits should be used, one for each hydraulic rotor drive motor. Circuit 500 transmits fluid pressure across lines 502, 504 for powering a single hydraulic drive motor. Alternatively, if enough horsepower is developed, lines 502, 504 may be connected across lines 502A, 502B (FIG. 9) to power two series connected hydraulic drive motors; in the case of a three rotor trowel (i.e., with three direct drive hydraulic motors 45, 45A and 46), connection can be made to lines 502B, 504B (FIG. 10). An internal combustion engine 40 drives a hydrostatic, bi-directional piston pump 505 through a mechanical coupling 508. The pump 505 is controlled by a servo pump control valve 510. An air cooled oil cooler 506 runs between reservoir 518 and the pump 505 via line 507. Charge pump 512 draws in fluid though line 514 and suction filter 516 that is in fluid flow communication with fluid reservoir 518. A charge pump relief valve 520 connected to pump 512 is responsible for setting control pressure. Control ports on pump 505 are connected across pump control valve 510 via lines 524, 525. Valve 510 may be remotely actuated by a suitable linkage (not shown) for controlling pressure (for speed control) by adjusting the swash plate position in pump 505. Depending upon the setting of valve 510, hydraulic pressure appears across lines 532 and 534, reaching hot oil shuttle valve 536 and hot oil purge relief valve 538. Cross over relief valves 540 and 542 connected across high pressure lines 532 and 534 provide overpressure protection for the closed loop design. It is preferred that excessive heat accumulated by the hydraulic fluid is dissipated; this is accomplished by the return loop created by valve 536. Motor driving output lines 502 and 504 discussed previously connect to lines 534 and 532 respectively. Pump 505 is capable of delivering a variable hydraulic flow at a constant pressure, depending upon the setting of valve 510, which may be controlled electrically or manually to vary the rotor speeds. This creates variable rotor speed control at a constant torque output. Circuit 500 provides directional control, variable speed control, and relatively constant torque under varying speed conditions. During operation the internal combustion motor 40 provides substantially constant horsepower over an optimum RPM range. A three rotor trowel with multiple hydraulic drive motors is seen in FIGS. 11-16. It is designed to quickly and reliably flat finish large areas of concrete surface 621. The triple-rotor trowel 620 is equipped with hydraulic steering and hydraulic pitch control, utilizing a hydraulic steering circuit substantially the same as that detailed in FIG. 5. Trowel 620 comprises a trio of separate rotor assemblies. Each rotor assembly is independently, pivotally gimbaled from the rigid frame and directly driven by a separate hydraulic motor 45, 45A and 46 (FIG. 10). In the best mode each hydraulic motor is powered by a separate circuit 500 (FIG. 8). An operator (not shown) comfortably positioned upon seat assembly 623 can operate the entire machine with an easy-to-use lever controlling system comprising, in the best mode, left joystick 624B and right joystick 624A. The left hand joystick 624B is preferably wired according to circuit 400 (FIG. 7) and the right hand joystick 624A is preferably wired according to circuit 300 (FIG. 6). A foot-operated motor throttle control 674 (FIG. 11) is accessible from seat assembly 623 for throttling the internal combustion motor. Trowel 620 has a rigid metallic frame 625 fabricated from channel steel. In the three rotor mode the frame is triangular, and comprises a front 626 (FIG. 1) and a rear 627 (FIG. 12). A transverse base 629 extends across the rear 627 of the frame between frame ends 631 (FIG. 11), and 632 (FIG. 12). Ends 631, 632 are rigidly affixed to frame sides 633, 634 (FIG. 14) which preferably form the sides of a triangle and terminate at a transverse, frame front 635 (FIGS. 11, 13). The frame is internally reinforced by transverse strut 640 (FIGS. 13, 14) that is parallel with and spaced apart from base 629. The parallel frame braces 642, 644 extend from strut 640 to front 635 to further reinforce the frame. Similarly, transverse struts 646, 647 (FIGS. 13, 14) extend between braces 644, 642 to sides 633, 634 respectively for reinforcement. An internal brace 650 that is parallel with and spaced apart from front 635 extends between braces 642, 644 (FIGS. 13, 14). A recessed hydraulic motor mounting region 653 is defined between brace 650, front 635 and braces 642, 644. In the best mode, each rotor assembly is pivotally disposed within a similar frame mounting region defined between adjacent and intersecting frame elements. The left rear of the frame is reinforced with a doubled, channel steel brace 656 (FIG. 16) that extends between frame base 629 and strut 640. A recessed hydraulic motor mounting region 658 (FIGS. 14, 16) for the left rear rotor is defined between frame end 631, brace 656, strut 640 and base 629. Similarly, recessed hydraulic motor mounting region 662 (FIG. 13) for the right rear rotor is defined between frame end 632, brace 664, strut 640 and base 629. Trowel 620 comprises two spaced apart, bladed rotors at its rear and one at its front that support the trowel upon the concrete surface 621. Alternatively, as explained above, the steering system can be employed with trowels having more or less rotor assemblies. In the best mode known at this time, however, each rotor assembly of the hydraulic triple trowel 620 is driven by a separate hydraulic drive motor through a circuit 500 (FIG. 8). For example, in trowel 620 a front motor 45A drives a front rotor assembly 670A (FIGS. 14, 15). The left rear motor 45 drives rotor assembly 672A (FIGS. 11, 13). Similarly the right rear motor 46 independently drives rotor assembly 676A. In the best mode the left and right rear rotors revolve in the opposite radial directions indicated by arrows 680, 681 (FIG. 13). The latter is termed "contra-rotation." Such rotation is also preferred with twin rotor trowels. In the best mode known to us at this time the front rotor (i.e., in a triple rotor trowel) revolves in a clockwise direction indicated by arrow 682 (FIG. 13). When the rear rotors revolve in this preferred "contra-rotation" mode, they press incoming concrete about the trowel periphery during forward trowel movement. However it is within the scope of the invention to employ "standard rotation" wherein the rear rotors revolve oppositely from arrows 680, 681. The latter, although not preferred, is referred to as "standard rotation." In the latter mode the rotors press incoming concrete toward the trowel center and between the rotors during forward movement. Standard rotation may be employed by twin rotor trowels as well. Preferably, the rotor assemblies 670A, 672A and 676A are powered by hydraulic motors 45, 45A, 46 similar to those previously discussed and illustrated in FIGS. 3, 4. Each rotor is protectively shrouded by a cage assembly 673 that prevents human contact with the revolving rotor blades that frictionally finish the concrete surface. A first fuel tank 684 (FIG. 11) is recessed within the frame area 683 defined between struts 640, and 646. A companion fuel tank 688 (FIG. 12) is mounted within mounting region 687 (FIG. 13) defined between internal frame struts 640, 647. The seat assembly 623 comprises a chair 689 disposed upon a ventilated, upright enclosure 690 positioned between the internal combustion motors 672, 676. Enclosure 690 houses a battery (not shown) for the electrical system hydraulic circuitry discussed previously. A cruise control 677 (FIG. 12) is accessible from the right side of the seat to lock in selected motor speed. Cables (not shown) from the variable foot control 674 (FIG. 1) establish motor speed by displacing the motor throttle linkages (not shown). Handle 677A may be conveniently grasped by the user to lock the throttles in a cruise control mode. In the triple rotor design, each rotor pivots in a single direction. The left and rear rotor preferably tilt in a direction parallel with the biaxial plane established by three axis of rotation of the left rear and right rear rotor assemblies. Rocking is caused by cylinders 150, 150B (FIG. 4) that are associated with the right rear and left rear rotor assemblies respectively in the three rotor design. The front rotor assembly pivots in a direction perpendicular with the biaxial plane, in response to cylinder 150A, which in the three rotor design 620, is associated with the front rotor. As before, joystick operated circuits 300 and 400 control operation. Each rotor assembly also comprises a blade pitch control valve and fork system of the type discussed previously. As explained in copending application Ser. No. 08/784,244, Filed Jan. 15, 1997, Group Art Unit 3506, and entitled Hydraulically Controlled Riding Trowel, which is owned by the same assignee as in this case, an additional valve, functioning similarly to valves 240 and 240A in bank 226B, drives a cylinder similar to cylinders 200 and 200A to control pitch of the front rotor assembly. The last mentioned patent application is hereby incorporated by reference. Operation In operation a variety of operator precautions must be observed, as is the case with prior art motorized trowels. The hydraulic tanks should be periodically inspected for proper level, and the rotor blades must be changed as necessary after routine inspections for wear. Fuel tank levels must be sufficient for extended periods of use. During the initial finishing of wet concrete, proper pans will first be installed on the rotors by coupling the rotor blades to the radially spaced apart brackets provided. If pressure is applied to the inside of the left and right rotors by tilting them appropriately with the double acting cylinders (i.e., by pulling the joysticks backwards), then the machine will move in reverse. To move left, with the rear rotors untilted (i.e., neutral) subsequent tilting of the right rotor by hydraulic cylinder 150 will cause the trowel to make a left hand, wide sweeping turn. With the rotors untilted in the biaxial plane (i.e., neutral) tilting of the right rotor (i.e., the front rotor in the triple trowel) to concentrate pressure at its rear (i.e., towards the interior of the riding trowel frame) will cause the trowel to make a right hand, wide sweeping turn. At this time the right hand joystick is moved to the right. As readily recognized by those skilled in the art, a variety of other trowel movements are possible by moving the joysticks generally in the same directions that old fashioned, lever-actuated trowels are driven. From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
High performance, multiple rotor riding trowels for finishing concrete comprise hydraulic circuitry enabling complete joystick control to the operator. The rigid trowel frame mounts separate spaced-apart, downwardly-projecting, bladed rotor assemblies that frictionally engage the concrete surface. The rotor assembly blades finish the surface while supporting the trowel. The rotor assemblies are tilted with double acting, hydraulic cylinders to effectuate steering and control. Double acting hydraulic cylinders also control blade pitch. Separate gimbaled, hydraulic motors revolve each rotor assembly. A joystick system enables operator hand control with minimal physical exertion. The joystick system activates electrical circuitry that fires solenoid control valves to energize various hydraulic cylinders that tilt the rotors and alter blade pitch. The hydraulic steering control circuit driven by a motor driven pump pressures a flow divider circuit to control the solenoid tilt control valves. A bypass-valve in line before the flow divider enables an operator to customize the trowel steering speed. A motor drive control circuit responsive to a hydraulic pump controls each hydraulic drive motor, and provides for speed control and heat dissipation.
4
BACKGROUND OF THE INVENTION [0001] 1. Field of Invention [0002] This invention, as used in a supercharger (an exhaust gas turbocharger) of internal combustion engines or the so forth, relates to the adjustable nozzle mechanism for variable capacity turbines and its production method, with regard to the radial flow turbine configured to make the actuating gas flow from the spiral scroll formed in the turbine casing to the turbine rotor in the radial axis through the multiple nozzle vanes having wings of variable angle. [0003] 2. Description of the Related Art [0004] In order to make a good match with regard to the internal combustion engine, between the outflow exhaust gas volume from the engine and the actuating gas flow volume which should be determined for the optimum operation condition of the supercharger, variable capacity superchargers, equipped with the variable capacity turbine capable of changing the exhaust gas volume to be sent from the spiral scroll to the turbine rotor in accordance with the operation condition of the engine, have been in widespread use in recent years. [0005] A supercharger with such a variable capacity turbine is equipped with the adjustable nozzle mechanism in order to change the wing angle of the nozzle vane by rotating the nozzle vane with the link assembly so that it is capable of being driven for rotations around said turbine rotor shaft by the actuator through the actuator rod and the driving lever. [0006] For the method to achieve assembling and adjustment of such variable nozzle mechanism, an invention of Japanese patent number 3,085,210 has been proposed. [0007] In the concerned invention, a jig should be placed in the inner radius of the nozzle vane to perform the setup for total shutdown of the nozzle vane and the link assembly to be driven for rotations around the turbine rotor shaft. The jig therein can be put in contact with the rear edge of the nozzle vane, wherein the stopper pin is mounted after the nozzle vane and the lever plates are welded together upon putting the nozzle vane in contact with the jig in the state that the stopper pin, that is to be fitted into the long slots given at the multiple positions along the circumferential direction of the link plate, is made non-functional or non-existing, and upon fitting the matching pin into the phase matching hole to finalize the entire link assembly in the perfectly total shutdown phase. [0008] However, problems, such as the following, are concerned with the invention of Japanese patent number 3,085,210. Two different processes are required one of which is to put the jig in contact with the nozzle vane in the nozzle vane-free state wherein the stopper pin to be fitted into the long slots of the link plate is non-functional, and the other is to mount the stopper pin after welding the nozzle vane and the lever plate in the perfectly total shutdown phase of the entire link assembly with the matching pin fitted into the phase-matching hole in the state. This in turn requires more assembling jigs, making the adjustable nozzle mechanism assembly and the related adjustment works troublesome, with additional man-hours resulting in cost increase. [0009] In addition, on the basis of the conventional art in which the structure becomes complex due to the link position determining pin included therein with the stopper pin fitted into the long slot at the multiple positions in the circumferential direction of the link plate, the number of the part category and the number of the parts themselves will therefore increase considerably. As a result, the device costs will increase accordingly. [0010] Furthermore, as the setup of the total adjustable nozzle mechanism should be carried out by means of fitting the stopper pin into the long slot at multiple positions in the circumferential direction of the link plate and by means of making a match of the relative angle of the contact of the jig at the nozzle vane rear edge against the lever plate, the setup of the total shutdown may vary to cause a setup error. The total shutdown position of the adjustable nozzle mechanism must be determined primarily by the dimensional accuracy of the component parts, which may make it difficult to obtain the proper setup accuracy. SUMMARY OF THE INVENTION [0011] In consideration of the problems with the conventional art mentioned above, the object of this invention is to propose the method to realize assembly and adjustment, and the related assembly and adjustment facilities for the variable capacity turbine, requiring neither adjustment of the total shutdown position in the nozzle assembly nor the jigs for assembly and adjustment thereof, by which the adjustment works can be simplified to decrease man-hours, as well as assembly and adjustment costs. The structure can also be simplified to decrease part category numbers and the number of the parts itself, thus decreasing part costs and furthermore enabling the nozzle vane setup of the adjustable nozzle mechanism to a comparatively high degree of accuracy without being influenced by the degree of dimensional accuracy of the component parts, such as the nozzle vane and the link assembly. [0012] In order to solve the concerned problems, the variable capacity turbine for applying this invention comprises; a number of nozzle vanes, which are arranged along the circumference of the turbine and provided on the nozzle shafts which are supported on the turbine casing in such a way that the nozzle vanes can rotate, and which vary the vane angle; a nozzle driving member driving the nozzle vanes, and enabled to rotate around the turbine shafts by the actuator; and a turbine rotor set free for rotation inside the inner radius of the nozzle vanes. The variable capacity turbine is driven for rotation of the turbine rotor by flowing the actuating gas from the scroll in the turbine casing toward the inner radial direction through the nozzle vanes to the turbine rotor. [0013] In the event of manufacturing the adjustable nozzle mechanism used in such variable capacity turbine, it is distinguished by the manufacturing method according to this invention which comprises the steps of: providing a plurality of joint members (lever plates) which are the same in number as the nozzle shafts, and connect the plurality of nozzle vanes and the nozzle driving member (link plate); fitting and fixing each nozzle shaft to one end of each lever plate after setting the predetermined positional relationship between the wing angle of the nozzle vanes and the fitting direction of the fixing section of the lever plate; and engaging another end of each lever plate with the nozzle driving member (link plate). [0014] For the concrete fixing method of the nozzle shaft to joint member (lever plate), the method comprises the steps of: forming a coupling hole in each joint member (lever plate), then forming a flat or curved surface on one sidewall of each coupling hole; forming a coupling shaft provided with a fitting surface on the end of the nozzle shaft for nozzle vane, the fitting surface corresponding to the shape of the coupling hole of the joint member (lever plate) for creating a stopper; fitting the coupling shaft into the coupling hole without causing plasticity deformation at the coupling shaft or coupling hole, and engaging the stopper surface of the shaft with the stopper surface on the coupling hole so that the joint member (lever plate) and the nozzle shaft cannot rotate relatively by the stopper, and finally processing for anti-decoupling to prevent the nozzle shaft from squeezing out of the side surface of the joint members by using the chamfered portion having a larger diameter (chamfered portion) at the edge portion of the nozzle shaft. [0015] The anti-decoupling is preferably processed by punching the shaft edge of the coupling shaft by using the chamfered portion at the edge after engaging the coupling hole of the joint member with the coupling shaft of the nozzle shaft. The anti-decoupling process thereof at the edge can be substituted by a light welding or the like. [0016] This invention further features that the concrete engaging method of the joint members (lever plate) with the nozzle driving member (link plate) is to fit the slots with the fitting pins equal in number to the joint members. The fitting pins protrude along the circumferential direction on the nozzle driving member. The slots are opened in a nearly radial axis on the other edge of each of the joint members to engage with the fitting pins of the nozzle driving member. [0017] The variable capacity turbine for applying this invention comprises; a number of nozzle vanes, which are arranged along the circumference of the turbine and provided on the nozzle shafts which are supported on the turbine casing in such a way that the nozzle vanes can rotate, and which vary the vane angle; a nozzle driving member driving the nozzle vanes, and enabled to rotate around the turbine shafts by the actuator; and a turbine rotor set free for rotation inside the inner radius of the nozzle vanes. The variable capacity turbine is driven for rotation of the turbine rotor by flowing the actuating gas from the scroll in the turbine casing towards the inner radial direction through the nozzle vanes to the turbine rotor. [0018] The adjustable nozzle mechanism used in such variable capacity turbine is distinguished by the configuration, comprising: a plurality of lever plates which are provided between the nozzle mount and the link plate, one end of each lever plate being fitted and fixed to each nozzle shaft after setting the predetermined positional relationship between the wing angle of the nozzle vanes and the fitting direction of the fixing section of the lever plate, and the lever plate being provided with a slot which is opened in a nearly radial axis on the other edge; and the same number of fitting pins protruding along the circumferential direction and toward the lever plate side on the nozzle driving member, the fitting pins being engaged with the slots of the lever plates. [0019] In accordance with this invention, adjustment of the adjustable nozzle mechanism, that is, the position setup of the wing angle of the nozzle vane and the nozzle driving member, can be made in such extremely simple processes. In this process, the coupling hole provided at one edge of the lever plate and the coupling shaft at the end of the nozzle shaft are fitted after being set up geometrically so that the wing angle and the rotating angle of the link plate composing the nozzle driving member may be in the predetermined relation. The edge of the nozzle shaft is then punched into one of the chamfered portion of the edge portion in order to be fixed on the lever plate. Then the lever plate and the link plate can be engaged to each other by engaging the pins with the slots provided at the end of the lever plate. [0020] With these simplified processes, adjustment of the adjustable nozzle mechanism during the nozzle assembly procedure is no longer required and therefore the assembling man-hours are decreased, particular assembling facilities such as the jigs are not needed, and as a result, assembling costs are decreased. The jigs are still required with the invention of the Japanese patent number 3,085,210 in such a way that the adjustment should be made for the total shutdown position during nozzle assembly procedure by using multiple long slots of the link plate, stopper pin and jigs. [0021] Furthermore, as the adjustable nozzle mechanism according to this invention is configured in the manner that the one edge side of the joint members (lever plate) and the nozzle shaft are fixed upon the set geometrical relations between thereto and the nozzle driving member (link plate) are joined to the other edge side of each joint member, the structure is simplified comparatively with the conventional art and the number of part category and parts itself are considerably decreased. Part costs are decreased accordingly. [0022] Furthermore, with this invention, configured such that the nozzle driving member is joined to the other edge of each joint member after these have been fitted on the condition that the wing angle of the nozzle vane and the rotating angle of the nozzle driving member (link plate) had been set previously in the geometrical relation as required, and that adjustment of the adjustable nozzle mechanism, that is, the position setup of the wing angle of the nozzle vane and the nozzle driving member is available neither with a setting error that would arise in the conventional art from the variable setup for the total shutdown caused by the adjustment for the total shutdown position during nozzle assembling procedure using the multiple long slots, the stopper pin and jig, nor the total shutdown position of the adjustable nozzle mechanism should be determined primarily by the component parts, the setup herein of the adjustable nozzle mechanism is available to a high degree of accuracy without fear of influence by the dimensional accuracy of the nozzle assembly and the link assembly, as well as the enabling of the various requirement settings of the adjustable nozzle mechanism. [0023] Still furthermore, with this invention, configured such that the lever plates equal in number to the nozzle vanes are placed between the nozzle mount and the link plate in the turbine shaft axis, that the one edge of the lever plate is fixed on the nozzle shaft of the nozzle vane, that the fitting pin protruding toward the lever plate side in the link plate is fitted into the slots on the other edge of the lever plate, that the stopper between the lever plate and the edge of the nozzle shaft is processed with the use of the chamfered portion in order to prevent the stopper portion from squeezing out of the side face of the lever plate, It becomes possible to assemble the link plate and lever plate with a minimum distance, therefore, the distant between the link plate and the nozzle mount over the lever plate sandwiched thereby becomes shorter, and the length in the shaft axis of the adjustable nozzle mechanism is, as a result, shortened. [0024] Still furthermore, the punched portion avoids protrusion from the link plate side, and erroneous operation of the adjustable nozzle mechanism by the friction and interference between the link plate and the punched portion is also avoided. BRIEF DESCRIPTION OF THE DRAWINGS [0025] [0025]FIG. 1 shows the cross-sectional view along the rotor shaft of the adjustable nozzle mechanism for the supercharger with the variable capacity turbine in connection with this invention, corresponding to the Z section in FIG. 8. [0026] [0026]FIG. 2 shows the cross-sectional view corresponding to the Y section in FIG. 1 for the coupling section of the nozzle shaft and the lever plate. [0027] [0027]FIG. 3 shows the C-arrowed view in FIG. 2. [0028] [0028]FIG. 4 shows the diagonal view of the coupling section of the nozzle vane and the lever plate. [0029] [0029]FIG. 5 shows the detailed cross-sectional view of the X section in FIG. 1. [0030] [0030]FIG. 6 shows the A-arrowed view in FIG. 1. [0031] [0031]FIG. 7 shows the B-arrowed view in FIG. 1. [0032] [0032]FIG. 8 shows the key cross-sectional view along the rotor shaft of the supercharger with the variable capacity turbine to which this invention is applicable. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0033] In the following section we shall give a detailed explanation of the invention with reference to the drawings. Insofar as the circuit components, control state, relative position of circuit components, or other features of the constitutive circuitry disclosed in this embodiment are not exhaustively delineated, they are not intended to limit the scope of the invention, but serve merely as examples to clarify the explanation. [0034] [0034]FIG. 1 shows the cross-sectional view along the rotor shaft of the adjustable nozzle mechanism for the supercharger with the variable capacity turbine in connection with this invention, corresponding to the Z section in FIG. 8. FIG. 2 shows the cross-sectional view corresponding to the Y section in FIG. 1 for the coupling section of the nozzle shaft and the lever plate. FIG. 3 shows the C-arrowed view in FIG. 2. FIG. 4 shows the diagonal view of the coupling section of the nozzle vane and the lever plate. FIG. 5 shows the detailed cross-sectional view of the X section in FIG. 1. FIG. 6 shows the A-arrowed view in FIG. 1. FIG. 7 shows the B-arrowed view in FIG. 1. FIG. 8 shows the key cross-sectional view along the rotor shaft of the supercharger with the variable capacity turbine to which this invention is applicable. [0035] In FIG. 8 showing the entire structure of the supercharger with variable capacity turbine to which this invention is applicable, 30 is a turbine casing, and 38 is a scroll formed in spiral around the circumference section in the turbine casing 30 . 34 is a turbine wheel, 35 is a compressor wheel, 033 is a rotor shaft to join the turbine wheel 34 to the compressor wheel 35 , both of which compose the turbine rotor 33 . [0036] [0036] 08 is a exhaust gas outlet sending out the exhaust gas having done the expansion work in the turbine rotor 33 . 31 is a compressor casing, 36 is the bearing housing to join the compressor casing 31 and the turbine casing 30 . 37 is the bearing supporting the turbine rotor 33 as mounted on the bearing housing 36 . [0037] [0037] 2 is a nozzle vane, as placed equidistant in multiple along the circumferential direction of the turbine on the inner radius of the scroll 38 , and the nozzle shaft 02 formed into thereof is supported for the rotary motion by the nozzle mount 4 fixed on the turbine casing 30 , the wing angle of which is changeable. [0038] [0038] 40 is the actuator rod, that is, the output end of the actuator 040 to drive the nozzle vane 2 , and the reciprocating motion of the actuator rod 40 is converted through the known link mechanism including the driving lever 41 into the rotating motion to be transferred to the link plate 3 of the adjustable nozzle mechanism 100 described later. [0039] In the supercharger with the variable capacity turbine in such composition, the exhaust gas from the internal combustion engine (not shown in figures here) flows into the scroll 38 and goes around along the spiral of the scroll 38 further to the nozzle vane 2 . The exhaust gas runs through the wings of the nozzle vane 2 to flow into the turbine rotor wheel 34 from the outer radius side thereof, and, after flowing in radial axis towards the shaft axis to perform the expansion work, flows in the shaft axis to the outside from the exhaust outlet 08 . [0040] [0040] 100 is the adjustable nozzle mechanism rotating the nozzle vane 2 in order to change the wing angle thereof by use of the link plate 3 driven in rotation around the rotating shaft 8 of the turbine rotor 33 through the link mechanism, including the actuator rod 40 and the driving lever 41 from the actuator 040 . [0041] This invention relates to the production method of such an adjustable nozzle mechanism and the structure of the adjustable nozzle mechanism 100 produced by such a method. [0042] In FIGS. 1 to 7 showing the preferred embodiments of this invention, 3 is a link plate formed in the disk, being joined to the actuator rod 40 for rotating motion around the rotating shaft 8 through the link mechanism including the driving lever 41 as described above. [0043] [0043] 4 is the ring-shaped nozzle mount fixed on the turbine casing 30 . 7 is the nozzle support, four of which (or any plural number of which) are placed along the circumferential direction between the nozzle mount 4 and the nozzle plate 12 as shown in FIG. 7 to fix the nozzle mount 4 and the nozzle plate 12 . The coupling section on the nozzle plate 12 side of the nozzle support 7 is processed for a detent function by fitting the parallel shaft section 7 a formed at the shaft edge section of the nozzle support 7 into the parallel hole section formed in the hole 12 a of the nozzle plate 12 , as shown in FIG. 5, to punch and fix the shaft edge of the nozzle support 7 on the nozzle plate 12 through the washer 012 . [0044] On the other hand, the nozzle vane 2 is placed at the inner radius section of the nozzle support 7 between the nozzle mount 4 and the nozzle plate 12 , and the nozzle shaft 02 fixed thereon (or formed into the nozzle vane 2 ) is supported for rotating motion. [0045] [0045] 1 is the lever plate to compose the joint members joining the link plate 3 to the nozzle shaft 02 on each nozzle vane 2 side, being placed equal in number to the nozzle vane 2 , where one edge side thereof is fixed on the nozzle shaft 02 and the other edge side is joined to the link plate 3 , as described later. [0046] As shown in FIGS. 2 and 4, the coupling hole 1 b is provided through to the nozzle shaft 02 on one edge side of the lever plate 1 . The coupling hole 1 b forms an oval shape having stopper surface in hole 1 d in parallel therein onto each of the two opposite surfaces. [0047] On the other hand, the coupling shaft 02 a is provided to be fitted to the coupling hole 1 b at the shaft edge of the nozzle shaft 02 of the nozzle vane 2 . The coupling shaft 02 a forms in the same oval shape as the coupling hole 1 b to be fitted thereto, and, as the stopper surface on shaft 02 b thereon in parallel to each other are attached to the stopper surface in hole 1 d , the lever plate 1 and the nozzle vane 2 are fitted firmly so as to disable relative rotation. [0048] After the coupling shaft 02 a is fitted to the coupling hole 1 b, the edge portion of the coupling shaft 02 a is processed by punching (at 2 a ) to prevent from disconnection, as shown in the FIG. 2. [0049] As shown in FIGS. 3, 4 and 6 , on the other edge side of the each lever plate 1 , slot 1 c is formed in the radial axis and the slot 1 c is fitted with the fitting pin section 3 a having the fitting pin 3 protruding towards the lever plate in the same quantity as the lever plate 1 protruding towards the lever plate 1 on the side surface of the lever plate 1 of the link plate 3 . [0050] And the lever plate 1 is placed between the nozzle mount 4 and the link plate 3 in the turbine shaft axis, and, as described above, the one edge side, that is the inner radius side, is fixed on the nozzle shaft 02 and the other edge side, that is the outer radius side, is fixed on the fitting pin section 3 a of the link plate 3 . [0051] In order to control the capacity of the variable capacity turbine equipped with the adjustable nozzle mechanism 100 in such a composition, the wing angle of the nozzle vane 2 should be set up by means of wing angle control (not shown in figures here) to the required flow volume of the exhaust gas flowing through the nozzle vane 2 against the actuator 040 . The reciprocating displacement of the actuator 040 corresponding to such wing angle is converted into rotating motion by the link mechanism including the actuator rod 40 and the driving lever 41 , and transferred to the link plate 3 to drive the link plate 3 for rotation. [0052] By the rotation of the link plate 3 , each lever plate 1 , joined by the fitting of fitting pin section 3 a and slot section 1 c to the link plate 3 , is shaken around the shaft of the nozzle shaft 02 by the shift of the fitting pin section 3 a in the circumferential direction of the rotation by the link plate 3 , then the nozzle shaft 02 is rotated by the rotation of lever plate 1 , and the nozzle vane 2 rotates in order to change itself to the wing angle set up by the actuator 040 . [0053] When fitting the coupling shaft section 02 a of the nozzle vane 2 to the coupling hole 1 b of the lever plate 1 in such an embodiment, the abovementioned stopper surface in hole id of the coupling hole 1 b and the stopper surface on shaft 02 b of the coupling shaft section 02 a are attached to be fitted after the wing angle of the nozzle vane 2 and the rotating angle of the link plate 3 are set geometrically in the required relation, and then processed for disconnection prevention by punching the edge of the coupling shaft section 02 a. [0054] In such a punching process, the outside of the coupling hole 1 b of the lever plate 1 is made as chamfered beforehand as shown in FIG. 2 ( 01 b showing the chamfered portio), and after the coupling hole 1 b of the lever plate 1 and the coupling shaft section 02 a of the nozzle shaft 02 are fitted, the coupling shaft section 02 a is punched along the chamfered portion 01 b . At this time, a punching process is taken in use of the chamfered portion 01 b so that the punched part 2 a at the shaft edge of the coupling shaft 02 a may not squeeze out towards the inside from the side surface 1 a of the lever plate 1 . [0055] By such a punching process, the punched part 2 a of the nozzle shaft 02 avoids protrusion from the link plate 3 , erroneous operation of the adjustable nozzle mechanism 100 by friction between the protruding part and the link plate 3 is prevented, the distance in the shaft axis of the lever plate 1 from the link plate 3 is made shortest, and therefore the length in the shaft axis of the adjustable nozzle mechanism is shortened. [0056] In accordance with such an embodiment, the coupling hole 1 b (stopper surface in hole 1 d ), formed at one edge side of the lever plate 1 , and the coupling shaft section 02 a (stopper surface on shaft 02 b ) of the nozzle shaft 02 are fitted upon setting beforehand the wing angle of the nozzle vane 2 and the rotating angle of the link plate 3 geometrically in the required relation, and adjustment of the adjustable nozzle mechanism 100 , that is, the position setup between the wing angle of the nozzle vane 2 a and the link plate 3 , is carried out by an extremely easy method such that, after the edge of the nozzle shaft 02 (coupling shaft section 02 a ) is punched at the chamfered portion 01 b to be fixed on the lever plate 1 , the fitting pin section 3 a of the link plate 3 is fitted to the slot 1 c formed at the other side of the each lever plate 1 . [0057] This easy method does not require adjustment of the adjustable nozzle mechanism 100 during the nozzle assembly procedure, in which the total shutdown position should be adjusted during the nozzle assembly procedure by using the multiple long slots of the link plate, the stopper pin and the jigs, as had been required with the invention of Japanese patent number 3,085,210. Therefore, the assembling man-hours are decreased, particular assembling facilities such as the jigs are not needed, and as the result the assembling costs are decreased. [0058] In addition, the adjustable nozzle mechanism 100 is so composed to join the link plate 3 to the other edge side of the each lever plate 1 after setting and fixing the geometrical relation between one edge side of the lever plate 1 and the nozzle shaft 02 as described above, therefore the structure is simplified comparatively with the technology, the number of part categories and the parts themselves are considerably decreased, and part costs are decreased accordingly. [0059] Further, in accordance with such an embodiment, adjustment of the adjustable nozzle mechanism 100 , that is the position setup between the wing angle of the nozzle vane 2 and the link plate 3 can be carried out by means of joining the link plate 3 to the other edge of the each lever plate 1 after fitting and fixing upon setting up beforehand the one edge of the lever plate 1 and the nozzle shaft 02 geometrically so that the wing angle of the nozzle vane 2 and the rotating angle of the link plate 3 are in the required relation, variations or error may not occur in the setup for the total shutdown, which occurred due to the adjustment to be done with the conventional art for the total shutdown position during nozzle assembling procedure using the multiple long slots of the link plate, stopper pin and jigs. However, with this invention, the total shutdown position of the adjustable nozzle mechanism is not determined primarily by the dimensional accuracy of the component parts, the setup of the adjustable nozzle mechanism 100 is available while securing a high degree of accuracy without being influenced by the dimensional accuracy of the nozzle assembly or the link assembly, and as a result, the adjustable nozzle mechanism 100 can be set up to the various requirements. [0060] Also, in accordance with such an embodiment, as the lever plate 1 equal in number to the nozzle vane 2 are placed between the nozzle mount 4 and the link plate 3 in the turbine shaft axis, one edge side of the lever plate 1 is fixed to the nozzle shaft 02 of the nozzle vane 2 , the fitting pin section 3 a protruding on the link plate 3 towards the lever plate side is fitted to the slot provided on the other edge side of the nozzle plate 1 , and punching is processed so that the punching portion 2 a between the lever plate 1 and the shaft edge of the nozzle shaft 02 does not squeeze out over the surface of the lever plate 1 , the link plate 3 and the lever plate 1 can be assembled with the minimum gap, the distance between the link plate 3 and the nozzle mount 4 having the lever plate 1 sandwiched thereby is shortened and the length in the shaft axis of the adjustable nozzle mechanism 100 is shortened as well. [0061] Furthermore, as described above, erroneous operation of the adjustable nozzle mechanism 100 is prevented due to friction between the protruding part and the link plate 3 as the possible protrusion of the punched portion 2 a of the nozzle shaft 02 from the side of the link plate is avoided. [0062] As mentioned above, according to this invention, In accordance with this invention, adjustment of the adjustable nozzle mechanism, that is, the position setup of the wing angle of the nozzle vane and the nozzle driving member, can be made in such extremely simple processes. In this process, the coupling hole provided at one edge of the lever plate and the coupling shaft at the end of the nozzle shaft are fitted after being set up geometrically so that the wing angle and the rotating angle of the link plate composing the nozzle driving member may be in the predetermined relation. The edge of the nozzle shaft is then punched into one of the chamfered portion having a larger diameter (chamfered portion) of the edge portion in order to be fixed on the lever plate. Then the lever plate and the link plate can be engaged to each other by engaging the pins with the slots provided at the end of the lever plate. [0063] With these simplified processes, adjustment of the adjustable nozzle mechanism during the nozzle assembly procedure is no longer required and therefore the assembling man-hours are decreased, particular assembling facilities such as the jigs are not needed, and as a result, assembling costs are decreased. [0064] Furthermore, as the adjustable nozzle mechanism according to this invention is configured in the manner that the one edge side of the joint members and the nozzle shaft are fixed upon the set geometrical relations between thereto and the nozzle driving member are joined to the other edge side of each joint member, the structure is simplified comparatively with the conventional art and the number of part category and parts itself are considerably decreased. Part costs are decreased accordingly. [0065] Furthermore, with this invention, configured such that the nozzle driving member is joined to the other edge of each joint member after these have been fitted on the condition that the wing angle of the nozzle vane and the rotating angle of the nozzle driving member had been set previously in the geometrical relation as required, and that adjustment of the adjustable nozzle mechanism, that is, the position setup of the wing angle of the nozzle vane and the nozzle driving member is available neither with a setting error that would arise in the conventional art from the variable setup for the total shutdown caused by the adjustment for the total shutdown position during nozzle assembling procedure using the multiple long slots, the stopper pin and jig, nor the total shutdown position of the adjustable nozzle mechanism should be determined primarily by the component parts, the setup herein of the adjustable nozzle mechanism is available to a high degree of accuracy without fear of influence by the dimensional accuracy of the nozzle assembly and the link assembly, as well as the enabling of the various requirement settings of the adjustable nozzle mechanism. [0066] Still furthermore, with the configuration mentioned in claims 5 and 3, configured such that the lever plates equal in number to the nozzle vanes are placed between the nozzle mount and the link plate in the turbine shaft axis, that the one edge of the lever plate is fixed on the nozzle shaft of the nozzle vane, that the fitting pin protruding toward the lever plate side in the link plate is fitted into the slots on the other edge of the lever plate, that the stopper between the lever plate and the edge of the nozzle shaft is processed with the use of the chamfered portion in order to prevent the stopper portion from squeezing out of the side face of the lever plate, It becomes possible to assemble the link plate and lever plate with a minimum distance, therefore, the distant between the link plate and the nozzle mount over the lever plate sandwiched thereby becomes shorter, and the length in the shaft axis of the adjustable nozzle mechanism is, as a result, shortened. [0067] Still furthermore, the punched portion using the chamfered portion avoids protrusion from the link plate side, and erroneous operation of the adjustable nozzle mechanism by the friction and interference between the link plate and the punched portion is also avoided.
The object of this invention is to propose the variable capacity turbine, in which the adjustment works can be simplified to decrease man-hours, as well as assembly and adjustment costs. The structure can also be simplified to decrease part category numbers and the number of the parts itself, thus decreasing part costs and furthermore enabling the nozzle vane setup of the adjustable nozzle mechanism to a comparatively high degree of accuracy without being influenced by the degree of dimensional accuracy of the component parts, such as the nozzle vane and the link assembly. To assemble the adjustable nozzle mechanism used in such variable capacity turbine, it needs the steps of providing a plurality of joint members (lever plates) which are the same in number as the nozzle shafts, and connect a plurality of nozzle vanes and the nozzle driving member; fitting and fixing each nozzle shaft to one end of each lever plate after setting the predetermined positional relationship between the wing angle of the nozzle vanes and the predetermined fitting direction of the fixed section of the lever plate; and engaging another end of each lever plate with the nozzle driving member.
8
CROSS-REFERENCE TO A RELATED APPLICATION [0001] This application is a National Phase Patent Application of International Patent Application Number PCT/EP2013/002303, filed on Aug. 2, 2013, which claims priority of German Patent Application Number 10 2012 107 116.2, filed on Aug. 2, 2012. BACKGROUND [0002] The present invention relates to a method for controlling an adjusting movement of a vehicle closing element to be closed in a manner actuated by an external force and also to a capacitive anti-trap system. [0003] With vehicle closing elements that can be adjusted increasingly in a manner actuated by an external force, in particular in a motor-driven manner, there is a considerable risk as the respective vehicle closing element closes that, for example, a body part of a person standing close to the vehicle will be trapped, which may lead to considerable injuries. A vehicle closing element of this type may be, for example, a side door, a tailgate lid, a window pane, or a sunroof of a motor vehicle. [0004] By way of example, US 2007/0035156 A1 describes an anti-trap system in which two electrode arrangements each having a transmitter electrode and a receiver electrode are provided on mutually opposed longitudinal-side closing edges of a vehicle tailgate lid. The individual electrode pairs each define a monitoring region on a closing edge of the tailgate lid, in which an obstacle in the path of adjustment of the closing tailgate lid can be detected. Here, the two electrode pairs are each activated and evaluated separately. An electronic evaluation unit of the anti-trap system of US 2007/0035156 A1 thus always receives at least two signals, on the basis of which the electronic evaluation unit can determine the presence of an obstacle in one or other of the monitoring regions. [0005] With capacitive anti-trap systems on vehicles, in particular on motor vehicles, known per se to a large extent, an obstacle in the path of adjustment of a vehicle closing element to be closed in a motor-driven manner is detected contactlessly by a changing electric capacitance and prevents an obstacle from being trapped between the closing vehicle closing element and a vehicle structure in the region of a body opening that is to be closed by the vehicle closing element in a closed position. Compared with purely tactile anti-trap systems, anti-trap systems with capacitive detection provide the advantage that a potential obstacle can be determined already before contact with the vehicle closing element or already shortly thereafter without having to exert a specific force on the sensors of the anti-trap system in order to trigger the system and stop and/or reverse the adjusting movement of the vehicle closing element. [0006] With capacitive anti-trap systems that form the basis of the present invention, use is made of the fact that, in an electrode arrangement of the anti-trap system consisting of at least one transmitter electrode and one receiver electrode, a signal characteristic for the presence of an obstacle can be received at the receiver electrode when the transmitter electrode is activated with electric alternating current. By activating the transmitter electrode with alternating current, an electric field is produced, which is influenced by an obstacle in such a way that an electric capacitance is changed in a manner that can be measured. This measurable change of the electric capacitance can be measured at the receiver electrode, which is arranged at a distance from the transmitter electrode, and can be evaluated on the basis of a signal received by the receiver electrode, usually a voltage signal, in order to trigger the anti-trap system and in order to influence the adjusting movement of the vehicle closing element. [0007] The adjustment of a vehicle closing element actuated by an external force not only poses an increased risk of injury by a possible entrapment. There is generally also a considerable injury risk by a locking part provided on a vehicle closing element, such as a lock. Locking parts of this type, by means of which the vehicle closing element is locked to the vehicle structure in the closed position, protrude in part on the vehicle closing element by a number of centimeters, such that collision of the locking part specifically and a person during adjustment of the vehicle closing element is likely. In addition, such locking parts are usually very heavy and are made largely from metal, such that a collision is thus particularly painful for a person. SUMMARY [0008] An object of the present invention is therefore to further improve a capacitive anti-trap system of the type mentioned in the introduction and in particular to minimize the risk of injury for a person by collision with a locking part, such as a door lock or a tailgate lid lock, provided on the vehicle closing element. [0009] The method for controlling an adjusting movement of a vehicle closing element to be closed in a manner actuated by an external force as described herein is characterized in that, by means of a capacitive anti-trap system, an obstacle in a monitoring region around a locking part provided on the vehicle closing element is also detected in order to prevent a collision of this locking part with an obstacle as the vehicle closing element closes. If an obstacle is detected in the monitoring region around the locking part, an adjusting movement of the vehicle closing element is stopped and/or reversed in order to avoid the collision with the obstacle. [0010] Due to the development according to the invention of a control method, not only is a situation of entrapment determined contactlessly by means of an anti-trap system, but also an imminent collision in the region of a locking part, such as a door lock, a luggage compartment lock or a tailgate lid lock. Due to the method according to the invention, protection against entrapment is thus combined with protection against collision in order to avoid selectively injuries caused by the locking part when closing and possibly also when opening the vehicle closing element. There is thus generally an increased risk of injury posed by a locking part on a vehicle closing element, since this locking part generally protrudes on the vehicle closing element and is comparatively heavy in order to provide a reliable locking to the vehicle structure. [0011] Especially in the case of a vehicle closing element in the form of a motor vehicle tailgate lid, a considerable part of a tailgate lid lock often protrudes on the lower closing edge of the tailgate lid. As a result, it may be possible in principle for this (locking) part to collide with a person, in particular in the region of the head, when the tailgate lid is adjusted from an open position in the direction of a shut or closed position. By extending a capacitive anti-trap system with protection against collision so as to be able to detect a person in the path of adjustment of the vehicle closing element as an obstacle, the risk of injury is considerably reduced. [0012] As also when detecting a situation of entrapment, the adjusting movement of the vehicle closing element is influenced by the anti-trap system in the case of an imminent collision as well, and the adjusting movement is preferably stopped and/or reversed. The evaluation as to whether a situation of entrapment is present and whether a collision of the locking part with an obstacle is imminent is preferably implemented by means of an electronic evaluation unit of the anti-trap system. This electronic evaluation unit has an evaluation logic suitable for evaluating received measurement signals and for example is integrated in a control apparatus. [0013] For the capacitive detection of a situation of entrapment, an anti-trap system preferably has at least one transmitter electrode and one receiver electrode on the vehicle closing element, wherein, by activating the transmitter electrode with electric alternating current, an electric field is produced, which is influenced by an obstacle in such a way that an electric capacitance is changed in a manner that can be measured. A signal received via an electronic evaluation unit can then be evaluated via an electronic evaluation unit of the anti-trap system in terms of whether an electric capacitance has changed by an obstacle in the path of adjustment of the vehicle closing element and whether the adjusting movement of the vehicle closing element at least is to be stopped accordingly. [0014] Since the evaluation of capacitively functioning sensors in the automotive field in the meantime has proven to be very easily handled technically and the detection of obstacles by a changing electric capacitance has proven to be extremely effective and reliable, it is also preferred in one variant for a change of an electric capacitance to be evaluated for the detection of an obstacle in the monitoring region for the locking part. Here, at least one receiver electrode and/or at least one transmitter electrode can be provided for the detection of an obstacle. [0015] In this context, just one receiver electrode for example may also be provided additionally on the vehicle closing element in the region of the locking part, such that an additional signal can also be evaluated in order to determine the presence of a possible obstacle. It would be conceivable accordingly for a single transmitter electrode to be combined with at least two receiver electrodes, wherein one receiver electrode is provided for determining a situation of entrapment and another receiver electrode is provided for collision avoidance selectively in the region of the locking part. [0016] Alternatively or additionally, for protection against collision, a dedicated, additional electrode pair consisting of at least one transmitter electrode and at least one receiver electrode can be arranged on the vehicle closing element in the region of the locking part in order to produce an electric field in the region of the locking part and so as to be able to measure an electric capacitance changing on account of an obstacle. [0017] The electrodes provided in the region of a locking part are preferably arranged within a housing or a cover of the locking part. Here, at least one electrode for example may be embedded in such a housing or such a cover made of plastic, in particular cast therein or laid therein, for example by bonding. [0018] In accordance with one variant, at least one transmitter electrode and an associated receiver electrode of the capacitive anti-trap system each extend over at least a part of two closing edges of the vehicle closing element in such a way that both a situation of entrapment at least at one of the closing edges and an imminent collision of the locking part with an obstacle can be detected hereby on the basis of an electric capacitance changing on account of an obstacle. A closing edge of the vehicle closing element is constituted by the portions at an outer edge of the vehicle closing element via which the vehicle closing element rests on the vehicle structure in the fully shut position or closed position of said vehicle closing element. Consequently, an obstacle between the vehicle structure and the vehicle closing element would be trapped precisely at such a closing edge if the anti-trap system were to function incorrectly and the adjusting movement of the vehicle closing element were not stopped and/or reversed. In the proposed variant, the electrodes of an electrode pair for the detection of a situation of entrapment are also used to monitor selectively a monitoring region around the locking part, that is to say for example to monitor a tailgate lid lock, in order to avoid a possible collision of the locking part with an obstacle. To this end, one of the electrodes, preferably both electrodes, can be arranged on the vehicle closing element in such a way for example that said electrode or electrodes extends/extend as far as or even beyond a portion on which the locking part is located. Here, an electrode can extend over a number of different closing edges (at least two) running at an angle relative to one another, that is to say, for example on a motor vehicle tailgate lid, both over a lateral, longitudinally running closing edge and over a lower, transversely running closing edge, on which a part of the tailgate lid lock or even the complete tailgate lid lock is usually arranged. [0019] In one variant the capacitive anti-trap system has at least one first and one second electrode pair, which are each designed and intended to produce an electric field in a monitoring region and also to determine an electric capacitance changing on account of an obstacle. The two electrode pairs, however, are also arranged and interconnected here such that a capacitance change can be detected by means of the two electrode pairs not only in the two respective monitoring regions, but also in a third monitoring region, which is different from the two (first and second) monitoring regions and in which the locking part is located. Here, an interconnection of the two electrode pairs is understood in particular to mean that a first transmitter electrode of a first electrode pair is activated and evaluated not only with a first receiver electrode of the same electrode pair, but also together with a second receiver electrode of the second electrode pair. Thus, at least three different physical monitoring regions, which for example can be evaluated selectively in succession by appropriate activation of the electrodes, can be defined by two electrode pairs in order to determine a capacitance change on account of an obstacle in the respective monitoring region. [0020] By way of example, a transmitter electrode of a first electrode pair and a receiver electrode of a second electrode pair and also a transmitter electrode of the second electrode pair and a receiver electrode of the first electrode pair can be interconnected in succession (crosswise) in order to be able to detect an obstacle in the additional third monitoring region, in which the locking part is arranged on the vehicle closing element. A connection of two electrode pairs can be controlled for example by means of a time multiplexer. An electronic evaluation unit of the anti-trap system can thus evaluate signals successively in a predefined order, said signals being representative of the respective monitoring region and forming the basis for detection of a capacitance change. Such a signal, for example, is a voltage signal that can be measured at each receiver electrode and that changes on account of an obstacle and the accompanying capacitance change. [0021] A connection of at least two electrode pairs such that they additionally cover a third monitoring region, in which the locking part is located, has the advantage that on the one hand no additional electrode has to be provided in the region of the locking part and on the other hand the sensitivity to interference is reduced. The problem that detection of a capacitive obstacle in the region of a metal locking part is not readily possible may thus be addressed. On the one hand there is a greater basic capacitance and on the other hand possibly a considerable influencing of the electric field. If at least one transmitter electrode and at least one receiver electrode are now interconnected and extend along the vehicle closing element preferably on different sides of the locking part, but not on the locking part itself, these disadvantages at the least can be minimized, and a reliable collision monitoring for the locking part can be provided without having to provide additional electrodes for this purpose. [0022] Both electrode pairs preferably extend at a distance from one another on different sides of the locking part, such that the locking part is located between the two electrode pairs. The third monitoring region produced by the connection of the two electrode pairs thus extends substantially between the two electrode pairs, preferably between the free ends of the elongate electrodes of the electrode pairs. [0023] A further aspect of the present invention concerns the provision of a capacitive anti-trap system as described herein. [0024] By means of this anti-trap system, an obstacle in the path of adjustment of a vehicle closing element to be closed in a manner actuated by an external force can be detected in order to prevent an obstacle from being trapped between the closing vehicle closing element and a vehicle structure in the region of a body opening that is closed by the vehicle closing element in a closed position. Here, a capacitive anti-trap system comprises at least the following: at least one electrode pair comprising a transmitter electrode and a receiver electrode, wherein an electric field is produced by activating the transmitter electrode with electric alternating current and is influenced by an obstacle in such a way that an electric capacitance is changed in a manner that can be measured, and an electronic evaluation unit, by means of which a signal received via a receiver electrode can be evaluated in terms of whether an electric capacitance has changed on account of an obstacle in the path of displacement of the vehicle closing element, such that an adjusting movement of the vehicle closing element has to be changed, in particular stopped and/or reversed. [0027] In addition to this function, which is known per se, of a capacitive anti-trap system, an anti-trap system according to the invention is also designed and intended to detect an obstacle in a monitoring region around a locking part on the vehicle closing element in order to prevent a collision of this locking part with an obstacle, for example the head of a person, at least as said vehicle closing element closes. [0028] A capacitive anti-trap system according to the invention is thus suitable in particular for carrying out a method according to the invention. The advantages and features explained in conjunction with a method according to the invention consequently apply also to an anti-trap system according to the invention, and vice versa. [0029] Means for being able to detect an obstacle in a monitoring region around the locking part, for example a lock, are thus provided on an anti-trap system according to the invention, such that protection against collision functioning independently of the presence of a situation of entrapment is provided by the anti-trap system. [0030] Here, by way of example and as already explained above, at least one electrode pair can be formed such that, in addition to detection of a situation of entrapment, an obstacle in a monitoring region around the locking part can also be detected by said electrode pair. An alternative variant can be provided here, in accordance with which an additional electrode pair is provided for the collision avoidance in the region of the locking part, whereas at least one further electrode pair is designed and provided (exclusively) for the detection of a situation of entrapment. [0031] Alternatively or additionally, two electrode pairs can be provided, which each, in addition to the detection of a situation of entrapment, also enable a capacitive detection of an obstacle in the region around the locking part. These electrode pairs can thus be arranged for example on the vehicle closing element such that the produced electric fields of the electrode pairs overlap and thus also cover the region around the locking part, such that an obstacle can be detected here. Alternatively, a suitable connection of two electrode pairs, preferably in the time multiplex, can be provided, by means of which an additional third monitoring region for the locking part can be evaluated by means of the two electrode pairs. [0032] In addition, it is noted that a motor-driven adjustment of a vehicle closing element is understood to mean any adjustment actuated by an external force, that is to say in particular the adjustment by means of an electric motor, hydraulic motor and/or pneumatic motor. BRIEF DESCRIPTION OF THE DRAWINGS [0033] Further advantages and features of the present invention will become clear with the following description of exemplary embodiments with reference to the figures. [0034] FIG. 1 schematically shows a variant of an anti-trap system according to the invention for a vehicle closing element in the form of a motor vehicle tailgate lid, in which an additional electrode pair is provided in the region of a locking part formed as a tailgate lid lock in order to provide additional electronic protection against collision. [0035] FIG. 2A in a view similar to FIG. 1 shows a second variant, in which electrodes extended into the lock region are provided for the protection against collision. [0036] FIG. 2B shows a development of the variant of FIG. 2A with a schematically illustrated shielding of an electrode pair in a sub-region of a lower closing edge. [0037] FIG. 3 schematically shows the structure of an anti-trap system according to FIGS. 2A and 2B with a connection of two electrode pairs in the time multiplex in order to monitor the lock region selectively for the presence of an obstacle. [0038] FIG. 4 in a view similar to FIG. 3 shows the structure of an anti-trap system according to the prior art. DETAILED DESCRIPTION [0039] FIG. 1 illustrates a detail of a motor vehicle K with tailgate lid 1 that can be adjusted in a motor-driven manner. Here, the tailgate lid 1 , in a closed position in which the tailgate lid 1 is fully shut, closes a body opening O at the rear of the motor vehicle K, via which a loading compartment of the motor vehicle K is accessible. The tailgate lid 1 here is adjustable automatically via a drive unit 2 . 1 , 2 . 2 from an opened position into a closed position along an adjustment direction V S . In the present case, two drive units 2 . 1 and 2 . 2 are provided for symmetrical adjustment of the tailgate lid 1 and each engage with the tailgate lid 1 on a respective longitudinal side of the tailgate lid, that is to say to the right or left. Each of these drive units 2 . 1 , 2 . 2 has a drive motor 3 . 1 , 3 . 2 . The two drive motors 3 . 1 , 3 . 2 are controllable here via an electronic control device in order to adjust the tailgate lid 1 along the adjustment direction V S in the closed position thereof. In one variant, the drive units 2 . 1 , 2 . 2 may additionally also be able, via the drive motors 3 . 1 , 3 . 2 thereof, to adjust the tailgate lid 1 hinged to the body of the motor vehicle along an opposite adjustment direction V O into a hinged-out and therefore opened position. [0040] However, it is essential in the present case that the motor vehicle K and in particular the tailgate lid 1 is equipped with a capacitive anti-trap system in order to be able to automatically stop and/or reverse an adjusting movement of the tailgate lid 1 when closing the tailgate lid 1 if an obstacle (not illustrated) is trapped between a closing edge 11 , 12 , 13 of the tailgate lid 1 and a vehicle structure F delimiting the body opening O. Thus, in the case of a tailgate lid 1 that can be closed in a motor-driven manner, as also in the case of other vehicle closing elements, for example in the form of window panes, side doors or sunroofs, there is the risk that in particular a body part of a person will be trapped, which may lead to considerable injuries. Here, a possible obstacle in the path of adjustment of the vehicle closing element, here the tailgate lid 1 , is now to be detected contactlessly as early as possible via an anti-trap system functioning with capacitive sensor arrangement in order to prevent an entrapment of the respective obstacle. Here, such a capacitive anti-trap system of course can also be supplemented by additional sensors, which for example detect the entrapment of an obstacle in a tactile manner. [0041] In the present case, the anti-trap system has two elongate transmitter electrodes S 1 , S 2 and also a number of elongate receiver electrodes, of which the receiver electrodes E 1 , E 1 A, E 1 B and E 2 can be seen in the figures. The receiver electrodes each form an electrode pair with an associated transmitter electrode, for example two electrode pairs S 1 , E 1 and S 2 , E 2 . Neither the transmitter electrodes S 1 , S 2 nor the receiver electrodes E 1 , E 2 are interconnected, but in each case are arranged at a distance from one another. The two electrodes S 1 , S 2 and E 1 , E 2 are thus separated from one another and are physically distanced from one another. [0042] The transmitter electrodes S 1 , S 2 here extend predominantly over a longitudinal-side closing edge 11 or 13 and also only slightly over the transversely running closing edge 12 of the tailgate lid 1 connecting the longitudinal-side closing edges 11 , 13 , resting on the vehicle structure F in the region of a bumper of the motor vehicle K in the closed state, and having centrally a locking part in the form of a lock 4 , provided in order to lock the tailgate lid 1 . The two transmitter electrodes S 1 and S 2 each run practically completely along one of the longitudinal-side closing edges 11 and 13 respectively. In the present case, the receiver electrode E 2 runs along the (right) closing edge 13 , whereas the receiver electrodes E 1 , E 1 A, E 1 B run in succession along the opposite (left) closing edge 11 . In particular, FIG. 1 is to illustrate here by way of example the fact that, instead of an individual continuous receiver electrode for a closing edge 11 , 12 , a number of receiver electrodes E 1 , E 1 A, E 1 B can also be combined with an individual transmitter electrode S 1 , for example when it is difficult to lay a continuous receiver electrode due to the installation space. [0043] Both the transmitter electrodes S 1 , S 2 and the receiver electrodes E 1 , E 2 preferably run on or within the tailgate lid 1 , that is to say for example below a protective plastic cover or a seal encasing one of the electrodes. [0044] In order to be able to detect an obstacle in the path of adjustment of the tailgate lid 1 during closure and thus to effectively prevent an entrapment of the obstacle, the two transmitter electrodes S 1 , S 2 are activated with electric alternating current. An electric field is thus produced in a monitoring region B 1 , B 3 and is influenced by an obstacle in such a way that an electric capacitance is changed in a manner that can be measured. Here, a change of the electric capacitance can then be detected via the respective associated receiver electrode E 1 , E 1 A, E 1 B (for the monitoring region B 1 on the closing edge 11 ) and E 2 (for the monitoring region B 3 on the closing edge B 3 ), such that it is possible to automatically evaluate via an electronic evaluation unit 5 , which is electrically connected via signal lines 50 to the receiver electrodes E 1 , E 1 A, E 1 B and E 2 , by means of an evaluation logic whether an obstacle is present in a monitoring region B 1 , B 3 of the respective transmitter electrode S 1 , S 2 in the path of adjustment of the tailgate lid 1 . [0045] FIG. 4 schematically shows the structure of an anti-trap system known from the prior art with an electronic evaluation unit 5 *. This electronic evaluation unit 5 * here comprises not only components connected to a receiver electrode E 1 , such as a receiver amplifier 5 . 4 and an evaluation circuit 5 . 5 (with integrated evaluation logic or with coupling to an evaluation logic), via which a voltage signal received via the receiver electrode E 1 can be amplified and evaluated in order to determine the presence of an obstacle in the path of adjustment of the tailgate lid 1 . Rather, components of the electronic evaluation unit 5 * are also connected to the transmitter electrodes S 1 , S 2 in the present variant. These components connected to the transmitter electrodes S 1 , S 2 and activating the transmitter electrodes S 1 , S 2 with electric alternating current are a signal generator 5 . 1 , an amplifier 5 . 2 arranged downstream of this signal generator 5 . 1 , and an analog multiplexer 5 . 3 a following the amplifier 5 . 2 . [0046] Here, alternating current with predefined amplitude and frequency is produced via the signal generator 5 . 1 and is forwarded alternately over time to the transmitter electrode S 1 or the transmitter electrode S 2 via the amplifier 5 . 2 and the analog multiplexer 5 . 3 a. As a result of the illustrated structure with an analog multiplexer 5 . 3 a, an alternating current with predefined amplitude and frequency is transmitted selectively to the (first) transmitter electrode S 1 or to the (second) transmitter electrode S 2 , such that it is possible to evaluate, on the basis of signals received in succession from the evaluation circuit 5 . 5 , whether a change to the electric capacitance has occurred in the monitoring region B 1 of the first transmitter electrode Si or in the monitoring region B 3 of the second transmitter electrode S 2 , said change indicating the presence of an obstacle in the path of adjustment of the tailgate lid 1 . A number of sensor channels in the time multiplex are thus measured in order to determine in a spatially resolved manner those monitoring regions B 1 , B 3 (defined by a transmitter electrode S 1 , S 2 ) on the tailgate lid 1 in which the collision with an obstacle will occur if the adjusting movement of the tailgate lid 1 is not stopped and/or reversed. [0047] The actual evaluation is performed in each case in particular with the aid of the evaluation circuit 5 . 5 of the evaluation unit 5 *, as also in the case of the evaluation unit 5 . Here, a capacitance signal or a number of capacitance signals, which are each representative of a transmitter electrode S 1 , S 2 , is/are obtained via the evaluation circuit 5 . 5 from a received voltage signal, and the respective capacitance signal is converted into a digital signal, in order to thus control the stopping and/or reversal of the adjusting movement of the tailgate lid 1 . Here, the evaluation unit 5 , 5 * is part of a control apparatus accommodated in the motor vehicle K. [0048] The anti-trap system with an evaluation unit 5 * according to the prior art does not provide for a monitoring at the lower, transversely running closing edge 12 comprising the lock 4 . Rather, an unmonitored region B s is provided, in which the presence of an obstacle cannot be detected by the anti-trap system. Thus, the detection of a situation of entrapment focused previously on the longitudinally running lateral closing edges 11 , 13 ; this is particularly the case since, on account of metal materials in the lock region of the lock 4 and counterpiece thereof on the motor vehicle K, a reliable detection of a situation of entrapment is not readily possible. [0049] However, irrespectively of a situation of entrapment, there is a risk of injury by the lock 4 protruding at the lower closing edge 12 of the tailgate lid 1 , since the lock 4 can easily collide with a person, for example the head of said person, as the tailgate lid 1 closes. The present invention is applicable precisely in this case and combines a capacitive anti-trap system with protection against collision for a locking part, here in the form of the lock 4 , which is arranged on a vehicle closing element such as the tailgate lid 1 . [0050] In the case of the variant of FIG. 1 , an additional electrode pair comprising a transmitter electrode S 3 and a receiver electrode E 3 is provided for this purpose in the region of the lock 4 . The transmitter electrode S 3 and the receiver electrode E 3 here are accommodated for example in a housing or a cover of the lock 4 , in particular embedded in a plastic material of the housing or of the cover. An obstacle in a monitoring region B 3 around the lock 4 is detected via the electrode pair S 3 , E 3 , likewise capacitively. Here, the transmitter electrode S 3 also produces an electric field in a monitoring region B 3 , such that a possible obstacle, for example a person, causes a capacitance change that can be measured at the receiver electrode E 3 . [0051] Since the control apparatus or the evaluation unit 5 of the capacitive anti-trap system is in any case designed and intended to determine any capacitance changes on the basis of voltage signals received by the receiver electrodes E 1 , E 1 A, E 1 B and E 2 , the evaluation unit 5 can also be used readily to evaluate a voltage signal of the receiver electrode E 3 for the lock region. Accordingly, an imminent collision of the lock 4 with an obstacle can be determined via the electronic evaluation unit 5 as the tailgate lid 1 closes, and the motor-driven drive units 2 . 1 , 2 . 2 are prompted to stop and/or reverse the adjusting movement of the tailgate lid 1 in order to avoid the collision. [0052] For the coupling of the additional electrode pair S 3 , E 3 , separate inputs and outputs can be provided on the evaluation unit 5 . However, it is alternatively also possible to connect in parallel the transmitter electrode S 3 to one of the other transmitter electrodes S 1 , S 2 , such that these are activated simultaneously with electric alternating current. These possibilities are illustrated by dashed lines in the illustration of FIG. 1 . [0053] In the variant of FIG. 2A , no additional transmitter and receiver electrodes S 3 , E 3 are provided in order to provide protection against collision, but transmitter and receiver electrodes S 1 , S 2 , E 1 , E 2 already provided for the detection of a situation of entrapment are used. Here, the transmitter and receiver electrodes S 1 , S 2 , E 1 and E 2 , which extend along one of the longitudinal-side closing edges 11 , 13 , are each longer compared with the variant of FIG. 1 , such that they also extend along the lower, transversely running closing edge 12 of the tailgate lid 1 . Here, each electrode pair S 1 , E 1 and S 2 , E 2 runs approximately as far as the middle of the lower closing edge 12 up to a portion on the lower closing edge 12 on which the lock 4 is arranged. [0054] Due to the extension of the electrodes S 1 , S 2 , E 1 , E 2 into the lock region on the lower closing edge 12 , a monitoring region B 1 ′ or B 2 ′ also covers the region around the lock 4 with activation of the respective transmitter electrode S 1 , S 2 , such that an obstacle in the vicinity of the lock 4 can be determined on the basis of a capacitance change. Here, the two electrode pairs S 1 , E 1 and S 2 , E 2 can also be arranged relative to one another such that the respective monitoring regions B 1 ′ and B 2 ′ covered thereby overlap in the region of the lock 4 , such that a lock monitoring region B 12 ′ defined by the two electrode pairs S 1 , E 1 and S 2 , E 2 is created. This lock monitoring region B 12 ′ can also be provided by an intelligent interconnection of the two electrodes pairs S 1 , E 1 and S 2 , E 2 , as will be explained hereinafter in greater detail in conjunction with FIG. 3 . [0055] FIG. 2B shows a further possible development of the variant of FIG. 2A . Here, a portion on the lower closing edge 12 , along which the transmitter electrode S 1 and the receiver electrode E 1 extend, is provided in part with a shielding. Due to this shielding, a shielded region B 0 , in which no obstacle detection is possible, is produced along the extension of the two electrodes S 1 , E 1 of an electrode pair. [0056] In the present case, the shielding at the lower closing edge 12 divides a monitoring region covered by the receiver electrodes E 1 , E 1 A and E 1 B and the transmitter electrode S 1 into two monitoring sub-regions B 1 a ″ and B 1 b ″. Here, the shielding at the lower closing edge 12 , the transmitter electrode S 1 , and the receiver electrode E 1 are dimensioned and arranged such that the monitoring sub-region B 1 b ″ still covers the lock region around the lock 4 . Here, in the case of the variant of FIG. 2B , merely one of the electrode pairs, specifically the electrode pair S 1 , E 1 , is extended into the lock region in order to thus additionally provide capacitively functioning protection against collision. Accordingly, merely one electrode pair is formed here such that an obstacle in the monitoring sub-region B 1 b ″ around the lock 4 thus also can be detected in order to counteract a collision of the lock 4 with a person. [0057] Thus, a capacitive monitoring of a lock region around the lock 4 is provided with the aid of an electrode pair S 1 , E 1 (possibly together with a further electrode pair S 2 , E 2 , as explained hereinafter) by extending the electrodes S 1 , E 1 of this electrode pair into the lock region at the lower closing edge 12 , even though a shielding is provided in a (large) part of the lower closing edge 12 . By way of example, such a shielding may be advised if interfering influences would otherwise increase excessively in the region of the lower closing edge 12 , for example by the vehicle structure F or components provided thereon. [0058] Alternatively or additionally, the partly shielded electrode pair S 1 , E 1 can be combined with an adjacent electrode pair S 2 , E 2 according to FIG. 1 , likewise extended into the lock region. Connection to the other adjacent electrode pair S 2 , E 2 for collision detection around the lock 4 is thus possible. [0059] A possible structure of the evaluation unit 5 in order to provide collision monitoring in the lock monitoring region B 12 ′ on account of intelligent connection of two electrode pairs S 1 , E 1 and S 2 , E 2 is shown with FIG. 3 . This may be advantageous for example in order to avoid an increased basic capacitance and in order to make the system less susceptible to any interference. [0060] Here, in contrast to an evaluation unit 5 * known from the prior art in accordance with FIG. 4 , a second analog multiplexer 5 . 3 b is provided on the receiver side in a variant formed in accordance with the invention in order to not only activate in the time multiplex, but also evaluate the electrode pairs S 1 , E 1 and S 2 , E 2 . The evaluation unit 5 is thus able to connect through the individual receiver electrodes E 1 and E 2 in the time multiplex. By way of example, the first transmitter electrode S 1 can thus be activated, and the voltage signal produced hereby at the associated first receiver electrode E 1 and then the voltage signal produced at the other second receiver electrode E 2 can then be evaluated in succession by connection through the analog multiplexer 5 . 3 b between the two receiver electrodes E 1 and E 2 . With the aid of the transmitter-side analog multiplexer 5 . 3 a, the second transmitter electrode S 2 is then activated, and the voltage signal received by the associated second receiver electrode E 2 is evaluated. With the aid of the receiver-side analog multiplexer 5 . 3 b, the voltage signal at the first receiver electrode E 1 can then be evaluated with further maintained activation of the second transmitter electrode S 2 . Due to the resultant cross-connection of the two electrode pairs S 1 , E 1 and S 2 , E 2 preferably structured substantially symmetrically to one another, a region around the lock 4 is also monitored capacitively for the presence of an obstacle. The resultant lock monitoring region B 12 ′ consequently covers not only the lock 4 , but also a region around the lock 4 , such that a possible obstacle in the vicinity of the lock 4 can be determined on the basis of the voltage signals of the receiver electrodes E 1 , E 2 . [0061] Although the two electrode pairs S 1 , E 1 and S 2 , E 2 here are not guided as far as the lock 4 , but the lock 4 lies between the ends of the respective electrodes S 1 , E 1 , S 2 , E 2 , an additional monitoring of the lock region can be provided by the shown connection of the electrode pairs S 1 , E 1 and S 2 , E 2 arranged on different sides of the lock 4 . Indeed, it would also be possible in principle to evaluate successively the receiver electrode E 1 on the first (left) side with respect to the lock 4 and then the other receiver electrode E 2 on the other (right) side of the lock 4 merely with activation of the individual first transmitter electrode S 1 in order to also be able to determine contactlessly an imminent collision of the lock 4 with an obstacle, in particular a person, in addition to a situation of entrapment. However, due to the crosswise connection with chronologically successive activation of both transmitter electrodes and evaluation of both receiver electrodes beyond the lock 4 , it is possible to determine more reliably the presence of an obstacle in the lock region. [0062] Although each of the figures illustrates a tailgate lid 1 , the present invention can also be used of course with other vehicle closing elements, such as a luggage compartment lid.
The invention relates to a method for controlling an adjusting movement of a vehicle closing element of a vehicle to be closed in a manner actuated by an external force, such as a tailgate lid, wherein an obstacle in the path of adjustment of the vehicle closing element can be detected by means of a capacitive anti-trap system in order to prevent this obstacle from being trapped, and the vehicle closing element has a locking part, via which the vehicle closing element can be locked in a closed position. An obstacle in a monitoring region around the locking part provided on the vehicle closing element can also be detected via the capacitive anti-trap system in order to prevent a collision of this locking part with an obstacle at least as the vehicle closing element closes.
4
FIELD OF THE INVENTION The present invention relates to a breathable mesh panel enclosure, used as a crib bumper which allows air to circulate through the crib compartment and prevents a baby from hitting their head or appendages on the vertical balusters on a crib or from getting their head or appendages stuck between the crib's balusters. The breathable mesh panel enclosure helps to prevent Sudden Infant Death Syndrome (SIDS) by preventing the re-breathing of exhaled carbon dioxide and in other embodiments it is used as an insect and animal barrier. BACKGROUND OF THE INVENTION Since the introduction of crib, many different types of prior art cribs have been developed in the past to contain and protect infants, babies and small children. Most of these devices are produced using balusters held in place using top and bottom horizontal rails on either side of the crib or on all four sides of the crib, allowing airflow through the crib. Usually one side of the crib is adjustable, allowing easy access into the crib compartment. Another crib innovation allows the mattress to be raised or lowered inside of the crib compartment using an adjustable mattress platform. Since the introduction of the crib, infants, babies and small children have become lodged between the balusters, resulting in injury or death. Cribs are now manufactured with smaller spacing between the balusters. The padded crib bumper was invented to prevent infants, babies and small children from becoming lodged between the balusters or from becoming injured when impacting the balusters. The down side to the padded crib bumper, is that it prevents the circulation of air within the crib compartment and allows a baby to re-breath exhaled carbon dioxide which may cause Sudden Infant Death Syndrome (SIDS). The following prior art references, which the inventor is aware of, are distinctly different than the present invention described in this patent application. Many types of cribs and crib innovations have been patented in the past. Some prior art crib designs using balusters in the wall construction include; U.S. Pat. No. 1,432,190 issued on Oct. 17, 1922 to Krueger, titled “CRIB”, U.S. Pat. No. 2,357,218 issued on Aug. 29, 1944 to Merrett, titled “CRIB CONSTRUCTION”, U.S. Pat. No. 2,635,257 issued on Apr. 21, 1953 to Kroll, titled “BABY CRIB”, U.S. Pat. No. 3,879,773 issued on Apr. 29, 1975 to Spencer, titled “CRIB”, U.S. Pat. No. 3,979,783 issued on Sep. 14, 1976 to Spencer, titled “CRIB OR YOUTHBED” and U.S. Pat. No. 6,611,976 issued on Sep. 2, 2003 to Guillot, titled “CHILD'S CRIB”. There have also been attempts to produce cribs without balusters to keep a baby from hitting their head and appendages on the crib's balusters and for keeping the head and appendages from getting stuck between the balusters. U.S. Pat. No. 4,359,792 issued on Nov. 23, 1982 to Dale, titled “CRIB” describes a crib replacing the crib's balusters with mesh panels on the left and right wall sections and on the head and foot wall sections. U.S. Pat. No. 6,256,813 issued on Jul. 10, 2001 to Aaron, titled “CRIB” describes a crib using a mesh sleeping surface and replaces the crib's balusters with mesh panels on the left and right wall sections and on the head and foot wall sections. These improvements to the crib's design have merit, but a majority of the cribs presently used and manufactured throughout the world today still use the standard vertical spindle or rail design. Many types of crib bumpers for preventing a baby from hitting their head or appendages on the balusters on a crib and for keeping the head and appendages from getting stuck between the crib's spaced balusters have been patented in the past. Although there have been a multitude of patents issued on the crib bumper throughout the years, the basic design is still the same. Some of the more important prior art crib bumper patents and innovations are briefly described hereafter. U.S. Pat. No. 3,018,492 issued on Jan. 30, 1962 to Rosen, titled “PROTECTIVE BUMPER DEVICE” describes an inflatable crib bumper manufactured out of a resilient, flexible, air tight material of rubber, latex or plastic. The inflatable crib bumper is releasably secured on all four corners of the crib and at the top and bottom sections, on both ends of the four wall sections, to the balusters. Unlike the present invention, the inflatable crib bumper does not allow air to circulate through it, the inflatable crib bumper does not protect the baby from impacting the balusters above the bumper, the baby can become lodged between the bumper and the mattress or between the bumper and the balusters and the inflatable crib bumper can be punctured by a sharp object, making the bumper inoperable from protecting a baby from impacting the balusters through the deflated bumper. U.S. Pat. No. 3,619,824 issued on Nov. 16, 1971 to Doyle, titled “CRIB BUMPER” describes a crib bumper manufactured out of a cushioning material of flexible resilient compressible foam rubber or down. The covering of the bumper is preferably an un-breathable waterproof fabric or plastic. A waterproof fabric or plastic extension is on the bottom of the bumper, for securing the bumper underneath or against the mattress. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the bumper and the mattress or between the bumper and the balusters. U.S. Pat. No. 3,877,090 issued on Apr. 15, 1975 to Schultz, titled “CRIB BUMPER AND MATTRESS” describes a crib bumper manufactured out of a cushioning material of flexible resilient compressible foam rubber or down and attached to a crib's balusters using a tying or snapping tab method. The crib bumper also has a means of attaching elastic tabs with male and female interlocking snaps from the bottom of the bumper to the mattress support or to a mattress manufactured with bumper attaching mating means on the sides or bottom of the mattress. The covering of the bumper is preferably an un-breathable waterproof fabric or plastic. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the bumper and the mattress or between the bumper and the balusters. U.S. Pat. No. 4,670,923 issued on Jun. 9, 1987 to Gabriel et al., titled “TRANSPARENT CRIB BUMPER PADS” describes an inflatable crib bumper manufactured out of a transparent waterproof plastic material. The inflatable crib bumper is releasably secured on all four corners of the crib and at the top and bottom sections, on both ends of the four wall sections, to the balusters. All four bumper sections are connected for inflation. An alternative embodiment of the invention connects all four bumper sections to an inflatable mattress bottom section. Unlike the present invention, the inflatable crib bumper does not allow air to circulate through it, the baby can become lodged between the bumper and the mattress or between the bumper and the balusters and the inflatable crib bumper can be punctured by a sharp object, making the bumper or bumper and mattress inoperable from protecting a baby from impacting the balusters through the deflated bumper. U.S. Pat. No. 4,890,346 issued on Jan. 2, 1990 to Rist, titled “INFANT CRIB ENCLOSURE” describes a fabric crib bumper filled with a resilient compressible material and attached to a crib's balusters using tie strings and each bumper panel is attached to a mattress sheet using hook and loop Velcro™ fasteners. The crib bumper also has a means of subdividing the compartment into two separate compartments for a newborn or for twins using a fifth bumper panel. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,010,611 issued on Sep. 7, 1983 to Pope, titled “BUMPER PAD FOR INFANT CRIB” describes a soft fabric material crib bumper filled with padding attached to a crib's balusters and four corner posts using flaps secured closed using Velcro™ or snaps. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,161,269 issued on Nov. 10, 1992 to McLean et al., titled “CRIB COVER” describes a form fitted soft, flexible material crib bumper attached to a crib's balusters using tie strings or straps. The form fitted crib bumper fits between the mattress and the balusters and has a notch for receiving the mattress. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,241,718 issued on Sep. 7, 1993 to Pope, titled “BUMPER PAD FOR INFANT CRIB” describes a hollow one piece crib bumper manufactured out of a soft fabric for receiving padding at an open end which is releasably secured closed forming a closed loop. The bumper is attached to a crib's balusters and four corner posts using flaps on the outside surface with snaps or a hook and loop securing method. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the bumper and the mattress or between the bumper and the balusters. U.S. Pat. No. 5,410,765 issued on May 2, 1995 to Dicken, titled “CRIB BUMPER PAD” describes a hollow crib bumper cover made out of a washable soft cloth material for receiving cushioning padding material and a stiffener at an open end which is secured closed using Velcro™ or a zipper, etc. The bumper is attached to a crib's balusters and four corner posts using tie strings on the bumper's outside surface. The lower portion of the bumper fits tightly between the bottom section of a crib's balusters and the side of the mattress. The bumper pad con be used on the left and right sides of the crib or it can surround all four sides of a crib. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,421,046 issued on Jan. 6, 1995 to Vande Streek, titled “BED BUMPER PAD” describes individual inflatable crib bumper panels manufactured out of a flexible and transparent material. Each inflatable crib bumper panel has an independent means of inflation. Each inflatable crib bumper is secured using one horizontal centrally located long strap with Velcro™ securing ends attached to the outside of the bumper for wrapping around the crib posts and the balusters. Unlike the present invention, the inflatable crib bumper does not allow air to circulate through it, the baby can become lodged between the bumper and the mattress or between the bumper and the balusters and the inflatable crib bumper can be punctured by a sharp object, making the bumper or bumper and mattress inoperable from protecting a baby from impacting the balusters through the deflated bumper. U.S. Pat. No. 5,437,071 issued on Aug. 1, 1995 to Feigenbaum, titled “INDIVIDUAL PROTECTIVE PADS FOR CRIB BALUSTERS” describes a baluster crib pad secured onto the crib baluster using a Velcro™ securing means. Unlike the present invention, the baluster crib pad does not allow total air circulation, the crib bumper does not protect the baby from impacting the four corner posts and the baby can still become lodged between the balusters. U.S. Pat. No. D365,957 issued on Jan. 9, 1996 to Ferrari, titled “CRIB BUMPER PAD” shows a fabric side rail barrier secured over the top of a crib's horizontal rail using snaps and tie strings. The barrier fits between the mattress and the balusters. Unlike the present invention, the crib barrier does not allow air to circulate through it unless it is manufactured out of a mesh fabric and the crib barrier does not protect the baby from impacting the balusters. U.S. Pat. No. 5,577,276 issued on Nov. 26, 1996 to Nicholson et al., titled “CRIB BUMPER PAD WITH RELEASABLE SHEET” describes a one piece box shaped crib bumper with four side walls and a bottom section made out of a padded material using a hook Velcro™ securing means on the inside upper walls for receiving a custom fit open corner box sheet using a loop Velcro™ securing means on the outside upper surface of the conformable box sheet. The bumper is attached to a crib's balusters using centrally located tie strings on the one piece box shaped crib bumper's outside surface. Unlike the present invention, the one piece box shaped crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,561,876 issued on Oct. 8, 1996 to Petruzella, titled “INFANT MATTRESS” describes a mattress like structure used as a partial crib bumper. The rectangular shaped mattress uses four straight sections interconnected to four corner sections inserted into a mesh sleeve with a zippered closure means. Unlike the present invention, the crib bumper does not protect the baby from impacting the balusters above the top of the mattress and the baby can still become lodged between the top of the mattress and the balusters. U.S. Pat. No. 5,706,534 issued on Jan. 13, 1998 to Sherman, titled “PROTECTIVE BUMPER PAD” describes a one piece flexible fabric material crib bumper filled with flexible foam or foam rubber, which is secured to the crib's balusters using tie strings, located on the bumper's outside fabric surface. The lower section of the flexible fabric crib bumper is positioned underneath the mattress. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,806,112 issued on Sep. 15, 1998 to Harms, titled “BABY CRIB LINER” describes a one piece crib bumper attached to a flexible base member, located beneath a mattress, which is secured to the crib's balusters using tie strings, located on the bumper's outside fabric surface. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,881,408 issued on Mar. 16, 1999 to Bashista, et al., titled “MESH CRIB LINER” describes a crib liner made of netting placed on the inside of the crib's balusters extending beneath the mattress and extending over the top of the top horizontal rail. The sides of the crib liner are secured to the top of crib's side balusters using Velcro™ fasteners. The head and foot section of the crib liner are attached to the top of the crib using rods inside sleeves, with four ties for attaching the rods to the four corners of the crib. The lower portion of the crib liner uses four ties to secure the crib liner to the crib. Unlike the present invention, the crib bumper does not protect the baby from impacting the balusters. U.S. Pat. No. 5,926,873 issued on Jul. 27, 1999 to Fountain, titled “CRIB RAILING GUARD” describes a resilient cushion or inflatable one piece crib bumper “crib railing guard”, which is secured to the crib's balusters using fasteners, located on the bumper's outside surface. The lower section of the crib bumper is placed between the crib's balusters and the mattress or continues underneath the mattress. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,933,885 issued on Aug. 10, 1999 to Glassford, titled “BABY CRIB BUMPER” describes a one piece flexible fabric material crib bumper filled with flexible foam or foam rubber, which is secured to the crib's balusters using tie strings or Velcro™ fasteners, located on the bumper's outside fabric surface. The removable lower section of the flexible fabric crib bumper is a mesh material and is positioned underneath the mattress. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,937,458 issued on Aug. 17, 1999 to DeRosa, titled “CRIB BUMPER SAFETY SYSTEM” describes a one piece crib bumper which is secured to the crib's balusters using tie strings or Velcro™ fasteners, located on the bumper's outside surface. The bottom panel of the crib bumper fits between the mattress and the balusters. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 5,960,493 issued on Oct. 5, 1999 to Rhey et al., titled “SAFETY BUMPER PAD” describes a one piece crib bumper with a mattress retaining sheet which is secured to the crib's balusters using locking straps, located on the bumper's outside surface. The mattress retaining sheet of the crib bumper fits between the mattress and the balusters and under the mattress. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 6,055,690 issued on May 2, 2000 to Koenig, titled “SLEEPING PAD, BEDDINGS AND BUMPERS TO IMPROVE RESPIRATORY EFFICIENCY AND ENVIRONMENTAL TEMPERATURE OF AN INFANT AND REDUCE THE RISKS OF SUDDEN INFANT DEATH SYNDROME (SIDS) AND ASPHYXIATION” describes individual baluster pads, ventilated bedding and a rectangular ventilated crib bumper which is secured to the crib's corner posts using Velcro™. Unlike the present invention, the patent does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 6,131,216 issued on Oct. 17, 2000 to Pine, titled “METHOD AND APPARATUS FOR REMOVING HEAVY GASES FROM INFANT CRIBS” describes multiple partially ventilated crib bumpers using gravity or a fan to remove heavy gases from the bottom of a crib's bumper compartment. Unlike the present invention, the crib bumper does not allow air to circulate through the entire bumper and only through a small portion of it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 6,170,101 issued on Jan. 9, 2001 to McCloud, titled “SEE THROUGH PROTECTIVE CRIB COVER CONSTRUCTION” describes a crib bumper with netting recessed in geometric viewing portals. The crib bumper is attached to the crib's balusters using straps and a Velcro™ securing means. Unlike the present invention, the crib bumper does not allow air to circulate through the entire bumper and only through a small portion of it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 6,178,573 issued on Jan. 30, 2001 to Wagner et al., titled “VENTILATED UPGRADE KIT FOR A CRIB BUMPER AND METHOD OF USING IT” describes a partially ventilated crib bumper which is secured to the crib's balusters using tie strings, located on the bumper's outside fabric surface. Unlike the present invention, the crib bumper does not allow air to circulate through the entire bumper and only through a small portion of it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. D444,329 issued on Jul. 3, 2001 to Newman, titled “PROTECTIVE NET FOR INFANTS COT” shows a crib liner made of netting placed on the inside of the crib's side rail sections secured over the top of the top rail using a continuous top rail hook and extending down to the bottom rail. The two sides of the crib liner are secured to the outermost balusters using Velcro™ fasteners. Unlike the present invention, the crib bumper does not protect the baby from impacting the balusters or the corner posts. U.S. Pat. No. 6,421,857 issued on Jul. 23, 2002 to Whatman et al., titled “LINER FOR AN INFANT BED” describes a rectangular crib liner made of a mesh material located on the inside of the crib and secured over the top of the top rails using hooks or a Velcro™ securing means. Unlike the present invention, the crib bumper does not protect the baby from impacting the balusters or the corner posts. U.S. Pat. No. 6,438,775 issued on Aug. 27, 2002 to Koenig, titled “SLEEPING PAD, BEDDING AND BUMPERS TO IMPROVE RESPIRATORY EFFICIENCY AND ENVIRONMENTAL TEMPERATURE OF AN INFANT AND REDUCE THE RISKS OF SUDDEN INFANT DEATH SYNDROME (SIDS) AND ASPHYXIATION” describes individual baluster pads, ventilated bedding and a rectangular ventilated crib bumper which is secured to the crib's corner posts using Velcro™. Unlike the present invention, the patent does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 6,564,403 issued on May 20, 2003 to Titus, titled “BABY BUMPER PAD” describes a one piece crib bumper which is secured to the crib's balusters using tie strings, located on the bumper's outside surface. A bottom panel is zipper attached to the crib bumper and fits between the mattress and the balusters. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 6,772,457 issued on Aug. 10, 2004 to Alaback, titled “BABY CRIB PAD” describes multiple crib pad segments which are secured together on the outside of the crib using Velcro™. Each crib pad segment has multiple padded flaps for securing around each baluster using a Velcro™ securing means. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 6,684,437 issued on Feb. 3, 2004 to Koenig, titled “SLEEPING PAD, BEDDING AND BUMPERS TO IMPROVE RESPIRATORY EFFICIENCY AND ENVIRONMENTAL TEMPERATURE OF AN INFANT AND REDUCE THE RISKS OF SUDDEN INFANT DEATH SYNDROME (SIDS) AND ASPHYXIATION” describes individual baluster pads, ventilated bedding and a rectangular ventilated crib bumper which is secured to the crib's corner posts using Velcro™. Unlike the present invention, the patent does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 6,957,464 issued on Oct. 25, 2005 to Coauette, titled “CRIB BUMPER” describes a one piece box shaped bumper which is secured to the crib's balusters using tie strings, located on the bumper's outside surface. Open pockets on the outside of the bumper receive L-shaped inserts which are positioned between the balusters and underneath the mattress. Unlike the present invention, the crib bumper does not allow air to circulate through it, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. U.S. Pat. No. 7,003,823 issued on Feb. 28, 2006 to Reed et al., titled “CRIB SAFETY NET” describes a rectangular box crib liner made of a mesh material located on the inside of the crib and secured over the top of the top rails using hooks or a Velcro™ securing means. The mattress is placed over the bottom of the rectangular box crib liner. Unlike the present invention, the crib bumper does not protect the baby from impacting the balusters or the corner posts. U.S. Pat. No. 7,055,192 issued on Jun. 6, 2006 to Waters et al., titled “CRIB SHIELD SYSTEM AND OTHER BREATHABLE APPARATUS” describes crib shield panels made of a mesh material located on the inside of a crib and secured onto itself, onto the corner posts, onto the balusters or onto the horizontal rails using a Velcro™ securing means. Unlike the present invention, the crib bumper does not protect the baby from impacting the balusters or the corner posts. U.S. Pat. No. 7,213,282 issued on May 8, 2007 to Wojtowicz, titled “CRIB ACCESSORY AND ASSEMBLY” describes a rectangular crib bumper with a bottom section which is secured to the crib's corner posts and balusters using a Velcro™ securing means, located on the bumper's outside surface. Unlike the present invention, the crib bumper does not allow air to circulate through the bumper, the crib bumper does not protect the baby from impacting the balusters above the bumper and the baby can still become lodged between the top of the bumper and the balusters. All of the previously described prior art patents do not allow air to circulate through the crib bumper, or do not protect the baby from impacting the balusters above the crib bumper, or the baby can become lodged between the crib bumper and the mattress or between the top of the crib bumper and the balusters, or the baby can use the crib bumper as a step for crawling out of the crib and falling onto the floor. Many other types of patents and innovations for enhancing the health and well being of a baby have been invented and patented in the past. Some of the more important prior art patents and innovations, in which the present invention improves upon, are briefly described hereafter. U.S. Pat. No. 4,359,792 issued on Nov. 23, 1982 to Dale, titled “CRIB” describes a crib which replaces balusters in the head, foot and sides sections with mesh panels. The crib also has a pivoting canopy section which opens and closes the top of the crib. Unlike the present invention, the crib does not protect the baby from impacting the four corner posts. U.S. Pat. No. 5,161,269 issued on Nov. 10, 1992 to McLean et al., titled “CRIB COVER” describes screen or mesh crib cover for preventing animals from entering a crib. The cover is secured to the top of the crib using Velcro™. Unlike the present invention, the crib cover does not protect the baby from impacting the balusters and corner posts, and the baby can still become lodged between the balusters. U.S. Pat. No. 5,555,577 issued on Sep. 17, 1996 to Volpe, titled “CRIB ADAPTER” describes an air permeable sleeping surface suspended from the top of a crib's rails. The sleeping surface is secured to the top of the side rails using hooks. Unlike the present invention, the crib cover does not protect the baby from impacting the balusters and corner posts, and the baby can still become lodged between the balusters. U.S. Pat. No. 5,699,571 issued on Dec. 23, 1997 to Yowell, titled “INFANT BEDDING APPARATUS” describes a mesh sleeping surface suspended in a crib above a mattress using a rectangular frame spacer or below a crib's top head and foot rails using long hooks. Unlike the present invention, the crib cover does not protect the baby from impacting the balusters and corner posts, and the baby can still become lodged between the balusters. U.S. Pat. No. 6,256,813 issued on Jul. 10, 2001 to Aaron, titled “CRIB” describes a crib which replaces balusters in the head, foot and sides sections with mesh panels. Unlike the present invention, the crib does not protect the baby from impacting the four corner posts or the horizontal support rails behind the mesh panels. Many other types of patents and innovations for protecting a baby from insects using mesh containment have been invented and patented in the past. U.S. Pat. No. 1,264,734 issued on Apr. 30, 1918 to Williams, titled “INSECT SCREENS FOR CRIBS OR BEDS” describes screening mounted in wooden rectangular frames and positioned inside of a crib using brackets fastened to the corner posts. The top of the crib is covered with a two section screen panel hinged centrally to allow lifting a left or right section independently. Unlike the present invention, the screens mounted in wooden rectangular frames do not protect the baby from impacting the balusters and corner posts or the screen frames themselves. U.S. Pat. No. 2,927,331 issued on Mar. 8, 1960 to Ruiz, titled “INSECT NETTING FOR CRIBS AND THE LIKE” describes a six sided boxed netting enclosure suspended in a crib enclosure for receiving a mattress and a baby. The six sided boxed netting enclosure is secured to the top of the crib's four vertical corner posts using adjustable loops located on all four top corners. Zippered access to the six sided boxed netting enclosure is located on the front vertical section. The bottom section of the six sided boxed netting enclosure is a non-mesh fabric. Unlike the present invention, the six sided boxed netting enclosure does not protect the baby from impacting the balusters and corner posts. U.S. Pat. No. 4,862,534 issued on Sep. 5, 1989 to Gomez-Marcial, titled “INSECT NETTING FOR A CRIB AND THE LIKE” describes a open bottom five sided boxed netting enclosure suspended in a crib enclosure. The open bottom five sided boxed netting enclosure is secured to the top of the crib's four vertical corner posts using adjustable loops and/or ties located on all four top corners. Zippered access to the open bottom five sided boxed netting enclosure is located on the top section. The bottom section of the open bottom five sided boxed netting enclosure use elasticized corners for an adjustable “fitted” fit. Unlike the present invention, the open bottom five sided boxed netting enclosure does not protect the baby from impacting the balusters and corner posts and small insects may still enter through the bottom fitted section. U.S. Pat. No. 6,263,894 issued on Jul. 24, 2001 to LaMantia, titled “INSECT NETTING ASSEMBLY” describes a four sided netting enclosure fitted over the outside of a crib enclosure. The top of the four sided netting enclosure is stretchable band which reduces the openings diameter. Two connected and curved dowels support a tented netting dome shaped hood that fit around and over the top of the four sided netting enclosure. Unlike the present invention, the four sided netting enclosure does not protect the baby from impacting the balusters and corner posts and small insects may still enter through the bottom section. U.S. Pat. No. 6,550,083 issued on Apr. 22, 2003 to LaMantia, titled “CRIB AND PLAYPEN PROTECTIVE COVERING” describes a five sided boxed netting enclosure connected to a tented netting dome shaped hood, supported with two connected and curved dowels, for receiving a mattress and a baby. The five sided boxed netting enclosure is secured to the top of the crib's side rails using Velcro™ straps and secured around the head and foot section of the crib using long Velcro™ straps. Zippered access to the tented netting dome shaped hood is located on the front section. Unlike the present invention, the six sided boxed netting enclosure does not protect the baby from impacting the balusters and corner posts. U.S. Pat. No. 6,859,958 issued on Mar. 1, 2005 to LaMantia, titled “CRIB AND PLAYPEN PROTECTIVE ENCLOSURE” describes a five sided boxed netting enclosure connected to a tented netting dome shaped hood, supported with two connected and curved dowels, for receiving a mattress and a baby. The five sided boxed netting enclosure is secured to the top of the crib's side rails using Velcro™ straps and secured around the head and foot section of the crib using long Velcro™ straps. Zippered access to the tented netting dome shaped hood is located on the front section. Unlike the present invention, the six sided boxed netting enclosure does not protect the baby from impacting the balusters and corner posts. Many solutions to improve existing prior art problems have been made, but many are not well suited for the standard crib design and for the needs of a baby inside a crib. An easier use breathable crib insert bumper is needed. Without adequate ventilation inside a crib, using a non-porous non-breathable baby bumper, a baby re-breathes expired gasses, namely carbon dioxide, built up inside the crib compartment chamber. Sudden Infant Death Syndrome (SIDS) may be caused by the re-breathing of expired carbon dioxide and inadequate air circulation inside a crib compartment. Sleeping infants with low level intakes of oxygen and an increased re-breathing of carbon dioxide produces an anesthetic effect on a sleeping baby and may cause increased apneas (absences of breathing). The earth's atmosphere is made up of 79% asphyxiant gases (mainly nitrogen), and around 21% oxygen, depending upon where you live. Carbon dioxide (CO2) is an asphyxiant gas and is about 1.5 times the density of air, which means it will settle in the lowest point it finds. Breathing carbon dioxide (CO2) concentrations in the air above 10% can be lethal. No one knows exactly how Sudden Infant Death Syndrome happens, but the re-breathing of exhaled carbon dioxide has an anesthetic effect, creating a decrease in heart rate, brain function and breathing. The technical term for excessive carbon dioxide in the blood is called hypercarbia, which may lead to asphyxia, where the normal breathing reflex stops. Asphyxia is a condition of severely deficient supply of oxygen to the body. As a baby sleeps, the heavier than air exhaled carbon dioxide sits on the bottom of the four walled sealed crib chamber, causing the continual re-breathing of exhaled carbon dioxide. A baby sleeping on their stomach, re-breathes a higher percentage of exhaled carbon dioxide than a baby sleeping on their back does. Hypoxia is the term to describe low oxygen levels in the blood. Hypercapnia is the term to describe high carbon dioxide (CO2) levels in the blood. Acidosis is the term to describe the buildup of lactic acid in the blood and tissues, a by-product of an anaerobic metabolism (without oxygen). Human extremities can be deprived of blood flow for more than 30 minutes without damage. Breathing is triggered by rising carbon dioxide levels in the blood rather than diminishing oxygen levels. The central nervous system, specifically those portions involved in consciousness, will not continue to function for more than a few seconds without oxygen. The disruption of cell metabolism in the tissues and the accumulation of toxic by-products result in patho-physiological consequences such as tissue necrosis, loss of consciousness and death. Carbon dioxide dissolved in blood forms carbonic acid, which acidifies the blood. Too much of it causes acidosis, which can kill. Asphyxia causes hypoxia, which primarily affects the tissues and organs most sensitive to hypoxia, the brain, resulting in cerebral hypoxia. Lack of oxygen, either partial [hypoxia] or total [anoxia], can cause death. Impairment of cognitive and motor function can manifest at oxygen concentrations of 10-15%. Loss of consciousness occurs at less than 10%. Death usually occurs at less than 8%. A person can lose consciousness in 40 seconds and die within a few minutes when ambient oxygen levels are as low as 4-6%. Periodic pauses in breathing is a normal occurrence and is called apnea, the absence of breathing. It has been proven that increased levels of ambient oxygen reduces the occurrences of apnea in infants. This was the reason why newborns were placed in oxygen tents after birth more than 50 years ago, but the side effects were poor eye development and sometimes blindness would occur. The American Academy of Pediatrics recommends that a baby be positioned on their back (supine position) when sleeping to reduce the possibility of Sudden Infant Death Syndrome (SIDS) occurring. It is recommended that you should not let a baby lie on their back to sleep when they are experiencing respiratory distress or have been just fed, in case of excessive regurgitation after feeding. It is also believed that excessive bedding and clothing produce hyperthermia, the overheating of a infant. Interesting cases related to carbon dioxide asphyxiation have occurred in the past. Around 11:30 p.m. on Aug. 15, 1984, a carbon dioxide eruption occurred from the bottom of Lake Monoun, in west Africa, killing 37 people living around Lake Monoun. At 9:30 p.m. on Aug. 12, 1986, a cloudy mixture of carbon dioxide and water droplets rose violently from the deep waters of the tropical crater Lake Nyos, in Cameroon, west Africa. The heavier than air carbon dioxide cloud was about 50 meters thick. It quickly enveloped houses within the crater that were 120 meters above the shoreline of the lake. The Lake Nyos lethal gas cloud of carbon dioxide was estimated to be filled with around 1,940,000 tons of carbon dioxide. Part of the carbon dioxide cloud escaped over a low spillway, cut in the northern rim of the maar crater, and flowed down the slopes into the valleys below at a rate of 20 to 50 km per hour, towards the villages of Nyos, Kam, Cha, and Subum. The deadly carbon dioxide cloud traveled more than 23 km, bringing sudden death to all life in the vicinity. 1,746 people, thousands of cattle, birds, animals and insects died of carbon dioxide induced asphyxiation. Children are often the first victims because they breathe air nearest the earth. It was estimated that a liter of water, in the lower part of the lake, contained between 1 to 5 liters of dissolved carbon dioxide (CO2). The US Federal Mine Safety and Health Act of 1977 established ventilation standards in which mines should be ventilated by a current of air containing not less than 19.5 volume per centum of oxygen and not more than 0.5 volume per centum of carbon dioxide (CO2). SUMMARY OF THE INVENTION The following descriptions of the preferred embodiments of the present invention are all manufactured using four connected breathable fabric mesh panels, preferably a nylon mesh screen material or secondly a polyester mesh screen material, to increase air circulation inside the crib compartment and to prevent the re-breathing of expired carbon dioxide gas. The crib dimensions used throughout the world vary, but most cribs in the United States accept the standard rectangular crib mattress size. The crib mattress is positioned on an immovable support spring, lattice support attached to the crib's lower horizontal rail section or on a vertically adjustable horizontal support member attached to the crib's lower horizontal rail section. The distance from the top of the mattress to the top rail of the crib varies, depending on the height of the side rails or on the position of the vertically adjustable horizontal support member attached to the crib's lower horizontal rail section. The present invention uses the same concept used in a boxing ring. A boxing ring uses padded rope sections suspended inside four vertical posts producing a square shaped ring for absorbing the impact of a body coming in contact with the boxing ring's ropes. The present invention uses four connected vertical panels made out of rectangular shaped breathable mesh fabric. The mesh fabric is preferably a nylon mesh screen material or some other material such as a polyester mesh. The four connected vertical panels are attached to and suspended from the inside of the crib's four vertical posts. The four connected vertical panels are attached from the top of and from the bottom of the vertical posts using adjustable straps or a fastening means. The four top and four bottom adjustable straps or fastening means are preferably sewn onto the outside edges and/or inside corners of the rectangular shaped breathable mesh fabric bumper sections. The four top and four bottom adjustable straps or fastening means are preferably held in place on the crib's four vertical posts using an adjustable hook and loop Velcro™ fastening means, buckle or other means of fastening and securing the mesh crib bumper tautly to the crib's four corner posts. The breathable mesh crib bumper, when attached and secured into place, provides a rigid but slightly flexible barrier, keeping a baby from coming in contact with the balusters and corner posts. If a baby were to fall against the vertical walls of the breathable mesh crib bumper, the impact would be absorbed by the taut flexible mesh walls and would act as a type of shock absorber or trampoline surface. Detaching the removably attached breathable mesh fabric crib bumper device from the crib frame support structure, allows the device to be washed when dirty. After removing the breathable mesh fabric crib bumper device from the crib, all closable seam means (buttons, zippers, buckles, snaps, hook and loop Velcro™ fasteners, etc.) should preferably be sealed closed before washing the device, preventing non-mating closure means and fasteners from becoming entangled with each other or from damaging the crib bumper's parts. Another embodiment of the present invention can be manufactured with a breathable mesh fabric base attached to the bottom of all four vertical mesh panels. The suspended breathable mesh fabric base can come in direct contact with the crib mattress or can be suspended above the crib mattress. The four sided mesh bumper with the mesh base can also be used in a crib without using a mattress, allowing the mesh base to be used as the sleeping surface. If a baby became positioned on their stomach while sleeping, the baby will be able to continue breathing through the mesh base while facing downward, preventing the possibility of Sudden Infant Death Syndrome (SIDS) or asphyxiation. Another embodiment of the present invention using the four sided mesh bumper with the mesh base, can also be manufactured with a breathable mesh fabric cover removably attached to the upper sections on all four vertical walls, preventing objects, animals or insects from entering the completely encapsulated breathable mesh fabric containment area. Other embodiments of the present invention, can be modified to attach inside cribs without four corner posts or inside rectangular support structures. Some cribs have head and foot panels which are solid panels and other cribs have back side panels which are solid panels. To attach the mesh crib bumper to a crib with a vertical solid panel section, two lengths of strapping to wrap around the outside of the vertical solid panel section are needed. When installing the mesh crib bumper, the installer places the two lengths of strapping on the outside of the vertical solid panel section and places the four ends, on the two lengths of strapping, through the four strap connecting buckles or fastening means and tightens the straps until the four vertical mesh panels are taut. To ensure the safety if the child while in the crib, all lengths of strapping longer than six inches should be cut to a length less than six inches. If the strap ends become frayed, cutting the frayed edges and then using a lighter or a match to melt the edges will prevent future fraying. Modifications of the present invention can also include using a mesh fabric wrapped around a horizontal and vertical support structure, preferably four breathable perforated foam panels, inflatable bladders, etc. and installing the mesh crib bumper inside a crib by securing four vertical mesh panels to the four vertical corner posts or vertical balusters. It is an object of the present invention to provide a mesh crib bumper insert enclosure which is breathable and that air circulates through the enclosure's mesh walls. It is another object of the present invention to provide a breathable crib bumper insert enclosure that prevents a baby from impacting their head or appendages against a crib's balusters or crib posts. It is still another object of the present invention to provide a breathable crib bumper insert enclosure that prevents a baby from sticking their head or appendages through a crib's balusters. It is yet another object of the present invention to provide a breathable mesh crib bumper enclosure that is installed into and removed out of the crib fast and easily, for crib maintenance and for the cleaning of the mesh crib bumper. It is a further object of the present invention to provide a breathable mesh crib bumper enclosure that spaces the vertical mesh panels at least an inch or two away from the cribs vertical posts and balusters. It is yet a further object of the present invention to provide a breathable mesh crib bumper enclosure also including a lower horizontal surface base for laying a baby onto or for positioning the mesh fabric base on top of a mattress. Finally, it is a another object of the present invention to provide a breathable mesh crib bumper sealed enclosure including four walls, a lower horizontal surface and a re-sealable top horizontal cover for keeping insects and animals out of the crib's breathable enclosure. The present invention and many preferred embodiments of the present invention all use a taut breathable mesh fabric enclosure secured to four posts and horizontal rails for preventing an object from getting in or out of the enclosure, or from an object within the enclosure coming in contact with another object located outside the enclosure. These and other objects, features and advantages of the present invention are provided within this patent application and will be better understood in connection with the following drawings and descriptions of the preferred embodiments. Additional objects of the present invention will become apparent as the description proceeds. It is to be understood that the present invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The present invention is capable of other embodiments and of being practiced and carried out in various ways. It should be also understood that the phraseology and terminology used in this patent application are for the purpose of describing and claiming the present invention and should not be regarded as limiting. DESCRIPTION OF THE DRAWINGS For a better understanding of the invention as well as other objects, features and advantages thereof, reference is made to the following detailed description to be read in conjunction with the accompanying drawings, wherein: FIG. 1 shows a perspective view of the present invention, depicting a standard crib without a mattress support, a crib mattress and a mesh crib bumper showing only the front panel with horizontal fastening straps, and tie string fasteners for securing the mesh crib bumper to the bottom crib rail. FIG. 2 shows a perspective view of the present invention, depicting a standard crib without a mattress support, a crib mattress and a mesh crib bumper showing only the front panel with horizontal fastening straps, and tie string fasteners for securing the mesh crib bumper to the bottom crib rail, and one corner having a pocket for receiving a vertical support member. FIG. 3 shows a perspective view of the present invention, depicting a standard crib without a mattress support, a crib mattress and a mesh crib bumper showing only the front panel with horizontal and vertical connecting straps. FIG. 4 shows a cross sectional view of the present invention, depicting a mesh crib bumper, with horizontal straps sewn onto the top and bottom edges, installed inside a crib on top of a crib mattress. FIG. 5 shows a perspective view of another embodiment of the present invention, depicting a standard crib without a mattress support, a crib mattress and a mesh crib bumper showing only the front panel with horizontal and vertical connecting straps. FIG. 6 shows a cross sectional view of the present invention, depicting a mesh crib bumper, with horizontal straps sewn onto the top and bottom edges and vertical support straps sewn onto the inside surface of the mesh crib bumper, installed inside a crib on top of a crib mattress. FIG. 7 shows a perspective view of the present invention, depicting a standard crib without a mattress support, and a mesh crib bumper with a mesh fabric base showing only the front panel with horizontal fastening straps, and tie string fasteners for securing the mesh crib bumper to the bottom crib rail. FIG. 8 shows a perspective view of the present invention, depicting a standard crib without a mattress support, and a mesh crib bumper with a mesh fabric base showing only the front panel with horizontal fastening straps, and vertical fastening straps for securing the mesh crib bumper to the bottom crib rail. FIG. 9 shows a cross sectional view of the present invention, depicting a mesh crib bumper with an attached mesh panel base, with horizontal straps sewn onto the top and bottom edges, installed inside a crib. FIG. 10 shows a perspective view of the present invention, depicting a standard crib without a mattress support, and a mesh crib bumper with a mesh fabric base and a re-sealable top panel showing only the front panel with horizontal fastening straps, and vertical fastening straps for securing the mesh crib bumper to the bottom crib rail. FIG. 11 shows a cross sectional view of the present invention, depicting a mesh crib bumper with an attached mesh panel base, with horizontal straps sewn onto the top and bottom edges, and a Velcro edged removable mesh fabric top panel installed inside a crib. FIG. 12 shows a cross sectional view of the present invention, depicting a mesh crib bumper with two attached mesh panel bases, with horizontal straps sewn onto the top and bottom edges, and a Velcro edged removable mesh fabric top panel installed inside a crib. FIG. 13 shows a perspective view of the present invention, depicting a standard crib without a mattress support, a crib mattress and a mesh crib bumper showing fastening straps in all four corners, and horizontal support members inserted in the top and bottom seams for the head, foot and side mesh fabric panels, and tie string fasteners for securing the mesh crib bumper to the bottom crib rail. Vertical support members not shown. FIG. 14 shows a cross sectional view of the present invention, depicting a mesh crib bumper, installed inside a crib from four corners on top of a crib mattress. FIG. 15 shows a cross sectional view of the present invention, depicting a mesh crib bumper, with horizontal support members inserted in the top and bottom edges, installed inside a crib from four corners on top of a crib mattress. FIG. 16 shows a perspective view of the present invention, depicting a standard crib without a mattress support, a crib mattress and a mesh crib bumper with four top vertical connecting straps connected to the four top corners of the mesh crib bumper and four bottom vertical connecting straps connected to the four bottom corners of the mesh crib bumper. FIG. 17 shows a perspective view of the present invention, depicting a standard crib without a mattress support, a crib mattress and a mesh crib bumper with horizontal and vertical connecting straps and top panel extensions for wrapping and securing over the top of four crib rails. FIG. 18 shows a cross sectional view of the present invention, depicting a mesh crib bumper, with horizontal straps sewn onto the top and bottom edges and vertical support straps sewn onto the inside surface of the mesh crib bumper, installed inside a crib on top of a crib mattress with top panel extensions for wrapping and securing over the top of four crib rails. LIST OF REFERENCE NUMBERING 1 labels a crib. 2 labels a crib mattress. 3 labels a mesh crib bumper. 10 labels a vertical crib corner post. 12 labels a top horizontal crib rail. 14 labels a bottom horizontal crib rail. 16 labels a vertical crib baluster. 20 labels a top edge of a crib mattress. 22 labels a crib mattress platform. 24 labels a crib mattress platform vertical support edge. 30 labels a vertical breathable mesh fabric panel. 32 labels a top horizontal strap for the breathable mesh fabric panel. 34 labels a bottom horizontal strap for the breathable mesh fabric panel. 36 labels a vertical strap for securing the mesh fabric panel to the crib. 38 labels a mesh panel corner pocket for receiving a vertical support member. 39 labels a vertical support member for the mesh fabric panel. 40 labels a strap connecting buckle. 42 labels a strap end sewn around the strap connecting buckle. 44 labels a strap end fed through the connecting buckle. 46 labels a hook Velcro™ fastener strip sewn onto the outside end of a strap. 48 labels a loop Velcro™ fastener strip sewn onto the outside surface of a strap. 50 labels a hook Velcro™ fastener strip sewn onto the inside mesh fabric panel top. 52 labels tie string fasteners for securing the bumper to the bottom crib rails. 54 labels a horizontal support member for the head and foot mesh fabric panel. 56 labels a horizontal support member for the side mesh fabric panels. 60 labels a mesh fabric panel base. 60 b labels a secondary mesh fabric panel base fur use without a mattress. 62 labels a mesh fabric panel lid. 64 labels mesh fabric extension panels which extend over the crib's top rail. 66 labels a double bar buckle. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT In order to more fully understand the invention, during the course of this description, the mesh crib bumper and enclosure invention and preferred embodiments, will be labeled and explained to easily identify like elements according to the different figures which illustrate some of the preferred embodiments of the invention. It is apparent that FIGS. 1-18 all show breathable mesh panels spaced away from any hard surface inside a crib or support structure. Additional objects of the present invention will become apparent as the description proceeds. Referring to FIG. 1 , there is shown a front elevational view of a rectangular crib 1 having four vertical corner posts 10 extending from the floor to the top horizontal crib rails 12 , and having four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 receives a rectangular crib mattress 2 which sits on an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a vertically adjustable horizontal support member attached to the crib's lower horizontal rail section 14 . The immovable mattress support or vertically adjustable horizontal mattress support member is not shown. The breathable mesh crib bumper 3 is positioned and secured inside of the rectangular crib 1 from four vertical corner posts 10 , preferably when the baby is not in the crib 1 and the crib mattress 2 is covered with a waterproof barrier, sheets and/or bedding. The mesh crib bumper 3 has four vertical mesh panels 30 connected at four vertical corners or a continuous vertical mesh panel 30 connected at one of the vertical corners The crib securing method uses four adjustable bottom straps 34 with a fastening means 40 at one end, preferably a buckle device, and a length of strap to wrap around an outside vertical corner post 10 and feed through and secure to the fastening means 40 ; and four adjustable top straps 32 with a fastening means 40 at one end, preferably a buckle device, and a length of strap to wrap around an outside vertical corner post 10 and feed through and secure to the fastening means 40 . The fastening means 40 in FIG. 1 shows a belt loop and a length of the top strap 32 and a length of the bottom strap 34 to feed through and secure to the fastening means 40 , with a hook Velcro™ fastener strip 46 sewn onto the outside end of a top strap 32 and bottom strap 34 and a loop Velcro™ fastener strip 48 sewn onto the outside surface of a top strap 32 and bottom strap 34 . The fastening means 40 can also use a self locking buckle to increase manufacturing times and reduce manufacturing costs. The bottom edge of the mesh crib bumper 3 device is preferably vertically secured onto the top surface of the mattress 2 using four adjustable fastening means 52 , preferably tie string fasteners, located on the four bottom edge corners, for securing the mesh crib bumper 3 to the bottom crib rails 14 . The mesh crib bumper 3 device can also be vertically secured onto the top surface of the mattress 2 without the four attached adjustable fastening means 52 , using shoe strings of an appropriate length or some other length of material wrapped around, over or through the four bottom fastening means 40 and tied around the four bottom horizontal crib rails 14 until the bottom edge of the mesh crib bumper 3 is vertically secured onto the top surface of the mattress 2 . Referring to FIG. 2 , there is shown a front elevational view of FIG. 1 with the four connected vertical mesh panels 30 having four vertical corner pockets 38 for receiving a vertical support member 39 to prevent the four connected vertical mesh panels 30 from being vertically compressed and to maintain horizontal and vertical tension of the four vertical mesh panels 30 . Referring to FIG. 3 , there is shown a front elevational view of FIG. 1 without the four adjustable fastening means 52 , preferably tie string fasteners, located on the four bottom edge corners, for securing the mesh crib bumper 3 to the bottom crib rails 14 . The four connected vertical mesh panels 30 have eight adjustable vertical straps 36 , two on each corner, for wrapping around a top rail 12 and a bottom rail 14 of the crib 1 . The eight adjustable vertical straps 36 with a fastening means 40 at one end to wrap over a top rail 12 , preferably a the buckle device, and a length of strap to wrap around a bottom rail 14 and feed through and secure to the fastening means 40 . The fastening means 40 in FIG. 3 shows a belt loop and a length of the eight vertical straps 36 to feed through and secure to the fastening means 40 , with a hook Velcro™ fastener strip 46 sewn onto the outside end of eight adjustable vertical straps 36 and a loop Velcro™ fastener strip 48 sewn onto the outside surface of eight adjustable vertical straps 36 . Referring to FIG. 4 , there is shown a cross sectional view of FIGS. 1-3 . The mesh crib bumper 3 is installed inside a rectangular crib 1 with four top horizontal crib rails 12 and four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 receives a rectangular crib mattress 2 which sits on an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a structurally reinforced edge 24 vertically adjustable horizontal support member 22 attached to the crib's lower horizontal rail section 14 . The mesh crib bumper 3 has four vertical mesh panels 30 connected at four vertical corners and preferably a securing method attached to the four corners of the four adjustable bottom horizontal straps 34 for securing the mesh crib bumper 3 to the bottom of the crib rails 14 . The bottom edge of the horizontal strap 34 is preferably positioned on top of the inside surface of the mattress top edge 20 . Referring to FIG. 5 , there is shown a front elevational view of FIG. 3 where an additional adjustable vertical strap 36 , one for each side mesh panel 30 , for wrapping around a top rail 12 and a bottom rail 14 of the crib 1 and preventing each side mesh panel 30 from being vertically compressed. Referring to FIG. 6 , there is shown a cross sectional view of FIG. 3 and FIG. 5 . The mesh crib bumper 3 is installed inside a rectangular crib 1 with four top horizontal crib rails 12 and four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 receives a rectangular crib mattress 2 which sits on an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a structurally reinforced edge 24 vertically adjustable horizontal support member 22 attached to the crib's lower horizontal rail section 14 . The mesh crib bumper 3 has four vertical mesh panels 30 connected at four vertical corners and preferably a securing method attached to the four corners of the four adjustable bottom horizontal straps 34 for securing the mesh crib bumper 3 to the bottom of the crib rails 14 . The bottom edge of the horizontal strap 34 is preferably positioned on top of the inside surface of the mattress top edge 20 . Vertical straps 36 are attached to the inside or outside surfaces of the vertical mesh panels 30 . The vertical straps 36 wrap around the top of the top rail 12 and the bottom of the bottom rail 14 and are attached on the outside of the crib 1 . The end of the vertical strap 36 , wrapped around the top of the top rail 12 , preferably uses a strap connecting buckle 40 sewn onto the vertical strap end 42 . The opposite vertical strap end 44 of the vertical strap 36 , wrapped around the bottom of the bottom rail 14 , is inserted through the connecting buckle 40 , and using a hook 46 and loop 48 securing means. Referring to FIG. 7 , there is shown a front elevational view of FIG. 1 where the four vertical mesh panels 30 are approximately twice the height of the four vertical mesh panels 30 in FIG. 1 , a mesh panel base 60 is attached the bottom edges of the four vertical mesh panels 30 and the fastening means 40 uses a double bar buckle at the fastening end. Referring to FIG. 8 , there is shown a front elevational view of FIG. 7 without the four adjustable fastening means 52 , preferably tie string fasteners, located on the four bottom edge corners, for securing the mesh crib bumper 3 to the bottom crib rails 14 . The four connected vertical mesh panels 30 have eight adjustable vertical straps 36 , two on each corner, for wrapping around a top rail 12 and a bottom rail 14 of the crib 1 . The eight adjustable vertical straps 36 with a fastening means 40 at one end to wrap over a top rail 12 , preferably a double bar buckle, and a length of strap to wrap around a bottom rail 14 and feed through and secure to the fastening means 40 . Referring to FIG. 9 , there is shown a cross sectional view of FIG. 7 and FIG. 8 . The mesh crib bumper 3 is installed inside a rectangular crib 1 with four top horizontal crib rails 12 and four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 has an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a structurally reinforced edge 24 vertically adjustable horizontal support member 22 attached to the crib's lower horizontal rail section 14 . The mesh crib bumper 3 has a bottom mesh panel base 60 attached to the bottom of the four connected vertical mesh panels 30 for laying a baby onto. Referring to FIG. 10 , there is shown a front elevational view of FIG. 8 with a top mesh panel 62 attached to the top edge on the back vertical mesh panel 30 . The left, right and front edges of the top mesh panel 62 have a hook Velcro™ fastener strip 50 sewn onto the inside surface of the mesh fabric panel top 62 . The four connected vertical mesh panels 30 have a loop Velcro™ fastener strip 48 sewn onto the outside surface of the connected vertical mesh panels 30 on the left, right and front edges. Referring to FIG. 11 , there is shown a cross sectional view of FIG. 10 . The mesh crib bumper 3 is installed inside a rectangular crib 1 with four top horizontal crib rails 12 and four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 has an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a structurally reinforced edge 24 vertically adjustable horizontal support member 22 attached to the crib's lower horizontal rail section 14 . The mesh crib bumper 3 has a bottom mesh panel base 60 attached to the bottom of the four connected vertical mesh panels 30 for laying a baby onto. The mesh crib bumper 3 also has a top mesh panel lid 62 attached to the top of the four connected vertical mesh panels 30 using a preferred hook 50 and loop 48 Velcro™ fastening means. Referring to FIG. 12 , there is shown a cross sectional view of FIG. 10 . The mesh crib bumper 3 is installed inside a rectangular crib 1 with four top horizontal crib rails 12 and four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 has an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a structurally reinforced edge 24 vertically adjustable horizontal support member 22 attached to the crib's lower horizontal rail section 14 . The mesh crib bumper 3 has a bottom mesh panel base 60 b attached to the bottom of the four connected vertical mesh panels 30 for laying a baby onto and a second bottom mesh panel base 60 to prevent an insect from biting a baby while it is laying on the bottom mesh panel base 60 b . The mesh crib bumper 3 also has a top mesh panel lid 62 attached to the top of the four connected vertical mesh panels 30 using a preferred hook 50 and loop 48 Velcro™ fastening means. Referring to FIG. 13 , there is shown a front elevational view of FIG. 7 where the four vertical mesh panels 30 are approximately twice the height of the four vertical mesh panels 30 in FIG. 1 . The means of supporting the four connected vertical mesh panels 30 within the crib 1 , use four double sided adjustable vertical straps 36 , one in each corner, for wrapping around and securing to an outside vertical corner post 10 . Each double sided adjustable vertical straps 36 has a fastening means 40 on an inside strap, preferably a double bar buckle at the fastening end, and a length of strap for wrapping around an outside vertical corner post 10 and feeding it through and securing it through the fastening means 40 . The four double sided adjustable vertical straps 36 use a fastening means 40 on the top and bottom ends of an inside strap. Four adjustable fastening means 52 , preferably tie string fasteners, located on the four bottom edge corners, for securing the mesh crib bumper 3 to the bottom crib rails 14 . The top and bottom edges of the two side vertical mesh panels 30 receive a horizontal support member 56 in the sewn edge receiving pocket to prevent vertical compression. The top and bottom edges of the head and foot vertical mesh panels 30 receive a horizontal support member 54 in the sewn edge receiving pocket to prevent vertical compression. When the mesh crib bumper 3 is properly installed in a crib 1 , the head and foot vertical mesh panel 30 sections are so taut, the horizontal support members 54 are not needed. Horizontal support members 54 and 56 are not needed when the top and bottom edges of the vertical mesh panels 30 are reinforced with a rigid binding means. An alternative construction means to increase manufacturing speed and reduce manufacturing costs, uses an adjustable vertical strap 36 attached to the four inside corners and a fastening means 40 , preferably an adjustable double bar buckle attached to the top and bottom section adjacent to the mesh crib bumper 3 corners, with the excess length of strap for wrapping around an outside vertical corner post 10 and feeding it through and securing it through the fastening means 40 . Vertical support members are not shown inserted into the four corners of the vertical mesh panels 30 , but are preferably required to prevent vertical compression of the four vertical mesh panels 30 and maintain uniformity of the mesh crib bumper 3 structure. Referring to FIG. 14 , there is shown a cross sectional view of FIG. 13 . The mesh crib bumper 3 is installed inside a rectangular crib 1 with four top horizontal crib rails 12 and four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 receives a rectangular crib mattress 2 which sits on an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a structurally reinforced edge 24 vertically adjustable horizontal support member 22 attached to the crib's lower horizontal rail section 14 . The mesh crib bumper 3 has four vertical mesh panels 30 connected at four vertical corners and preferably a securing method attached to the bottom of four corners of the four adjustable the vertical straps 36 for securing the mesh crib bumper 3 to the bottom of the crib rails 14 . The bottom edge of mesh crib bumper 3 is preferably positioned on top of the inside surface of the mattress top edge 20 . The top and bottom edges of the head and foot vertical mesh panels 30 preferably receive a horizontal support member 56 , not shown, in the sewn edge receiving pocket to prevent vertical compression. Referring to FIG. 15 , there is shown a cross sectional view of FIG. 13 . The mesh crib bumper 3 is installed inside a rectangular crib 1 with four top horizontal crib rails 12 and four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 receives a rectangular crib mattress 2 which sits on an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a structurally reinforced edge 24 vertically adjustable horizontal support member 22 attached to the crib's lower horizontal rail section 14 . The mesh crib bumper 3 has four vertical mesh panels 30 connected at four vertical corners and preferably a securing method attached to the bottom of four corners of the four adjustable the vertical straps 36 for securing the mesh crib bumper 3 to the bottom of the crib rails 14 . The bottom edge of mesh crib bumper 3 is preferably positioned on top of the inside surface of the mattress top edge 20 . The top and bottom edges of the head and foot vertical mesh panels 30 preferably receive a horizontal support member 56 in the sewn edge receiving pocket to prevent vertical compression. Referring to FIG. 16 , there is shown a breathable mesh crib bumper 3 positioned and secured inside of the rectangular crib 1 from four vertical corner posts 10 . The mesh crib bumper 3 has four vertical mesh panels 30 connected at four vertical corners. The crib securing method uses four adjustable bottom straps 34 attached to the bottom of the four vertical corners and a fastening means 66 , preferably a double bar buckle, attached to the bottom straps 34 next to the bottom of the four vertical corners. The four adjustable bottom straps 34 wrap around an outside vertical corner post 10 and feed through and secure to the fastening means 66 . Four adjustable top straps 32 are attached to the top of the four vertical corners and a fastening means 66 , preferably a double bar buckle, attached to the top straps 32 next to the top of the four vertical corners. The four adjustable top straps 32 wrap around an outside vertical corner post 10 and feed through and secure to the fastening means 66 . The four connected vertical mesh panels 30 have four vertical corner pockets 38 for receiving a vertical support member 39 to prevent the four connected vertical mesh panels 30 from being vertically compressed and to maintain horizontal tension. Referring to FIG. 17 , there is shown a front elevational view of FIG. 1 without the four adjustable fastening means 52 , preferably tie string fasteners, located on the four bottom edge corners, for securing the mesh crib bumper 3 to the bottom crib rails 14 . The four connected vertical mesh panels 30 have eight adjustable vertical straps 36 , two on each corner, for wrapping around a top rail 12 and a bottom rail 14 of the crib 1 . The eight adjustable vertical straps 36 with a fastening means 40 at one end to wrap over a top rail 12 , preferably a the buckle device, and a length of strap to wrap around a bottom rail 14 and feed through and secure to the fastening means 40 . The fastening means 40 in FIG. 3 shows a belt loop and a length of the eight vertical straps 36 to feed through and secure to the fastening means 40 , with a hook Velcro™ fastener strip 46 sewn onto the outside end of eight adjustable vertical straps 36 and a loop Velcro™ fastener strip 48 sewn onto the outside surface of eight adjustable vertical straps 36 . The top of the four vertical mesh panels 30 have mesh fabric extension panels 64 which extend over the crib's top rail 12 to prevent a child from sticking an appendage or object in between the mesh crib bumper 3 and the crib rails 12 and 16 . The top edges of the mesh fabric extension panels 64 preferably have a means of securing the top edges to the outside surface of the crib rails 12 and 16 . Referring to FIG. 18 , there is shown a cross sectional view of FIG. 16 . The mesh crib bumper 3 is installed inside a rectangular crib 1 with four top horizontal crib rails 12 and four bottom horizontal crib rails 14 with vertical crib balusters 16 connecting the top and bottom crib rails 12 and 14 . The rectangular crib 1 receives a rectangular crib mattress 2 which sits on an immovable support spring or lattice attached to the crib's lower horizontal rail section 14 or on a structurally reinforced edge 24 vertically adjustable horizontal support member 22 attached to the crib's lower horizontal rail section 14 . The mesh crib bumper 3 has four vertical mesh panels 30 connected at four vertical corners and preferably a securing method attached to the four corners of the four adjustable bottom horizontal straps 34 for securing the mesh crib bumper 3 to the bottom of the crib rails 14 . The bottom edge of the horizontal strap 34 is preferably positioned on top of the inside surface of the mattress top edge 20 . Vertical straps 36 are attached to the inside or outside surfaces of the vertical mesh panels 30 . The vertical straps 36 wrap around the top of the top rail 12 and the bottom of the bottom rail 14 and are attached on the outside of the crib 1 . The end of the vertical strap 36 , wrapped around the top of the top rail 12 , preferably uses a strap connecting buckle 40 sewn onto the vertical strap end 42 . The opposite vertical strap end 44 of the vertical strap 36 , wrapped around the bottom of the bottom rail 14 , is inserted through the connecting buckle 40 , and preferably uses a hook 46 and loop 48 securing means. The top of the four vertical mesh panels 30 have mesh fabric extension panels 64 which extend over the crib's top rail 12 to prevent a child from sticking an appendage or object in between the mesh crib bumper 3 and the crib rails 12 and 16 . The top edges of the mesh fabric extension panels 64 preferably have a means of securing the top edges to the outside surface of the crib rails 12 and 16 . These and other features of the present invention will be more fully understood by referencing the drawings. In summary, the breathable mesh crib bumper invention, according to the preferred embodiments and alternative preferred embodiments of the invention, provides a mesh crib bumper insert which is breathable and allows air to circulate through it, an enclosure that prevents a baby from impacting their head or appendages against a crib's balusters or four corner posts, an enclosure that prevents a baby from sticking their head or appendages through a crib's balusters or reaching over the top of the crib enclosure, an enclosure that prevents objects from falling outside of the enclosure, an enclosure that is installed into and removed out of the crib fast and easily for crib maintenance and for cleaning, an enclosure including a bottom horizontal mesh surface for laying a baby onto or for positioning on top of or under a mattress and an enclosure with a sealable top mesh panel for keeping insects and animals out of the crib's enclosure. The present invention and its many preferred embodiments, disclosed and not disclosed, all use taut connected breathable mesh fabric panels preferably secured to four vertical corner posts, allowing air to circulate through the crib compartment, while preventing an object within the enclosure from coming in contact with object located outside the enclosure or from an object getting inside the enclosure through the taut breathable mesh fabric panels. While the invention has been described with reference to the preferred embodiments thereof, it will be appreciated by those of ordinary skill in the art that various modifications can be made to the invention without departing from the spirit and scope of the invention as a whole.
A mesh crib bumper enclosure having four connected vertical mesh fabric panel sections installed in a crib by suspending it from top and bottom corners and securing it to four corner posts. The enclosure panels are stretched tightly between the corner posts using a locking fastener. The mesh fabric panels allow air to circulate through the crib to prevent exhaled carbon dioxide from building up. The enclosure corners receive vertical support members for vertical structural integrity while top and bottom edges can receive horizontal support members for horizontal structural integrity. The enclosure bottom corners use tie string fasteners to secure the enclosure to bottom crib rails to keep the bottom edges in contact the mattress. Other embodiments use a mesh panel base attached to the enclosure bottom and/or a mesh panel sealable top for sealing off the top to prevent insects and animals from entering the mesh crib bumper enclosure.
8
CROSS-REFERENCE TO RELATED APPLICATION This application is based upon and claims priority on U.S. Provisional Application No. 60/920,430, filed on Mar. 26, 2007, the contents of which are fully incorporated herein by reference. BACKGROUND OF THE INVENTION This invention relates to a device for leveling, aligning and properly spacing tiles. Tiles are usually laid on a substrate or subsurface such a floor or other flat surface adjacent to each other and spaced apart from each other by a small gap. Typically an adhesive is troweled on the surface where the tile is to be applied. Adhesive may also be applied to the back side of the tile. The tile is then placed and adhered to the subsurface. Another tile is then adhered to the subsurface in the same manner next to the previous tile. Typically, spacers may be used to evenly space one tile from the other. However, depending on the unevenness of the subsurface e, i.e., floor, on which the tiles are applied and the unevenness of the applied adhesive, adjacent tiles are not always aligned and thus are not level relative to each other. In this regard, an edge of one tile may extend beyond an edge of an adjacent tile. To overcome this problem, a leveling device has been created which includes a leveling member 10 and a wedge 12 , as for example shown in FIG. 1 . The leveling member has a vertically aligned member 14 and a generally horizontally curving member 16 (the “horizontal member”), as shown in FIG. 1 . The vertical member extends from the horizontal member. A breakaway line 22 is defined on the vertical member on either surface thereof proximate the horizontal member. The breakaway line is defined by removing material from either surface of the vertical member such that the thickness of the vertical member along the line is reduced and the vertical member is weaker along such line. The device is placed such that one end of the tile sits on one end of the horizontal member of the device and abuts one surface of the vertical member of the device and an adjacent tile sits on the other end of the horizontal member and abuts an opposite surface of the vertical member, as for example shown in FIGS. 2 and 3 . The wedge member is then pushed through opening 20 . As the wedge is continually pushed through opening 20 due to its increasing thickness, it causes the edge of each tile to be compressed downward pressing the horizontal member beneath it toward the subsurface. As a result the tiles are aligned and leveled, as shown in FIG. 4 . The spacing between the tiles is controlled by the thickness of the vertical member. Once the tiles set, the vertical member along with the wedge is broken off by kicking or applying a force on the vertical member such that it breaks along the weaker breakaway line 22 . As can be seen in FIG. 5 , the breakaway line is positioned such that it is flush with the undersurface of the tiles when the tiles are adhered to the floor. The problem with this device is that at times, adhesive fills out the breakaway line. In this regard, it is very difficult to break off the vertical member from the horizontal member due to the adhesive on the breakaway line. Moreover, adhesive at times may not extend over the horizontal member. Consequently, the ends of the portions of the tile which extend over the horizontal member are not adhered to the undersurface or to the horizontal member which may have adhered to the undersurface. As such, these non-adhered ends of the tiles are susceptible to cracking, as they are not properly supported. Consequently, a leveling, aligning and spacing device is required that overcomes the problems of the prior art. SUMMARY OF THE INVENTION In an exemplary embodiment a tile leveling device and tile combination is provided. The combination includes a first tile having a first surface opposite a second surface, a second tile having a first surface opposite a second surface and a device having a main member, a first section extending transversely from the main member and a second section a second section extending transversely from the main member in a direction opposite the first section. The first tile is located over the first section and the second tile is located over the second section. An opening is formed through the main member and a member is provided for penetrating the opening and exerting a force against both tiles pressing the tiles against the first and second sections. A breakaway section is defined along the main member. The breakaway section is located between the first and second surfaces of each of the first and second tiles. In another exemplary embodiment, an opening is formed through the first section for allowing an adhesive to flow there through. In a further exemplary embodiment, an opening is formed through the second section for allowing an adhesive to flow there through. In another exemplary embodiment, the opening formed through the main member includes a first edge opposite a second edge such that the first edge is further from the first and second sections than the second edge. A stiffener portion is formed proximate the first edge for bolstering the first edge. In yet another exemplary embodiment, the main member includes a first notch extending from a first edge of the main member and a second notch extending from a second edge of the main member and the breakaway section extends from the first notch to the second notch. In yet a further exemplary embodiment, each of the first and second sections have at least a curved portion having a curvature when viewed in cross-section, such that the force causes this curvature to reduce. In another exemplary embodiment a tile leveling device is provided including a main member, a first section extending transversely from the main member for receiving a first tile having a first surface opposite a second surface, and a second section extending transversely from said main member in a direction opposite the first section for receiving a second tile having a first surface opposite a second surface. A first opening is formed thought the first section. A second opening formed thought the second section. A third opening formed though the main member. In yet another exemplary embodiment, the opening formed through the main member includes a first edge opposite a second edge such that the first edge is further from the first and second sections than the second edge. A stiffener portion is formed proximate the first edge for bolstering the first edge. In yet a further exemplary embodiment, the device further includes a reduced thickness breakaway section formed on the main member. The main member is also includes a first notch extending from a first edge of the main member and a second notch extending from a second edge of the main member and the breakaway section extends from the first notch to the second notch. In a further exemplary embodiment, a method for leveling tiles is provided. The method includes providing a tile leveling device which includes a main member, a first section extending transversely from the main member and having a first opening formed there through, a second section extending transversely from the main member in a direction opposite the first section and having a second opening formed there through. A third opening is formed through the main member, and a breakaway section is defined along the main member. The method further includes placing the leveling device over a subsurface, placing a first tile over the first section, where the tile has a first surface opposite a second surface, and the second surface if farther from the first section than said first surface, and placing a second tile over said second section, where the second tile has a first surface opposite a second surface and the second tile second surface if farther from the second section than said second tile first surface. The method further includes applying a first adhesive between the first tile and the subsurface, applying a second adhesive between the second tile and the subsurface, and placing a member through the third opening such that the member exerts a force on the first and second tiles pressing the tiles against the first and second sections leveling the first tile second surface relative to the second tile second surface whereby the first adhesive penetrates the first opening and contacts the first tile first surface and the subsurface, and the second adhesive penetrates the second opening and contacts the second tile first surface and the subsurface, and causing the breakaway section to be located between the first and second surfaces of each tile. The method also includes curing the adhesives for adhering the tiles relative to the subsurface and breaking the main member along the breakaway section. In another exemplary embodiment, the second adhesive is the same as the first adhesive. In yet a further exemplary embodiment, the tiles are abutted against said main member prior to curing. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a prior art leveling and spacing device. FIGS. 2 , 3 , 4 and 5 are cross-sectional views showing use of the prior art leveling device. FIG. 6 is a cross-sectional view of an exemplary embodiment leveling and spacing device of the present invention installed. FIG. 7 is an end view of an exemplary embodiment leveling device, including an exemplary embodiment wedge. FIG. 8 is a perspective view of an exemplary embodiment leveling device with a wedge of the present invention. FIG. 9 is a perspective view of yet a further exemplary embodiment leveling and spacing device with a wedge of the present invention. DETAILED DESCRIPTION OF THE INVENTION An inventive leveling and spacing device 110 is provided. The inventive device includes a first member 114 and a transverse member 116 which includes a section 116 a on one side of the first member and a second section 116 b on the other side of the first main member as for example shown in FIG. 6 . Each section 116 a , 116 b in an exemplary embodiment shown in FIG. 6 is curved or has at least a portion which curves so as to define a convex curvature 117 on a distal surface or lower surface of the transverse member 116 . An opening 118 is formed on the first member to accommodate a wedge 112 . A breakaway section or line 122 is formed on the first member and is spaced such that it will extend into the thickness of the tiles 134 a , 134 b when installed, as for example shown in FIG. 6 . To achieve this, the breakaway line is located at or above the highest points of the horizontal member sections 116 a , 116 b . In this regard, when the tiles rest on such points, the breakaway line is at or located above the lower surface of such tiles and when the wedge is installed through opening 118 and presses the tiles against the transverse member sections 116 a and 116 b causing these sections to compress (and flatten if they include a curved portion) toward the subsurface on which such tiles are installed, such that the breakaway line is located at a height within the thickness of the installed tiles. Consequently, the breakaway line is not exposed to the adhesive 132 which is used to adhere the tiles to a floor or subsurface 130 . In this regard, the breakaway line allows for a consistently clean breakaway of the first main member from the transverse member. Furthermore, to help the breakaway of the first main member from the transverse member, the breakaway line may be formed by two opposing V-shaped or U-shaped notches 123 extending from opposite surfaces of the vertical member 114 , as for example shown in FIG. 7 . In another exemplary embodiment, the breakaway line is formed by a reduction in the thickness of the material. Moreover, a portion of the breakaway line or the material defining a breakaway line at the edges of the vertical member may be removed, defining cutouts 125 , as for example shown in FIG. 8 . This also helps with the breakaway of the first main member from the transverse member. In another exemplary embodiment, the breakaway line 122 may extend all the way to the edges of the vertical member, as for example shown in FIG. 9 . “Breakaway line” or “breakaway section” as used herein refers to a section of reduced thickness that would promote the breakaway and thus, the separation of such section. In addition, a stiffener portion 127 may be formed at the upper edge of the opening 118 which accommodates the wedge 112 , bolstering such edge. In this regard, as the wedge is inserted into the opening, it does not crush the upper edge of the opening. Furthermore, at least one opening 129 is formed through each section 116 a , 116 b of the transverse member 116 on either side of the first main member 114 . In another exemplary embodiment, multiple openings may be formed through each section of the transverse member. These openings allow for the adhesive 132 to penetrate the opening and extend over the surface of the transverse member sections 116 a , 116 b , as for example shown in FIG.6 . In this regard, the transverse member sections adhere to the subsurface or floor and the tiles get adhered to the transverse member. Consequently, the tile end portions 131 a , 131 b which extend over the transverse member sections 116 a , 116 b , respectively get proper support, thereby reducing the risk of cracking, crumbling and separating from the subsurface. In an exemplary embodiment, an upper surface 126 of the wedge 112 is tapered downwards and includes teeth 150 . Each of these teeth is defined by a vertical surface 152 or riser and an obliquely extending surface 154 from the top of the vertical surface 152 in the same general direction as the upper surface 126 of the wedge. In this regard, these teeth latch on to the upper edge of the opening when the wedge is inserted into the opening 118 , thereby preventing the wedge from inadvertently slipping out of the opening 118 . In the exemplary embodiment shown, a center portion of the wedge is hollow, defining two opposing edges. The teeth are formed on these opposing edges. In an exemplary embodiment, adhesive is applied to the subsurface of where tiles are to be adhered and is also applied to the undersurface of a first tile. As the tile is being placed on the subsurface with the adhesive, an exemplary embodiment leveling and spacing device is positioned such that the tile undersurface sits on top of the transverse member section 116 a and it abuts the device first main member 114 . The device is positioned on the subsurface such that both transverse member sections sit on the adhesive applied to the subsurface. Adhesive is applied on the undersurface of a second tile. Adhesive may also be further applied to the subsurface if necessary. The second tile is laid on the subsurface such that the second tile undersurface sits on top of the second transverse member section 116 b and also abuts the first main member 114 . The wedge is then fitted through the opening 118 . As the wedge wedges itself in the opening it applies pressure on the upper surfaces of the tiles leveling such tiles relative to each other. The pressure causes the adhesive to travel through the openings formed on the transverse member sections ensuring that the adhesive is spread on the top and bottom and through each of the transverse member sections. It should be understood that if the tiles are being installed so that they are adjacent to more than one other tile, than a leveling device should be placed along each side of a tile that will be adjacent to another tile. For example, if a first tile is going to be surrounded by four other tiles, than a leveling device must be placed adjacent each side of the first tile such that a transverse member section of each device is sandwiched between the first tile and the subsurface. Once the adhesive cures, the vertical member may be removed by “kicking it” off or by pushing it sideways or pulling it off. Since the breakaway lines on the exemplary devices are positioned such that they are within the tile thickness of the tile and away from the adhesive, the vertical sections should consistently break off when subjected to the same force. In an exemplary embodiment, wedges may be used having a sufficient thickness such that when they are pushed beyond a certain point through the opening of the vertical member, they will apply a sufficient force to break the vertical member along the breakaway line. In such an embodiment, the vertical member may be removed by further pushing the wedge through the vertical member opening. Although the present invention has been described and illustrated to respect to exemplary embodiments, it is to be understood that it is not to be so limited, since changes and modifications may be made therein which are within the full intended scope of this invention as hereinafter claimed.
A tile leveling device is provided. The device includes a main member, a first section extending transversely from the main member for receiving a first tile and a second section extending transversely from the main member in a direction opposite the first section for receiving a second tile. A member is provided for penetrating the main member and exerting a force on the tiles for leveling them relative to each other. A method for leveling tiles is also provided.
4
RELATED APPLICATIONS [0001] This application is continuation-in-part (CIP) of prior U.S. patent application Ser. No. 10/751,546 applied on Jan. 5, 2003, which is fully incorporated herein. BACKGROUND OF THE INVENTION [0002] 1. Field of Invention [0003] This invention relates to a toilet system attached a hand held water spraying apparatus, engaging in delivering instant water supply for personal and environmental hygiene. [0004] 2. Description of Related Art [0005] The invention in earlier application has been improved by adding new features, which include multiple layered reinforced flexible hose to bear the continuous high pressures, a filter for separating solid particles and impurities from water, a mixing valve that provides tempered water for the use in the cold temperature, a T-adapter together with matching couplings to tap water from an existing plumbing fixtures, a modified hose hanger mounted on the existing toilet seat fasteners, a holder assembly with new features for placement of the sprayer with various positions, a filler element around the bracket on the top edge of water tank to keep the toilet lid in the flat position, and a toilet seat having a water splash guard under the seat to protect water escape through the gap between the toilet seat and the bowl. [0006] The flexible hose in the current market has limited options available for the use of this invention. One choice is a shower hose, which is used to convey the high pressurized water for the bathtub or sink. The shower hose generally has two layers, in which one layer of the inner flexible hose is wrapped with the other layer of the flexible metal or plastic tube. The shower hose has a cosmetic appearance, but it is not durable enough to be used for an extended amount of time under the continuous high water pressure. Besides, the inner flexible tube has a large diameter to carry much of water for the use in the bath or sink. The hose with the larger diameter holds more pressures than the one with the smaller, causing more inflexibility of the hose under the internal built-up pressures. [0007] Another choice is one of the plumbing hoses, which are designed to supply water under the continuous high pressure. The plumbing hoses have large inner diameter to deliver much of water and general categories of the PVC-reinforced hoses and stainless steel braided hoses. The plumbing hoses are good to supply water in a static environment, but they are not enough flexible for dynamic movement and lack of the ornamental appearances. The present invention includes a reinforced hose having the decorative appearances by combining the good features of the shower hose and the plumbing hose. This invention requires small amount of water for the purpose of the use, adopting a flexible inner hose with small diameter. The inner hose with small diameter absorbs less of the pressure from the source to contribute more flexibility, and affords room to place the second layer of braided metal mesh for reinforcement. The exterior ornamental layer including the flexible stainless steel adds more durability as well as the cosmetic appearances. [0008] The mixing valve is provided to supply tempered water for the use in the cold environment or for better personal care. The previous application uses only cold water tapped into the existing water supply line, which may not be allowed for the use if the water temperature is extremely cold. If the hot water source is available, the present invention utilizes it to supply warm water by employing the mixing valve connected to both of the hot and cold water. Since the hot water source is located in the various areas around the toilet, the present invention employs an angle stop valve behind the toilet as for the illustration. [0009] The T-adapter is applied for this invention, which includes but not limited two outlet male threads and one inlet female rotatable nut. The female rotatable nut is affording convenience for connection in a confined area, because it can be connected without rotation of the large body and locked with the body placed in various directions. The T-adapter may require matching couplings for the inlet and for the outlet to adapt to the various sizes of the existing plumbing fixtures. The various sized T-adapter may eliminate the matching couplings, but it brings more complexity and costs more for productions. [0010] The modified hose hanger with new features is introduced for this invention to reinforce and facilitate arrangement of the hose and installation to the existing seat fasteners. The single body of hose hanger has prop lines on the body to fortify its structure and protruding lines to prevent the hose being mobile in the openings. The protruding lines make the hose placement easier at any part of the free length, because they lock in the hose to prevent slippage. The opening for permanent placement of the hose locks a part of the hose so that the hose hanger is not easily pivoted side to side. The indentation surface is provided on the mounting area for more friction to prevent spinning around. [0011] A holder of the holder assembly has an additional feature for placement of the sprayer, in which the sprayer can be placed in various ways including a high placement and a low placement. The high placement that implements the controller body of the sprayer requires an angled base in the opening of the holder. However, the low placement that takes on the extension bar of the sprayer requires a straight lined base in the opening of the holder. Therefore, the low placement has need of the offset element so that the sprayer is placed in level in the holder. [0012] The adjustable bracket of the holder assembly is introduced for mounting on various types of the water tank of toilets. The outlook of the toilet water tank takes varied shapes including rectangles and trapezoids. The adjustable bracket has the features to be adjusted to the varied environment. It also has the feature to be mounted on any available surfaces if the toilet water tank does not have room for the bracket to be placed on. The adjustable bracket accommodates the filler element such as a foam strip around the top edge for the leveled placement of the toilet lid. [0013] The toilet seat having a water splash guard underbody is presented to protect water escape through the opening between the toilet seat and the bowl. The splash guard around the seat opening is located between the seat and the bowl to add more protection from water splash whenever the sprayer is used inside bowl. The shape and width of the water splash guard is determined from the features of the seat and the bowl. However, the width of the water splash guard is preferably larger than the gap between the seat and the bowl for better protection. The water splash guard can be placed with full or partial enclosure according to the seat opening type. SUMMARY OF THE INVENTION [0014] The present invention provides a toilet system attached a hand held sprayer, wherein the new features are added to achieve more functions than the prior application. The hand held sprayer, namely a “sprayer”, requires a special long flexible hose including multiple layered structures to hold the continuous high pressurized water, to be flexible to maneuver under the internal high pressures built up, to be thin as much as possible for easy handling, and to be aesthetic as possible. Because the existing hose does not satisfy these specifications, the new hose is presented to meet the purposes. The inner tube with smaller diameter supports the flexibility under the high pressures and maintains the thinness for easy handling. The smaller tube also offers the room for placement of the next layer such as the flexible metal braided mesh to hold the high pressures for continuous use. The flexible braided metal layer is again wrapped with the flexible ornamental material to add more durability and aesthetic beauties. [0015] The flexible hose is connected to the valve to obtain water supply. The valve is for adjusting the water flow to the system and turning off in the emergency. The valve is then connected to the mixing valve for supplying tempered water. Two inlets of the mixing valve are connected to the hot water source through a water supply line and the cold water source through a T-adapter tapped into the existing water supply line leading to the toilet water tank. The mixing valve has a control knob to adjust mixture of the hot and the cold water for the individual use. The T-adapter may require two matching couplings to adapt to the various sizes of the plumbing fixtures. [0016] The modified hose hanger is supplied for arrangement of the long flexible hose. The one opening under the body is for permanent placement of a part of the flexible hose connected to the valve. The hose hanger is reinforced with the protruding prop lines aligned on the body. The prop lines lock the hose to prevent the hose hanger being pivoted side to side. The upward opening on the body is for temporary placement of the loose part of the hose. The protruding lines in the opening support stable placement of the hose without slippage over the hanger. The indented surface on the mounting area adds more resistance for the hose hanger to be rotated. [0017] The new sprayer holder assembly has more adaptability to the various environments for placement using a spacer. The attachable spacer at the base of the holder enables the sprayer to be placed in the low placement with a stable state. The holder is secured to the bracket with the fasteners to be mounted over the rim of the water tank. The filler element placed around the bracket on the lid or on the top of the water tank is introduced for levelness of the lid. The bracket is fully adjustable within a limit in accordance with the varied angled mounting surfaces. Finally, the toilet seat has a water splash guard under the seat body to protect from water escape through the gap between the seat and toilet bowl. The water splash guard is fully or partially enclosed around the opening of the seat according to the seat configurations and the purposes of the use. BRIEF DESCRIPTION OF THE DRAWINGS [0018] FIG. 1 is a perspective view showing a toilet system attached a hand held sprayer connected to the existing hot and cold water supply lines. [0019] FIG. 2 is an exploded perspective view of the plumbing fixtures that include a filter, a valve, a mixing valve, a hot water supply line, a T-adapter, and matching couplings to supply tempered water to the hand held sprayer. [0020] FIG. 3 is a perspective view of the new flexible hose for the hand held sprayer. [0021] FIG. 3A is a structural view of the conventional shower hose having a large inner hose enclosed with a flexible ornamental metal tube. [0022] FIG. 3B is a structural view of the conventional plumbing hose or water supply line having a large inner hose braided with a metal mesh to hold the continuous high pressures. [0023] FIG. 3C is a structural view of the currently invented flexible hose taken on the line 3 - 3 of FIG. 3 having a small inner hose braided with a metal mesh and then enclosed with a flexible ornamental metal tube. [0024] FIG. 4 is a perspective view of the hose hanger. [0025] FIG. 4A is a section view of the hose hanger taken on the line 4 - 4 of FIG. 4 . [0026] FIG. 5 is a perspective view of the sprayer holder assembly having an adjustable bracket attached on the body. [0027] FIG. 5A is a perspective view of the holder body isolated from FIG. 5 . [0028] FIG. 5B is a perspective view of the adjustable bracket isolated from FIG. 5 . [0029] FIG. 6 is a perspective view of the adjustable bracket. [0030] FIG. 6A is a section view taken on the line 6 - 6 of FIG. 6 with the body in an upright position. [0031] FIG. 6B is a section view taken on the line 6 - 6 of FIG. 6 with the body in an angled position. [0032] FIG. 7 is a perspective view of the toilet water tank lid with foam strips attached as a filler element except the places for the bracket. [0033] FIG. 7A is a perspective view of the toilet water tank with foam strips attached on the top edge as a filler element except the places for the bracket. [0034] FIG. 8 is a front view of the holder assembly for the sprayer mounted over the side top edge of water tank with its lid covered. [0035] FIG. 8A is a side view of the holder assembly for the sprayer taken on the line 8 - 8 in FIG. 8 . [0036] FIG. 9 is a side view of the holder assembly for the sprayer and for the lavatory items mounted over the side top edge of the water tank having two angled side walls with its lid covered. [0037] FIG. 9A is a side view of the holder assembly for the sprayer taken on the line 9 - 9 in FIG. 9 . [0038] FIG. 10 is a perspective view of the close-ended toilet seat with the upside down having the water splash guard attached on underbody. [0039] FIG. 10A is a section view taken on the line 10 - 10 of FIG. 10 . [0040] FIG. 10B is a cross-sectional side view of the toilet bowl with the toilet seat in FIG. 10 closed. [0041] FIG. 11 is a perspective view of the open-ended toilet seat with the upside down having the water splash guard attached on underbody. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0042] Reference is now made in detail to the present invention, examples of which are illustrated in the accompanying drawings wherein reference numerals having the same first two digits indicate related elements, such as 36 and 365 . The numerals having the same first three digits indicate same components with different elements, such as 365 and 3651 . General structures of the present invention will be described following by details and the function of components. Referring to FIG. 1 , a perspective view of the present invention, a toilet system attached a hand held sprayer, is shown and indicated the number 1 . The system is generally composed of a hand held sprayer 10 , namely “sprayer”; a flexible hose 31 ; a filter 43 ; a valve 40 ; a mixing valve 91 ; a hot water supply line 92 from a hot water source 59 ; a T-adapter 93 with a matching coupling 94 for the water supply line 55 and a matching coupling 95 for the existing angle stop valve 52 ; a hose hanger 36 mounted on the toilet seat fastener 28 using a nut 281 ; a holder assembly 76 for the sprayer 70 ; a holder assembly for the lavatory items 75 ; a water splash guard 812 for the toilet seat 818 . There are filler elements included on the top edge of the water tank 65 and on the lid 60 , but they are hidden. More details are in the following with full descriptions. [0043] The sprayer 10 in FIG. 1 , comprising a controller 101 with a pushbutton 20 and an extension bar 103 with a spray tip 105 , is connected to a flexible hose 31 in FIG. 1 with means to secure including but not limited a coupling 315 of FIG. 3 . The flexible hose 31 utilizes a filter insert 319 in FIG. 3 to eliminate impurities in the water. The sprayer 10 utilizes small amount of water, requiring the flexible hose 31 having an inner hose with small diameter. It does not demand as much water as the conventional hose delivers, wherein the conventional hose has the inner hose with large diameter to supply much of water. The flexible hose 31 for the use of the sprayer 10 requires multiple conditions of (1) the length being long enough to support for personal and environmental hygiene, (2) the durability being strong enough to hold continuous high pressurized water for a long period, (3) the flexibility being comfortable to move for the use under the high internal pressures built up, (4) the thickness being as small as possible to maneuver for the application, and (5) the appearance being aesthetic for the display in the bathroom. The conditions of (1) through (4) are related to the functional elements and the condition of (5) is related to the aesthetic element for the hose. [0044] The conventional shower hose having two layers as in FIG. 3A includes an inner hose 312 having a large diameter 3186 enclosed by an ornamental element 3141 made of metal or plastic. The flexible inner hose 3121 having a large diameter 3186 absorbs high pressures from the water supply source, if not released, causing severe inflexibility of the hose. The outer ornamental element 3141 is usually not strong enough to hold the continuous high pressures for a long period. The plumbing hose as in FIG. 3B used for the water supply line includes a reinforced inner hose 3122 enclosed with the outer layer of the braided metal mesh 3131 . The plumbing hose having the large inner hose and heavy braided metal mesh 3131 is sturdy to hold the high pressure but not much flexible to use for the hand held sprayer. Its outer appearance is not decorative due to the lack of ornamental element. The present invention as in FIG. 3C includes a flexible inner hose 3123 having a small diameter 3188 , wherein the small inner hose affords room for the next layer while keeping the same or smaller thickness. The inner hose 3123 is enclosed with the next layer of the braided metal mesh 3132 and then with the outer layer of the ornamental element 3142 including but not limited flexible metal tube to fulfill the conditions of said functional and aesthetic elements. [0045] The hose 31 in FIG. 3 is further connected to the outlet 435 of the filter 43 with means to secure for further eliminating the pollutants in the water. The means to secure include but not limited the rotatable female threaded nut of the hose 311 and the male thread 4351 of the filter 43 for connection with seals. The inlet 431 of the filter 43 is connected to the outlet 405 of the valve 40 with means to secure to get the flow of water regulated. The means to secure include but not limited the female inlet thread 4311 of the filter 43 and the male thread 4051 of the valve 40 for securing with seals. The valve 40 is used for regulating and turning off the water flow with the handle 402 for use of the sprayer. The inlet 401 of the valve 40 is connected to the outlet 915 of the mixing valve 91 with the means to secure with seal to receive the tempered water. The means to secure include but not limited the rotatable female threaded nut 4011 of the valve 40 and the male thread 9151 of the mixing valve 91 for connection with seals. The rotatable female threaded nut is useful for connection, because it allows the valve 40 secured to the mixing valve 91 while maintaining the handle 402 in any position. All the means to secure have seals including but not limited washers, gaskets, or tapes between the female threaded openings and the male thread for sealing in the connection. [0046] The mixing valve 91 connected to the valve 40 is introduced for mixing the hot water and the cold water carried from the two inlets. One inlet 913 of the mixing valve 91 is connected to the hot water source 59 in FIG. 1 through the water supply line 92 with means to secure. The means to secure include but not limited the rotatable female threaded nut 923 of the water supply line 92 and the male thread 913 of the mixing valve 91 for connection with seals. The other inlet 911 of the mixing valve 91 is connected to the outlet 935 of the T-adapter 93 with the means to secure to receive the cold water. The means to secure include but not limited the rotatable female threaded nut 9111 of the mixing valve 91 and the male thread 9351 of the T-adapter 93 for connection with seal. The handle 916 of the mixing valve 91 is used for regulating the water temperature for various usages. The hot water source 59 is located at the various places in the bathroom, which may require special skills for the proper work. [0047] The T-adapter 93 is connected between the existing angle stop valve 52 in FIG. 1 and the water supply line 55 leading to the toilet water tank. The T-adapter having the sizes of ½ IPS is generally used for receiving the water supply from the angle stop valve 52 , delivering to the water supply line 55 and to the mixing valve 91 . The inlet 931 of the T-adapter 93 is connected to the angle stop valve 52 with means to secure. The means to secure include but not limited the rotatable female threaded nut 9311 of the T-adapter 93 and the male thread of the existing angle stop valve 52 for connection with seals. The outlet 933 is connected to the inlet 552 of the water supply line 55 in FIG. 1 with means to secure. The means to secure include but not limited the rotatable female threaded nut 5521 of the water supply line 55 in FIG. 1 and the male thread 9331 of the T-adapter 93 for connection with seals. [0048] The matching coupling 95 in FIG. 2 is employed for the T-adapter 93 to connect to the existing angle stop valve 52 having unlike size with means to secure. The means to secure include but not limited the rotatable female threaded nut 9311 of the T-adapter 93 and the male thread 9531 of the matching coupling 95 for connection with seals. The inlet 951 of the matching coupling 95 is connected to the outlet 522 of angle stop valve 52 with means to secure. The means to secure include but not limited the female thread 9511 of the matching coupling 95 and the male thread 5221 of the angle stop valve 52 for connection with seals. The matching coupling 94 in FIG. 2 is used for the T-adapter 93 to connect to the existing water supply line 55 having unlike size with means to secure. The means to secure include but not limited the female thread 9411 of the matching coupling 94 and the male thread 9331 of the T-adapter 93 for connection with seals. The outlet 943 of the matching coupling 94 in FIG. 2 is connect to the inlet 552 of water supply line 55 in FIG. 1 with means to secure. The means to secure include but not limited the rotatable female threaded nut 5521 of the water supply line 55 in FIG. 1 and the male thread 9431 of the matching coupling 94 for connection with seals. [0049] The hose hanger 36 in FIG. 4 includes the extended lengthy flat bar 364 having multiple openings for placement of the flexible hose 31 in FIG. 3 . The opening 361 in FIG. 4 located but not limited under the bar in the direction having but not limited lateral path is for permanent placement of the hose at one near end connected to the filter 43 as shown in FIG. 1 . The opening 361 in FIG. 4A of the hose hanger 36 has a raised element 3611 at the entrance to prevent the hose being displaced and a protruding line 3612 to lock in the hose. The hose hanger 36 stays stable at a certain position without much pivotal movement because the protruding line 361 of the hose hanger 36 locks a part of the hose 31 which is connected to the immobilized filter. The upward opening 362 in FIG. 4A of the hose hanger 36 is for temporary placement of any free part of the flexible hose 31 as shown in FIG. 1 . The raised elements 3621 , 3623 in FIG. 4A at the entrance of the opening 362 assist to prevent the hose 31 being displaced and the protruding line 3622 supports to lock in the hose 31 at any position. The prop lines 3643 , 3644 in FIG. 4A on the bar 364 are located to reinforce the bar strength. The mound 365 is provided to reinforce the area for mounting and the small hole 3651 on the mound 365 in FIG. 4A is located for securing on to the fastener 28 in FIG. 1 using the nut 282 . The indented surface 3652 on the mound 365 around the hole 3651 is added for the hose hanger 36 to prevent its pivotal movement. Because the toilet body 651 generally has the angled edge 6511 near the mounting location, the hose hanger 36 is supplied with angled body 3641 for placement over the edge 6511 as shown in FIG. 1 . [0050] The holder assembly 76 in FIG. 5 for placement of the lengthy sprayer 10 in FIG. 1 comprises the holder body 77 and the bracket 78 . The holder body 77 in FIG. 5A has a body 771 that contains the opening 773 for placement of the bracket 78 and the opening 772 for placement of the sprayer 10 . The holder body 77 includes the concave element 774 for securing the lengthy sprayer 10 in FIG. 1 in the place using the same concave element of the sprayer body. The concave element 1013 in FIG. 1 on the controller 101 of the sprayer 10 is for the high placement and the one 1039 on the extension bar 103 is for the lower placement of the sprayer 10 . The lower placement of the sprayer 10 requires the spacer 776 in FIG. 5A on the base of the opening 772 to offset the difference arisen from the dissimilar thicknesses between the controller and the extension bar in order that the sprayer is placed in the evenly manner. The holes 775 on the holder body 771 are for the fasteners to be secured to the bracket 78 or to any available mounting places. [0051] The adjustable bracket 78 in FIG. 5B for the holder 77 in FIG. 5A includes the body 781 having a reversed U-type clamp 785 with an opening 7855 for mounting over the top edge of the water tank 65 . The reversed U-type clamp 785 in FIG. 6 have three body elements: first body element 7854 being secured inside of the toilet water tank preferably but not limited above the water line 651 as shown in FIG. 8A , second body element 7852 being secured outside of the water tank, and third body element 7851 connecting first and second body elements for being placed on the top edge of the water tank. First body element 7854 in FIG. 6 includes small openings 7853 for means to secure 7858 in FIG. 8A . Second body element 7851 in FIG. 6 has the surface element 7841 for placing securing means including but not limited the foam tape 789 having adhesive on both sides for additional bondage. Second body element 7852 in FIG. 6 is extended for connection with the spacer element 7843 through the cutout element 7842 , wherein the spacer element 7843 has means for securing including but not limited the loop hole 7844 at the end using means to secure 787 including fasteners with the lock washer 7871 . The cutout element 7842 is located to facilitate pivotal movement of the spacer element 7843 at the end of second body element 7852 . [0052] The adjustable bracket 78 in FIG. 5B also includes the body 781 having an adjustable frame 782 that formulates the various angles for the reversed U-type clamp 785 . The adjustable frame 782 in FIG. 6 is connected to second element 784 of the reversed U-type clamp 785 through the bridge element 7822 . The bridge element 7822 having the cutout 7821 is located below third element 7851 of reversed U-type clamp 785 to give room 7855 for the toilet lid 60 in FIG. 8A . The cutout 7821 in FIG. 6 on the bridge element 7822 is located for the adjustable frame 782 to be easily pivoted. The adjustable frame 782 includes the prop element 7824 to reinforce the body structure, wherein the prop element 7824 contains the mound elements 7823 for the fasteners 778 in FIG. 8 to be secured. The prop element 7824 in FIG. 6 also contains the lengthy loop hole 7825 having the indentations 7826 around, wherein the indentations are located for more friction to lock the spacer element 7843 over the loop hole 7825 . The spacer element 7843 in FIG. 6 is secured anywhere along the lengthy loop hole 7825 with means to secure including but not limited screw and the lock washer 786 , making the reversed U-type clamp 785 be angled with certain degrees as shown in FIG. 6A and FIG. 6B . [0053] The adjustable bracket 78 assembled with the holder body 77 is placed over the top edge of the toilet water tank having straight wall as in FIG. 8 or angled wall as in FIG. 9 . The adjustable bracket 758 FIG. 9 is applied to placement of lavatory items with the holder body 75 attached and secured to the reversed U-type clamp. The most part of the bracket 78 is hidden in the holder body 77 except the reversed U-type clamp 785 , wherein the clamp 785 is secured to the interior wall of water tank 65 with the fasteners 7858 . Third element 7851 in FIG. 8A of the reversed U-type clamp 785 has some material thickness, leaving the gap between the water tank 65 and its lid 60 surrounding the area. The filler element 607 including but not limited foam tape 789 having adhesive on one side is employed to offset the gap. The filler element 607 in FIG. 7 is located on the body 601 of the water tank lid 60 to be leveled except the areas 605 , 606 for mounting brackets. The filler element 657 is alternatively located on the body 651 in FIG. 7A of the water tank 65 to level the lid 60 except the places 655 , 656 for mounting brackets. [0054] The water splash guard 812 in FIG. 10 is placed for the use of the sprayer inside of the bowl. It is located underbody 8184 of the toilet seat 81 around the opening 8182 to protect water escape through the gap between the toilet bowl 85 and the seat 81 in FIG. 11 . The seat 81 in FIG. 10 generally contains multiple bumpers 814 on the underbody 8184 around the opening 8182 in the middle of the seat body 818 in FIG. 10 . The bumpers around the opening 8182 create the gap 857 in FIG. 10B when the seat 81 is placed on the top edge 853 of the toilet bowl 85 in FIG. 10B . The water splash guard 812 in FIG. 10 is mounted for covering the gap 857 through the means to secure including but not limited the fasteners 8127 on the base 8124 of the water splash guard 812 with sealer 8125 as in FIG. 10A . The closed-ended water splash guard is fully located around the opening 8182 as in the FIG. 10 to protect the full surrounding gap. The width of the splash guard 812 is preferably greater than the thickness of the bumper 814 , and the edge 8121 is to be placed inside the bowl as close as possible, so that the water escape through the gap 857 can be minimized. The edge 8121 having round or beveled rim facilitates the placement of the water splash guard into the toilet bowl 85 . The open-end water splash guard is partially located around the opening 9192 as in the FIG. 11 for the open-ended seat 91 . The water splash guard 912 in FIG. 11 for the open-ended seat 91 is mounted on the underbody 9184 of the seat 918 using means to secure 9127 on the base 9124 . The edge 9121 of the water splash guard is preferably placed into the bowl as close to the inner top edge of the bowl to minimize water escape.
The invention relates to a toilet system affording hygienic environment by attachment of a hand held sprayer and additional features on the existing toilet system. The hand held sprayer that delivers water spray comprises a reinforced flexible hose, a filter to eliminate the pollutants in the water, a valve to regulate the flow, a mixing valve that supplies tempered water, a T-adapter assembly to tap water from an existing plumbing fixture, a holder assembly for placement of the sprayer with various positions using an adjustable bracket, and a hose hanger for arrangement of the hose. The new features include a toilet seat having a water splash guard on underbody of the seat and a filler element around the bracket to offset the inclined toilet lid.
4
This application is a continuation-in-part of application Ser. No. 08/698,608, filed Aug. 16, 1996 now U.S. Pat. No. 5,823,226 issued Oct. 20, 1998. TECHNICAL FIELD This invention relates to new assemblies and methods for connecting and releasing perforating guns for downhole use in oil and gas fields. More particularly, this invention relates to new assemblies and methods for connecting and releasing perforating gun sections that do not require rotating to latch and release the perforating gun connector. BACKGROUND OF THE INVENTION Conventional perforating gun sections used in perforating well casings typically include charge carriers designed to support several separate perforating charges within the desired longitudinal spacing and sometimes a desired radial orientation. Examples of various convention perforating gun sections are illustrated in U.S. Pat. No. 5,095,999 issued to Daniel C. Markel on Mar. 17, 1992, the specification of which is incorporated herein in its entirety. In particular, the Markel patent illustrates a conventional enclosed perforating gun section having a plurality of perforating charges mounted on a carrier strip and enclosed and protected within a carrier tube. (See U.S. Pat. No. 5,095,999, Column 5, lines 20-39 and FIG. 5.) As is well known in the industry, perforating gun sections use perforating shaped explosive charges designed to shape and direct the explosion with great precision along the focal axis. Typically, a perforating shaped charge will shape and direct a liner material to create a uniform circular jet that is highly focused and directed along the focal axis. The focused jet penetrates the casing that lines the well bore and the surrounding geological formation. The detonation of the perforating charges is intended to increase production of the well, which is hoped will result in a substantial increase in production pressure at the well head. Usually, maximizing the perforations achievable in a single-shot downhole procedure is desirable. For example, it is sometimes desirable to perforate hundreds even thousands, of linear feet of downhole casing to enhance well production. However, the length of the typical perforating gun section is about thirty feet. Of course, it is possible to achieve increased perforation of the downhole well casing by repeating the procedure of lowering a perforating gun section to perforate the downhole well casing and retrieving the spent perforating gun section until the desired longitudinal portion of the downhole well casing has been perforated. However, the time and expense involved in repeating each such downhole procedure mitigate in favor of perforating the desired portion of the well bore in a single downhole procedure. Thus, if it is desirable to perforate such lengths of the downhole casing, as is frequently desirable, two or more perforating gun sections must be connected together. The assembled string of perforating gun sections is then lowered downhole to perforate the well in a single shot. In the past, conventional threaded pin-and-bell connectors have been used to connect perforating gun sections. For example, after a first perforating gun section is positioned and set in a slip assembly at the rig floor of a well (usually with a threaded pin connector at the upper end thereof), a second perforating gun section is picked up and brought into position over the first perforating gun section. As the second perforating gun section (usually with a threaded bell connector at the lower end thereof) is swinging in the blocks of the rig, it must be carefully axially aligned with the first perforating gun section so that it can be set on the pin connector of the first perforating gun section. The second perforating gun section is then rotated to make up the threaded connection. There are several problems of using threaded pin-and-bell connections. For example, the process of carefully aligning and threading one elongated perforating gun section to the next is time consuming. Skilled oil-field hands need about one to two minutes to make up or break apart perforating gun sections using threaded pin-and-bell connectors. The step of aligning the second perforating gun section can be particularly difficult in windy conditions, which cause the thirty-foot section to swing in the blocks. If the second perforating gun is not properly aligned, the threads of the pin-and bell connectors are likely to gall and bind. Furthermore, connecting perforating gun sections with such conventional threaded pin-and-bell connectors presents special problems and risks. For example, manually rotating the second perforating gun section with a hand wrench is more time consuming than the with the use of power tongs. With a hand wrench, however, the oil-field hands can feel the process of threading the connector and be more sensitive to whether the threads are properly aligned to prevent galling. But while the use of power tongs to rotate a perforating gun section to make up the threaded connection is faster, if it works, the threads of the connection are much more likely to gall because of the speed of rotation and the oil-field hands' inability to feel the threading and make any necessary adjustments in the alignment of the threads. A galled threaded connector for perforating gun sections presents particular problems and dangers because of the explosives used in the sections. For example, if the threads gall and bind in a threaded pin-and-bell connector between two perforating gun sections, the transmission of the detonating signal between the two sections may not be reliable. Thus, it is usually desirable or necessary to separate the galled connection, and replace the connector and possibly both the perforating gun sections. However, unthreading the galled threads of the connector is sometimes difficult or impossible. Furthermore, cutting or shearing galled perforating gun sections, which contain high explosives, is counter indicated for obvious safety concerns. Thus, a galled threaded connection between perforating gun sections presents a serious problem. In the past, one of the only solutions to the problem of a seriously galled threaded connection has been to raise the two galled perforating gun sections and unthread the lower connection from the remainder of the perforating gun string, to then safely remove and handle the two improperly joined sections. However, this is wasteful of expensive perforating gun section equipment and extremely time consuming. For these reasons, it can take several minutes to align, set, and manually make-up each threaded connection between the perforating gun sections, and a galled connection can seriously impede the process of perforating a well. Thus, there has been a long-felt need for a better, more reliable, and faster connector for perforating gun sections. As an alternative to conventional threaded pin-and-bell connectors, some perforating gun connectors are activated or released by certain types of rotational movements other than threading. However, it is becoming increasingly common to use perforating gun sections with coil tubing. Coil tubing may be hundreds or thousands of feet long, such that it is extremely difficult or completely impractical to attempt to rotate the coil tubing to operate a latch or release connection. Thus, it would be desirable to provide a latch and release connector for use with perforating gun sections that does not have to be rotated. Additional problems are encountered in using perforating guns through a blowout preventer. The typical drilling well is provided with a blowout preventer ("BOP") at the well head, which is intended to maintain any pressure within the well head and prevent a blowout of the well. A blowout preventer is also used for safety to recomplete an existing well. A blowout can be an extremely hazardous situation if the oil or gas explodes or catches fire. Furthermore, even if the oil or gas does not ignite, allowing such uncontrolled escape is extremely wasteful of a valuable resource and harmful to the environment. In some countries such as the United States, an uncontrolled escape can subject the producer to substantial government fines for the environmental pollution and the costs of environmental clean up. Blowout preventers are well known in the art, and represented, for example, by U.S. Pat. No. 4,416,441 entitled "Blowout Preventer" issued to Denzal W. Van Winkle on Nov. 22, 1983 and by U.S. Pat. No. 4,943,031 entitled "Blowout Preventer" issued to Denzal W. Van Winkle on Jul. 24, 1990, both of which patents are incorporated herein by reference in their entirety. According to the art, two or more blowout preventers are typically used in a stack at the well head. For example, the rams of a lower blowout preventer are employed as slip rams, which have serrated metal teeth for gripping and holding a section of downhole tubing or other tool. The slip rams are useful as a type of slip assembly for holding a section of downhole tubing or perforating gun section, which can have many additional sections connected to and suspended from the lower end thereof. The rams of a second blowout preventer above the first are employed as sealing rams, having rubber seals adapted to be compressed against the downhole tubing or other tool to form a pressure-tight seal around the tubing or tool. Having additional blowout preventers in the stack is common. For example, the rams of a third blowout preventer above the sealing BOP can be equipped with shearing blades for cutting a piece of tubing for which the threads have seized onto the next tubing and cannot be normally unthreaded. The rams of a fourth blowout preventer above the rest can be employed as a blind seal, such that the well head can be completely sealed. Thus, a production well usually has at least two blowout preventers at the well head used for controlling the well. However, working through a stack of blowout preventers presents several additional problems and challenges. This is true even though the pressure at the well head is initially substantially balanced such that the well head can be opened for the insertion of a perforating gun section. For example, after using the perforating gun section to perforate the downhole well bore, it hopefully increases the well production and the production pressure at the well head. Thus, a problem is then presented of how to withdraw the spent perforating gun section through the blowout preventer. The problem is particularly problematic because a spent perforating gun section has itself been thoroughly perforated by the detonation of the perforating shaped charges. For example, the sealing rams of the sealing blowout preventer may have difficulty fully sealing against the warped, twisted, and punctured metal of the perforating gun section. Furthermore, the open holes created in the spent perforating gun section provide multiple conduits for the pressurized fluid in the well beneath the blowout preventers to enter the spent perforating gun section. Thus, the spent perforating gun section provides an undesired conduit through the blowout preventer stack, leaking or spewing the pressurized production. A prior art method of addressing this problem of how to remove a spent perforating gun section has been to balance the pressure in the well. Balancing the pressure is normally accomplished by pumping the appropriate density of drilling mud into the well head to equalize the pressure below and above the well head. However, this balancing procedure is sometimes called "killing" the well because it inhibits the production and can create other pressure management and technical difficulties. There has been a long-felt need for an apparatus and method for withdrawing the spent perforating gun section through the stack of blowout preventers at the well head without having to even temporarily kill the enhanced well production. Furthermore, enhancing the well production of a well that has some positive well pressure at the well head is often desirable. In such a case, perforating the downhole casing is still desirable. Of course, working through a blowout preventer stack with an intact perforating gun section before it has been detonated can be accomplished by employing a lubricator above the blowout preventer stack. The perforating gun sections can be made up with the lubricator according to techniques well known to those of skill in the art. However, the use of a lubricator above the blowout preventer further limits the length of the perforating gun sections that can be used to the practical length of the lubricator. A typical lubricator for such applications can accommodate perforating gun sections of up to about 35 feet (11 meters). Unfortunately, the use of conventional threaded pin-and-bell connectors through a lubricator above a blowout preventer stack is particularly time consuming. For example, it typically requires about five minutes for skilled oil-field hands to make up perforating gun sections together through a lubricator above a blowout preventer stack. There has been a particular long-felt need for an apparatus and method that would permit much faster connection and release of perforating gun sections through a lubricator and blowout preventer stack. The cost of oil field hands and recovered production time involved in stringing several perforating gun sections together has driven the search for faster apparatuses and methods. Nevertheless, to the knowledge of the inventors there is still a great need for additional improvements and methods. In some applications, perforating gun sections and connector assemblies must be able to pass through reduced diameter tubing or other downhole restrictions to reach the location in the casing where the perforation is to be performed. In these applications, the axial cross-section profile of the perforating gun string is particularly important. For example, in the perforation of a five-inch casing, passing through a small bore may be necessary for the perforating gun assemblies, such as two-and-one-half inch or one-and-eleven-sixteenth inch tubing or other passageway. These through-tubing perforating gun assemblies can be characterized as low-profile assemblies because of the restricted passageways through which they must pass to reach the desired downhole perforation location. These low-profile perforating gun assemblies do not have the luxury of design spacing which is present in perforating gun assemblies whose maximum outside dimensions approximate that of the casing that is to be perforated. These small profile or through-tubing perforating gun assemblies present particular problems that are not present in their larger profiled cousins. Thus, there has been a long-felt need for assemblies and methods capable of more quickly stringing two perforating guns together for firing in a single downhole procedure, thereby reducing the time and expense involved in perforating a well. There has been a long-felt need for apparatuses and methods of withdrawing and more quickly separating spent perforating gun sections from a well. In addition, there has been a particular need for apparatuses and methods for connecting and separating perforating gun sections through a blowout preventer stack while maintaining the pressure below the blowout preventer stack. SUMMARY OF THE INVENTION According to a first aspect of the invention, assemblies and methods are provided for connecting perforating gun sections for downhole use. According to this first aspect of the invention, a perforating gun connector includes a stinger and a stinger receptacle. The stinger is adapted to be stabbed into the stinger receptacle. A loaded engaging member movable between a running position before the stinger is stabbed into the stinger receptacle and a latched position when the stinger is stabbed into the stinger receptacle to latch the stinger and the stinger receptacle together. A release member retains the loaded engaging member in the running position. When the stinger is stabbed into the stinger receptacle and a set force is applied to the stinger and stinger receptacle, the release member releases the loaded engaging member to move to the latched position and latch the stinger and the stinger receptacle together. Neither the stinger nor the stinger receptacle have to be rotated to make up the connection between the perforating gun sections. According to a second aspect of the invention, a perforating gun connector is releasable. The perforating gun connector further includes a releasable stop member to stop the engaging member in the latched position. When the stop member is released, the engaging member moves to a released position such that the stinger and stinger receptacle are separable. Thus, the perforating gun sections can also be released without rotating. According to a third aspect of the invention, a perforating gun connector is provided with an internal explosive transfer system for transferring the detonation signal from one perforating gun, through the perforating gun connector, and to the next perforating gun. The internal explosive transfer system protects the booster charges to provide additional safety. These and other aspects, features, and advantages of the present invention will be apparent to those skilled in the art upon reading the following detailed description of preferred embodiments according to the invention. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings are incorporated into and form a part of the specification to provide illustrative examples of the present invention. These drawings with the description serve to explain the principles of the invention. The drawings are only for purposes of illustrating preferred and alternate embodiments of how the invention can be made and used. The drawings are not to be construed as limiting the invention to only the illustrated and described examples. Various advantages and features of the present invention will be apparent from a consideration of the accompanying drawings in which: FIG. 1 is an axial cross-section view of the stinger subassembly for a latch and release perforating gun connector according to the presently most preferred embodiment of the invention; FIG. 2 is an detail cross-section view of part of the internal explosive transfer system of the stinger subassembly according to FIG. 1; FIG. 3 is a detail cross-section view of an alternative embodiment of the probe portion of the stinger subassembly shown in FIG. 1, wherein the tip is disposable; FIG. 4 is an axial diagrammatic cross-section view of the latch and release subassembly for a latch and release perforating gun connector with parts being broken away to more clearly illustrate details of construction according to the presently most preferred embodiment of the invention; FIG. 5 is a horizontal cross-section view through the line 5--5 of FIG. 4 showing the spring-loaded stop/release pads in more detail; FIG. 6 is a horizontal cross-section view through the line 6--6 of FIG. 4 showing the collet fingers in more detail; FIG. 7 is an axial cross-section view showing the latch and release subassembly according to FIG. 4 in a running position for engaging the stinger subassembly according to FIG. 1; FIG. 8 is an axial cross-section view showing the latch and release subassembly according to FIG. 4 in a latched position on the stinger subassembly according to FIG. 1; and FIG. 9 is an axial cross-section view showing the latch and release subassembly according to FIG. 4 in a released position on the stinger subassembly according to FIG. 1. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The present invention will be described by referring to drawings of examples of how the invention can be made and used. Like reference characters are used throughout the several figures of the drawing to indicate like or corresponding parts. The structures of the stinger subassembly 10 shown in FIG. 1 will first be described in detail, and then the structures of the latch subassembly 100 shown in FIG. 4. Thereafter, how the structures cooperate and are used to latch perforating gun sections with ordinary slips and a clamp or through a blowout preventer stack will be described in detail. Regarding the use with a blowout preventer stack, the stack is assumed to have lower seal/slip rams and upper operating rams. STINGER SUBASSEMBLY Referring now to FIG. 1, a stinger subassembly 10 according to the presently most preferred embodiment of the invention is shown in an axial cross-section view. In general, the stinger subassembly 10 has a probe portion 12, a slip landing portion 14, a bell connector portion 16, and a stinger internal explosive transfer system 18. According to the presently most preferred embodiment of the invention, the stinger subassembly is generally symmetrical about a stinger central axis A 1 . In FIG. 1, the stinger subassembly 10 is shown with its central axis A 1 in a vertical orientation and such that the probe portion 12 is oriented upward. This illustrated orientation is how the stinger subassembly 10 would normally be oriented for use at the well head of a well. References to "upward," "downward," "above," "below," and other relative terms are understood to be with reference to the orientation of the stinger subassembly 10 shown in FIG. 1 of the drawing. The stinger subassembly 10 is adapted to mate with the latch subassembly 100 shown in FIG. 2 of the drawing and as hereinafter described in detail. Probe Portion of Stinger Subassembly Referring to FIG. 1, the probe portion 12 of the stinger subassembly 10 preferably has tip 20, a probe first ramp surface 22, a shank surface 24, a probe second ramp surface 26, a probe recess 28, a probe first shoulder surface 30, a probe landing surface 32, a probe second shoulder surface 34, and a centralizer surface 36. Of the stinger overall axial length L 1 of the stinger subassembly 10, the probe portion 12 has an axial probe length L 2 . According to the presently most preferred embodiment of the invention, the tip 20 presents a flat, circular surface that has a tip diameter D 1 . From the tip 20, the probe first ramped surface 22 is frusto-conical and expands in diameter downward along the axis A 1 from the tip 20 to the shank surface 24. This probe first ramp surface 22 faces upward and helps deflect and guide the probe portion 12 of the stinger subassembly 10 into the latch subassembly 100 as hereinafter described in detail. The shank surface 24 provides a structure for mating with the latch subassembly 100 and has a shank diameter D 2 . Below the shank surface 24 is the probe second ramp surface 26, the probe recess 28, and probe first shoulder surface 30. According to the presently most preferred embodiment of the stinger subassembly 10 illustrated in FIG. 1, the probe second ramp surface 26 is preferably frusto-conical and reduces in diameter downward along the axis A 1 from the shank surface 24. Thus, this probe second ramp surface 26 faces downward and helps deflect collet fingers of the latch subassembly 100 out of the recess 28 when the collet fingers are moved upward relative to the stinger subassembly 10 as will hereinafter be described in detail. According to the presently most preferred embodiment of the invention, the probe recess 28 is preferably a circumferential recess. Thus, the collet fingers can engage the probe recess 28 regardless of the relative rotational positions of the stinger subassembly 10 and the latch subassembly 100 as hereinafter described in detail. The circumferential probe recess 28 has a recess diameter D 3 . The probe first shoulder surface 30 faces upwards and defines the lower end of the recess 28. Below the probe first shoulder surface 30 is the probe landing surface 32 and the probe second shoulder surface 34. According to the presently most preferred embodiment of the stinger subassembly 10 illustrated in FIG. 1, the probe landing surface 32 is cylindrical and adapted to fit within the lower portion of the housing of the latch subassembly 100 as hereinafter described in detail. The cylindrical probe landing surface 32 has a landing diameter D 4 . The probe second shoulder surface 34 faces upward and serves as a mechanical stop to the further insertion of the probe portion 12 of the stinger subassembly 10 into the housing of the latch subassembly 100 as hereinafter described in detail. Below the probe second shoulder surface 34 is the centralizer surface 36. According to the presently most preferred embodiment of the stinger subassembly 10 illustrated in FIG. 1, the centralizer surface 36 is cylindrical having a centralizer diameter D 5 and is adapted to help centralize the stinger subassembly 10 within the tubulars of a well bore. Slip Landing Portion of Stinger Subassembly Continuing to refer to FIG. 1 of the drawing, the slip landing portion 14 of the stinger subassembly 10 is below the centralizer surface 36 of the probe portion 12. The slip landing portion 14 has a slip landing first shoulder surface 38, a slip landing surface 40, and a slip landing second shoulder surface 42. The slip landing portion 14 is preferably integrally formed with the probe portion 12 of the stinger subassembly. Of the overall length L 1 of the stinger subassembly, the slip landing portion 14 of the stinger subassembly 10 has an axial landing length L 3 . The slip landing first shoulder surface 38 faces downwards and defines the upper end of the slip landing surface 40. The slip landing surface 40 is cylindrical having a slip landing diameter D 6 and is structurally adapted to be engaged and held by a slip assembly at the rig floor or the seal/slip rams of a blowout preventer as hereinafter described in detail. The slip second shoulder surface 42 faces upwards and defines the lower end of the slip landing surface 40. The recessed slip landing surface 40 helps indicate a positive engagement of the seal/slip rams of a blowout preventer. However, it is to be understood that the slip landing surface 40 need not be recessed compared with the largest overall diameter of the stinger subassembly 10. Bell Connector Portion of Stinger Subassembly Continuing to refer to FIG. 1, the bell connector portion 16 of the stinger subassembly 10 is below the slip second shoulder surface 42 defining the lower end of the slip landing portion 14. The structure of the bell connector portion 16 can be of a standard form to adapt with correspondingly standard pin connectors on perforating gun sections. The bell connector portion 16 is preferably integrally formed with the slip landing portion 14 of the stinger subassembly. Of the overall length L 1 of the stinger subassembly, the bell connector portion 16 of the stinger subassembly 10 has an axial bell length L 4 . According to the presently most preferred embodiment of the invention, the bell connector portion 16 is a generally tubular body symmetrical about stinger central axis A 1 and defining a cylindrical connector surface 44 having a bell diameter D 7 . The interior of the bell connector portion 16 has a bell sealing area 46, a female threaded bore section 48, and an end seat section 50 formed therein. The interior of the bell connector portion 16 is adapted for receiving and engaging a correspondingly threaded and structured male pin connector. For example, the bell sealing area 46 is adapted to provide a surface for compressing one or more O-ring seals on a correspondingly structured pin connector. The cooperation of the bell sealing area 46 with the corresponding structure and O-ring seals of a corresponding pin connector forms a pressure-tight seal. Thus, the bell connector portion 16 is structurally adapted to be made-up with the correspondingly structured and threaded male pin connector of a perforating gun connector (not shown). The bell diameter D 7 is normally also adapted to help centralize the stinger subassembly 10 within the tubulars of a well bore. Stinger Internal Explosive Transfer System of Stinger Subassembly Continuing to refer to FIG. 1 of the drawing, the stinger internal explosive transfer system 18 is preferably located centrally within the stinger subassembly 10. According to the presently most preferred embodiment of the invention, the stinger internal explosive transfer system 18 includes a stinger internal chamber 52 that extends from a first end 54 adjacent the tip 20 of the probe portion 12 through the probe portion, through the slip/seal ram landing portion 14, and into the bell connector portion 16 to a second end 56 adjacent the end seat section 50 of the bell connector portion. The first end 54 of the stinger internal chamber 52 is sealed by the web material 58 defining the tip 20 of the probe portion 12. Positioned within the stinger internal tubular chamber 52 adjacent the first end 54 is a stinger booster charge 60. The booster charge is adapted to ignite a stinger detonating cord 62 positioned throughout substantially the entire length of the chamber 52. A stinger initiator section 64 is located at the second end 56 of the stinger internal chamber 52. Referring now to FIG. 2 of the drawing, the stinger initiator section 64 of the stinger internal explosive transfer system 18 is shown in more detail. The section 64 is shown adjacent the threads 48 of the bell connector portion 16 of the stinger subassembly. According to the presently most preferred embodiment of the invention, the stinger initiator section 64 includes a firing pin housing 66 with initiator retainer 68 that are threaded into the second end 56 of the stinger internal chamber 52 and sealed with initiator O-ring seals 70 and 72. The end of the detonating cord 62 is provided with an end seal 74 adjacent the firing pin housing 66. A firing pin 76 is mounted within the firing pin housing 66 with shear pins 78. The firing pin 76 is adapted to be fired by the detonating cord 62 toward the stinger initiator 80. According to the invention, the initiator 80 is deformed, but not breached by the firing pin 76, thus, a seal between the interior of the bell connector portion 16 is maintained. As will hereinafter be described in detail, the stinger internal explosive transfer system 18 is adapted to continue and transfer the detonation of the perforating charges from one perforating gun section, through the stinger subassembly 10, and to the next perforating gun section made-up with the bell connector portion 16 of the stinger subassembly 10. To help with the transfer of the detonation from the stinger subassembly 10 through the bell connector portion 16 to the next perforating gun section made up with the bell connector portion, the interior of the bell connector portion 16 is sealed against well fluids as previously described. Alternative End Portion and Disposable End Cap for Stinger Subassembly Referring to FIG. 3 of the drawing, according to an alternative embodiment of the present invention, an alternative structure is provided for a probe portion 12a of a stinger subassembly. The probe portion 12a includes an upper end portion 82, which is adapted to receive a disposable end cap 84. The upper end portion 82 of the probe portion 12 of the stinger subassembly 10 has the first end 54 of the stinger internal chamber 52 formed therein. The stinger receiving initiator charge 60 is positioned within the first end 54 of the stinger internal chamber 52. The upper end portion 82 has male threads 86 formed thereon. Beneath the male threads 86 is formed an O-ring groove 88 adapted to receive and trap a sealing O-ring 90. The disposable end cap 82 has outer surfaces 20a, 22a, and 24a that substantially conform to the surfaces 20, 22, and 24 previously described for the probe portion 12. The disposable end cap 84 also has an end web portion 58a that corresponds to the web portion 58 previously described for the probe portion 12. The body of the end cap 84 has a generally bell-shaped interior with a female threaded portion 92. The female threaded portion 92 of the end cap 84 is adapted to be threaded onto correspondingly male threaded portion 86 formed on the body of the probe portion 12a. Below the female threaded portion 92 is an end cap sealing surface 94, which is adapted to seal against the O-ring 90 positioned in the O-ring groove 88 when the end cap is threaded onto the probe portion 12a. Thus, the stinger subassembly 10 can be provided with a disposable end cap 82, thereby making the stinger subassembly reusable. LATCH SUBASSEMBLY Referring now to FIG. 4 of the drawing, a latch subassembly 100 according to the presently most preferred embodiment of the invention is shown in an axial cross-section view. In general, the latch subassembly 100 has a pin connector portion 102, a body portion 104, spring-loaded stop/release pads 106, a spring-loaded housing 108, collet fingers 110, and a latch internal explosive transfer system 112. According to the presently most preferred embodiment of the invention, the latch subassembly 100 is generally symmetrical about its central axis A 2 except as otherwise noted. In FIG. 4, the latch subassembly 100 is shown with its central axis A 2 in a vertical orientation and such that the housing portion 108 is downward. This orientation is how the latch subassembly 100 would normally be oriented for use at the well head of a well. Again, references to "upward," "downward," "above," "below," and other relative terms are understood to be with reference to the orientation of the latch subassembly 100 shown in FIG. 4 of the drawing. Pin Connector Portion of Latch Subassembly Referring now to FIG. 4 of the drawing, the latch subassembly 100 is described and shown in detail. In particular, the pin connector portion 102 is at the upper end of the latch subassembly 100. The structure of the pin connector portion 102 can be of a standard form to adapt with correspondingly standard bell connectors on perforating gun sections. Of the overall length L 5 of the latch subassembly 100, the pin connector portion 102 of the latch subassembly has an axial pin length L 6 . For the purposes of this description, it will be assumed that a corresponding bell connector portion of a perforating gun assembly (not shown) to be made up with the latch subassembly will have the same structure as the bell connector portion 16 previously described for the stinger subassembly 10. Thus, the pin connector portion 102 is a generally tubular body symmetrical about latch axis A 2 and defining an end surface 114, a male threaded pin section 116, a pin ramped surface 118, pin sealing surfaces 120, pin O-ring grooves 122, a pin shoulder surface 124, and a connector centralizer surface 126. The pin connector portion 102 is adapted to be made up with a correspondingly structured and threaded bell connector portion of a perforating gun section. When the pin connector portion 102 and a corresponding bell connector portion of a perforating gun section are moved toward each other, the pin connector portion 102 is guided into the open end section of the bell connector portion. The male threaded pin section 116 is made up with the female threaded section of the corresponding bell connector portion. The pin ramped surface 118 helps guide the pin connector portion 102 into the open end section of the corresponding bell connector portion. The pin O-ring grooves 122 formed in the pin sealing surface 120 are adapted to receive O-rings for helping to seal the pin sealing surface 120 with the bell sealing area of a corresponding bell connector portion of a perforating gun section. The pin sealing surface 120 also helps in aligning the latch central axis A 2 of the latch subassembly and its pin connector portion 102 with the corresponding bell connector portion of a perforating gun section. The pin end surface 114 and pin shoulder surface 124 provide mechanical stops against over-tightening the threaded connection between the pin connector portion 102 and a corresponding bell connector portion of a perforating gun section. The connector centralizer surface 126 having a pin diameter D 8 is adapted to help centralize the latch subassembly 100 within the tubulars of a well bore. According to the presently most preferred embodiment of the invention, the lower end of the bell connector portion 102 further has an inwardly facing shelf 128. As will hereinafter be described in detail, this shelf 128 helps in retaining the spring-loaded stop/release pads on the body portion 104. Body Portion of Latch Subassembly Continuing to refer to FIG. 4 of the drawing, the body portion 104 of the latch subassembly 100 is a structural member attached to the pin connector portion 102. The body portion 104 has an upper body portion 130 extending into the pin connector portion 102, a central body portion 132, and a lower body portion 134. The upper body portion 130 is for securely mounting the body portion 104 to the pin connector portion 102. As will hereinafter be described in detail, the spring-loaded stop/release pads 106 are connected to the central body portion 132, and the spring-loaded housing 108 and the collet fingers 110 are mounted to the lower body portion 134. According to the presently most preferred embodiment of the invention, the upper body portion 130 is a structural member in the general form of a cylindrical mandrel or other solid structural member adapted for connecting to the pin connector portion 102 of the latch subassembly 100. The upper body portion has a male threaded section adapted to be threaded into corresponding female threads formed in the pin connector portion 102. According to the presently most preferred embodiment of the invention, the central body portion 132 is a structural member having a generally cylindrical structure with an overall central body diameter D 9 . The central body portion 132 is preferably integrally formed with the upper body portion 130. The overall central body diameter D 9 is less than the connector centralizer diameter D 8 of the pin connector portion 102 to allow the spring-loaded stop/release pads 106 to be mounted to the outside of the central body portion 132. Nevertheless, the spring-loaded stop/release pads 106 still present an overall profile for the latch subassembly 100 that is not greater than the connector centralizer diameter D 8 . Thus, the latch subassembly 100 can pass through downhole tubing of a desired size. A plurality of alignment bores are formed in the central body portion 132, such as the illustrated two alignment bores 136a and 136b. Each of the alignment bores is preferably a cylindrical bore formed in the central body portion 132 and oriented radially about the latch central axis A 2 . As will hereinafter be described in detail, the alignment bores 136a-b are adapted to help maintain the stop/release pads 106 on the central body portion 132. Two additional alignment bores (not shown) are preferably radially oriented 180 degrees from each other and 90 degrees from the alignment bores 136a and 136b, respectively. Thus, a total of four alignment bores are radially spaced apart 90 degrees about the latch central axis A 2 . A plurality of spring bores are formed in the central body portion 132, such as the illustrated two upper spring bores 138a-b and the two lower spring bores 140a-b illustrated in FIG. 4. Each of the spring bores 138a-b and 140a-b is preferably a cylindrical bore formed in the central body portion 132 and oriented radially about the latch central axis A 2 . The upper spring bores 138a-b are each adapted to receive an upper spiral spring 142 therein, and the lower spring bores 140a-b are similarly each adapted to receive a similar spiral spring 144 therein. The two upper spring bores 138a and 138b are preferably radially opposed 180 degrees about the latch central axis A 2 as shown in FIG. 4. Thus, the upper spiral springs 142 positioned in these two upper spring bores can be loaded to exert opposed radial forces. Two additional upper spring bores (not shown) are preferably radially oriented 180 degrees from each other and 90 degrees from the upper spring bores 138a and 138b, respectively. Thus, a total of four upper spring bores are radially spaced apart 90 degrees about the latch central axis A 2 . As will hereinafter be described in detail, each of the four upper spiral springs 142 (only two shown in FIG. 4) mounted in the upper spring bores can be loaded to exert a force opposed to another upper spiral spring 142 mounted in a radially opposed upper spring bore. Similarly, the two lower spring bores 140a and 140b are preferably radially opposed 180 degrees about the latch central axis A 2 as shown in FIG. 4. Two additional lower spring bores (not shown) are preferably radially oriented 180 degrees from each other and 90 degrees from the lower spring bores 140a and 140b, respectively. Thus, a total of four lower spring bores are radially spaced apart 90 degrees about the latch central axis A 2 . As will hereinafter be described in detail, each of the four lower spiral springs 144 (only two shown in the FIG. 4) mounted in the lower spring bores are loaded to exert a force opposed to another lower spiral spring 144 mounted in a radially opposed lower spring bore. According to the presently most preferred embodiment of the invention, the lower body portion 134 is a structural member having a generally cylindrical structure with a lower body diameter D 10 . The lower body portion 134 is secured to the central body portion 132. The lower body portion 134 has a collar portion 146, which is preferably integrally formed thereon. The collar portion 146 defines an upwardly facing collar shoulder surface 148. As will hereinafter be described in detail, the collar shoulder surface 148 helps in mounting the spring-loaded housing 108 to the lower body portion 134. Furthermore, the collar portion 146 provides added structural material for helping in connecting the spring-loaded housing 108 thereto. The bottom end of the lower body portion 134 defines a generally bell-shaped opening 150. As will hereinafter be described in detail, the bell-shaped opening 150 is adapted to receive the probe tip 20 and the probe first ramped surface 22 of the probe portion 12 of the stinger subassembly 10. Further according to the presently most preferred embodiment of the invention, the bottom end of the lower body portion 134 adjacent the bell-shaped opening 150 has the collet fingers 110 connected thereto. The lower body diameter D 10 is preferably substantially the same as the overall central body diameter D 9 for central body portion 132. The lower body diameter D 10 of the lower body portion 134 is less than the connector centralizer diameter D 8 of the pin connector portion 102 to allow the spring-loaded housing 108 to be mounted to the outside of the lower body portion 134. Nevertheless, the spring-loaded housing still presents an overall profile for the latch subassembly 100 that is not greater than the connector centralizer diameter D 8 . Thus, the latch subassembly 100 can pass through downhole tubing of a desired size. Similarly, the diameter of the collar portion 146, although greater than the lower body diameter D 10 , is still less than the connector centralizer diameter D 8 of the pin connector portion 102. This smaller diameter allows the spring-loaded housing 108 to be mounted to the outside of the lower body portion 134 yet still present an overall profile for the latch subassembly 100 that is not greater than the connector centralizer D 8 . Thus, the latch subassembly 100 can pass through downhole tubing of a desired size. Spring-Loaded Stop/Release Pads of Latch Subassembly Referring now to FIGS. 4 and 5 of the drawing, the spring-loaded stop/release pads 106 are mounted to the central body portion 132. Of the overall length L 5 of the latch subassembly 100, the spring-loaded stop/release pads 106 have an axial pads length L 7 . According to the presently most preferred embodiment of the invention, the structure of the spring-loaded stop/release pads 106 is based on a tubular structure divided into four identical portions, as represented in the drawing by the two pads 152a and 152b shown in FIG. 4. All four of the pads 152a-d are shown in FIG. 5. Together, the four pads of the spring-loaded stop/release pads 106 present an overall pads diameter D 11 . The overall pads diameter D 1 , of the spring-loaded stop/release pads 106 is not greater than the connector centralizer diameter D 8 of the pin connector portion 102. Thus, the latch subassembly 100 can pass through downhole tubing of a desired size. As best shown in FIG. 5, the four pads 152a-d are positioned on the central body portion 132 over the radially oriented springs, such as upper springs 142. Thus, the springs 142 exert radially outward forces on the pads 152a-d. The upper end of each of the pads, as shown in FIG. 4 for the two pads 152a and 152b, also includes a peg 154a and 154b, respectively, adapted to fit within any of the four alignment bores, such as illustrated in FIG. 4 for the alignment bores 136a and 136b. Thus, the pegs help in retaining the vertical position of the pads on the central body portion 132. Further according to the presently most preferred embodiment of the invention, the upper end of each of the pads, as shown in FIG. 4 for the two pads 152a and 152b, extend into the shelf 128 of the pin connector portion 102. This helps in retaining the pads against the springs 142 and 144. As shown in FIG. 4, in the lower end of each of the pads, as shown for the pads 152a and 152b, is formed a shallow recess 156a and 156b, respectively. The shallow recesses are identically positioned on each of the pads such that when the four pads are positioned about the central body portion 132, the recesses define an at least partially circumferential recess. Thus, the recesses are adapted to position a tubular collar 158 over the lower end of the pads 152a-d. The cooperation of the shallow recesses with the tubular collar 158 retains the four pads, represented by pads 152a and 152b, against the upper springs 142 and lower springs 144. Thereby, the four pads are spring-loaded to the central body portion 132. To assemble the spring-loaded stop/release pads onto the central body portion 132, the body portion 104 is separated from the bell connector portion 102. The plurality of upper springs 142 are positioned in the upper spring bores 138a-d of the central body portion 132 as shown in FIGS. 4 and 5, and the plurality of lower springs 144 are positioned in the lower spring bores of central body portion, as shown in FIG. 4 for lower spring bores 140a-b. The pads 152a-d are then positioned over the central body portion 132, such that the peg 154 of each pad is positioned in one of the alignment bores, as shown in FIG. 4 for alignment bores 136a-b. The tubular collar 158 is positioned over the pads as shown in FIG. 4 to restrain them against the upper springs 142 and lower springs 144. The upper body portion 130 of the body portion 104 is then secured to the bell connector portion 102 such that the upper ends of the pads are restrained against the upper springs 142 and lower springs 144 as shown in FIG. 4. Spring-Loaded Housing of Latch Subassembly Continuing to refer to FIG. 4 of the drawing, the spring-loaded housing 108 is mounted on the lower body portion 134. The overall housing diameter D 12 of the spring-loaded housing 108 is not greater than the pin centralizer diameter D 8 , whereby the latch subassembly 100 can pass through downhole tubing of a desired size. When the spring-loaded housing 108 is set and ready for use as illustrated in FIG. 4 of the drawing, the housing 108 is spaced apart from the lower end of the spring-loaded stop/release pads 106 by an axial spacing length L 8 . As will hereinafter be described in detail, however, the spring-loaded housing 108 is adapted to be axially moved upward on the lower body portion 134, first to close the axial spacing length L 8 , and then to overlap with the lower end of the spring-loaded stop/release pads 106. Of the overall length L 5 of the latch subassembly 100 when it is in the set position shown of FIG. 4, the spring-loaded housing 108 has an axial length L 9 . According to the presently most preferred embodiment of the invention, the spring-loaded housing 108 includes a substantially tubular housing member 160 adapted to slide over the lower body portion 134. As will hereinafter be described in more detail, the tubular housing member 160 is preferably formed in two sections, an upper housing portion 160a and a lower housing portion 160b. The tubular housing member 160 has an inner diameter that is larger than the lower body diameter D 10 of the lower body portion 134, but adapted to slide over the collar portion 146 of the lower body portion 134. Thus, there is a first annular space 162 defined between the lower body diameter D 10 of the lower body portion 134 and the inner diameter of the tubular housing member 160 of the spring-loaded housing 108. The upper end of the first annular space 162 is open. The tubular member 160 has an inwardly facing flange 164 that can slide with the tubular member 160 along the lower body portion 134 and defines the lower end of the first annular space 162. As will hereinafter be described in detail, the first annular space 162 is adapted to move over the lower ends of the four pads 152a-d when the pads are radially compressed against the springs 142 and 144 such that the pads 152a-d present a smaller diameter profile. The flange 164 defines the upper end of a second annular space 166. The lower end of the second annular space 166 is defined by the upwardly facing collar shoulder surface 148 on the collar portion 146 of the lower body portion 134. The housing spring 168, which is trapped at its lower end by the upwardly facing collar shoulder surface 148 of the collar portion 146, exerts an upward force against the flange 164 of the tubular housing member 160. This upward force exerted by the spring 168 is parallel to the latch central axis A 2 . One or more retaining pins, such as screws 170 are tapped or threaded through the tubular housing member 160 and into the collar portion 146 of the lower body portion 134. Thus, the retaining screws 170 retain the tubular housing member over the lower body portion 134 against the force of the housing spring 168 positioned within the second annular space 166. The lower end of the tubular housing member 160 has an inwardly facing deflecting structure 172, which is for engaging the collet fingers 110 with the stinger subassembly 10 as will hereinafter be described in detail. According to the presently most preferred embodiment of the invention, the deflecting structure 172 has a deflecting first ramped surface 174, an engaging surface 176, and a deflecting second ramped surface 178. The deflecting first ramped surface 174 is frusto-conical and reduces in diameter downward along the axis A 2 of the latch subassembly 100. The engaging surface 176 defines an inner cylindrical wall below the deflecting first ramped surface 174. The deflecting second ramped surface 178 is frusto-conical and expands in diameter downward along the axis A 2 of the latch subassembly 100. As previously mentioned, according to the presently most preferred embodiment of the invention, the tubular housing member 160 is preferably formed into two portions, upper housing portion 160a and lower housing portion 160b. The upper housing portion 160a and the lower housing portion 160b are threaded together and retained with one or more set screws 180. This separable housing structure permits the latch assembly 100 to be more easily assembled. For example, the lower body portion 134 is removed from the central body portion 132, so that the upper housing portion 160a can be placed over the lower body portion 134 from its upper end. Otherwise, if the lower housing portion 160b were integrally formed with the upper housing portion 160a, the deflecting structure 172 would not slide over the diameter of the collar portion 146 on the lower body portion 134. Finally, according to the presently most preferred embodiment of the invention, a housing snap-ring seal 181 is provided between the lower body portion 134 and the tubular housing member 160 to prevent the housing from moving downward and accidentally releasing while running into and out of the well. The snap-ring 181 expands beyond the inside diameter of the pin threads on housing 160a. To assemble the spring-loaded housing 108 onto the lower body portion 134, the lower body portion 134 is separated from the central body portion 132. The housing spring 168 is positioned over the lower body portion 132 and slid downward until it is stopped by the upwardly facing collar shoulder surface 148 on the collar portion 146 of the lower body portion 134. The upper housing portion 160a is then positioned over the lower body portion 132 and slid downward such that the inwardly facing flange 164 compresses the spring 168 as shown in FIG. 4. The one or more retaining screws 170 are tapped or threaded through the tubular housing member 160 and into the collar portion 146 of the lower body portion 134. Thus, the retaining screws 170 retain the tubular housing member over the lower body portion 134 against the force of the housing spring 168 positioned within the second annular space 166. The lower housing portion 160b is slid upward from the lowermost end of the lower body portion 134. Then the lower housing portion 160b is threaded to the upper housing portion 160a and retained with one or more set screws 180. Collet Fingers of Latch Subassembly Continuing to refer to FIG. 4 of the drawing, the collet fingers 110 of the latch subassembly 100 are attached to the lower body portion 134. At least two collet fingers 110, such as the first and second collet fingers 182a and 182b are employed. However, it is to be understood that additional collet fingers can be used, which may be particularly desirable for a larger latch subassembly for use in larger downhole tubing applications. The arcuate extension of each of the collet fingers 182a and 182b is a matter of design choice, and is expected to range up to nearly 90 degrees of radial arc about the latch axis A 2 . Thus, if desired, four or more collet fingers 110 can be employed in the latch subassembly 100. According to the presently most preferred embodiment, as shown in FIG. 6 of the drawing of the invention, six collet fingers 182a-f are employed. Referring back to FIG. 4 of the drawing, each of the individual collet fingers, as represented by collet fingers 182a and 182b, has a dog portion 184 and a finger tip portion 186. The upper end of the dog portion 184 of each collet finger 182a-b is an extension of the lower body portion 134. The dog portion 184 is adapted to be sufficiently deformable to be deflected inward or outward relative to the relaxed position shown in FIG. 4 of the drawing. Alternatively, the dog portion 184 of each collet finger 182a-b can be pivotally mounted to the lower body portion 134 adjacent the bottom of the bell-shaped opening 150. According to the presently most preferred embodiment of the invention, the finger tip portion 186 of each of the collet fingers 182a-b has a plurality of surfaces adapted to be deflected by and engage with other surfaces of the stinger subassembly 10 and the latch subassembly 100. In particular, the finger tip portion of each of the collet fingers 182a-b has a first outwardly facing ramped surface 188, an outwardly facing vertical surface 190, a second outwardly facing ramped surface 192, a first inwardly facing ramped surface 194, an inwardly facing vertical surface 196, and a second inwardly facing ramped surface 198. The cooperation of these surfaces 188-198 with other surfaces and structures will hereinafter be described in more detail. Latch Internal Explosive Transfer System Continuing to refer to FIG. 4 of the drawing, the latch internal explosive transfer system 112 is preferably located centrally within the latch subassembly 100. According to the presently most preferred embodiment of the invention, the latch internal explosive transfer system 112 includes a latch internal chamber 200. The chamber 200 extends from a first end 202 adjacent the end surface 114 of the pin connector portion 102 and through the entire body portion 104 to a second end 204 adjacent the bell-shaped opening 150 of the lower body portion 134. Positioned within the latch internal chamber 200 adjacent the first end 202 is a latch receiving booster charge 206. A latch detonating cord 208 is positioned through substantially the entire length of the chamber 200. A latch booster charge 210 and a downward focused shaped charge 212 are positioned in the chamber 200 adjacent the second end 204 of the chamber 200. As will hereinafter be described in detail, the latch internal explosive transfer system 112 is adapted to continue and transfer the detonation of the perforating charges from one perforating gun section made-up with the pin connector portion 102 of the latch subassembly 100, through the latch subassembly 100, and to a stinger subassembly 10 latched to the latch subassembly 100. As previously mentioned, the stinger subassembly 10 in turn continues and transfers the detonation to the next perforating gun section made-up with the bell connector portion 16 of the stinger subassembly 10. Method of Using Latch and Release Perforating Gun Connector Referring now to FIG. 7 of the drawing, the stinger subassembly 10 is shown as it is positioned when the slip landing surface 40 of the slip landing portion 14 are held by the seal/slip rams of a blowout preventer (not shown). For the purposes of this description, the stinger subassembly 10 has already been made up with a lower perforating gun section (not shown), which has been inserted through the blowout preventer seal/slip rams. The latch subassembly 100 has been made up with an upper perforating gun section (not shown), which has been moved into a lubricator above the blowout preventer. The upper perforating gun section with the latch subassembly 100 at the lower end thereof is then lowered through the blowout preventer onto the probe portion 12 of the stinger subassembly 10. The latch subassembly 100 is lowered until the deflecting structure 172 of the spring-loaded housing 108 is stopped by the second shoulder surface 34 above the centralizer surface 36 of the stinger subassembly 10, as shown in FIG. 7. In this running position illustrated in FIG. 7, the tip 20 of the probe portion 12 of the stinger subassembly 10 is slightly spaced apart from the upper end of the bell-shaped opening 150 formed in the lower body portion 134. In this running position, the finger tip portion 186 of each of the individual collet fingers 182a and 182b can at least partially begin to be deflected into the recess 28 of the probe portion 12 on the stinger subassembly 10. As can be seen in FIG. 7, the housing spring 168 is trapped in the second annular space 166 defined by the lower body portion 134, the tubular housing member 160, and the flange 164. As previously described, the potential energy of the housing spring 168 is retained by the retaining screws 170 threaded through the tubular housing portion 160 into the collar portion 146 of the lower body portion 134. At this point, a downward force is applied to the latch subassembly 100. This force is transmitted axially through the latch subassembly 100 to the lower body portion, through the retaining screws 170, through the spring-loaded housing 108 at the deflecting structure 172 to the second shoulder surface 34 above the centralizer surface 36 of the stinger subassembly 10. A sufficiently strong downward force is applied to the latch subassembly that the retaining screws 170 are sheared between tubular housing member 160 and the lower body portion 134. Once the retaining screws 170 have been sheared, the tubular housing member 160 is released from the lower body portion 134. Thus, the housing spring 168, which is trapped between the surface 148 of the collar portion 146 of the lower body portion 134 and the flange 164 of the tubular housing member 160, is now free to drive the slidably mounted tubular housing body 160 upward on the lower body portion 134. Referring now to FIG. 8 of the drawing, the latch subassembly 100 is shown in a latched position on the stinger subassembly 10. Each of the retaining screws 170 are shown as having been sheared into two portions. An outer portion 170a of the sheared retaining screw travels with the upwardly moving tubular housing member 160. An inner portion 170b of the sheared retaining screw remains with the collar portion 146 of the lower body portion 134. The upward movement of the tubular housing member 160 on the lower body portion 134 permits the latch subassembly 100 to settle onto the tip 20 of the probe portion 12 of the stinger subassembly 10. Driven by the released housing spring 168, the tubular housing member 160 moves upward on the lower body portion 134 until it is stopped by the pads, such as pads 152a-b, of the spring-loaded stop/release pads 106. At this point, the potential energy of the housing spring 168 is only partially released in driving the tubular housing member 160 upward. The upward movement of the tubular housing member 160 also causes the deflecting structure 172 to force and deflect the collet fingers inward. More particularly, the deflecting first ramped surface 174 of the deflecting structure 172 engages the second outwardly facing ramped surface 192 of the finger tip portion 186 inward. Thus, the finger tip portion 186 of each of the collet fingers 182a and 182b are deflected into the probe recess 28 of the probe portion 12 of the stinger subassembly 10. The various surfaces on the probe portion 12 of the stinger subassembly and the deflecting structure 172 of the tubular housing member cooperate to trap the finger tip portions 186 of the collet fingers 182a-b in the probe recess 28. Thus, the latch subassembly 100 is securely latched onto the probe portion 12 of the stinger subassembly. This process of latching the latch subassembly 100 to the stinger subassembly 10 can be accomplished in a matter of seconds. The stinger subassembly 10 and the latch subassembly 100 form a completed connection between the lower and upper perforating gun sections (not shown). The perforating gun sections can then be lowered downhole to perforate the well. It is to be understood, of course, that additional perforating gun sections can be successively added to the string using successive additional pairs of stinger subassemblies 10 and latch subassemblies 100. Furthermore, according to the presently most preferred embodiment of the invention, a detonating signal can be transmitted from the latch subassembly 100 to the stinger subassembly 10. Referring back to FIG. 4 of the drawing, a detonating signal is transmitted from an upper perforating gun to the latch internal explosive transfer system 112 of the latch subassembly 100. The detonating signal from the upper perforating gun detonates the latch receiving booster charge 206. The booster charge 206 in turn ignites the latch detonating cord 208 positioned within the latch internal chamber 200. The latch detonating cord 208 transfers the detonating signal to the latch booster charge 210, which detonates the latch downward focused shaped charge 212. The shaped charge 212 pierces the web material of the lower body portion 134 below the second end 204 of the chamber 200 and fires through the stinger tip web 58 of the stinger subassembly 10 that is latched to the latch subassembly 100. Referring again to FIG. 8 of the drawing, which shows the latch subassembly 100 in a latched position on the stinger subassembly 10, the tip 20 of the probe 12 of the stinger subassembly 10 is preferably flush with the inner surface of the bell-shaped opening 150 of the lower body portion 134 of the latch subassembly 100. The latch shaped charge 212 pierces through the thickness of the web material 58 defining the tip 20 of the probe portion 12. The latch downward focused shaped charge 212 is adapted to pierce the tip 20 of the subassembly 10. According to the previously described alternative embodiment of the stinger subassembly with respect to FIG. 3 of the drawing, the latch downward focused shape charge 212 pierces the disposable end cap 84. Referring back to FIG. 1 of the drawing, which shows the stinger subassembly 10 in detail, piercing the web material 58 defining the tip 20 of the probe portion 12 initiates the stinger internal explosive transfer system 18. More particularly, the latch shaped charge 212 pierces the material to initiate the stinger booster charge 60. The stinger booster charge 60 in turn ignites the stinger detonating cord 62 within the stinger internal chamber 52. The stinger detonating cord 62 transfers the detonating signal to the stinger initiator section 64, best shown in FIG. 2. The firing pin 76 mounted within the firing pin housing 66 is fired by the detonating cord 62 toward the stinger initiator 80. According to the invention, the initiator 80 is deformed, but not breached by the firing pin 76; thus, a seal between the interior of the stinger internal chamber 52 and the bell connector portion 16 is maintained. The deforming material of the initiator drives downward to detonate the initiator. This detonation of the initiator initiates a booster charge in a perforating gun section connected to the bell connector portion 16 of stinger subassembly 10. Thus, the detonating signal is transferred from the stinger subassembly 10 to a booster charge and detonating cord in the lower perforating gun section (not shown). The detonating cord in the lower perforating gun section serially detonates the perforating charges in that perforating gun section. If a plurality of perforating gun sections are connected using the stinger subassembly 10 and latch subassembly 100, the detonating signal is carried through the successive connections as described herein. After the perforating gun sections have been detonated downhole to perforate the well, they are raised back toward the well head. The second (upper) perforating gun section is raised through the blowout preventer stack until the slip landing portion 14 of the stinger subassembly 10 aligns with the seal/slip rams of the blowout preventer stack. The seal/slip rams of the blowout preventer stack are engaged to seal and hold the perforating gun section string at the stinger subassembly 10. Since the integrity of the stinger subassembly 10 has been maintained, the latch subassembly 100 can be removed from the stinger subassembly 10 without allowing any fluid to escape through the seal/slip rams of the blowout preventer stack. According to the presently most preferred embodiment of the invention, a clamp or the operating rams of another blowout preventer above the seal/slip rams in the blowout preventer stack are employed to release the latch subassembly 100 from the stinger subassembly 10. As used herein, the term "operating" rams refers to any of a number of different types of rams that are usually employed above the seal/slip rams, except shearing or other type rams that would undesirably damage the latch subassembly. Referring to FIG. 8, the operating rams engage the spring-loaded stop/release pads 106 and radially compress the pads 152a-b toward the latch central axis A 2 . This compressing force opposes the radially outward force of springs 142 and 144 and deflects the pads 152a-d inward toward the central body portion 132. Thus, the effective diameter of the spring-loaded stop release pads 106 is reduced. Meanwhile, the tubular housing member 160 is still being acted upon by the housing spring 168 trapped within the second annular space 166. Thus, once the spring-loaded stop release pads 106 are sufficiently compressed, the open end of the tubular housing member 160 can slide upward over the pads 152a-d. Referring now to FIG. 9 of the drawing, the latch subassembly is shown in a released position. The housing spring 168 maintains the tubular housing member 160 over the pads 152a-d, which retains them in the reduced diameter form against the opposing forces of the springs 142 and 144 of the spring-loaded latch pads 106. The further upward movement of the tubular housing member 160 also causes the deflecting structure 172 to move upward. This releases the finger tip 186 of the collet fingers 182a-b, such that the latch subassembly 100 can be lifted off the probe portion 12 of the stinger subassembly 10. More particularly, as the latch subassembly 100 is lifted upward, the probe second ramp surface 26 deflects the second inwardly facing ramped surface 188 of the finger tip portion 186 of each of the collet fingers 182a-b. Thus, the finger tip portion 186 of each of the collet fingers 182a-b is deflected out of the probe recess 28 of the probe portion 12 of the stinger subassembly 10. This process of releasing the latch subassembly 100 from the stinger subassembly 10 can be accomplished within a few seconds. Throughout the process, the integrity of the blowout preventer stack pressure seal at the well head can be maintained. An Example of Latch and Release Gun Connector for Use Through 5-inch Tubing Of course, the particular dimensions of the stinger subassembly 10 and latch subassembly 100 according to this invention are a matter of engineering design choice depending on many parameters. Such parameters, include, for example, the particular size of the well tubing and casing in which the stinger subassembly is to be used. The stinger subassembly 10 and latch subassembly 100 can be designed, for example, for use in 5-inch tubing. However, this illustrative example is for the purposes of more fully describing the presently most preferred embodiment of the invention, but not to limit the invention to the particular dimensions of such a disclosed preferred embodiment. Accordingly, referring back to FIG. 1 of the drawing, the stinger subassembly 10 can have, for example, the following basic dimensions: an overall axial stinger length L 1 of about 24 inches (61 cm), an axial probe length L 2 of about 10 inches (26 cm); an axial landing length L 3 of about 10 inches (26 cm); an axial bell length L 4 of about 5 inches (13 cm); a tip diameter D 1 of about 1 inches (2.5 cm); a shank diameter D 2 of about 2 inches (5 cm); a recess diameter D 3 of about 1.5 inches (4 cm); a probe landing diameter D 4 of about 2.5 inches (6.5 cm); a centralizer diameter D 5 of about 3.5 inches (9 cm); a slip landing diameter D 6 of about 3 inches (8 cm); and a bell diameter D 7 of about 3.5 inches (9 cm). Referring again to FIG. 4 of the drawing, the latch subassembly 100 can have, for example, the following basic dimensions: an overall axial latch length L 5 of about 30 inches (76 cm); an axial pin length L 6 of about 8 inches (20 cm); an axial pads length L 7 of about 9 inches (23 cm); an axial spacing length L 8 of about 1.2 inches (3 cm); an axial housing length L 9 of about 12 inches (30 cm); a pin diameter D 8 of about 3.5 inches (9 cm); an overall central body diameter D 9 of about 3.2 inches (8 cm); a lower body diameter D 10 of about 2.2 inches (5.6 cm); an overall pads diameter D 1 of about 3.2 inches (8 cm); and an overall housing diameter D 12 of about 3.5 inches (9 cm). The embodiments shown and described above are only exemplary. For example, the preferred embodiment for the spring-loading the housing is representative of a structure for storing potential energy for moving the housing. Even though numerous characteristics and advantages of the present inventions have been set forth in the foregoing description, together with the details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in the detail, especially in the matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad and general meaning of the terms used in the attached claims. The restrictive description and drawings of the specific examples above do not point out what an infringement of this patent would be, but are to provide at least one explanation of how to make and use the inventions. The limit of the inventions and the bounds of the patent protection are measured by and defined in the following claims.
A perforating gun connector is provided for downhole use in oil and gas fields. The perforating gun connector includes a stinger and a stinger receptacle. The stinger is adapted to be stabbed into the stinger receptacle. A loaded engaging member movable between a running position before the stinger is stabbed into the stinger receptacle and a latched position when the stinger is stabbed into the stinger receptacle to latch the stinger and the stinger receptacle together. A release member retains the loaded engaging member in the running position. When the stinger is stabbed into the stinger receptacle and a set force is applied to the stinger and stinger receptacle, the release member releases the loaded engaging member to move to the latched position and latch the stinger and the stinger receptacle together. According to a second aspect of the invention, the perforating gun connector is releasable, further including a releasable stop member to stop the engaging member in the latched position. When the stop member is released, the engaging member moves to a released position such that the stinger and stinger receptacle are separable. According to a third aspect of the invention, a perforating gun connector is provided with an internal explosive transfer system for transferring the detonation signal from one perforating gun, through the perforating gun connector, and to the next perforating gun. In addition, a method of connecting a first perforating gun section to a second perforating gun section is provided.
4
FIELD OF THE INVENTION The present invention is directed to wireless communications systems and more particularly, to methods and apparatus for constructing, organizing, and allocating traffic channel segments in order to use the air link resource in an efficient manner. BACKGROUND In a wireless communication system, air link resources generally include bandwidth over time or code over time. The air link resource that transports data and/or voice traffic is called a traffic channel. The design of the traffic channel, e.g., how to partition the bandwidth over time available and how to allocate the partitioned bandwidth over time between competing users, is important, as the traffic channel generally occupies the major portion of the system's air link resource. A plurality of users, e.g., wireless terminals, throughout the cells of the system will be operating concurrently and will request use of the traffic channel for the transmission of data and/or voice traffic, e.g. segments of the traffic channel(s) of the system. The number and type of users will vary in the system over time and compete for those air link resources. The levels of resource requested by different types of users, e.g., a wireless data terminal vs a cell phone will also vary. The level of resource requested by a single user will change over time, e.g. a wireless terminal may transition between states from a sleep state to a hold state to an on state, with each state requiring different levels of resources. The levels of performance tolerated, requested, or required by different users in terms of: acceptable signal-to-noise levels, tolerated error rates, tolerated delays between requests for resources and grants of resources, power requirements, and burst data rates may also vary. The location of the user, e.g., wireless terminal, with respect to: the base station, adjacent cell/sector introducing interference, and obstructions may influence the selection of how to divide and allocate the available air link resource. Certain structures of traffic segments, e.g., more bandwidth per segment maybe more advantageous for one set of problems, while other types of structures, e.g., less bandwidth but for a longer time duration may be more beneficial to address other concerns. Based upon the above discussion, it should be apparent that there is a need for improved methods and apparatus for segmenting and/or using communications resources. SUMMARY OF THE INVENTION In a wireless communications system the air link resource, e.g., bandwidth over time or code over time, that transmits information is called a channel. The description of this summary is made with reference to an exemplary OFDM system; however the invention is also applicable to other types of communication systems, e.g., CDMA. Communications systems may have a plurality of channels, such as, e.g., an uplink traffic channel for data and/or voice transmissions from the wireless terminals to the base station, a downlink traffic channel for data and/or voice transmissions from a base station to the wireless terminals, request channels, and assignment channels. The transmission units that carry the information, are grouped into transmission segments. In the case of an exemplary OFDM implementation transmission units may be in the form of tone-symbols where a tone-symbol represents one tone that is allocated for use for one symbol transmission time. The transmission segment is the basic unit of a channel. Over time, a series of segments are assigned for each channel. The invention describes methods and apparatus for constructing, organizing, and allocating transmission segments in order to utilize the air link resource in an efficient manner, minimize interference levels amongst users, reduce overhead, conserve energy of users, balancing the system, provide flexibility, and increase overall system performance. The channels may be subdivided, e.g. in the frequency domain into sets of tones. The subdivided channels may be referred to as sub-channels or simply as channels. For example, an uplink traffic channel may be subdivided into a plurality or channels, e.g., with each channel having a set of assigned tones. Each channel may be subdivided into a plurality of segments in the time domain. In accordance with the invention, there may be a plurality of different transmission segment types. Different transmission segment types are structured, in accordance with the invention, to achieve different benefits. Sets of information defining each transmission segment type are stored in memory prior to assigning segments of the transmission segment type to one or more transmitters. The sets of information defining the transmission segment types includes information specifying a number of transmission units to be transmitted over a period of time, e.g. number of tone-symbols/segment. The period of time is segmented into slots. The time slot may correspond to the time used to transmit any single transmission unit, e.g. the time slot may be an OFDM symbol time. Alternatively, the time slot may be a fixed number of OFDM symbol times. Segments of each transmission segment type includes a specified number of transmission units per unit time, e.g. total number of tone-symbols/time slot. The period of time over which a segment of a transmission segment is transmitted may be different for different transmission segment types, e.g., some segments occupy more time than other segments. In some embodiments, the number of transmission units per unit time for one type of transmission segment may be the same as for another type of transmission segment, e.g., same number of tone-symbols in each segment. In some embodiments, the number of transmission units per unit time for segments of different transmission segment type may be different, e.g. some segments may have occupy more tones in the frequency domain than other segments. In some embodiments, the number of transmission units per segment may be different or some of the segments. In some embodiments, the total number of transmission units per segment may be the same for one transmission segment type as for another transmission segment type, e.g., the same total number of tone-symbols are in each segment. This embodiment has advantages in facilitating rapid retransmission, as any lost segment will fit into any other segment and thus delay is reduced in segment allocation for retransmission purposes. This embodiment also has advantages in allowing flexibility in allocation, in allowing relative characteristics to be pre-defined between different types of segments, and then allowing the segments to be allocated to users to take advantage of those properties. There may be a plurality of N traffic channels, and sets of information on each of those traffic channels may be defined and stored, in accordance with the invention. The information on each traffic channel includes information defining segments of a specific transmission segment type and information indicating start times of segments within the channel. In accordance with the invention, the start times of segments within different channels may be different. In some embodiments the start times of segments within one channel may be different than the start times of segments within another channel. While offset segment start times can be beneficial they are not mandatory. If the start times of the segments were identical, the users, with requests occurring randomly, may have to wait until the next single start time for an allocation; this may result in significant delays. Offsetting segment start times tends to reduce these delays and thereby improve performance. Also, if start times are aligned, significant allocation processing may occur concurrently which is not desirable in cases where processing resources are limited. In addition, with segment start times occurring concurrently, there will tend to be a concentration of the active segments. With offset start times, the active segment transmissions will tend to be more distributed, reducing interference throughout the system. In accordance with the invention, the start times of a plurality of segments in different channels may be defined and stored so that the start times are distributed to minimize the variation in the maximum number of segments that start in any given time slot. By minimizing the variation in the maximum number of slots that start in any given slot, the allocation message structure can be made more efficient, and require less resources, e.g. bandwidth, making that bandwidth available for other uses, e.g., more user data. For a high variation in start times, the allocation channel allocates bandwidth for the highest number of possible concurrent start time messages; however, when lower numbers of segments start, those reserved may go partially unused yet still use up bandwidth, and thus the bandwidth can be wasted. With minimum variation in start times, air link resources can be conserved. In accordance with the invention, in comparing transmission segment types with the same number of transmission units, e.g. tone-symbols, transmission segment types may be differentiated between segments with more transmission units per unit time sometimes referred to as “tall” segments, e.g. those with more tones, as opposed to segments with less transmission units per unit time sometimes referred to as “long” segments, e.g., less tones per symbol time but longer time duration of the segment. In accordance with the invention, allocation of segments to different devices, e.g., wireless terminals, or users may be based upon a determination made as to which user has the better transmission channel conditions. In accordance with the invention, the user with the better transmission channel conditions is assigned segments with more transmission units per unit time, while another user is assigned segments with less transmission units per unit time. Also considerations such as limited transmission power concerns of the wireless terminals may be taken into account when assigning segments. In accordance with the invention, the allocation of power per transmission unit to be used to transmit segments of different transmission segment types may also be based upon the type of segment, e.g. does the segment type have more transmission units per unit time or less transmission units per unit time. In some embodiments the transmission segments with less transmission units per unit time are allocated more transmission power per transmission unit than the transmission segments with more transmission units per unit time. In some cases, the power level difference allocated on per transmission unit basis between the two types of segments is at least a factor of 2. In accordance with the invention, the base station utilizes the segmentation and allocation methods of the invention to effectively utilize the air link resources. The base station and wireless terminals interchange information to classify users, based upon interference levels, channel quality reports and evaluations, power information, user requests, and user priority. The base station uses the structural information in the segmentation scheme, e.g. classifications of types of segments, with known performance advantages and disadvantages associated with each type, to match users to types of segments to effectively and efficiently balance the system. BRIEF DESCRIPTION OF THE FIGURES FIG. 1 illustrates two exemplary traffic channel segments illustrating that the air link resource occupied by a traffic segment may vary from one segment to another. FIG. 2 illustrates air link resources in the context of an exemplary OFDM system. FIG. 3 illustrates one embodiment of constructing traffic channel segments where the traffic channel is divided into multiple sub-channels in the frequency space and each sub-channel is divided into a sequence of segments in the time space in accordance with the present invention. FIG. 4 illustrates one example of arranging the assignment channel and the traffic channel in accordance with the present invention. FIG. 5 illustrates another example of arranging the assignment channel and traffic channel, where the traffic channel segments have been staggered achieving more efficient use of assignment channel segments, in accordance with the present invention. FIG. 6 illustrates an exemplary system using the methods and apparatus of the present invention. FIG. 7 illustrates an exemplary base station implemented in accordance with the present invention. FIG. 8 illustrates an exemplary end node (wireless terminal) implemented in accordance with the present invention. FIG. 9 illustrates an exemplary set of traffic segment information which may be stored in a base station and/or wireless terminal prior to traffic segment assignments. FIG. 10 illustrates sets of traffic channel information, e.g., predetermined traffic channel information, that may be stored in base stations and/or wireless terminals and used to make or interpret traffic channel segment assignments which can correspond to different traffic channels for which predetermined information is stored. DETAILED DESCRIPTION In one embodiment of the invention, the traffic channel includes a plurality of series of traffic channel segments. A traffic channel segment occupies certain air link resources for fixed finite time duration. For example, an exemplary traffic segment may occupy a specified bandwidth for a given time interval. At any given time, there can be multiple traffic channel segments that are active. For example, different traffic segments concurrent in the time domain with non-overlapping bandwidth allocation may have been assigned to different users. The amount of air link resource occupied by a traffic channel segment may vary from one traffic channel segment to another. FIG. 1 shows a graph 100 of frequency on the vertical axis 102 and time on the horizontal axis 104 . The frequency domain includes two equal size frequency units 106 , 108 . The time domain includes 4 equal size slots 110 , 112 , 114 , 116 . In FIG. 1 , an exemplary first segment, segment A 118 , illustrated with vertical line shading, occupies one time slot 110 and two frequency units 106 and 110 . An exemplary second segment, segment B 120 , illustrated with horizontal line shading, occupies three time slots 112 , 114 , and 116 and one frequency unit 106 . Segment A 118 may be assigned and used by a first user, user # 1. Segment B 120 may be assigned and used by a second user, user #2. The air link resource could have been structured in terms of code units over time. In a similar manner to the FIG. 1 exemplary illustration, if air link resource is represented in terms of code units over time, segment A could have been structured to include one time slot and two code units while segment B could have been structured to include three time slots and one code unit. FIG. 2 illustrates a graph 200 of frequency on the vertical axis 202 vs time on the horizontal axis 204 which may be illustrative, for the purpose of explanation of the invention, in the context of an exemplary OFDM system using traffic channel segments. In the OFDM system, available bandwidth 206 is divided into a number of orthogonal tones 208 , e.g. six tones are shown in FIG. 2 . At any OFDM symbol period 210 , any of the tones 208 can be used to transmit a complex number representing the information to be communicated. FIG. 2 shows 5 OFDM symbol periods 210 . The basic unit of the air link resource is a tone 208 at an OFDM symbol 210 , which is called a tone-symbol 214 , illustrated by a square in FIG. 2 . Air link resource 212 of FIG. 2 includes 30 tone-symbols 214 . Each tone-symbol 214 can be used to transmit a modulation symbol that carries information. A segment includes one or a plurality of tone-symbols 214 over a fixed time interval. The invention is described in this application using the OFDM system as an exemplary system, with the understanding that the invention is applicable to other systems as well, such as, e.g., systems using Code Division Multiple Access (CDMA), Time Division Multiple Access (TDMA). A traffic channel segment is the basic unit of the traffic channel resource. In the some embodiments, there are downlink and uplink traffic channel segments. The traffic channel resource is allocated in a form of traffic segment allocation. That is, the base station assigns traffic channel segments to the users, e.g., wireless terminals, in the cell such that the assigned users receive data/voice traffic in the assigned downlink traffic segments or transmit data/voice traffic in the assigned uplink traffic segments. The allocation of traffic segments can be different from one segment to another. For example, in FIG. 1 , segment A 118 is assigned to user #1 and segment B 120 is assigned to use #2. In order to enhance the system performance and user experience, in some embodiments, the time duration of a traffic segment is short such that the base station can rapidly assign the traffic channel segments to different users according to their traffic needs and channel conditions, which may be time varying in general. The traffic channel can be thus effectively shared and dynamically allocated among different users in a segment-by-segment manner. In one embodiment, the amount of air link resource, i.e., the number of tone-symbols, of individual traffic channel segments is the same. For example, one segment can have 10 tone-symbols over 5 OFDM symbol periods, while another segment can have 2 tone-symbols over 25 OFDM symbol periods. Advantageously, having the same number of tone-symbols for all the traffic channel segments can facilitate retransmission (ARQ, automatic repeat request). For example, suppose that the user data information is conveyed by a set of modulation symbols with certain coding and modulation scheme. Those modulation symbols are transmitted with the tone-symbols of a traffic channel segment. Assume the receiver is unable to successfully receive the segment. Then, the same set of modulation symbols can be retransmitted with any subsequent traffic channel segment, as each of the segments have the same number of tone-symbols. One embodiment of constructing traffic channel segments is to first divide the traffic channel into multiple sub-channels in the frequency space and then divide each sub-channel into a sequence of segments in the time space. FIG. 3 illustrates such a construction of traffic channel segments in an exemplary OFDM system. FIG. 3 includes a graph 300 of frequency on the vertical axis 302 vs time on the horizontal axis 304 . Suppose the traffic channel occupies a fixed number of tones. In FIG. 3 , exemplary traffic channel 322 occupies 4 tones, tone 1 306 , tone 2 308 , tone 3 310 , and tone 4 312 , those traffic channel tones are contiguous for the sake of Illustration in FIG. 3 . In reality, those tones can be, and often are, non-contiguous. The set of traffic channel tones 306 , 308 , 310 , 312 , is divided into a few disjoint subsets, each of which is to be used by a sub-channel. FIG. 3 shows 3 sub-channels: sub-channel 1 324 , illustrated with diagonal line shading, sub-channel 2 326 , illustrated with cross hatch shading, and sub-channel 3 328 , illustrated with horizontal line shading. Note that the number of tones occupied by each sub-channel can be different. Sub-channel 1 324 occupies 2 tones: tone 3 310 and tone 4 312 ; sub-channel 2 326 occupies 1 tone, tone 2 308 ; sub-channel 3 308 occupies 1 tone, tone 1 306 . Each sub-channel 324 , 326 , 328 is further divided into a sequence of an infinite number of segments. FIG. 3 illustrates the first 4 time slots: slot 1 314 , slot 2 316 , slot 3 318 , and slot 4 320 . If one supposes the segments have the same size, e.g. same amount of air link resource, then the time duration of a segment of a sub-channel with larger number of tones is shorter than that of a segment of a sub-channel with smaller number of tones. Each “tall” segment 330 , 332 , 340 , 344 of sub-channel 1 324 occupies 2 tones (tone 3 310 and tone 4 312 ) over one time slot. Each “short” segment 336 , 338 of sub-channel 2 326 occupies one tone (tone 2 308 ) over 2 time slots. Each “short” segment 334 , 342 of sub-channel 3 328 occupies one tone (tone 1 306 ) over two time slots. A reason of organizing the traffic channel in segments is to have great freedom of allocating the traffic channel. U.S. patent application Ser. No. 09/706,377 describes a system where each traffic channel segment is independently allocated. Thus, those segments can be potentially allocated to different users rapidly, thereby enabling highly efficient statistical multiplexing. In that system, there is an assignment channel, which is separate from the traffic channel. Each traffic channel segment is associated with an assignment channel segment, which is used to send an allocation message that specifies the identifier of the user allocated to that traffic segment. In general, an assignment segment is transmitted no later than the corresponding traffic segment. In one embodiment of the system, the time difference between an assignment segment and the corresponding traffic segment is constant, which represents the minimum requirement due to storing or decoding the received control information. FIG. 4 and FIG. 5 illustrates two examples of arranging the assignment channel and the traffic channel. In both examples, each assignment channel segment has a fixed number information bits. Although not necessary, this arrangement may be desirable because each assignment segment now can use the same coding and modulation scheme. FIG. 4 includes a graph 400 of frequency on the vertical axis 402 vs time on the horizontal axis 404 . Assignment segments 406 are indicated with dot shading, and include an assignment, a segment 410 and an assignment B segment 412 . Traffic segments 408 are subdivided into sub-channels. Sub-channel 1 424 is illustrated with diagonal line shading and includes a traffic segment # 1 414 and a traffic segment # 4 420 . Sub-channel 2 426 is illustrated with cross hatch shading and includes a traffic segment 92 416 . Sub-channel 3 428 is illustrated with horizontal line shading and includes traffic segment # 3 418 . In FIG. 4 , the time domain is divided into slots, and successive six slots 430 , 432 , 434 , 436 , 428 , 440 are shown. In the first example of assignment/traffic segment arrangement shown, illustrated by FIG. 4 , the segments of the sub-channels are structured such that the number of the traffic segments that start at any slot varies from 1 to 3. For example, at the start slot 434 , 3 traffic segments 414 , 416 , 418 start; however, at the start of time slot 436 one traffic segment 420 starts. Consequently, each assignment channel segment 410 , 412 includes the capability to include at least three allocation messages. Assignment A segment 410 conveys 3 allocation messages for traffic segments 1 414 , traffic segment 2 416 , and traffic segment 3 418 . When only one traffic segment starts, the corresponding assignment segment includes only one allocation message, and the remaining information bits, which would be available for another two allocation messages, are unused. Assignment B segment 412 conveys one allocation message for traffic segment 4 420 . As the assignment channel is to be broadcast to most of the users in the system, any information bits in the assignment channel cause significant power resource. Hence, in the example of FIG. 4 , the unused information bits in the assignment channel, e.g. in assignment B segment 412 , waste the system resource. FIG. 5 includes a graph 500 of frequency on the vertical axis 502 vs time on the horizontal axis 504 . Assignment segments 506 are indicated with dot shading, and include an assignment A segment 510 and an assignment B segment 512 . Traffic segments 508 are subdivided into sub-channels. Sub-channel 1 524 is illustrated with diagonal line shading and includes a traffic segment # 1 514 and a traffic segment # 3 520 . Sub-channel 2 526 is illustrated with cross hatch shading and includes a traffic segment # 2 516 . Sub-channel 3 528 is illustrated with horizontal line shading and includes traffic segment # 5 518 . In FIG. 5 , the time domain is divided into slots, and seven successive slots 530 , 532 , 534 , 536 , 538 , 540 , 542 are shown. FIG. 5 illustrates another exemplary embodiment of the invention in which the segments of the sub-channels are staggered in time such that the number of the traffic segments that start at any slot has the minimum variation. Specifically, the segments of the sub-channels are structured such that the number of the traffic segments that start at any slot is 2. For example, at the start of time slot 534 , traffic channel segment # 1 514 and traffic channel segment # 2 516 start based upon the assignment from assignment A segment 510 . At the start of time slot 536 , traffic channel segment # 3 520 and traffic channel segment # 4 518 start based upon the assignment from assignment B segment 512 . Consequently, each assignment channel segment 510 , 512 include two allocation messages and does not leave information bits unused due to structure. Thus the implementation of FIG. 5 , using reserved bits (resources) for 4 allocation messages/4 traffic segments is more efficient over the implementation of FIG. 4 , using reserved bits (resources) for 6 allocation messages/4 traffic segments. Given a coding and modulation scheme, traffic channel segments of different shapes result in different burst data rates, and therefore can be allocated to meet the rate and delay requirement of different users. For example, a “tall” segment, which has a large number of tones over a short time interval, e.g. segment 514 of FIG. 5 , results in higher burst data rate than a “long” segment, which has a small number of tones over a long time interval, e.g., traffic segment 516 of FIG. 5 . Hence, a tall segment can be allocated to a user that is sensitive to delay while a long segment can be allocated a user that is insensitive to delay. In addition to the above traffic service consideration, the physical layer consideration can also be taken into account when traffic channel segments are allocated. In the uplink, when a user, e.g., wireless terminal, transmits a traffic channel segment to the desired base station, the user also generates interference to adjacent base stations as well. Roughly speaking, if the ratio of the signal power received at the desired base station to the interference power received at the adjacent base stations is small, the user is considered in a “bad” location. If the ratio is large, the user is considered in a “good” location. In one embodiment, tall segments should be allocated to users in a good location, while long segments should be allocated to users in a bad location to control the interference. In addition, the user terminal has often limited transmission power capability, because of the battery power or power amplifier consideration. To improve the air link robustness, it is desirable to allocate long segments to users far from the base station from the path loss perspective. In the downlink, when a user receives a traffic channel segment from the desired base station, the user also sees interference from adjacent base stations as well. Roughly speaking, if the ratio of the signal power received from the desired base station to the interference power received from the adjacent base stations is small, the user is considered in a “bad” location. If the ratio is large, the user is considered in a “good” location. For a user in a good location, the capacity of the communication channel is often bandwidth limited, in the sense that even if the transmission power is doubled, the capacity may be much less than doubled (power saturation). For a user in a bad location, the capacity of the communication channel is often power limited, in the sense that even if the transmission bandwidth is doubled, the capacity may be much less than doubled (bandwidth saturation). In one embodiment, multiple users are allocated to the simultaneous traffic segments, each with a sub-channel. The set of simultaneous scheduled users includes users in a good location and users in a bad location. Users in a good location are allocated to tall segments, while users in a bad location are allocated to long segments. Furthermore, consider the normalized transmission power of those traffic segments, which is defined as the allocated power for each tone-symbol of the segments. The normalized transmission power used in tall segments is preferably smaller than that used in long segments. In one embodiment, each sub-channel is allocated a fixed budget, which is a fraction of the total transmission power budget. The transmission power of the segments of each sub-channel is thus bounded by that fixed budget. In some embodiments users may be classified in a plurality of levels between “good location” and “bad location” definitions. Similarly, the types of segments may be classified in a plurality of levels between “tall segments” and “long segments. In accordance with the invention, the base station may selectively match the pluralities of location definitions with the pluralities of segment definitions to improve overall system performance and robustness. FIG. 6 illustrates an exemplary communications system 600 using apparatus and methods in accordance with the present invention. Exemplary communications system 600 includes a plurality of base station base station 1 (BS 1 ) 602 , base station N (BS N) 602 ′. BS 1 602 is coupled to a plurality of end nodes (ENs), EN 1 608 , EN N 610 via wireless links 612 , 614 respectively. Similarly, BS N 602 ′ is coupled to a plurality of end nodes (ENs), EN 1 608 ′, EN N 610 ′ via wireless links 612 ′, 614 ′ respectively. Cell 1 604 represents the wireless coverage area in which BS 1 602 may communicate with ENs, e.g., EN 1 608 . Cell N 606 represents the wireless coverage area in which BS N 602 ′ may communicate with ENs, e.g., EN 1 608 ′. ENs 608 , 610 , 608 ′ and 610 ′ may move throughout the communications system 600 . The base stations BS 1 602 , BS N 602 ′ are coupled to a network node 616 via network links 618 , 620 , respectively. The network node 616 is coupled to other network nodes, e.g., other base station, routers, home agent node, Authentication Authorization Accounting (AAA) server nodes, etc., and the internet via network link 622 . Network links 618 , 620 , 622 may be, e.g., fiber optic cables. Network link 622 provides an interface outside the communications system 600 , allowing users, e.g. ENs, to communicate with nodes outside system 600 . FIG. 7 illustrates an exemplary base station 700 in accordance with the present invention. Exemplary base station 700 may be a more detailed representation of base stations 602 , 602 ′ of FIG. 6 . Exemplary base station 700 includes a receiver 702 , a transmitter 704 , a processor 706 , e.g., CPU, an I/O interface 708 and memory 710 coupled together via a bus 709 . The various elements 702 , 704 , 706 , 708 , and 710 may exchange data and information over bus 709 . The receiver 702 and the transmitter 704 are coupled to antennas 703 , 705 , respectively, providing a means for the base station 700 to communicate, e.g. interchange data and information, with end nodes, e.g. wireless terminals, within its cellular coverage area. The receiver 702 , including a decoder 712 , receives and decodes signaling, which had been encoded and transmitted by end nodes operating within its cell. The transmitter 704 includes an encoder 714 , which encodes signaling prior to transmission. The memory 710 includes routines 718 and data/information 720 . The processor 706 controls the operation of the base station 700 by executing routines 718 and utilizing data/information 720 in memory 710 to operate the receiver 702 , the transmitter 704 , and the I/O interface 708 , to perform the processing controlling basic base station functionality, and to control and implement the new features and improvements of the present invention including scheduling of users to traffic segment. I/O interface 708 provides base station 700 with an interface to the internet and other network nodes, e.g., intermediate network nodes, routers, AAA server nodes, home agent nodes, etc., thus allowing end nodes communicating through wireless links with base station 700 to connect, communicate, and interchange data and information with other peer nodes, e.g., another end node, throughout the communication system and external to the communication system, e.g., via the internet. Routines 718 include communications routines 722 , and base station control routines 724 . The base station control routines 724 includes a scheduler 726 with a segment matching routine 728 . The data/information 720 includes data 734 , segment information 736 , and user data/info 738 . The user data/info 738 includes a plurality of user information, user 1 information 740 , user n information 754 . Each user information, e.g., user 1 info 740 , terminal Identification (ID) 742 , data 744 , request information 746 , status info 748 , quality report information 750 , and classification information 752 . Data 734 may include received data from end nodes (wireless terminals), data to be transmitted to end nodes, data being processed, and data to support the functionality of the base station 700 . Segment information 736 includes information on the number of segments, type of segments, status of segments, size of segments, sets of tones in segments, number of tone-symbols per segment, relative positioning of segments, categorization of segments, traffic segment information 730 and assignment segment information 733 . Traffic segment info 730 includes segment type information for a plurality of predetermined segment types. Traffic segment information includes information defining segment slot times, and information defining which segments are “tall segments”, e.g. large # of tones, and which segments are “long segments”, e.g., longer time interval but fewer tones. Sets of information defining aspects of individual traffic segment types are included in some embodiments. Traffic channel information 731 includes information about different traffic channels. Each traffic channel includes a plurality of segments normally corresponding to a single segment type. A single segment is included in most traffic channels at any given time, e.g., traffic channels are normally one segment high. Traffic channel information 731 includes traffic channel size and structure, information defining sub-channel composites. It also includes information about segment start times for each traffic channel. An exemplary set of traffic segment information 730 is shown in FIG. 9 . In the illustrated embodiment, traffic segment information includes a plurality of X sets of information, each one of the x sets of information defining a different type of traffic segment. Each set of traffic segment type definition information 780 , 780 ′ includes information 782 , 782 ′ indicating the number of transmission units per unit time period which are included in a traffic segment. This information may be thought of as defining the height of a traffic segment since it indicates the number of units to be transmitted in a unit time period, e.g., a symbol time, in a segment of the type defined by the information set 780 , 780 ′. The set of traffic segment type information 780 , 780 ′ also includes total transmission unit number information 784 , 784 ′. This information indicates the total number of transmission units in a segment of the type defined by the set 780 , 781 of traffic information. The total number of transmission units may be specified as a fixed number, as a number of unit transmission time periods or in some other manner. When specified as a number of unit transmission time periods, the number of total transmission units in a segment of the defined type is equal to the transmission units per unit time indicated in information 782 , 782 ′ times the corresponding number of unit transmission time periods indicated in information 78 , 784 ′. Each transmission segment is divided into one or more time slots. Each set of information 780 , 780 ′ includes information indicating the number of transmission unit time periods, e.g., transmission symbol times, in each time slot for the defined traffic segment type. When considered in combination with the transmission unit per unit time information 782 . 784 , information 786 , 786 ′ can be considered as indicating the number of transmission units per traffic segment time slot for a segment of the defined type. As will be discussed below, both base stations and wireless terminals may store traffic segment information 730 and use this information in combination with assignment information to determine the shape, duration and/or total data capacity of an assigned traffic segment. Traffic segment information 730 is used in combination with traffic channel information 731 . FIG. 10 illustrates and exemplary set of traffic channel information 731 . The exemplary traffic channel information 731 includes N sets of traffic channel information 990 , 990 ′ where each set includes information corresponding to, e.g., defining, one of N traffic channels. The set of information 990 , 990 ′ corresponding to each traffic channel includes information 992 , 992 ′ indicating the type of segment used in the traffic channel and information 994 , 994 ′ indicating the start time of the segments which form the traffic channel. Segment start times of different channels may, and often are, staggered to minimize the maximum delay between any two consecutive segment start times of a set of traffic channels being used. Thus, segment start time information 994 and 994 ′ will normally be different. Assignment segment information 733 includes information specifying the number of traffic segments that may be assigned at the start of one slot based on the traffic segment system structure, and timing information between the assignment segments and traffic segments. Terminal ID 742 is a base station defined identification for the user, e.g., wireless terminal. Data 744 may include specific user data such as data to be transmitted to user 1 . Request info 746 may include requests from the user for a change of state, requests for more allocation of bandwidth, power requests, burst data rate requests, sensitivity of the user to delays, etc. Status information 748 may include the present state of the user, e.g. sleep, hold, on, user power level status and interference levels the user is experiencing. Quality report information 750 may include feedback information from the user concerning downlink channel quality, levels of interference being experienced, etc. Classification information 752 may include a category that the user has been placed in concerning type of traffic segments to be allocated, e.g. whether the wireless terminal is considered a “good location” unit or a “bad location” unit. Communications routines 722 includes various communications applications which may be used to provide particular services, e.g., IP telephony services or interactive gaming, to one or more end node users. Base station control routines 724 performs functions including basic control of the signal generation and reception, control of data and pilot hopping sequences, control of encoder 712 and decoder 714 , scheduling, allocation of bandwidth to users, scheduling users to terminal IDs 744 , and control of the output transmission power from the base station 700 . The base station control routines also include a scheduler 726 , which schedules users, e.g., wireless terminals, to terminal IDs 742 . The scheduler 726 includes a segment matching routine 728 which performs segment matching, e.g. allocation of traffic channel segments to wireless terminals, in accordance with the methods, features, techniques, and structures of the present invention. In some embodiments, segment matching routine allocates segments of different segment types as a function of transmission channel. As part of the allocating process, the segment matching routine determines which of multiple devices, e.g., first and second wireless terminals, has better transmission channel conditions. This is normally determined from channel quality feedback information provided by each of the wireless terminals to the base station for power control and/or scheduling purposes. In accordance with one such embodiment, the segment matching routine allocated transmission segments of a first type to the wireless terminal with the better channel conditions and segment of a second type to a wireless terminal that has a lower quality communications channel. The segments of the second type are usually longer than the segments of the first type. Thus, wireless terminals with comparatively bad channel conditions are likely to be allocated segments which include fewer tones per symbol time but include more symbol times than the segments which are allocated to wireless terminals with better channel conditions. In accordance with the present invention, segments of the first and second type are often transmitted at the same time, e.g., with segments of different types being allocated to different wireless terminals. Power allocation routine 729 allocates power to be used in transmitting segments. In some embodiments the routine allocates a first amount of power per transmission unit to be used in transmitting segments of the first type and a second amount of power per transmission unit to be used in transmitting segments of the second type. In some cases, the second amount of power per transmission unit is at least twice the first amount of power per transmission unit. Since the segments of the second type include fewer tones per symbol time period, the comparatively larger amount of power allocated to the second channel as compared to the first channel does not place an undue burden on the base stations total transmission power budget. Furthermore, since the transmission segment of the first type are used for transmitting to the wireless terminals with the comparatively good channel conditions, lower per tone power transmissions than the power level used when transmitting segments of the second type still provides adequate transmission quality. By allocating a large number of tones to devices with good channel conditions and a comparatively smaller number of tones to devices with poor channel conditions, efficient use of a limited total transmission power budget can be achieved. In various embodiments the schedule matching routine 728 uses the segment info 736 and the user data/info 738 to attempt to match the user's requests for traffic segments to appropriate segments based upon information such as classification 752 , request info 746 , and quality report info 750 . Segment matching routine 728 tries to balance the requests of the users while trying to maintain an overall high level of performance throughout the system. FIG. 8 illustrates an exemplary end node 800 in accordance with the present invention. Exemplary end node 800 may be a more detailed representation of end nodes 608 , 610 , 608 ′, 610 ′ of FIG. 6 . Exemplary end node 800 , e.g., wireless terminal, may be a mobile terminal, mobile, mobile node, fixed wireless device, etc. In this application, references to end node 800 may vary, e.g., wireless terminal, mobile node, etc., and may be used interchangeably. Exemplary end node 800 includes a receiver 802 , a transmitter 804 , a processor 806 , e.g. CPU, and memory 808 coupled together via a bus 810 . The various elements 802 , 804 , 806 , 808 may exchange data and information over bus 810 . The receiver 802 and the transmitter 804 are coupled to antennas 803 , 805 , respectively providing a means for the end node 800 to communicate with the base station 700 via wireless links. The receiver 802 includes a decoder 812 . The receiver 802 receives and decodes signaling, e.g. data transmissions, which were encoded and transmitted by a base station 700 . The transmitter 804 includes an encoder 816 , which encodes signaling prior to transmission. The memory 808 includes routines 820 and data/information 822 as well as traffic segment information 730 and traffic channel information 731 . This information may be the same as, or similar to, the information included in the base station. The processor 806 controls the operation of the end node 800 by executing routines 820 and utilizing data/information 822 in memory 808 to operate the receiver 802 and the transmitter 804 , to perform the processing controlling basic wireless terminal functionality, and to control and implement the new features and improvements of the present invention including signaling and processing related to traffic segment requests and allocation in accordance with the invention. Routines 820 include communications routines 824 and wireless terminal control routines 826 . The data/information 822 includes user data 832 and user info 834 . User data 832 may include data to be transmitted to the base station 700 and data received from base station 700 , e.g., the data conveyed in the traffic segments. Terminal ID info 836 includes the base station assigned user ID. Base station ID information 838 includes information for the wireless terminal to identify the base state, e.g. a value for slope. The wireless terminal 800 may use the terminal ID 836 and the base station ID 838 to determine the data/control and pilot tone hopping sequences. The terminal ID 836 may also be used to recognize in an assignment segment that resources have been allocated to the wireless terminal 800 . Interference information 840 may include measured levels or interference experienced by the wireless terminal. Status information 842 may include state of the wireless terminal sleep, hold, on. Request information 844 may include requests from the wireless terminal for a change of state, more resources, e.g., traffic segments, requests for more power, requests for higher burst data rates, etc. Quality channel report 846 includes information collected such as Signal-to-Noise ratio, downlink channel information, and information on the status of the wireless terminal 800 that may be feed back to the base station 700 . Traffic channel assignment information 848 includes information about the assignment segments and the predetermined relationship to traffic segments of various traffic channels. Traffic channel assignment information 848 may also include received assignment information, e.g., information received from one or more assignment segments indicating the assignment of particular traffic channel segments to the wireless terminal. The received assignment information in combination with traffic segment information 730 and traffic channel information 731 is used by the wireless terminal to determine which traffic segments it can use for transmission and/or reception of data and the start time of the assigned segments in the various channels. Communications routines 824 include various communications applications that may be used to provide particular services, e.g., IP telephony services or interactive gaming, to one or more end node users. Wireless terminal control routines 826 control the basic functionality of the wireless terminal 800 including the operation of the transmitter 804 and receiver 802 , signal generation and reception including data/control hopping sequences, state control, and power control. The wireless terminal control routines 826 include a device status control and signaling module 828 and a data and data signaling module 830 . The device status control and signaling module 828 uses the data/info 822 including status info 842 and request info 844 to perform operations including control of signaling and processing related to changes in state which includes requests for more bandwidth, e.g. request for traffic segments in accordance with the present invention. Wireless terminal control routines 826 may also process and evaluate, user info 834 including interference info 840 , generate quality report information 846 and signal information included in report info 846 to the base station 700 , in accordance with the invention. The data and data signaling module, 830 uses the data/info 822 including terminal ID 836 and traffic channel assignment 848 to performs operations including recognition of assigned traffic segments and signaling associated with the those traffic segments in accordance with the present invention. The present invention may be implemented in hardware and/or software. For example, some aspects of the invention may be implemented as processor executed program instructions. Alternately, or in addition, some aspects of the present invention may be implemented as integrated circuits, such as, e.g., ASICs.
The invention describes methods and apparatus to structure the air link resources, e.g. traffic channel, into segments of different transmission segment types and effectively use that novel structure. Different segment types are structured to achieve different performance characteristics. The segments may be aligned with different offsetting start times chosen to minimize the variation in the maximum number of segments starting at any given time slot. This staggering of segment start times minimizes waste in unused assignment messages due to structural inefficiencies, and has an overall effect of balancing the traffic. Information collected on the channel quality that various user's are experiencing may be used to classify the users. Stored information on different segment types, each with different benefits, is used in the allocation process to effectively match classified users to well-suited segment types to increase performance, balance the system, conserve power, and satisfy the users.
8
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] Not applicable. STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not applicable. REFERENCE TO A MICROFICHE APPENDIX [0003] Not applicable. BACKGROUND OF THE INVENTION [0004] 1. Field of the Invention [0005] The present invention relates to a light transmitting panel for metal roofing systems. Although other references teach away from the use of fasteners, it would be a benefit to have a light transmitting panel adapted for connection in a metal roofing system that would allow the use of fasteners and the like to secure the light transmitting panel to the metal panel. It is thus an object of this invention to provide a light transmitting panel for use in metal roofing systems for allowing ambient light to enter a structure and which meets UL 90 and ASTM E 1592 bag test specifications with and without the use of conventional fasteners or clips. One such assembly would be built using a metal panel, with multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with or without linear coefficient barriers. [0006] 2. Description of the Related Art [0007] For many years commercial buildings have utilized sheet metal roofs. Recently it has become more common and popular to utilize sheet metal roofs on residential homes, shops, patios and the like. Typically, the standing seam metal roof utilizes metal sheets having lateral upturned edges. The panels are laid side by side with the lateral edges of one panel contiguous with the upstanding edge of adjacent panels. The panels are joined together by a cap piece or by folding over the upstanding edge to tightly hold the panels together. The roofs are sloped so that water runs down the trough formed between the upstanding edges of each panel. [0008] The above referenced roofing systems may take many forms such as, but not limited to, trapezoidal, 90-degree modular, architectural, and industrial. Metal roofs may have minor ribs, stiffener ribs, or no ribs at all and may be a screw down roofing system. All of these roofing systems are similar in the requirement of attaching the panels at adjacent edges or side rails. [0009] It is very often desirable with metal roofing systems to have additional natural lighting whereby sunlight is permitted to enter the structure through the roof. Heretofore, this natural lighting was provided by installing domed skylights of either the curb or curbless variety. Unfortunately, skylights can be expensive and create water leakage. One of the causes of water leakage is due to the restricted flow path of water between the domed skylight and the standing seam, whereby the water level rises such as to penetrate the roof at the panel junctions. Additional problems arise with domed skylights when freezing temperatures are encountered. Ice and/or snow may collect between the skylight and the dome, and as the ice melts it is blocked by ice dams resulting in the level of water rising and penetrating the panel seam. [0010] Curbed skylights include a “curb” which is a raised structure formed around the opening in the roof upon which the transparent material is attached. The curb raises the seal between the curb and the transparent material above the point of water flowing down the roof. However, curbs are expensive to construct and to install. If not installed correctly leaks will develop around the curb and roof junction resulting in expensive repair. Additionally, installing curbed skylights requires cutting a hole in the existing roof which is performed at the job site increasing the cost of the skylight. [0011] Curbless skylights have been utilized and by definition do not require a raised frame. However, the prior art skylights typically utilize flashing, mechanical fasteners, and or sealing rings to install and to alleviate water leakage. Although curbed skylights do provide benefits over curbless skylights, curbed skylights often increase the weight of the panel with framing, increase the likelihood of water leakage and increase the cost of the metal roofing. [0012] In addition, OSHA requires that skylights be less than twelve inches in width or length, or a metal grate is required to be placed over the skylight. In order to meet these requirements the skylights and light transmitting panels in the prior art required a combination of fasteners, clips, clips, and fasteners, flanges, etc. in order to secure the transparent or semi-transparent material to the sheet metal surfaces. The differences in the respective linear coefficients of expansion of the various materials of construction resulted in systems that would inherently fail over time. The failures resulted from movement of the various materials in various directions due to the heating and cooling affect that occurs every day. With materials often moving in opposite directions fatigue occurs causing cracks, leaks and the inability to meet OSHA and UL testing requirements as discussed below. [0013] During the heating and cooling cycle of a typical day, the metal roof and its components expand and contract. For example, it is not an unusual occurrence in a normal pitched roof to expand and contract as much as 6″ over a 100 linear feet. As a result of this and other effects, UL 90 requires that a panel withstand a 90 mph wind created uplift without loss of containment. In order to achieve this, again the prior art systems employed very elaborate clip and/or conventional fasteners. However, due to the vastly different linear expansion coefficients of the fasteners, metal panels, clips, and metal panels and light transmitting panels, loss of containment or component failure would occur as noted above over time. [0014] Although other references teach away from the use of fasteners, it would be a benefit to have a light transmitting panel adapted for connection in a metal roofing system that would allow the use of fasteners or adhesives or a combination of both to secure the light transmitting panel to the metal panel while at the same time meeting ASTM E 1592 bag test and UL 90 requirements. It would be a further benefit to have a light transmitting panel which has side rails adapted for connecting with metal roofing panels. It would be a still further benefit to have a light transmitting panel prefabricated for installation on site in a metal roofing system in the same manner as standard metal roofing panels. It would be a still further benefit to have a light transmitting panel having substantially the same strength characteristics as adjacent metal panels. BRIEF SUMMARY OF THE INVENTION [0015] It is thus an object of this invention to provide a light transmitting panel for use in metal roofing systems for allowing ambient light to enter a structure and which meets UL 90 and ASTM E 1592 bag test specifications with and without the use of conventional fasteners or clips. [0016] It is a further object of this invention to provide a light transmitting panel which is inexpensive and may be constructed off site. [0017] It is a still further object of this invention to provide a light transmitting panel which is readily connectable in a metal roofing system in the same manner as standard metal roofing panels. [0018] It is yet a further object of this invention to provide a light transmitting panel that will have multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel. [0019] Accordingly, a light transmitting panel of the type for connecting within a metal roofing system is provided. The light transmitting panel includes a translucent panel, a metal panel and a mechanical fastener or a linear coefficient buffer or mechanical fastener and a linear coefficient buffer therebetween. Additionally, the panel may have multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel. [0020] The linear coefficient buffer is adapted to connect the translucent panel and the metal panel in such a way as to allow the translucent panel and metal panel to expand and contract according to its individual linear coefficient relative to the other without loosing containment. Although, it should be noted that a mechanical fastener may be used in place of a linear coefficient buffer. This assembly can be built using a metal panel, with multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with no linear coefficient barrier. In this case the panels would be simply lying against one another and can attach to the roof using mechanical fasteners for attachment. [0021] The linear coefficient buffer may comprise any material which allows the light transmitting panel to expand and contract along the metal panel and vice versa, without loss of containment or seal therebetween. In a preferred embodiment, the linear coefficient buffer comprises and may be selected from the group consisting of adhesives, adhesive gaskets, adhesive foam and adhesive rubber. In a most preferred embodiment the linear coefficient buffer is an adhesive. In order to allow for the expansion and contraction of the materials the linear coefficient buffer thickness will be generally in the range of about 0.1 mil.-20 mil., and more specifically in the range of 2 mil.-10 mil. in thickness. While we have disclosed that certain adhesives, gaskets, and other materials may comprise the buffer, one skilled in the art will understand that any material capable of adhering to the translucent panel and the metal panel so as to allow the respective panels to move according to their respective linear coefficients without resulting in a loss of containment so that if they can do that, then they fall within the scope of the linear coefficient buffers according to the present invention. And, although a linear coefficient buffer may be more desirable, a mechanical fastener will also be suitable for the present invention. [0022] The light transmitting panel may further comprise a pair of side rails on both the metal panel and light transmitting panel. The side rails may form a 90° angle, a trapezoid shape or any other shape. In this embodiment, the light transmitting panel side rails are disposed adjacent to the metal panel side rails in the metal roofing system. [0023] The light transmitting panel may comprise material such as, but not limited to, fiberglass, polycarbonates, and acrylic so as to allow ambient or exterior light to enter a structure through the light transmitting panel. It is not required for the translucent material to be transparent. The translucent section may be planar, substantially planar, or have a domed section formed therein. The translucent section has a planar section running approximate the lateral or longitudinal sides which may turn into an angled portion extending from the planar portion. The angle of departure between the angled portion and the planar portion is chosen so as to match the configuration of the side rail of the particular metal roofing system in which it is to be installed. [0024] The side rails are chosen to match the roofing system in which the light transmitting panel is to be installed. The side rails may be obtained from cutting the middle section out of an existing metal panel. The side rails may be individually turned to match particular roofing systems. Typically the side rails will have at least one horizontal portion and an angled portion extending therefrom. The adhesion surface of the horizontal portion, and the angled portion if desired, should be cleaned to remove foreign material, protective coatings and metal oxides before the adhesive is applied to join the side rails with the translucent material. [0025] Once the translucent material is formed to match the side rails chosen for the installation a chemical adhesive or bonding material is applied to either or both the translucent material and the adhesion surface of the side rails. An adhesive or a urethane compound adhesive is desired because of its ability to bond many combinations of material without a chemical degradation and its strength. The side rails and translucent material are then compressed at the contact point and the adhesive is allowed to cure. Once the adhesive has cured the light transmitting panel will have substantially the same configuration and strength characteristics of the metal roofing panels for a particular installation. If preferred, mechanical fasteners may be used in place of an adhesive. The light transmitting panel will have properties which allow it to be installed in a metal roofing system in a manner so as not to require metal grating to be installed in conjunction. The light transmitting panel may then be shipped to the site to be installed and will not require any additional equipment or additional expertise of the on-site personnel for installation. [0026] Once on site the light transmitting panel may be installed in the same manner as the metal roofing panels utilized in the construction. The adjacent side rails may be connected by rolling, folding, or caps and additionally may include screws or other types of mechanical fasteners. Light transmitting panels may be installed adjacent to other light transmitting panels and/or metal roofing panels. [0027] The light transmitting metal panels may have multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with no linear coefficient barrier. In this case the panels can simply lie against one another and can attach to the roof using mechanical fasteners for attachment. In this case, the main strength of the assembly would be retained by the mechanical fasteners primarily, but the safety benefits of the perforated panel would still be available. [0028] The foregoing has outlined the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0029] FIG. 1 is a perspective view of a light transmitting panel of the present invention. [0030] FIG. 2 is a front, planar view of the light transmitting panel of the present invention in connection with adjacent panels. [0031] FIG. 3 is a front, planar view of an alternative connection of the light transmitting panel of the present invention and an adjacent panel. [0032] FIG. 4 is a perspective view of another configuration of the light transmitting panel of the present invention. [0033] FIG. 5 is a perspective view of another embodiment of a light transmitting panel of the present invention. [0034] FIG. 6 is a plan view of another embodiment of the light transmitting panel. [0035] FIG. 7 is a front, planar view of the embodiment of the light transmitting panel of FIG. 6 . [0036] FIG. 8 is a perspective view of the embodiment of the light transmitting panel of FIG. 6 . [0037] FIG. 9A is a plan view of another embodiment of the light transmitting panel. [0038] FIG. 9B is a layered view of the embodiment of the light transmitting panel of FIG. 9A . [0039] FIG. 9C is another layered view of the embodiment of the light transmitting panel of FIG. 9A . [0040] FIGS. 9D and 9E are illustrative embodiments of the light transmitting panel. [0041] FIGS. 10A and 10B are an end and a top view of a light transmitting panel of the present invention in the trapezoidal configuration. [0042] FIGS. 11A , 11 B, and 11 C are two end views and a top view of a light transmitting panel of the present invention in the trapezoidal standing seam configuration with multiple perforations. Additionally FIGS. 11A and 11B show that the translucent material may be on the top or bottom of the metal panel. [0043] FIGS. 12A , 12 B, 12 C are two end views and a top view of a light transmitting panel of the present invention in the “R” panel configuration with multiple perforations. Additionally FIGS. 12A and 12B show that the translucent material may be on the top or bottom of the metal panel. DETAILED DESCRIPTION OF THE INVENTION [0044] Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views. [0045] FIG. 1 is a perspective view of a light transmitting panel of the present invention, generally designated by the numeral 10 . Light transmitting panel 10 includes a translucent section 12 , first side rail 14 , second side rail 16 , and a chemical adhesive 18 . [0046] Translucent section 12 in the embodiment shown is constructed of fiberglass and permits the passage of light exterior of the structure, such as sun light, to be transmitted into a structure on which it is installed. Translucent section 12 may be constructed of thermoset or thermoformed material such as, but not limited to, fiberglass, polycarbonates, and acrylic either singularly or in combination. Translucent section 12 is constructed of material so as to substantially match the characteristics of the metal panels utilized in the roofing system. It is desired that translucent section 12 have strength characteristics which alleviate requirements of metal grating. As shown, and in the present embodiment, light transmitting panel 12 is constructed so as to withstand at least 200 pounds per square foot of pressure so as not to require metal grating pursuant to OSHA regulations. [0047] Translucent section 12 includes a planar section 20 , and may have a first and second lateral, angled portion 22 , 24 . As shown in FIG. 1 , when present, lateral portions 22 , 24 are angled approximately perpendicular to planar section 20 to form a 90-degree modular system. Translucent section 12 may be formed to fit and match any metal roofing design configuration. [0048] Side or locking rails 14 , 16 are constructed of metal of the same type as the roofing system in which the present invention is to be installed. Side rails 14 , 16 are formed by taking a metal panel section of the design type chosen for a roof and cutting the side rails from the metal panel. As shown in FIG. 1 , side rails 14 and 16 are adapted for incorporation in metal roofing systems in which the roofing panels have male and female side rails 14 , 16 which are interconnected by rolling or folding, and possibly caps or mechanical fasteners. However, the present invention is adaptable to many shapes, and forms of side rails 14 , 16 , three examples of which are shown in FIGS. 1 through 4 . [0049] As shown in FIG. 1 , first side rail 14 is a female side rail having a first horizontal portion 26 and a first angled portion 28 which extends substantially perpendicular and upward from first horizontal portion 26 . Second side rail 16 is a male side rail also having a first portion 26 and first angled portion 28 which extends substantially perpendicular and upward from first horizontal portion 26 . Both side rails 14 and 16 have a top locking section 30 . In the female side rails, top locking section 30 of side rail 14 extends in the same direction as first horizontal portion 26 and is substantially parallel to first portion 26 . In the male side rails, top locking section 30 of side rail 16 extends in the opposite direction as first portion 26 and is substantially parallel to first portion 26 . As shown in FIG. 1 , side rails 14 and 16 are adapted for connecting to adjacent light transmitting panels 10 or adjacent metal roofing panels 32 ( FIG. 2 ) by rolling or folding and therefor include tongues 34 . One or both tongues 14 may be deleted still allowing a rolled connection via locking section 30 . Additionally, at least first horizontal portion 26 and possibly first angled portion 28 have an adhesion surface 36 for connecting translucent section 12 such that section 12 is located below side rails 14 and 16 . However, as shown in FIGS. 5 and 6 , translucent section 12 may be adhered atop side rails 14 and 16 . [0050] Side rails 14 and 16 are connected to translucent section 12 by an adhesive or bonding agent to form light transmitting panel 10 . It is desired to utilize a urethane based adhesive. Although, a mechanical fastener may be used in place of adhesives or bonding agents. [0051] To connect side rails 14 and 16 to translucent section 12 adhesion surface 36 and the surface of a portion of first planar section 20 adjacent to lateral angled portion 22 and lateral angled portion 22 should be cleaned to remove any foreign materials, protective coatings such as terne, and metal oxides. An adhesive or bonding agent 18 is applied to adhesion surface 36 and/or translucent section 12 and side rails 14 and 16 are placed in position whereby horizontal portions 26 are disposed upon a portion of planar section 20 and first angled portion 28 is disposed upon first lateral portion 22 of translucent section 12 . Side rails 14 and 16 and translucent section 12 are compressed together and adhesive 18 is allowed to cure to form light transmitting panel 10 . [0052] FIG. 2 is a front, planar view of light transmitting panel 10 of the present invention in connection with adjacent metal roofing panels 32 . As shown, adjacent side rails 14 and 16 are positioned so that a male side rail 16 overlaps a female side rail 14 . To connect panels 10 and panels 32 or panels 10 to adjacent panels 10 (not shown) by folding tongues 34 in the direction of the arrows. It should be recognized that tongue 34 is not necessary. [0053] FIG. 3 is a front, planar view of an alternative connection of light transmitting panel 10 of the present invention and an adjacent metal roofing panel 32 . FIG. 3 demonstrates the connection of adjacent roofing panels 10 and 32 utilizing a cap 38 . Metal roofing panel 32 utilizes a female side rail 14 as does light transmitting panel 10 . Each panel 32 and 10 are placed side by side in a manner such that side rails 14 are adjacent and top locking sections 30 extend away from each other. A cap 38 is slid onto both side rails 14 along top locking sections 30 or cap 38 is placed atop locking sections 30 and crimped thereon. Although not shown this connection may be made between adjacent light transmitting panels 10 in the same manner. Note that the embodiment shown in FIG. 3 , the lateral, angled portion 22 of the translucent section 12 is optional. [0054] FIG. 4 is a perspective view of another configuration of light transmitting panel 10 of the present invention shown in a trapezoidal configuration. In the trapezoidal configuration translucent section 12 has a first angled portion 22 which extends upwardly from planar portion 20 at an angle to match the angle that first angled portion 28 of side rails 14 and 16 extends from first horizontal portion 26 of side rails 14 and 16 . In this embodiment translucent material 12 is connected to side rails 14 and 16 in the same manner as described above. Additionally, light transmitting panel 10 as shown in FIG. 4 may be connected to adjacent light transmitting panels 10 and/or metal roofing panels as shown in FIG. 2 . [0055] FIG. 5 is a perspective view of another embodiment of light transmitting panel 10 of the present invention. Light transmitting panel 10 includes a translucent section 12 , first side rail 14 , second side rail 16 , and a chemical adhesive 18 . [0056] Translucent section 12 in the embodiment shown is constructed of a translucent or transparent material, such as fiberglass, and permits the passage of light exterior of the structure, such as sun light, to be transmitted into a structure on which it is installed. Translucent section 12 may be constructed of thermoset or thermoformed material such as, but not limited to, fiberglass, polycarbonates, and acrylic either singularly or in combination. Translucent section 12 is constructed of material so as to substantially match the characteristics of the metal panels utilized in the roofing system. It is desired that translucent section 12 have strength characteristics which alleviate requirements of metal grating. [0057] Translucent section 12 includes a planar section 20 , and may have a first and second lateral, angled portion 22 , 24 . As shown in FIG. 1 , when present, lateral portions 22 , 24 are angled approximately perpendicular to planar section 20 to form a 90-degree modular system. Translucent section 12 may be formed to fit and match any metal roofing design configuration. [0058] Side or locking rails 14 , 16 are constructed of metal of the same type as the roofing system in which the present invention is to be installed. Side rails 14 , 16 are formed by taking a metal panel section of the design type chosen for a roof and cutting the side rails from the metal panel. [0059] Although not shown, it is contemplated to connect a cap or seal atop or about translucent section 12 so as to aid in the prevention of water entry through the connection between section 12 and side rails 14 , 16 . [0060] Use of light transmitting panel 10 is now described with reference to FIGS. 1 through 5 . A metal roofing panel (not shown) is taken and the panel is cut so as to provide two side rails 14 and 16 . Side rails 14 and 16 may be of any configuration so as to match the roofing system in which light transmitting panel 10 is to be installed. Additionally, side rails 14 and 16 may be turned individually to match the side rails of the roofing installation in which to be installed. A translucent section 12 formed of thermoset or thermoformed material such as, but not limited to, fiberglass, polycarbonates, and acrylic is formed so as to have a planar section 20 and may have an adjacent lateral angled section 22 . Translucent section 12 is formed so that lateral angled portions 22 are angled from planar section 20 to match the angle between first horizontal section 26 and first angled portion 28 of side rails 14 , 16 . Adhesion surface 36 of side rails 14 , 16 should be cleaned as well as the contacting surface of translucent material 12 . An adhesive or bonding agent 18 is applied to adhesion surface 36 and/or translucent section 12 . Side rails 14 and 16 are placed in contact with translucent material 12 such that horizontal portions 26 and planar sections 20 and angled portions 28 and lateral angled portions 22 are aligned. Compression is applied to side rails 14 , 16 and translucent section 12 and adhesive 18 is allowed to cure. Once adhesive 12 is cured light transmitting panel 10 is completed and may be shipped for installation in a metal roof system. Light transmitting panel 10 may be installed in any system in which side rails 14 , 16 are adapted, whether it be by rolling, folding, caps, and/or mechanical fasteners for connection with adjacent metal roofing panels. Also a mechanical fastener may be used in place of or in combination with an adhesive or bonding agent. [0061] With reference to FIGS. 6-9 , further embodiments of the present invention are disclosed. The embodiment of FIGS. 6-8 shows a bonded light transmitting panel 10 ′ comprising translucent panels 12 ′ a and 12 ′ b , ( 12 ′ a and 12 ′ b can also be a single translucent panel) a roofing panel 32 ′. The utilization of a standard roofing panel 32 ′ in this embodiment provides compatibility with other roofing panels 32 ′ and/or light transmitting panels 10 ′. [0062] With reference to FIG. 6 , a plan view of the bonded light transmitting panel 10 ′ is shown. In this embodiment, the roofing panel 32 ′ has a portion cut-out, allowing exposure of the planar sections 20 ′ a and 20 ′ b , corresponding to translucent panels 12 ′ a and 12 ′ b ( FIG. 8 ). Thus, the light can be transmitted through translucent panels 12 ′ a and 12 ′ b ( FIG. 8 ) while the exterior portions of roofing panel 32 ′—as described below—allow connection with other roofing panels and/or light transmitting panels. [0063] With reference to FIG. 7 , a front, planar view of the bonded light transmitting panel 10 ′ is shown. Translucent panels 12 (indicated 12 ′ a and 12 ′ b in FIG. 8 ) includes a planar section 20 ′ (indicated 20 ′ a and 20 ′ b in FIG. 6 ), and may have a first and second lateral, angled portion 22 ′, 24 ′. In this embodiment, when present, lateral portions 22 ′, 24 ′ are angled approximately perpendicular to planar section 20 ′ to form a 90-degree modular system. While these lateral portions 22 ′, 24 ′ are shown in this embodiment, other embodiments may not have them. In the embodiment shown in FIG. 7 , lateral portions 22 ′, 24 ′ extend upward toward side rails 14 ′, 16 ′. By this illustration, it should become apparent to one of ordinary skilled in the art that translucent panels 12 (indicated 12 ′ a and 12 ′ b in FIG. 8 ) may be formed to fit and match any roofing design configuration. [0064] With reference to FIG. 8 , a perspective view of the bonded light transmitting panel 10 ′ is shown. The two translucent panels 12 ′ a and 12 ′ b in this embodiment permit the passage of light exterior of the structure, such as sun light, to be transmitted into a structure on which it is installed. The translucent panels 12 ′ a and 12 ′ b may be constructed of thermoset material such as, but not limited to fiberglass, polycarbonates, and acrylic either singularly or a combination of polycarbonates. Furthermore, the translucent panels 12 ′ a and 12 ′ b can be constructed so as to substantially match the characteristics of the roofing panels utilized in the roofing system. [0065] In the embodiment shown in FIG. 8 , side rails 14 ′ and 16 ′ of roofing panel 32 ′—as briefly described above—are adapted for incorporation in roofing systems in which the roofing panels have male and female side rails 14 ′, 16 ′ which are generally interconnected by rolling or folding, or by utilizing caps or mechanical fasteners. As an illustrative example, roofing panel 32 ′ can be a standard roofing panel, adapted to connect with other standard roofing panels, which is removed and cut out in the manner describe with reference to FIG. 6 . In other embodiments, the light transmitting panels 10 ′ can be adaptable to many shapes and forms of side rails 14 , 16 (both from standard roofing panels and those adapted for connection with the metal roofs, in general). [0066] With reference once again to FIG. 8 , first side rail 14 ′ is a female side rail and second side rail 16 ′ is a male side rail. Both side rails 14 ′ and 16 ′ have a top locking section 30 ′. As shown in FIG. 8 , side rails 14 ′ and 16 ′ are adapted for connecting to adjacent light transmitting panels 10 ′ or adjacent roofing panels 32 ′. At least horizontal portion 26 ′ and possibly first angled portion 28 ′ are coupled to the roofing panels 32 ′. [0067] With reference to FIGS. 9A-9C , another embodiment of the invention is shown with a translucent section 12 ′ coupled to a roofing panel 32 ′. FIGS. 9A-9C are similar to the embodiment of FIGS. 6-8 in that a standard roofing panel 32 ′ can be utilized with a portion thereof cut-out, exposing the translucent section 12 ′. FIG. 9A shows a top plan view of a single translucent section 12 ′ being divided by a portion of the roofing panel 32 ′ into two separate light transmitting areas. As will be appreciated by those in the art, such a configuration can be used in some embodiments to facilitate structural integrity (e.g., desired force per surface area support) of each light transmitting area of the translucent section 12 ′. [0068] FIG. 9B is a layered view showing the translucent section 12 ′ with the roofing panel 32 ′ shown in partial phantom view. FIG. 9C is another layered view showing an illustrative example of an area for the location of the linear coefficient buffer 18 ′, generally referenced in other embodiments. It will become apparent to one of ordinary skill in the art that such an area can change depending on the desired structural dynamics of light transmitting panel 10 ′ and linear coefficient buffer 18 ′ utilized. [0069] With reference to FIGS. 9D-9E , an illustrative embodiment shows how the side rails 14 ′ and 16 ′ can be connected to translucent section 12 ′ by a linear coefficient buffer 18 ′, thereby absorbing the expansion and contraction between the roofing panel 32 ′ and the translucent section 12 ′. Additionally, this illustrative embodiment shows how the linear coefficient buffer 18 ′ may also serve as an adhesive or bonding agent to form the bonded light transmitting panel 10 ′. Examples of adhesives or bonding agents are UNI-WELD, a two-part epoxy from Kent Industries, adhesives from Dynatron Bondo Adhesives, and adhesives by SIKA or Michigan Adhesive Mfg. Inc, (other brands are also available). In addition, it may be desirable to utilize a neutral cure, or urethane, silicone adhesive on the edges of the translucent section 12 ′ as a secondary seal. If preferred, mechanical fasteners may be used in place of an adhesive. [0070] To connect side rails 14 ′ and 16 ′ to translucent section 12 ′ adhesion surface 36 and the surface of a portion of first planar section 20 ′ adjacent to lateral angled portion 22 ′ and lateral angled portion 22 ′ should be cleaned according to procedures known in the art to remove any foreign materials, protective coatings such as terne, and metal oxides. The linear coefficient buffer 18 ′ is applied to adhesion surface 36 ′ so that translucent section 12 ′ may be disposed upon a portion of planar section 20 ′ and first angled portion 28 ′. Side rails 14 ′ and 16 ′ and translucent section 12 ′ are compressed together and adhesive 18 ′ is allowed to cure to form light transmitting panel 10 ′. [0071] As can be seen with reference to embodiments of FIGS. 9A-9E , the translucent section 12 ′ of the light transmitting panel 10 ′ can be connected to side rails 14 ′ and 16 ′ or directly to the roofing panel 32 ′. In addition, as discussed above, the side rails 14 ′ and 16 ′ may be adapted individually to match the side rails of the roofing installation in which they are to be installed. Therefore, the translucent section 12 ′ can be formed to fit and match any metal roofing design configuration. [0072] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. For example, many configurations of metal roofing panels exist to which the light transmitting panel of the present invention may be adapted, many translucent materials are available for use in the light transmitting panel, and additionally it is contemplated that mechanical fasteners such as screws and nuts and bolts may be used for additional security between adjacent metal roofing panels and light transmitting panels, and adhesion of the light transmitting panels along a single portion or section of the side rails. [0073] The invention will be further described by the following example. This example is not intended to be limiting, in any way, the invention being defined by the appended claims. Example [0074] A light transmitting panel assembly according to the present invention was constructed for testing under UL 90 test requirements. A five (5) panel assembly was created wherein one of the panels included a light transmitting panel. The panels were nominally ten feet ( 10 ′) in length and two feet ( 2 ′) wide. The panel which comprised the light transmitting panel assembly included a metal panel including one cut-out nominally 17″×53″ and two cut-outs that nominally 17″×24″. A translucent fiberglass panel nominally 8 oz./ft 2 (˜0.045″ thick) was overlaid onto the bottom of the metal panel so as to cover the cut-outs. An adhesive was used as the linear coefficient buffer and was disposed between the metal panel and translucent fiberglass panel to a thickness of 2.5 mil. The same material was used as an additional adhesive/buffer on the light transmitting panel edges as a secondary seal and to prevent the infusion of air or water under the panel in the event of a void in the adhesive. The five (5) panel assembly including the light transmitting panel assembly was testing according to ASTM E specification 1592 and UL 90. After the testing, the light transmitting panel assembly was inspected and no break down or fatigue of the component parts was observed. [0075] In the above example one could also take a standing seam metal panel, of the same configuration, with holes of varied design, and overlay it over a fiberglass or other polymer panel and mechanically fasten it to the perimeter of the metal roof or perimeter of the polymer panel assembly, using mechanical fasteners. This can also be done by applying it to the underside of the polymer panel. [0076] Turning to FIGS. 10A and 10B , an end view and a top (or bottom) view, respectively, of the light transmitting panel of the present invention are illustrated. A panel 50 of the present invention for use in a metal roof system includes a metal panel 54 cut into any design. The metal panel 54 in FIGS. 10A and 10B is in the trapezoidal configuration similar to the light transmitting panel shown in FIG. 4 . The panel 50 also includes a translucent material 52 substantially in the same shape as the metal panel 54 placed below the metal panel 54 . The translucent material 52 is sealed to the metal panel 54 with an appropriate linear coefficient buffer as described herein. In various embodiments, the translucent material 52 includes a planar section 20 ″ and may include first and second lateral angled portions 22 ″ and 24 ″. [0077] The composition of the translucent material 52 is preferably a plastic, which may be a laminate, such as used in melt-away domed skylights. Most of these materials are proprietary to the manufacturer, but are will known in the art. In various embodiments, the translucent material 52 is a meltable and/or shrinkable acrylic. In some embodiments, the translucent material 52 has a melting point of less than 200 degrees Fahrenheit. Note that in vent 50 embodiment of the present invention, structural support for weight by the translucent material 52 need not rise to the level of the structural support supplied by translucent material 12 in other embodiments of the light transmitting panels of the present invention. In the embodiment of FIGS. 10A and 10B , the openings 56 are cut with a plasma cutting machine. Other manufacturing methods are contemplated. Note also that the translucent material 52 may be transparent or translucent. Additionally, as shown in FIG. 11A , note that the translucent material 2 is below the metal panel 1 with linear coefficient barrier 3 . Another configuration is shown in FIG. 11B where the translucent material 2 is above the metal panel 1 with linear coefficient barrier 3 . Also, mechanical fasteners may be used in place of linear coefficient barrier 3 . [0078] In the top view shown in FIG. 10B , a pattern may be seen in the metal panel 54 such that safety cross-over material 58 is present between openings 56 to protect from fall-through. The geometry of the pattern may of different designs in different embodiments. In one embodiment, the area of any one opening 56 is less than twelve square inches. In another embodiment, the cross-over material 58 is capable of supporting up to 200 pounds per square foot. [0079] While the panel 50 has been illustrated with respect to the trapezoidal configuration, other configurations are contemplated. Other contemplated configurations include architectural standing seam with or without minor ribs, architectural standing seam with or without geometric differences in the openings 56 to allow for the use of a protective grate, exposed fastener roof panels with or without minor ribs, exposed fastener roof panels with or without geometric differences in the openings 56 to allow for the use of a protective grate, including the well-known “R” panel and “U” panel. In particular, the panel 50 may be configured in various embodiments compatible with the embodiments of the light transmitting panels 10 , 10 ′ shown in FIGS. 1-3 , FIG. 5 , FIGS. 6-9 d , and FIG. 9 e . Other configurations are contemplated based on aesthetic and/or safety considerations. [0080] In the presence of flame or high temperature, according to the material used for the translucent material 52 , the translucent material 52 will melt and fall out. The safety cross-over material 58 is configured to allow for workers or firemen to cross the panel 50 without falling through to the floor below. In a preferred embodiment, the safety cross-over material 58 provides fall protection that meets OSHA Regulation §1926.501 “Duty to have Fall Protection.” In some embodiments, the safety cross-over material 58 provides fall protection that meets local or state regulations. In some cases, a grate may become necessary. [0081] In addition to the standing seam systems, a corrugated or exposed fastener panel assembly must also be considered. This assembly would be of a type or similar to “R”, U, 2.67, 7.2 or the many other panel configurations used in the metal building industry. [0082] This “R” assembly shown in FIGS. 12A , 12 B, and 12 C would be built using a metal panel, with multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with a linear coefficient barrier for attachment and then the assembly would be mechanically attached to the roof assembly. FIG. 12C shows that different sized perforations may be used in creating the ribbed panel. FIG. 12A shows that the translucent material 2 is below the metal panel 1 with linear coefficient barrier 3 . Another configuration is shown in FIG. 12B where the translucent material 2 is above the metal panel 1 with linear coefficient barrier 3 . Thus, the translucent material can either be on top or bottom of the metal panel. [0083] Another assembly would be built using a metal panel, with multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with no linear coefficient barrier. In this case the panels would be simply lying against one another and would be attached to the roof using mechanical fasteners for attachment. In this case the main strength of the assembly would be retained by the mechanical fasteners only, but the safety benefits of the perforated panel would still be available. [0084] The foregoing disclosure and description of the preferred embodiments are illustrative and explanatory thereof, and various changes in the components, elements, configurations, and connections, as well as in the details of the illustrated construction and method of operation may be made without departing from the spirit and scope of the invention
A light transmitting panel that can connect within a metal roofing system is provided. The light transmitting panel includes a translucent panel, a metal panel and mechanical fastener or a linear coefficient buffer or mechanical fastener and a linear coefficient buffer therebetween to allow the respective panels to expand and contract with respect to the other without loss of containment or seal.
4
CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of copending application Ser. No. 040,991, filed Apr. 20, 1987. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates broadly to laser devices designed to operate in a submarine environment. More particularly, it concerns safety features for such devices that prevent them from emitting coherent light unless they are immersed in water. 2. Description of the Prior Art Laser devices can be effectively used in submarine environments for a variety of applications. One such application is disclosed in copending application Ser. No. 040,991, the disclosure of which is incorporated herein by reference, wherein laser units are used in obtaining underwater visual recordings with photographic or video cameras to assist in insuring that the subject being recorded will be at the correct distance and within the field of view at the time of exposure. Also, the laser units assist in (1) attaining more efficient use of battery or other power, (2) saving of film, (3) avoid triggering of exposure by spurious materials or events and (4) obtaining consistently well focused recordings. Because of the magnitude of the energy flux in the coherent light emitted by the submarine laser devices used in such applications, there exists the constant danger of injury to the eyes or other body parts of persons working with such devices, particularly during periods of time when the devices are being lowered into or lifted out of the water. The present invention provides the laser devices with safety features that prevent the occurrence of such injuries or other damage in the use of the submarine laser devices. OBJECTS A principal object of the invention is the provision of improved submarine laser devices. Further objects include the provision of: 1. Safety features for submarine laser devices that automatically prevent them from emitting coherent light unless they are immersed in water below a certain depth. 2. Such safety features that do not require electric power to function. Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter; it should be understood, however, that the detailed description, while indicating preferred embodiments of the invention, is 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. SUMMARY OF THE INVENTION The objects are accomplished, in part, in accordance with the invention by the provision of laser devices for use in submarine service that comprise a window portion through which the unit emits coherent light and means to permit coherent light to be emitted through the window portion only when the laser device is immersed in water. Typically, such devices will include a waterproof housing enclosing the laser unit plus an electric conduit means for supplying power from an outside source to the laser unit or an internal battery as the power supply. In a preferred embodiment, shutter means prevents coherent light from being emitted through the window portion unless the laser device is immersed in water. Such shutter means may comprise a body member having a rear wall, a front wall and a side wall with a first bore extending through the body member from the rear wall to the front wall and a chamber within the body member that intersects the first bore. A plurality of second bores extend through the side wall and the body member into the chamber to ensure flushing. A ball having a relative density less than 1 and a diameter greater than the lumen of the first bore is captured in the chamber for free movement therein. Finally, means is included to mount the body member with its rear wall covering the window portion of the the laser device in a manner as to permit coherent light that exits the window portion to pass only into the first bore. With such a shutter arrangement, when the laser device is out of the water, the ball falls down in the chamber to block the lumen of the first bore and prevent light emitted from the laser to pass through such bore. However, when the laser device is immersed in water to a depth where the ball will float, it rises in the chamber, opening the lumen in the first bore to provide a clear channel for coherent light from the laser to pass into the ambient water. In preferred forms of such shutter units, the side wall is circular in shape, the chamber is cylindrical in shape and has a diameter slightly larger than the diameter of the ball. Additionally, the body member has a threaded opening in the top of its side wall that communicates with the chamber and such opening is closed by a vented plug that is threaded therein so the ball is retained in the chamber, but may be removed by unscrewing the closure plug. Advantageously, the means to mount the shutter unit on the laser device is a flange on the rear wall portion of the body member. Further, the shutter unit has a third bore that extends through its side wall and intersects the first bore between the chamber and the rear wall. This is used to override the float/shutter for testing. In another embodiment of the safety features of the invention, a normally open pressure switch permits flow of the power to the laser unit only when the device is immersed to at least a predetermined depth in water and thereby prevents coherent light from being emitted by the laser unit until immersed to a least a predetermined depth in water. If desired, the shutter embodiment and the switch embodiment may be used in combination to increase safety potential of the laser devices. BRIEF DESCRIPTION OF THE DRAWINGS A more complete understanding of the invention may be had by reference to the accompanying drawings in which: FIG. 1 is a fragmentary plan view of a first embodiment of a submarine laser device constructed in accordance with the invention. FIG. 2 is lateral section view of the shutter unit of the laser device shown in FIG. 1. FIG. 3 is a front end view of the shutter unit shown in FIG. 2. FIG. 4 is a lateral view of a vented closure plug for the shutter unit. FIG. 5 is a sectional view of a second embodiment of a submarine laser device of the invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring in detail to the drawings and first to FIG. 5, the invention comprises a submarine laser device 2 useable for a variety of submarine applications, e.g., to assist in making consistently in-focus visual records of benthic or other submarine objects with a camera (not shown). Also, for recording size information on photographic records, both still and video. The laser device 2 is structured to emit a beam 4 of coherent light. A power source (not shown) is connected by electrical conductor means 6 and pressure switch 8 to the laser unit 10, enclosed in the pressure housing 12, to energize it to emit the coherent light beam 4 through the window portion 14 of the laser device 2. The housing 12 also contains electrical control means 16 in the form of printed circuit board and a foam cushion 62. The removable end cap 64 serves as a mounting base for the control means 16, the pressure switch 8 and the conductor means 6. Standard O-rings are used for sealing of the laser devices 2. The laser unit 10 typically will be 20" long by 2" diameter and will have a starting voltage of 10KV, input power of 23-33V d.c. at 0.6 A, an output power of 2 mW minimum producing, in red beam embodiment, a laser beam of wavelength 632.8 nm. having a bandwidth less than 0.1 nm. with a beam diameter of 0.7 mm and a divergence of 1.2 m radian (full angle), e.g. the beam is 0.05" at window 14, 0.10" at 5 ft, 0.15" at 10 ft and 0.20" at 15 ft with an effective range up to 20 ft depending on water clarity and observation system sensitivity. In a green beam embodiment, the laser beam typically will have wavelength 543.5 nm. having a bandwidth less than 0.1 nm. with a beam diameter of 0.5 mm and a divergence of 1.6 m radian (full angle). The coherent light beam 4 is visible in daylight or in the presence of floodlights. The housing 12 is typically 25" long by 3" diameter, weight in air 5.5 lbs (in water 0.5 lbs) made of 6061-T6 aluminum with plastic hardware and is capable of operating at depths up to 3,000 ft. or even deeper with increase housing wall thickness. Pressure switch 8 will typically be structured to enable input power at a depth of 20 ft. or greater. The laser unit 10 is on during operation of the device 2, providing input power is available and the safety feature 8 is enabled. Hence, emission of the coherent light beam 4 is prevented from the device until it is immersed in water. A preferred embodiment of a laser device 2' of the invention is shown in FIGS. 1-4. The device 2' includes shutter means 20 held on the pressure housing 12 by its rear flange 22 and the compression ring 24. Shutter means 20 comprises a body member 24 having a rear wall 26, a front wall 28 and a side wall 30, a first bore 32 extending through the body member 24 from the rear wall 26 to the front wall 28. A chamber 34 within the body member 24 intersects the first bore 32, and a plurality of second bores 36 extend through the side wall 30 and the body member 24 into the chamber 34. A ball 38 having a relative density less than 1 and a diameter greater than the lumen of the first bore 32 is captured in the chamber 34 for free movement therein. As indicated previously, the body member 24 is mounted with the rear wall covering the window portion of the laser device 2' in a manner to permit light that exits the window to pass into the first bore 32. The body member 24 has a threaded opening 40 in the side wall 30 that communicates with the chamber 34 and such opening 40 is closed by a plug 42, having a vent hole 43, that is threaded therein. A third bore 44, provided to flush the laser window, extends through the side wall 30 and intersects the first bore 32 between the chamber 34 and the rear wall 26. The bores 36 & 44 allow water to freely flow into the chamber 34 when the laser device 2' is immersed in water. Also, bore 36 allows a small pin to be inserted to temporarily fix the ball 38 in its "open" position for in-air testing of the device 2'. When the device 2' is out of water the ball 38 will rest on bottom of chamber 34 as shown by the lower ball 38 in FIG. 2 and prevent coherent light from being emitted from the exit end 32' of the bore 32. Thus, such light will be scattered and emanate from the body member 24 diffusely and harmlessly. When the ball 38 blocks the first bore 32 and the laser is ON, the whole body 24, being made of white translucent plastic, will glow, indicating the laser is on, but the shutter is closed. When the device 2' is immersed in water, the ball 38 will float to the top of chamber 34 as shown by the upper ball 38a in FIG. 22 and allow the passage of coherent light through the bore 32. In a typical shutter unit 20 of the invention, the body member is cylindrical in shape with a diameter of about 1 inch. and 1 inch in length between rear wall 26 & 28. The bores 32, 36 & 44 are 0.125" in diameter, the chamber 34 is 23/64" in diameter and the ball 0.25" in diameter. The plug 42 is 7/16" in diameter and 3/8" in height. The body member 24 is made of white, translucent "Deldrin" plastic and the ball 38 is made of polypropylene. The indica UP and the arrow shown in FIG. 3 are engraved on the front wall 28 to ensure that the shutter unit will properly positioned on the pressure housing 12 of the laser device 2'.
A laser device for use in submarine service having a window portion through which it emits coherent light has a safety feature that permits coherent light to be emitted through the window portion only when the laser device is immersed in water. In one embodiment, the safety feature involves a pressure switch and in a second embodiment, it involves a shutter float.
6
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 14/329,083, which is the continuation of U.S. patent application Ser. No. 12/310,373 that issued as U.S. Pat. No. 8,811,242. U.S. patent application Ser. No. 12/310,373 is the US National Stage of International Application No. PCT/EP2007/055231, filed May 30, 2007 and claims the benefit thereof. The International Application claims the benefits of European Patent Office application No. 06017663.3 EP filed Aug. 24, 2006. The International Application and the European Patent Office application are incorporated by reference herein in their entirety. FIELD OF INVENTION The invention relates to a method for providing a wireless mesh network and an arrangement for providing a wireless mesh network. BACKGROUND OF INVENTION A wireless mesh network is a meshed network implemented for example in a Wireless Local Area Network (WLAN). In a mesh network a mobile node can forward data originating from another mobile node to a further mobile node or transmit it to a base station. Mesh networks can cover long distances, in particular in uneven or problematic terrain. Mesh networks also operate very reliably, since each mobile node is connected to several other nodes. If a node fails, for example due to a hardware defect, its adjacent nodes seek an alternative data transmission route. Mesh networks can include fixed or mobile devices. As mentioned above, FIG. 1 shows a mesh network MESH, which is connected to an infrastructure network INFRASTRUCTURE NETWORK and as well as nodes MP, MAP of the mesh network also has non-mesh stations, for example a station STA operating according to WLAN. This station STA operating according to WLAN is connected to the mesh network MESH by way of a mesh network node MAP, which operates as a WLAN access point. The mesh network MESH of the WLAN station STA here can also allow access to an infrastructure network INFRASTRUCTURE NETWORK, for example a company network or the internet. In this process mesh nodes MP and/or WLAN stations STA are authenticated for example using an authentication server AAA-server (AS), with the mesh network MESH being coupled to the infrastructure network INFRASTRUCTURE NETWORK by way of a gateway component GW in the example shown. FIG. 2 shows an independent mesh network MESH, as known in the prior art. Independent here means that the mesh network MESH is formed exclusively from mesh nodes MP. These can be both infrastructure nodes and also so-called end user nodes, such as a notebook or PDA for example. In contrast FIG. 3 shows an independent mesh network with an access point MAP, as known from the prior art, which allows non-mesh-capable devices, such as the WLAN stations STA shown for example, to register with the network MESH. The WLAN stations STA shown do not however take part in mesh routing themselves. SUMMARY OF INVENTION In the arrangements shown according to the prior art it is standard for the devices to identify themselves in the network by means of a so-called MAC address (Media Access Control Ethernet ID). A MAC address here is the layer-2 address of a node for communication in communication networks based on the IEEE 802 standards, for example in the case of WLAN according to IEEE 802.11 and in the case of the mesh networks MESH shown according to IEEE 802.11S. This address should generally be connected to the respective hardware in a universally unique manner. It is however known that non-trusted subscribers ATTACKER MP can use the MAC address of a trusted subscriber GOOD MP erroneously or completely intentionally. Such a manipulation, also known as MAC address spoofing, causes disruption of the targeted networks, for example denial of service (DoS) attacks, because the sacrificial subscriber GOOD MP can no longer communicate, as their wireless link is no longer valid. Also the communication session of the trusted subscriber GOOD MP can be taken over at a WLAN hotspot with a purely http-browser-based registration. Measures for identifying such WLAN MAC address spoofing are disclosed in Joshua Right Detecting Wireless LAN MAC Address Spoofing, 21.01.2003, with which firstly a check takes place to determine whether a so-called Organizationally Unique Identifier OUI allocated exclusively to the producers (see IEEE standards), which is part of the transmitted MAC address, is in fact allocated to a producer. WLAN MAC sequence numbers of a subscriber, which generally increase sequentially, can also be analyzed, such that as soon as a bigger gap occurs, it is an indication that the corresponding MAC frame was sent by another station (attacker). This has the disadvantage that the OUT check is only effective if the MAC address is generated randomly, but not if the attacker ATTACKER MP simply uses the MAC address of another trusted subscriber GOOD MP. The attacker ATTACKER MP can also generate MAC addresses randomly, provided that their OUI is allocated. A method for protecting IEEE 802.11 data traffic against MAC address spoofing is also known from the patent application US 2006/0114863, in which protection from MAC address spoofing takes place in WLAN networks such that an assignment table is created for the MAC address, and a user identity used during the WLAN registration and during subsequent WLAN registrations the MAC address used and the user identity are checked to determine correspondence with the entry in the assignment table and if they do not correspond, the registration is rejected. The object of the present invention is therefore to specify an improved method and arrangement for providing a wireless mesh network. With the inventive method for providing a wireless local network; in which stationary communication entities embodied according to the IEEE 802.11 standard and its derivatives, in particular IEEE 802.15 or IEEE 802.16, and mobile communication entities are connected as a subnetwork in the manner of the mesh, a communication entity registering with the subnetwork transmits a registering MAC address to the subnetwork, a check is carried out such that the registering MAC address is compared with the MAC addresses that are reachable on the part of the subnetwork and if the registering MAC address is disjoint in respect of the reachable MAC addresses, the registering communication entity is connected in the manner of a station of the subnetwork, while if the registering MAC address is already reachable in the subnetwork, an approval procedure is carried out such that such that use of the registering MAC address by two different communication entities within the subnetwork is prevented. One advantage of the inventive method is the immunization against effects of MAC address spoofing, since this inventive procedure specifically prevents registration using a MAC address that is already reachable, which, in contrast to approaches known from the prior art, does not require previously stored relationships between devices and MAC addresses, etc. In a development of the invention, the approval procedure takes the form of rejection of the registering communication. This is the simplest variant for ensuring that MAC address spoofing is prevented, as no further enquiries and data transmissions are required. It is also the quickest option for completing an approval procedure. Alternatively the approval procedure takes the form of conversion of the registering MAC address such that a MAC address that is disjoint in respect of the reachable MAC addresses is allocated to the registering communication entity within the subnetwork. This means that for the subnetworks only a MAC address that is valid locally for said subnetworks is allocated internally, regardless of the MAC address assigned in a universally unique manner to each device, thereby preventing spoofing; in other words MAC address spoofing has a negative effect on the function of the mesh subnetwork, in particular the routing and forwarding of data with the mesh subnetwork. The disjoint MAC address is preferably generated on the part of the subnetwork here, since this latter has information about existing MAC addresses and/or the addresses that are valid in the local network. It is also advantageous here if the disjoint MAC address is generated based on a pseudo-random sequence, in particular a “Number Used Once, Nonce” generated just once. It is also advantageous if, in a development, the disjoint MAC address is selected so that it is disjoint in respect of MAC addresses allocated universally, in particular on the part of organizations, as according to the OUI. This ensures that there are no collisions with universally assigned MAC addresses. The 41 st bit of the disjoint MAC address is preferably allocated the value 1 here, so that local validity is identified in a simple manner. In a further advantageous embodiment of the invention the approval procedure takes the form of a check carried out on the part of the subnetwork on the identity of the registering communication entity with the first communication entity determined by way of the reachable MAC address corresponding to the registering MAC address. It can thus be determined whether the registering communication entity is an already known communication entity, which simply wishes to set up a further link in the mesh network, as should also be ensured according to mesh architecture, and therefore is not a case of spoofing but a legitimate registration attempt and should therefore be permitted. In one development the identity check should be carried out such that the subnetwork transmits a first item of check information to the first communication entity by way of a route in the subnetwork established to the communication entity determined by way of the reachable MAC address corresponding to the registering MAC address, the subnetwork transmits a request to the first communication entity to return the first item of check information and the subnetwork awaits the return of the first item of check information by way of a route established in the context of the registration attempt on the part of the registering station, in other words by way of the link to be set up, in the subnetwork, after which if no return is made the registering communication entity is rejected or if the return is made the correlation of the first item of check information with the returned item of check information is checked and, if a specific degree of correlation is achieved, in particular in the case of identity, of the first item of check information with the returned item of check information, the registering communication entity is connected in the manner of a station of the subnetwork; otherwise the registering communication entity is rejected. This means that a check parameter is sent from the network to the already registered station by way of the existing route and an expectation that this check parameter will returned by way of the route to be set up is realized, this being successfully completed only if the device registering is the same device that is already incorporated in the network at the reachable MAC address. In a further variant of the identity check the subnetwork transmits a first item of check information to the first communication entity by way of a route in the subnetwork established in the context of the registration attempt on the part of the registering station, the subnetwork transmits a request to the first communication entity to return the first item of check information, the subnetwork awaits the return of the first item of check information by way of a route in the subnetwork established to the communication entity determined by way of a reachable MAC address corresponding to the registering MAC address; also if no return is made the registering communication entity is rejected, while if the return is made, it is checked whether the first item of check information correlates with the returned item of check information so that if a specific degree of emulation is achieved, in particular in the case of identity, of the first item of check information with the returned item of check information, the registering communication entity is connected in the manner of a station of the subnetwork; otherwise rejection of the registering communication entity again takes place. This is a variant in which the check parameter is sent from the network to the station just registering, with the route to be set up being used for this purpose and the network then waiting for the check parameter to be returned by way of the existing route. This can only happen if the registering device and the already reachable device are identical and both routes therefore lead to it, thus ensuring reliable verification of the identity of the registering and already reachable station. The subnetwork preferably initiates transmission of the second and/or third item of check information or alternatively transmission of the second and/or third item of check information takes place automatically on the part of the registering communication entity. In a further variant for the identity check a fourth item of check information calculated on the part of a cryptographic key authenticating the first communication entity determined by way of the reachable MAC address corresponding to the registering MAC address, in particular a first session key resulting from a network registration according to the so-called extensible authentication protocol EAP and available to the registering communication entity is transmitted by way of a route in the subnetwork established in the context of the registration attempt on the part of the registering station; the subnetwork determines the validity of the fourth item of check information based on a second cryptographic key authenticating the communication entity determined by way of a reachable MAC address corresponding to the registering MAC address, in particular a second session key resulting from a network registration according to the extensible authentication protocol EAP and available to the subnetwork; where there is validity, the registering communication entity is connected in the manner of a station of the subnetwork, otherwise the registering communication entity is rejected. Alternatively the identity check takes place such that the registering communication entity transmits a fifth item of check information calculated on the basis of a first cryptographic key authenticating the registering communication entity, in particular a first session key resulting from a network registration according to the so-called extensible authentication protocol EAP and available to the registering communication entity to the subnetwork by way of a route established to the communication entity determined by way of a reachable MAC address corresponding to the registering MAC address; the subnetwork also determines the validity of the item of check information based on a second cryptographic key authenticating the registering communication entity, in particular a second session key resulting from a network registration according to the extensible authentication protocol EAP and available to the subnetwork; where there is validity the registering communication entity is connected in the manner of a station of the subnetwork, otherwise the registering communication entity is rejected. These two variants allow particularly reliable verification of identity, since this is based on encryption information assigned to the respective communication entities or to existing links and/or links be set up to them. The first and/or second session keys here are preferably generated as Master Session Keys MSK formed according to the extensible authentication protocol EAP, so that the inventive method can be implemented in conventional EAP environments or those based on EAP. Alternatively or additionally the first and/or second session key can be generated as extended master session keys EMSK formed according to the extensible authentication protocol EAP. A function according to a cryptographic hash function, in particular the SHA-1, SHA-256 or MDS hash function, is suitable here for calculating the first, second, third, fourth and/or fifth item(s) of check information, as is it possible to use known routines. Alternatively or additionally it is advantageous if keyed hash functions, such as in particular EAS-CBC-MAC, HMAC-SHA1, HMAC-SHC256, HMAC-MD5, are used to calculate the first, second, third, fourth and/or fifth item(s) of check information, with the HMAC functions being defined according to RFC2104. In one advantageous embodiment the approval procedure is initiated when the registering communication entity registers with the subnetwork as a subscriber in the manner of the mesh, so that mesh subscribers and non-mesh subscribers can be distinguished and different variants of the inventive method can be deployed. In a further advantageous embodiment first, second, third, fourth and/or fifth item(s) of check information is/are generated in particular as a pseudo-random code, for example a nonce value. Alternatively or additionally in a further advantageous embodiment the first, second, third, fourth and/or fifth item(s) of check information is/are transmitted as a hash code generated from a value produced in particular as a pseudo-random code, for example a nonce code. This allows additional protection and a higher degree of verification. In a further alternative or additional embodiment a hash code generated from an operating parameter of the registering communication entity and/or first communication entity is transmitted as the first, second, third, fourth and/or fifth item(s) of check information. This has the advantage that known parameters can be used, so that no parameter has to be generated and the close link between said parameters and the terminal means that said terminal can be identified in a simple manner. The object underlying the invention is also achieved by the arrangement for providing the wireless local network, which is characterized by means for implementing the method. BRIEF DESCRIPTION OF THE DRAWINGS Further details and advantages of the invention are described in more detail below based on the prior art shown in FIGS. 1 to 4 and exemplary embodiments shown in FIGS. 5 to 12 , in which figures: FIG. 1 shows a mesh network scenario according to the prior art, FIG. 2 shows an independent mesh network according to the prior art, FIG. 3 shows a mesh network according to the prior art with an access point for non-mesh subscriber stations, FIG. 4 shows a scenario of a mesh ownership check according to the prior art, FIG. 5 shows a flow diagram of an exemplary embodiment of the invention, FIG. 6 shows a message flow diagram for a first variant of the inventive mesh ownership check, FIG. 7 shows a message flow diagram for a second variant of the inventive mesh ownership check, FIG. 8 shows a message flow diagram for a third variant of the inventive mesh ownership check, FIG. 9 shows a scenario with non-mesh subscriber stations connected by way of mesh access points according to the prior art, FIG. 10 shows a MAC data frame according to the prior art, FIG. 11 shows a flow diagram of the forwarding of mesh data frames according to the prior art, FIG. 12 shows a flow diagram with inventive address translation based on scenarios according to the prior art. DETAILED DESCRIPTION OF INVENTION Based on the scenarios shown in FIGS. 1 to 4 and the resulting problems, the invention advantageously intervenes and resolves the above-mentioned problems for a mesh network, as shown in the exemplary embodiment according to FIG. 5 based on a flow diagram illustrating the exemplary embodiment. The inventively embodied procedure starts here with a first step S 1 , showing an initial state START, and after the occurrence of an event, specifically receipt of a request from a subscriber station to register with a mesh network using the MAC address MA, moves in a second step S 2 to a third step S 3 , in which it is checked whether a station with the transmitted MAC address MA is already registered in the mesh network. This check, carried out in a fourth step S 4 , results, if it is an already registered reachable MAC address MA, in a further enquiry in a fifth step S 5 , in which it is checked whether the registering subscriber station is a mesh node, i.e. a mesh subscriber, or a non-mesh station. In a sixth step S 6 the registration request is rejected if it is a non-mesh station. Otherwise, in other words if it is a mesh node, in an eighth step S 8 a check takes place to determine MAC address ownership for the registering subscriber station and the MAC address MA. During this MAC address ownership check it is checked whether the subscriber station is authorized to use to the transmitted MAC address MA. If the enquiry shows that the result of the MAC address ownership check is OK, in other words it is an already registered subscriber station, in a tenth step S 10 the registration request is accepted and the subscriber station can set up this link. Otherwise the registration request is rejected again as in the sixth step S 6 , so that the inventive method reaches an end state in a seventh step S 7 . It is thus a core of the invention that during network access by a subscriber to a mesh network using a MAC address, it is checked by the mesh network whether a subscriber node with the MAC address used by the registering subscriber is already registered and is thus reachable in this network, with the registering subscriber being accepted, if the MAC address is not yet reachable in said network, but with the response being as described above if a subscriber with the MAC address is reachable. There are also alternatives to the approval procedure described above. It could be for example that when it is detected in the fourth step S 4 that it is an already reachable MAC address, the registering subscriber is rejected immediately. A further alternative or addition to the described proceedings in the context of the approval procedure is to carry out a MAC address translation, in other words replacing MAC addresses, as is also known for example with the so-called network address translation of IP addresses to convert private IP addresses to public IP addresses. However here a first MAC address is converted respectively to a second MAC address assigned to it, while with network address translation a number of private IP addresses are converted to the same public IP Address. According to the invention the MAC address given by the registering subscriber would be replaced by a free MAC address in respect of communication within the network, with the free MAC address meaning that it is an address that is not currently being used within the relevant network, in other words it is disjoint in respect of the reachable MAC addresses. The replacement address can be generated here by pseudo-random codes, with this preferably being restricted to a MAC address domain, which is not an address allocated to defined organizations according to OUI. This can be ensured for example in that the 41 st bit, the so-called “U/L” for Universal/Local bit of the MAC address, has the value 1, so that this MAC address is not universally unique but is administered locally and is therefore only unique there. The effect is then that a registering subscriber with an external non-unique MAC address is allocated an internally unique address uniquely as a result. There are a number of implementation variants for the MAC address ownership check shown in the flow diagram and these are described in more detail below. The basic core concept of the MAC address ownership check is that the registering station must demonstrate knowledge of a MAC ownership check parameter during registration. The condition that allows an identity check in this process is that the check parameter is only known to the station that has already registered and is reachable. This check parameter can be a number generated in a pseudo-random manner, a so-called nonce or a cryptographic value, i.e. a value calculated with the aid of cryptographic methods and a key or another known parameter, such as a serial number or counter value for example. If the registering station demonstrates knowledge of this check parameter, it is accepted. This demonstration is preferably provided by transmitting the check parameter on at least two different routes. One route is always the route to be set up and the other can be selected freely from already existing routes. Implementation variants result from different possible demonstration sequences. For example, a sequence can be such that the check parameter is sent from the network to the already registered station by way of the already existing route and the network then waits for the check parameter to be returned by way of the route to be set up. This ensures that the registering station and the already registered station are identical and only the registering station wishes to set up a further route, as is possible in principle according to mesh architecture, as the return of the check parameter by the route to be set up is only possible if they are one and the same station. An attacker would not have this information. One variant of this is that the check parameter is sent from the network to the station just registering by way of the route to be set up and the subsequent return of the check parameter by way of the already existing route is then awaited. This is essentially only a reversal of the transmission directions. In a further variant the check parameter, for example the above-mentioned random number generated in a pseudo-random manner or nonce, is transmitted from the registering station to the network by way of the two routes mentioned, namely the route to be set up and the previously existing route to the network. The network then only has to check the identical nature of the two parameters arriving by way of the different routes and in the simplest instance if the check parameters are identical or there is a high degree of correlation approve the registering station correspondingly and if they are not identical reject it. Sending can be initiated here by the stations involved or the check parameter is requested on the initiative of the network by way of the two different routes mentioned. A further possibility is that a check parameter is calculated using a cryptographic key by the station just registering. This can be done for example on the basis of a master session key MSK resulting from an EAP-based network registration. After calculation the check parameter is sent by way of the already existing route to the network, which itself calculates a check parameter for cross-checking purposes using the same key and checks it against the one received to determine identity. Similarly the registered station can calculate check parameters based on the cryptographic key assigned to it and send them to the network by way of the route to be set up. The core of the ownership check is therefore sending the check parameter, sending a value derived from the check parameter, for example the hash value of the check parameter or the input value of a hash function, which gives the check parameter as a result, for example SHA-1, SHA-256 or MD5, using the check parameter as input to calculate a cryptographic checksum, the so-called message authentication code, for example HMAC-SHA1, HMAC-SHA256, HMAC-MD5 or AES-CPC-MAC and sending the result. The two first variants of the demonstration sequences, i.e. rejection or MAC address conversion are advantageous here if it is known that a subscriber can or should only register once with this network, as is the case for example with conventional WLAN stations, while the third variant, in other words the ownership check, can be deployed expediently when a subscriber can legitimately maintain a number of access links to this network, as is permitted for example for mesh nodes within a mesh network. Therefore a development also provides for a distinction between different types of subscriber, in the above instance for example specifically between mesh subscribers and non-mesh subscribers, with a subscriber station being given the freedom to register with the network as a mesh subscriber or a non-mesh subscriber and with the check then being carried out in such a manner that if it registers as a non-mesh subscriber, it is checked according to the invention that no other subscriber with the same MAC address is registered as a mesh subscriber with the network. It can also be checked that no other subscriber with the same MAC address is already registered as a non-mesh subscriber with the network. FIG. 6 shows a detailed diagram of a first variant of the ownership check in the form of a message flow diagram. It shows the message flow between a station MP-A, which has the MAC address MACA, registering with a mesh network, which consists at least of the mesh nodes MP- 1 and MP- 2 , a first station MP- 1 having a first MAC address MAC 1 and the second station MP- 2 having a second MAC address MAC 2 . A possible message flow resulting according to the invention is shown as follows. At a first time T 1 . 1 the registering station MP-A sends a registration request to set up a link to a mesh node of the mesh network, in the example shown a second station MP- 2 . It is then checked at a time T 1 . 2 by MP- 2 whether the MAC address of the registering station MACA is already reachable in the mesh network, in other words if a node has already registered with this address. In the example shown it should be assumed that this is the case. A check could be carried out here to determine the presence of an already existing reachable address in that the second station MP- 2 searches its routing tables for an entry for the registration MAC address MACA or it could be done by means of a so-called route request message, which is preferably sent out with a destination only flag for the node with the registering MAC address MACA, to determine any existing route through the mesh network. Since in this instance the registration MAC address MACA already represents a reachable address in the mesh network, the second communication entity MP- 2 sends an error message back to the registering station MP-A at time T 1 . 3 , stating that a MAC address ownership demonstration MAO is required, this message being optional. Furthermore at a fourth time T 1 . 4 the second communication entity MP- 2 generates a check parameter N, for example a pseudo-random number, and stores it, optionally with further data, in particular the MAC address MACA of the registering station MP-A, to use this at a later stage for the ownership demonstration, such that the second communication entity MP- 2 sends this check parameter as a message to the registering station MP-A by way of a first communication entity MP- 1 , this message being sent first to the first communication entity MP- 1 , which then forwards it to the registering station MP-A. As well as the check parameter N this message also contains the MAC addresses of the second communication entity MP- 2 and the registering station MP-A as address information, so that even if the message is forwarded by way of a number of intermediate nodes, it still arrives successfully at the registering station MP-A. On receipt of this message, at a fifth time T 1 . 5 , the registering communication entity MP-A again sends a registration request to set up a link to the second communication entity MP- 2 , this message also containing the check parameter N in contrast to the request sent at the first time T 1 . 1 . Then at a sixth time T 1 . 6 the second communication entity MP- 2 can check the check parameter N sent by the registering station MP-A to determine whether it corresponds to the stored one, which should be the case in the scenario shown, so that at a seventh time T 1 . 7 the second communication entity MP- 2 sends an OK message for confirmation to the registering communication entity MP-A and the registering station MP-A is thus approved as a subscriber station in the network. FIG. 7 shows a further variant, in which the alternative realization of the demonstration sequence is such that the registering station MP-A itself generates a check parameter N, which is requested by the second communication entity MP- 2 via the existing link by way of the first communication entity MP- 1 . In the message flow diagram shown the demonstration sequence starts at a first time T 2 . 1 such that the registering station MP-A first sends a registration request to set up a link to the second communication entity MP- 2 in the usual manner. At a second time T 2 . 2 the second communication entity MP- 2 then checks whether the MAC address transmitted on the part of the registering communication entity MP-A, i.e. the registration address MACA, is already reachable in the mesh network, in other words a node is registered with this MAC address. This should be assumed in this example too, it being possible for the check to take place, as described with reference to FIG. 6 . With this variant too, at a third time T 2 . 3 the second communication entity MP- 2 sends an error message back to the registering communication entity MP-A stating that a MAC address ownership demonstration MAO is required, so that in contrast to the variant described above the registering station MP-A itself generates a check parameter N, for example a pseudo-random number, and stores this. In order now to allow the second communication entity MP- 2 to carry out the check, the registering station MP-A sends a message to the second communication entity MP- 2 by way of the first communication entity MP- 1 , this being sent first to the first communication entity MP- 1 , which then forwards it to the second communication entity MP- 2 , said message containing the check parameter N, which was generated by the registering communication entity MP-A. The communication entity stores the received check parameter N and optionally further data, in particular the MAC address MACA of the registering station MP-A. At a fifth time T 2 . 5 the registering communication entity again sends a registration request to set up a link to the second communication entity MP- 2 , this also containing the check parameter N in contrast to the message sent at the first time T 2 . 1 . At a sixth time T 2 . 6 , after the second communication entity MP- 2 has received the message from the registering communication entity MP-A, a check is carried out by the second communication entity MP- 2 to determine whether the check parameter sent by the registering communication entity MP-A corresponds to the check parameter received by way of the first communication entity MP- 1 , as is assumed in this example, so that at a seventh time T 2 . 7 the second communication entity MP- 2 sends an OK message for confirmation to the registering communication entity MP-A and allows this subscriber station access to the network. An alternative would be for the registering communication entity MP-A to insert a check parameter into the message during the first registration, resulting in an almost identical sequence, with the only difference being that the first two messages are omitted. The check parameters here can be random numbers generated in a pseudo-random manner (nonce) in particular. FIG. 8 shows a further variant and describes it using the example of a message flow diagram, in which the generation of a check parameter is dispensed with and instead the registering station MP-A uses existing information, i.e. parameters, which is requested on the part of the second communication entity MP- 2 by way of both routes, i.e. once by way of the route to be set up and by way of the already existing route. This variant has the advantage that any parameters can be requested, allowing a check in which the usual registration procedure itself does not have to be modified. It is sufficient simply for it to be possible to request parameter values assigned to the registering communication entity MP-A. These parameters can in particular be serial numbers of the registering communication entity MP-A, the type, model or software version of said communication entity; they can also be counter values of the registering communication entity MP-A, for example packet counters, sequence number counters for routing messages, the specific route request sequence number of the registering communication entity MP-A, in other words two route request messages are sent to it by way of the two routes Mentioned, to which it must respond with the respectively appropriate, i.e. very close sequence number, it being necessary here to ensure that no data relating to the destination sequence number is contained in the route request transmitted by way of the link or route to be set up, as otherwise a potential attacker node would learn the current and therefore the expected value. During the subsequent check it is then tested whether the values are identical or whether the counter values, which may be different because the requests are made at different times, are sufficiently close to one another. A threshold value comparison for example is preferable for this. The messages flow as follows. At a first time T 3 . 1 the known registration request is sent on the part of the registering communication entity MP-A, containing the registration address MACA, to the second communication entity MP- 2 , whereupon this latter checks whether the transmitted registration address MACA is already reachable in the mesh network and at a third time T 3 . 3 sends a request for any parameters to the registering station MP-A, whereupon the registering station MP-A sends the corresponding parameters to the second communication entity MP- 2 , which then stores these at a fifth time T 3 . 5 and at a sixth time T 3 . 6 sends a request for the same parameters by way of the first communication entity MP- 1 to the registering communication entity MP-A, whereupon the registering communication entity MP-A transmits the requested parameters by way of the first communication entity MP- 1 to the second communication entity MP- 2 , so that at an eighth time T 3 . 8 the second communication entity MP- 2 can transmit an OK message to the registering station MP-A, thus allowing this station access to the network. One alternative to this is to set the link up with certain conditions. The OK message would then be sent directly after the registration request and then in a conditional phase the checks would be carried out, as described above, so that, if the result of the checks is negative, the direct link is canceled again. The direct link between the registering station MP-A and the second communication entity MP- 2 is then preferably only treated as existent by the second communication entity MP- 2 for routing purposes if the check is successful, i.e. after the conditional phase. FIG. 9 shows a scenario in which during the registration of a node as a non-subscriber, i.e. for example as a WLAN station STA at a mesh access point MAP, the mesh network, i.e. one of the mesh access points MAP, checks whether a mesh node is already registered within the network using the same MAC address as the registering station that is registering as a non-mesh subscriber. The particular feature of this illustrated example is that only the MAC address of a node is checked during registration of a station as a non-mesh subscriber and only one check takes place in respect of those MAC addresses that belong to a mesh node, in other words a subscriber registered as a mesh subscriber. This ensures that no non-mesh subscriber uses the MAC address of a mesh node or is visible with this MAC address within the mesh network. It can be seen that a node is not a mesh subscriber by an entry in a table with a set flag, known as “isProxied” (see IEEE 802.11s D0.02, section 11A.3.5.2 MP Proxy Table), while a mesh node belonging to a mesh subscriber would be shown in the table with a flag that is correspondingly not set. According to the invention the following measures could be taken if the non-mesh subscriber station has an address which is identical to a mesh subscriber station and either the registration of the corresponding non-mesh station is rejected or the MAC address used by the non-mesh station is converted to a free MAC address using MAC address translation. In one variant the check could take place in such a manner that it is determined whether the MAC address is already in use both in respect of mesh subscribers and in respect of non-mesh subscribers; in other words it is checked whether any node MP, MAP, STA is reachable at this MAC address. This variant is particularly advantageous when no information is available to indicate whether a node with a specific MAC address is itself involved in mesh routing. The MAC address conversion MAC address translation will be described in more detail with reference to FIGS. 10 and 11 . FIG. 10 shows the structure of a MAC frame defined according to IEEE 802.11, which according to the standard can contain up to four address fields, so-called MAC addresses (see also IEEE 802.11 section 7.2). These can be the so-called source address SA, the destination address DA, the transmitting station address TA, or the so-called receiving station address RA. The source address SA here refers to the address of the original sender, while the destination address DA indicates the address of the final receiver node. Generally however frames are forwarded by way of a number of intermediate nodes within a mesh network, so that the address fields transmitting station address TA and receiving station address TA are used for this purpose. The transmitting station address TA and the receiving station address RA are always included in this frame, while the source address SA and the destination address DA are only filled as required, i.e. when they are different from the transmitting station address TA or the receiving station address RA. In principle the data frame also contains a field for useful data DATA and a field containing the checksum FCS. Further header fields that are not relevant for the description, such as frame control, duration/ID or sequence control, are not shown for the sake of simplicity. FIG. 11 shows the deployment of these MAC frames, the respective input being self-explanatory. FIG. 12 finally shows the inventive conversion of the MAC address in the case of an already used or reachable address, based on this prior art. It shows a conversion of the MAC address M-S of a non-mesh subscriber station STA to a MAC address M-R not used within the mesh network, e.g. generated in a pseudo-random manner, with “R” as random, on the part of a MAC address point MAP- 1 . The conversion is therefore also to be seen as the replacement of the MAC address M-S given by the non-mesh subscriber station STA, with the conversion only affecting the transmitter address TA of MAC frames from the non-mesh subscriber nodes STA, which is identical to the source address SA, and in the case of MAC frames sent to the non-mesh subscriber nodes STA the receiver address RA, which is identical to the destination address DA. It also shows the assignment table in the mesh access point, by way of which the non-mesh subscriber station STA registers. It shows that this contains entries which are used to store mesh-network-external MAC addresses (MAC EXT) to be mapped onto one another assigned respectively to mesh-network-internal MAC addresses (MAC INT). In one variant the MAC address conversion or translation mentioned always takes place, in other words regardless of whether the MAC address indicated is already reachable or not.
A method and an arrangement for providing a wire-free mesh network are provided. An approval procedure is carried out in situations in which a subscriber who is registering on the mesh network transmits an MAC address which already exists in the mesh network, such that two different subscribers within the mesh network never have identical MAC addresses.
7
TECHNICAL FIELD The present invention generally relates to vehicle brakes and more particularly relates to an actuating unit for an electromechanically operable disc brake for automotive vehicles which is arranged on a brake caliper. BACKGROUND OF THE INVENTION An electromechanical actuating unit of this general type is disclosed in DE 195 11 287 A1. In the actuating unit known in the art, the electric motor, by the intermediary of a planetary gear, drives the thread nut of a roller-and-thread drive whose threaded spindle actuates the first friction lining. The rotor of the electric motor additionally serves as the sun wheel of the planetary gearing, whose planet pinions are mounted in the thread nut and cooperate with a hollow wheel designed in the brake caliper. By way of the thread nut, the rotor is supported in a central bearing arranged in the brake caliper. The state of the art actuating unit has disadvantages inasmuch as, during its actuation, disturbances which are due to the clamping force of the electromechanical brake and also the transverse forces and bending moments which occur during operation are transmitted via the roller-and-thread drive to the rotor so that it is impossible to guarantee the presence of a constant air gap between the stator and the rotor. This impairs the rate of efficiency of the above-mentioned arrangement. Further, the rotor which is used as the sun wheel of the planetary gearing may become damaged by the effect of the above-mentioned forces or bending moments which may lead to an inclined positioning in relation to the stator. Therefore, an object of the present invention is to improve upon an electromechanic actuating unit of the type initially referred to in such a manner that the second reduction gear is uncoupled from the first reduction gear so that an equal position of the rotor relative to the planet pinions as well as of the planet pinions relative to the hollow wheel can be ensured. According to the present invention, this object is achieved in that the electric motor, the first reduction gear, and the second reduction gear are configured as at least two assemblies which can be handled independently, so that the electric motor is arranged outside of the flux of force of the clamping force and its operation cannot be impaired by interferences. To specify the idea of the present invention, the electric motor, the first reduction gear, and the second reduction gear are configured as each one assembly which can be handled independently. An electromechanic actuating unit of such a construction is distinguished by a high rate of efficiency, an extraordinary dynamics of brake actuation, and an extremely compact type of construction permitting the transmission of high mass-related brake torques. Further, the modular-design assemblies can be manufactured and tested separately. In a favorable improvement of the object of the present invention, the second reduction gear is arranged on the side of the electric motor remote from the brake linings. This measure permits uncoupling the second reduction gear from the first reduction gear in terms of construction so that deformation of the second reduction gear is reliably prevented and constant clearances may be maintained within the gear. In another favorable embodiment of this invention, a short force transmission travel of the clamping force is achieved because the first reduction gear is configured as a roll-body and thread drive whose thread nut cooperates with the second reduction gear. Alternatively, the first reduction gear can be designed as a roll-body and thread drive whose threaded spindle cooperates with the second reduction gear. This measure achieves optimizing the central bearing which cooperates with the threaded spindle. In another favorable aspect of the present invention, the first reduction gear is configured as a roller-and-thread drive, preferably a roller-and-thread drive with an inward roller return arrangement. Optimal force transmission can be achieved due to the high load capacities of the thread rollers, and the inward return arrangement of the thread rollers permits an easy manufacture of the thread nut. In another embodiment of the present invention which distinguishes particularly by a low sensitivity to transverse forces, the first reduction gear is configured as a ball-and-thread drive. In this arrangement, it is especially advantageous that the actuating element is in a force-transmitting connection with the threaded spindle of the roll-body and thread drive and is formed of a force transmission plate which is guided in an annular housing in which the roll-body and thread drive is incorporated. Preferably, the force transmission plate includes at least two radially opposite guiding pins which are accommodated by correspondingly designed guiding surfaces in the housing. These measures permit achieving an effective isolation of the clamping force from the transverse forces which occur during operation and are introduced into the brake caliper. In another favorable embodiment of the present invention, the thread nut is axially supported on a bearing ring arranged in the housing, and a force sensor is arranged between the bearing ring and the housing. These measures permit realizing a concept with a very short flux of force, with the force sensor representing a component which is arranged in the flux of force, yet is not entrained in movement. In still another favorable aspect of the present invention, a favorable distribution of load in the ball-and-thread drive is achieved by a conical bore incorporated in the threaded spindle of the ball-and-thread drive in which a push rod is received which serves to transmit pressure forces and the ends of which are supported in an axial extension of the force transmission plate or on the bottom of the bore in a rotationally fixed manner. The threaded spindle is only tensilely loaded due to these measures, and the load portions of the indivdiual balls are rendered more uniform. To effectively protect the actuating mechanism, especially against contaminants, for example splash water, an elastic seal is provided between the force transmission plate and the housing in another advantageous aspect of the present invention. In order to considerably reduce the necessary drive torque to be generated by the electric motor, the second reduction gear is configured as a planetary gearing. The planetary gearing is a non-friction gear in which shape variation is not needed and by which high efficiency in little mounting space can be reached. A higher gear ratio is achieved in another embodiment of the object of the present invention in that the second reduction gear is designed as a planetary gearing with stepped planet pinions. The attainable gear ratio can be increased further in that the planet pinions with their first step are in engagement with a sun wheel, while the planet pinions with their second step are in engagement with a hollow wheel, by the intermediary of each one spur wheel. However, it is also easily possible to design the second reduction gear as a two-step differential planetary gearing. In the latter type of gearing, an optimal overall length is achieved by using a larger sun wheel. In another favorable aspect of the object of the present invention, mounting space is optimized because the sun wheel of the planetary gearing is designed on the rotor, while the planet pinions are mounted in a pinion cage that is in a force-transmitting connection with the thread nut. The planet pinions are comprised of each one first large-diameter planet pinion that is in engagement with the sun wheel and each one smaller-diameter second planet pinion that is in engagement with a hollow wheel. The hollow wheel of the planetary gearing is preferably formed of an internally toothed outer ring of a radial bearing in which the pinion cage is supported. These measures achieve a high degree of integration of the arrangement. The transverse forces which occur during operation are effectively uncoupled in another preferred aspect of the present invention because the actuating element is the thread nut of the roll-body and thread drive. Uncoupling of the flux of force from the drive unit or the electric motor is ensured according to another feature of the present invention in that there is provision of a guiding element that embraces the thread nut and is supported on an annular housing receiving the roll-body and thread drive. The threaded spindle is axially supported on the guiding element. The axial support of the threaded spindle is effected by means of a radial bead by the intermediary of an axial bearing. This renders it possible to use a bearing with a very small diameter. Further, it is especially favorable that force-measuring elements are arranged on the guiding element so that force measurements can be performed on the part that is not entrained in movement and subjected to a defined deformation. An effective protection of the arrangement against contaminants and the ingress of water is reached by an elastic seal or gasket that is interposed between the thread nut and the guiding element. A direct introduction of the transverse forces which occur during operation into the housing of the first reduction gear is effected in that the thread nut on its end close to the first friction lining is guided in a guiding ring. In order to effectively protect also this arrangement against the ingress of contaminants, e.g. splash water, an elastic seal or gasket is provided between the thread nut and the guiding ring. In another favorable embodiment of the object of the present invention, the sun wheel of the planetary gearing is provided on the rotor, while the planet pinions are mounted in a pinion cage that is in a force-transmitting connection with the threaded spindle and are comprised of a first large-diameter planet pinion that is in engagement with the sun wheel and a second smaller-diameter planet pinion that is in engagement with a hollow wheel. In the above-mentioned embodiment, the mounting space is optimized in that the hollow wheel of the planetary gearing is formed of an internal toothing which is provided in a cover that represents a casing of the planetary gearing and is arranged on the housing of the electric motor. The assembly of the actuating unit of the present invention is considerably simplified in another embodiment of the object of the present invention in that the force is transmitted between the pinion cage and the threaded spindle by means of a form-locking plug coupling. In a low-cost design of the actuating unit of the present invention, the pinion cage is mounted in the cover by means of a radial bearing. A planetary gearing of this type is easy to manufacture and can be tested separately. It is expedient when the form-locking plug coupling is coupled to the pinion cage in a torsionally resistant, radially yielding and flexible manner. This measure ensures an effective isolation from interferences. The threaded spindle may preferably have a one-part or multi-part design. Another favorable embodiment of the object of the present invention is characterized in that the thread nut at its end remote from the first friction lining includes an axial projection which is movable into abutment on a stop that is designed on the threaded spindle also in an axial direction and acts in a circumferential direction. It is achieved by this measure that in particular in a faulty release action, where the thread nut is turned backwards until its stop, the first reduction gear will not be twisted or jammed. In order to simultaneously fulfil a parking brake function with the actuating unit of the present invention, it is proposed that electromechanical means be provided which allow mechanically locking the rotor of the electric motor. In a particularly fail-safe design which is based on the form-lock principle, the means is formed of a toothed rim connected to the rotor and an electromagnetically operable lock pawl. The lock pawl preferably includes catching means which permit locking engagement both in the actuated and the non-actuated position. In further favorable embodiments of the present invention, the electric motor may be configured as an electronically commutated electric motor energized by a permanent magnet (direct-current motor without brushes) or as a switch reluctance motor (SR motor). The mentioned types of motors are especially suitable for producing high torques during standstill. In order to electronically commutate the motor of the actuating unit it is required to arrange for a position detection system which renders possible to detect the position of the rotor of the electric motor relative to the stator and preferably includes a Hall sensor or a magnetoresistive element. The present invention will be explained in detail in the following description of three embodiments by making reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an axial cross-sectional view of a first embodiment of the electromechanical actuating unit of the present invention. FIG. 2 is a view of a second embodiment of the object of the present invention in an illustration that corresponds to FIG. 1 . FIG. 3 is a view of a third embodiment of the electromechanical actuating unit of the present invention in an illustration that corresponds to FIG. 1 . FIG. 4 is an exploded view showing the first reduction gear as used in the third embodiment according to FIG. 3 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The electromechanical actuating unit of the present invention, as shown in the drawings, serves for actuating a floating-caliper disc brake whose brake caliper (shown only schematically) is slidably mounted in a stationary holder (not shown). A pair of friction linings 4 and 5 are arranged in the brake caliper so that they face the left and the right lateral surface of a brake disc 6 . Hereinbelow, the friction lining 4 shown on the right in the drawing is referred to as first friction lining, while the other friction lining, designated by reference numeral 5 , is referred to as the second friction lining. While the first friction lining 4 is movable into engagement with the brake disc 6 directly by the actuating unit by means of an actuating element 15 , the second friction lining 5 is urged against the opposite lateral surface of the brake disc 6 by the effect of a reaction force generated by the brake caliper upon actuation of the arrangement. The actuating unit of the present invention which is fitted to the brake caliper by way of fastening means (not shown) has a modular design and is basically composed of three assemblies or modules which can be handled independently, i.e., a drive unit 1 , a first reduction gear 2 which actuates the first friction lining 4 , and a second reduction gear 3 which is interposed between the drive unit 1 and the first reduction gear 2 in terms of effect. The above-mentioned drive unit 1 is comprised of an electric motor 11 which, in the embodiment shown, is an electronically commutated motor energized by a permanent magnet, its stator 9 being immovably arranged in a motor housing 12 , and its rotor 10 being formed of an annular carrier 13 that carries several permanent magnet segments 14 . Arranged between the torque motor 11 and the above-mentioned Actuation Element 15 in terms of effect is the first reduction gear 2 which, in the embodiment shown, is configured as a ball-and-thread drive 16 to 18 mounted in a gear housing 19 . The ball-and-thread drive is comprised of a thread nut 16 and a threaded spindle 17 , and a plurality of balls 18 are arranged between the thread nut 16 and the threaded spindle 17 which circulate in a rotational movement of the thread nut 16 and initiate an axial or translatory movement of the threaded spindle 17 . The gear housing 19 may also be designed in one part with the above-mentioned brake caliper. The arrangement is preferably chosen such that the rotor 10 of the motor 11 , by the intermediary of the second reduction gear 3 , drives the thread nut 16 , while the threaded spindle 17 by means of a push rod 24 cooperates with the above-mentioned actuating element 15 that is preferably provided by a force transmission plate supported on the first friction lining 4 . The push rod 24 which is received in a conical bore 25 that is designed in the threaded spindle 17 is supported in a fashion fixed against rotation by means of a polygonal element 28 in an axial extension 26 of the force transmission plate 15 , on the one hand, and on the bottom of the bore 25 , on the other hand. In order to introduce the transverse forces which occur during operation of the actuating unit of the present invention into the gear housing 19 , the force transmission plate 15 has two radially opposite guiding pins 20 which are guided in guiding surfaces or bores 21 provided in the gear housing 19 . An axial bearing or ball bearing which is comprised of a radial collar 29 shaped on the thread nut 16 , a plurality of balls (not referred to in detail), and a bearing ring 22 is used for the mounting support of the thread nut 16 in the gear housing 19 . Arranged between the bearing ring 22 and an annular supporting surface designed in the gear housing 19 is a force sensor 23 which is used to determine the clamping force generated by the actuating unit. To protect the first reduction gear 2 against contaminants such as splash water, an elastic seal 27 which is configured as a cup seal in the embodiment shown is interposed between the force transmission plate 15 and the gear housing 19 . The necessary motor torque is reduced in the embodiment of the present invention shown in FIG. 1 by the expedient integration of a planetary gearing 30 to 34 which forms the above-mentioned second reduction gear 3 . The planetary gearing which is arranged between the rotor 10 and the thread nut 16 in terms of effect, is comprised of a sun wheel 30 that is preferably formed by an externally toothed area 42 on the rotor 10 , a plurality of stepped planet pinions (two of which are shown and designated by reference numerals 31 and 32 ), and a hollow wheel 33 . The stepped planet pinions 31 , 32 which are accommodated in a pinion cage 34 include a first step cooperating with the sun wheel 30 and a second step cooperating with the hollow wheel 33 , with the first step being formed of planet pinions 31 a, 31 b of large diameter and the second step being formed of planet pinions 31 b, 32 b of smaller diameter. Preferably, the above-mentioned pinion cage 34 is so configured that its area disposed between the points of support of the planet pinions 31 , 32 and the point of coupling of the thread nut 16 permits both a small axial and radial clearance and a small offset in angles and, for example, is designed as a lamellar disc or a pleated bellows. The hollow wheel 33 is provided by an internally toothed area of an outer ring 36 of a radial bearing 35 which is configured as a ball bearing in the embodiment shown, having an inner ring that is formed of the radially outward circumferential area of the pinion cage 34 . To achieve the function of a parking brake, the actuating unit of the present invention includes electromechanical means which cooperate with the rotor 10 of the electric motor 11 and permit its locking. In the embodiment shown in FIG. 1, the rotor 10 includes for this purpose a toothed rim 37 , and a lock pawl 38 can be engaged with the toothing of rim 37 . The electrical actuator system associated with the lock pawl 38 is designed in the type of a mechanical flipflop whose condition is changed with each short energization. In the embodiment shown, the lock pawl 38 is furnished with a permanent magnet 39 (shown only schematically) which is moved by means of a coil 40 . Besides, the lock pawl 39 can be equipped with locking means, designated by reference numeral 41 , that permit locking engagement of the lock pawl 39 in the actuated and the non-actuated position. It is especially suitable in this arrangement when the above-mentioned toothed rim is configured as a part of a radial bearing 43 in which rotor 10 is mounted. Besides, the toothed rim 37 may be configured as a part of a position detection system 46 (not shown in detail) which serves to determine the current position of the rotor 10 . The information about the said position is then determined by means of a Hall sensor or a magnetoresistive element. In the second embodiment of the object of the present invention illustrated in FIG. 2, the design of which largely corresponds to the embodiment of FIG. 1 and wherein like reference numerals have been assigned to like parts, the first reduction gear 2 is configured as a roller-and-thread drive, preferably, with an internal return arrangement of the rollers 52 . The actuating element 15 mentioned with respect to FIG. 1 is provided by the thread nut 50 of the roller-and-thread drive which, in its area close to the first friction lining 4 , is guided in a guiding ring 54 arranged in the gear housing 19 . The transverse force is dissipated into the gear housing 19 by this measure. In order to improve the sliding properties of the guiding ring 54 , the guiding ring 54 is furnished with a Teflon bushing 55 . The design of the thread nut 50 is so that the diameter of its part that is guided in the guiding ring 54 is smaller than the diameter of its abutment surface that bears against the friction lining 4 , whereby the necessary guiding length can be reduced. A threaded spindle 51 driven by the pinion cage 34 has a radial bead 53 of a large diameter by way of which it is axially supported on a bowl-shaped guiding element 56 that radially embraces the roller-and-thread drive. The arrangement is preferably chosen so that roll bodies, e.g. ball bearings 57 , are arranged between the bead 53 and the area of the guiding element 56 facing the bead, so that an axial bearing is produced. The clamping force generated during the actuation can be determined by means of force measuring elements such as wire strain gauges (not shown) which are preferably fitted to the guiding element 56 . A cup seal 58 which protects the roller-and-thread drive against contaminants is attached to the thread nut 50 , on the one hand, and to the guiding ring 54 , on the other hand. The radial bearing explained with respect to FIG. 1 for the mounting support of the pinion cage 34 is assigned reference numeral 44 in FIG. 2, while its outer ring has been given reference numeral 45 . The design of the parking brake and the second reduction gear 3 corresponds exactly to the design described with respect to FIG. 1 and, consequently, need not be explained in detail. In the third embodiment of the actuating unit of the present invention illustrated in FIGS. 3 and 4, a ball-and-thread drive is used as the first reduction gear 2 , its thread nut 60 forming the above-mentioned actuating element. The mounting support of the thread nut 60 in the guiding element 66 is effected both in its area facing the first friction lining 4 by means of a first slide ring 65 arranged in the guiding element 66 and in its end area remote from the friction lining 4 by means of a second slide ring 67 arranged on the thread nut 60 . Exactly as in the preceding embodiment, the second reduction gear 3 is configured as a planetary gearing with stepped planet pinions accommodated in a cover 69 forming its housing. Although it is possible to provide a one-part threaded spindle, the threaded spindle driven by the electric motor 11 by way of the second reduction gear has a three-part configuration in the embodiment shown and is comprised of a tubular first spindle part 61 that is in engagement with the thread nut 60 by means of a plurality of balls 64 , an annular second spindle part 62 that is supported on an axial bearing 68 arranged within the guiding element 66 , and a third spindle part 63 which is coupled to the pinion cage 34 of the second reduction gear 3 by means of a form-locking plug coupling. For this purpose, the end of the third spindle part 63 is e.g. designed as a “Torx” connection or a multi-faceted (e.g. sexagon) head which is slipped into a matingly shaped opening in the pinion cage 34 . It is especially advantageous that the form-locking plug coupling is coupled to the pinion cage 34 in a torsionally resistant, radially yielding and flexible fashion. Coupling is carried out by means of an outer ring 72 of a radial bearing 71 provided in the cover 69 , and a toothed area is desgined in the cover 69 and forms the hollow wheel 70 of the planetary gearing. An elastic cup seal 59 compressed between the thread nut 60 and the guiding element 66 prevents the ingress of contaminants into the interior of the ball-and-thread drive. As can be taken from FIG. 4 in particular, the thread nut 60 at its end remote from the friction lining 4 includes an axial projection 73 which cooperates with a stop 74 designed on the periphery of the spindle part 61 when the thread nut 60 is reset. Further resetting of the thread nut 60 is reliably prevented by supporting a lateral surface of the projection 73 on the stop 74 , so that the two parts 60 , 61 will not get jammed. Various modifications are of course possible in the spirit of the present invention. For example, the electric motor used as the drive unit 1 may be configured as a switch reluctance motor (SR motor). Different designs of the planetary gearing, such as a two-stage differential planetary gearing or a gear whose planet pinions, with their first step, are in engagement with a sun wheel and, with their second step, are in engagement with a hollow wheel by the intermediary of each one spur wheel are also possible. Of course, it is also suitable to use gears which achieve high reduction ratios by way of a deformable toothed ring and eccentricity.
The present invention discloses an actuating unit for an electromechanically operable disc brake for automotive vehicles which is generally comprised of a drive unit or an electric motor, an actuating element, by means of which one of two friction linings that are slidably arranged in a brake caliper is moved into engagement with a brake disc, as well as a first and a second reduction gear. In order to uncouple the second reduction gear from the first reduction gear, it is disclosed in the present invention that the electric motor, the first reduction gear, and the second reduction gear are configured as at least two assemblies which can be handled independently.
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CLAIM OF PRIORITY This application is a continuation of and claims priority to U.S. patent application Ser. No. 11/644,297 filed on Dec. 22, 2006 now U.S. Pat. No. 7,723,841 entitled “Thermal Spacer for Stacked Die Package Thermal Management,” now allowed. FIELD OF THE INVENTION Embodiments of the present invention generally relate to the field of integrated circuit packages, and, more particularly to a thermal spacer for stacked die package thermal management. BACKGROUND OF THE INVENTION The demand for enhanced performance and functionality of integrated circuit components continues to increase design and fabrication complexity. An integrated circuit package can have increased flexibility and functionality within the same footprint by stacking multiple dice on top of each other. However, if the dice to be stacked are high frequency active dice, there could be thermal management issues. BRIEF DESCRIPTION OF THE DRAWINGS The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings in which like references indicate similar elements, and in which: FIG. 1 is a graphical illustration of a three-dimensional view of a thermal spacer for stacked die package thermal management, in accordance with one example embodiment of the invention; FIG. 2 is a graphical illustration of a cross-sectional view of a stacked die package with a thermal spacer for stacked die package thermal management, in accordance with one example embodiment of the invention; and FIG. 3 is a block diagram of an example electronic appliance suitable for implementing a thermal spacer for stacked die package thermal management, in accordance with one example embodiment of the invention. DETAILED DESCRIPTION In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that embodiments of the invention can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form in order to avoid obscuring the invention. Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments. FIG. 1 is a graphical illustration of a three-dimensional view of a thermal spacer for stacked die package thermal management, in accordance with one example embodiment of the invention. In accordance with the illustrated example embodiment, thermal spacer 100 includes one or more of contact surface 102 , edge overhangs 104 , pin 106 , and wirebond edge 108 . Thermal spacer 100 may be made of any heat conductive material. In one embodiment, thermal spacer 100 is made primarily of ceramic. In another embodiment, thermal spacer 100 is made primarily of metal. Contact surface 102 is designed to contact the top surface of an integrated circuit die in a stacked die thermal package, as depicted in FIG. 2 . Heat from the integrated circuit die would be conducted through contact surface 102 to throughout thermal spacer 100 . Edge overhangs 104 are designed to hang over and extend along an outside edge of the associated integrated circuit die. In one embodiment, the height of edge overhangs 104 is designed to contact a package substrate. One skilled in the art would appreciate that edge overhangs 104 would enable heat to be further distributed. While depicted with two edge overhangs 104 , thermal spacer 100 may also be implemented with overhangs on just one or on three sides of contact surface 102 . Pin 106 , included in some embodiments of thermal spacer 100 , is designed to mate with a hole in a package substrate, as depicted in FIG. 2 , to further distribute heat. Wirebond edge 108 is designed to allow contacts on an associated integrated circuit die to be exposed to allow for wirebonding, as depicted in FIG. 2 . Wirebond edge 108 may also be implemented on two or three sides of contact surface 102 . FIG. 2 is a graphical illustration of a cross-sectional view of a stacked die package with a thermal spacer for stacked die package thermal management, in accordance with one example embodiment of the invention. As shown, package 200 includes one or more of substrate 202 , bottom die 204 , adhesive 206 , top die 208 , thermal spacer 210 , top die wire 212 , bottom die wire 214 , overhang edge 216 , pin 218 , mold 220 , and solder ball 222 . Substrate 202 represents a substrate that may comprise multiple conductive layers laminated together. Substrate 202 may be laminated with dielectric material as part of a substrate build-up and may have insulated traces and vias routed through it. Bottom die 204 represents an integrated circuit die. In one embodiment, bottom die 204 represents a memory device. In another embodiment, bottom die 204 represents a logic device. Bottom die 204 is mechanically attached to substrate 202 by adhesive 206 , which represents a thin-film attachment material. Top die 208 is mechanically attached to thermal spacer 210 by adhesive. In one embodiment, top die 208 is a radio frequency (RF) media access control (MAC) integrated circuit (IC) die and bottom die 204 is a RF radio IC die. Thermal spacer 210 is comprised primarily of a heat conducting material, such as silicon, diamond, ceramic or metal, to distribute heat from the top of bottom die 204 and the bottom of top die 208 . Top die wire 212 and bottom die wire 214 represents wirebonding that electrically couples top die 208 and bottom die 204 , respectively, to contacts on top of surface 202 . Overhang edge 216 of thermal spacer 210 overhangs and extends parallel with one outside edge of bottom die 204 . As shown, overhang edge 216 contacts substrate 202 enabling further distribution of heat. While shown overhanging one side of bottom die 204 , overhang edge 216 may be implemented on any number of sides so long as accommodations are made for wirebonding. Pin 218 may be coupled to overhang edge 216 to mate with a hole in substrate 202 , enabling further distribution of heat. Mold 220 is used to protect dice 204 and 208 as well as wires 212 and 214 . In one embodiment, mold 220 is an epoxy resin compound. Solder ball 222 may be added to package 200 to allow package 200 to be coupled, for example to a substrate or printed circuit board. Other electrical interfaces besides solder balls may also be utilized. FIG. 3 is a block diagram of an example electronic appliance suitable for implementing a thermal spacer for stacked die package thermal management, in accordance with one example embodiment of the invention. Electronic appliance 300 is intended to represent any of a wide variety of traditional and non-traditional electronic appliances, laptops, desktops, cell phones, wireless communication subscriber units, wireless communication telephony infrastructure elements, personal digital assistants, set-top boxes, or any electric appliance that would benefit from the teachings of the present invention. In accordance with the illustrated example embodiment, electronic appliance 300 may include one or more of processor(s) 302 , memory controller 304 , system memory 306 , input/output controller 308 , network controller 310 , and input/output device(s) 312 coupled as shown in FIG. 3 . Network controller 310 , or other integrated circuit components of electronic appliance 300 , may be housed in a package including a slotted substrate described previously as an embodiment of the present invention. Processor(s) 302 may represent any of a wide variety of control logic including, but not limited to one or more of a microprocessor, a programmable logic device (PLD), programmable logic array (PLA), application specific integrated circuit (ASIC), a microcontroller, and the like, although the present invention is not limited in this respect. In one embodiment, processors(s) 302 are Intel® compatible processors. Processor(s) 302 may have an instruction set containing a plurality of machine level instructions that may be invoked, for example by an application or operating system. Memory controller 304 may represent any type of chipset or control logic that interfaces system memory 306 with the other components of electronic appliance 300 . In one embodiment, the connection between processor(s) 302 and memory controller 304 may be referred to as a front-side bus. In another embodiment, memory controller 304 may be referred to as a north bridge. System memory 306 may represent any type of memory device(s) used to store data and instructions that may have been or will be used by processor(s) 302 . Typically, though the invention is not limited in this respect, system memory 306 will consist of dynamic random access memory (DRAM). In one embodiment, system memory 306 may consist of Rambus DRAM (RDRAM). In another embodiment, system memory 306 may consist of double data rate synchronous DRAM (DDRSDRAM). Input/output (I/O) controller 308 may represent any type of chipset or control logic that interfaces I/O device(s) 312 with the other components of electronic appliance 300 . In one embodiment, I/O controller 308 may be referred to as a south bridge. In another embodiment, I/O controller 308 may comply with the Peripheral Component Interconnect (PCI) Express™ Base Specification, Revision 1.0a, PCI Special Interest Group, released Apr. 15, 2003. Network controller 310 may represent any type of device that allows electronic appliance 300 to communicate with other electronic appliances or devices. In one embodiment, network controller 310 may comply with a The Institute of Electrical and Electronics Engineers, Inc. (IEEE) 802.11b standard (approved Sep. 16, 1999, supplement to ANSI/IEEE Std 802.11, 1999 Edition). In another embodiment, network controller 310 may be an Ethernet network interface card. Input/output (I/O) device(s) 312 may represent any type of device, peripheral or component that provides input to or processes output from electronic appliance 300 . In the description above, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details. In other instances, well-known structures and devices are shown in block diagram form. Many of the methods are described in their most basic form but operations can be added to or deleted from any of the methods and information can be added or subtracted from any of the described messages without departing from the basic scope of the present invention. Any number of variations of the inventive concept is anticipated within the scope and spirit of the present invention. In this regard, the particular illustrated example embodiments are not provided to limit the invention but merely to illustrate it. Thus, the scope of the present invention is not to be determined by the specific examples provided above but only by the plain language of the following claims.
In some embodiments, a thermal spacer for stacked die package thermal management is presented. In this regard, an apparatus is introduced having a top integrated circuit die, a bottom integrated circuit die, and a thermal spacer between the top and bottom integrated circuit dice, the thermal spacer comprising a heat conducting material and the thermal spacer overhanging and extending parallel with one outside edge of the bottom integrated circuit die. Other embodiments are also disclosed and claimed.
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CROSS-REFERENCE TO RELATED APPLICATIONS This application is related to U.S. patent application Ser. No. 10/034,885 entitled “METHOD AND APPARATUS FOR SCREENING DATABASE QUERIES PRIOR TO SUBMISSION TO A DATABASE” filed on Dec. 26, 2001 in the name of Michael Tedesco, the entirety of which is incorporated herein by reference. FIELD OF THE INVENTION The present invention relates generally to database management and, more particularly, to methods and apparatuses for accessing data from an established database using an alternate database engine. BACKGROUND OF THE INVENTION Businesses typically employ enterprise-wide database engines in order to allow employees, customers, and other such users, to access data stored in one or more data files maintained thereby. Users typically access a database engine over a computer network in which a user's computing terminal may communicate with one or more servers maintaining the database engine. Examples of such database engines include those supporting Structured Query Language (SQL) formats, Open-Database Connectivity (ODBC) and Javascript Database Connectivity (JDBC) protocols produced by MICROSOFT, ORACLE, SYBASE, SUN MICROSYSTEMS and the like. Businesses employing such database engines typically find that it is difficult to convert to or incorporate an alternate database engine that is produced by another database manufacturer or that employs a differing data format. This problem, known as entrenchment, arises due to costs that arise from conversion between competing database products. These costs are due largely to the nature of existing computer software, in that differing data standards, command structures, and file formats are typically used by competing database manufacturers. For example, conversion of any data stored by an established database engine to a format supported by the new database engine may be labor-intensive, and therefore, expensive. In addition, new data commands corresponding to the new database engine must be learned by users in order to interact efficiently with them. The process of learning new commands temporarily reduces the user's efficiency, thereby impacting his or her efficiency. Businesses then may determine that the costs associated with conversion would prevent them from selecting a new database engine, if when it would provide new or more desirable functionality. A business or other entity is thus largely wedded to a particular established database system once it has been selected and implemented. Over time, entrenchment may result in additional unwanted costs. For example, a database manufacturer may require its customers to purchase software upgrades periodically, in order to maintain service contracts and the like for the established database engine, even when such upgrades do not provide any additional functionality that is specifically beneficial to the business. In another example, a business may wish to expand database services to users by providing additional database servers on the computer network, particularly where large amounts of data are maintained or large numbers of users are provided with access. In such a case, the business would be forced to purchase another license for the established database engine to run on a new server, even when less costly database engines may be available. Various solutions to the entrenchment problem have been attempted. A first example involves certain database engines that periodically copy or replicate data stored by an established database engine and provide it to further users. However, this solution is not ideal in the case of temporally-sensitive data that changes on a continuing basis, such as a historical stock price data. There is inherently some delay associated between conversion of the data between the established and the new database engines. Also, there is a delay associated with data transfer between the two database engines. This may result in inaccurate result sets being generated and returned to users accessing such database engines. A second example is a class of software products known as middleware applications, such as ODBC produced by MICROSOFT, and JDBC by SUN MICROSYSTEMS. In such applications, the network connectivity layers of the middleware and the established database system are still tied together. Thus, database commands submitted to the middleware application must be processed by a command software layer of the established database system. In a case where the new database engine is implemented to relieve some of the processing performed by the established database engine, system usage resources and other costs, including financial costs, associated with the established database engine are still negatively-impacted. A final example is a class of software products commonly known as database gateway products. These products provide a command gateway between competing database engines of differing data formats, allowing users to submit one command to interact with two or more such separate, supported, database engines. Examples of such gateway products include TRANSPARENT GATEWAY by ORACLE, MICROKERNEL by PERVASIVE, OMNISQL by SYBASE, STARNET and STARGATE produced by POWERHOUSE and DB INTEGRATOR by DIGITAL EQUIPMENT CORPORATION. However, these gateway products generally require continuous maintenance and customization. For example, data mapping in a metadata mapping layer must be continuously changed with every change to the separate supported database engines. Furthermore, the command layer of each separate database engine is accessed by such gateway products in order to process database commands, thus impacting system resources of each server that maintains a database engine. Again, the desired purpose of having a separate database engine may be to relieve some processing from an established database engine. In such a case, this final example is not an optimal solution since system resources of both database engines are impacted. Accordingly, there is a need for a method and apparatus for implementing and using an alternate database engine with an existing database engine that addresses certain problems of existing technologies. SUMMARY OF THE INVENTION The present application is directed to particular features of a system for implementing and using an alternate database engine with an existing database engine in which queries directed to an existing database are intercepted and executed by an alternate database engine. According to a first embodiment, a method for processing a database command commences when a database command is received from a user that requires data from an established database engine. The established database engine has a command layer for processing database commands. However, in order to preserve system resources and the like of the established database server, the database command may be processed by accessing data from the established database engine using only a command layer of an alternate database engine without accessing the command layer of the established database engine. In a second embodiment, a method for implementing and using an alternate database engine in conjunction with an established database engine commences when a plurality of users are given access to an established database engine that has a command layer for processing database commands. An alternate database engine is then established on the same computing system. A database command is received from one of the plurality of users, where the database command is directed to data stored by the established database engine. The command is processed using only the alternate database engine without accessing the command layer of the first database engine. In addition, the alternate database engine may maintain a second database file including second data which is accessible to the user and queried through the command layer of the alternate database engine as well. The computing system is contemplated in various embodiments to include one or more of a local area network, a wide area network, an intranet, an extranet, a wireless network and the Internet. The submitted database command may compatible with any known data format or protocol, such as a Structured Query Language format, a Javascript Database Connectivity protocol and an Open-Database Connectivity protocol. In further embodiments, the command may be evaluated to determine its impact on available system resources or to determine whether the query can be optimized. In additional embodiments, the alternate database engine determines whether the command requires accessing the temporally sensitive data of the established database engine, and if so, accesses a transaction log of the first database engine without interacting with the command layer of the established database engine. Results of the query obtained by the alternate database engine may be provided to the user in a format associated with the established database engine. The methods and apparatuses of the present invention may be used with enterprise database systems, or any other scale database system. BRIEF DESCRIPTION OF THE DRAWINGS Further aspects of the present invention will be more readily appreciated upon review of the detailed description of the various embodiments provided below when taken in conjunction with the accompanying drawings, of which: FIG. 1 is a diagram of a first exemplary network for implementing the alternate database engine of the present invention; FIG. 2 is a diagram of a second exemplary network for implementing the alternate database engine of the present invention; FIG. 3 is a diagram of a third exemplary network for implementing the alternate database engine of the present invention; FIG. 4 is a diagram of a fourth exemplary network for implementing the alternate database engine of the present invention; FIG. 5 is a schematic block diagram of an exemplary server for use in the networks of any of FIGS. 1–4 ; FIG. 6 is an illustration of exemplary protocol layers used by the alternate database engine established on the server of FIG. 5 ; FIGS. 7 A– 7 F 3 are a flowchart depicting an exemplary general process for implementing an alternate database engine according to certain embodiments of the present invention; and FIGS. 8A–8C are a flowchart depicting an exemplary binary file access process for translating database commands according to certain embodiments of the present invention DETAILED DESCRIPTION OF THE INVENTION Various embodiments of the present invention involve a computer network having one or more servers that maintain an established database engine and an alternate database engine. The established database engine maintains legacy data that is accessible by a plurality of users having user terminals on the network. The alternate database engine may maintain further data that is stored after the alternate database engine is incorporated into the system. In some embodiments, the established database engine may also store some or all such further data. Various database commands, that may require result data from the established database engine, may be selectively intercepted, evaluated, optimized and processed by the alternate database engine. The alternate database engine may translate the query, when necessary, to a recognizable format and process the same directly with the database file maintained by the established database engine, without interacting with the command layer of the established database engine. In such manner, the system resources of the server maintaining the established database engine are not overly impacted. Furthermore, the database commands may be submitted to the alternate database engine in the format of the established database engine, which in turn translates such commands to a native format, thereby allowing users to operate in a command environment with which they are already familiar. A database command may be evaluated by the alternate database engine to determine system resources that will be impacted by a database command. For example, in a case where the database command is a query, the parameters of the query may be compared to historical or estimated performance data related to similar queries in order to estimate the impact on system usage. Particular parameters used for such evaluation are provided in exemplary fashion further below. In a particular example, it may be desired to selectively intercept queries and process them through an available alternate database engine, rather than an overly-impacted established database engine. Where a database command is found to be read-intensive, write-intensive, or read-write-intensive, the database command may be intercepted and processed by an alternate database engine having available system resources. Other, less-intensive database commands may be passed to the established database engine when desired. The database command may be further evaluated by the alternate database engine to determine whether temporally-sensitive data is requested from an established database engine. If so, the alternate database engine may access transaction logs of the established database engine to determine whether further data responsive to a database command has been submitted to the first database engine. Access of the transaction log may be performed without interacting with the command layer of the established database engine. Certain data from the transaction log may then be provided to the user in response to the database command, thereby ensuring accuracy of such generated results. The alternate database engine of the present invention is contemplated to be fully compatible with, and may incorporate, the query optimization systems described in the applicant's co-pending U.S. patent application Ser. No. 10/034,885 entitled “METHOD AND APPARATUS FOR SCREENING DATABASE QUERIES PRIOR TO SUBMISSION TO A DATABASE” filed on Dec. 26, 2001, the entirety of which is incorporated herein by reference. The query optimization may be used in conjunction with the processes 700 and 800 described below with respect to FIGS. 7A–8C , in a manner readily apparent to one of ordinary skill in the art. Particular aspects and functionalities of these query optimization systems are described with respect to FIGS. 3 and 4 below. Referring now to FIGS. 1–8C , wherein similar components of the present invention are referenced in like manner, preferred embodiments of a method and apparatus for implementing and using an alternate database engine with an existing database engine are disclosed. Turning now to FIG. 1 , there is depicted a first exemplary computer network 100 by which a plurality of users operating, for example, user terminal(s) 110 , data mining applications 112 and large-scale query systems 114 may communicate with one or more established database servers 104 that maintain established database engines. Such communications may be intercepted an processed by an alternate database server 102 maintaining an alternate database engine. Computer network 100 may be an Internet-based network such as the World Wide Web, a local area network (LAN), a wide-area network (WAN), an intranet environment, an extranet environment, a fiber optic network, or any other type of wired, wireless, or hybrid computer networks. User terminals 110 – 114 may each be any type of computing device, such as a personal computer, a workstation, a network terminal, a hand-held remote access device, a personal digital assistant (PDA) or any other device that can accomplish two-way electronic communication over the network 100 . Users may run a web browser or the like on user terminal 110 – 114 to communicate with the server 102 over the Internet. The alternate database engine may be a maintained on a single server or group of distributed servers. The established database engine may be maintained on server 104 in conjunction with a network listening device 106 for receiving submitted queries. In a UNIX environment, the server 104 may be in further communication with other UNIX processing devices 108 that maintain database files and the like utilized by the server 104 . The server 104 may store database management software, relational database tables for stored databases, index files for stored databases, and the like, the functions of which are readily known to one of ordinary skill in the art. Further specific functions and operations of user terminals 110 – 114 , alternate database server 102 , and established database server 104 are discussed further below. In FIG. 2 , there is depicted a second exemplary network configuration for the network 100 , in which the established database server 104 is in further operative communication with a query optimization server 109 that may be utilized by the network 100 to evaluate submitted database commands to determine their impact on system resources, and re-direct, edit, reject or limit data output based on the evaluation of the database command. A query optimization system of the present invention is operative to intercept an individual query containing search parameters and logical arguments, and dynamically process the same on a query-by-query basis to determine its projected impact on system resources of a database engine that will process the query. Groups of such queries may be intercepted and evaluated in this manner. The resources to be evaluated may include: (i) a number of relational databases to be utilized in fulfilling the query, (ii) a size of the data fields and number of rows and/or columns to be searched for the query, (iii) an availability of hardware resources (such as processing time, memory, input/output transfer rates and disk space usage) of a system maintaining the database, (iv) a number of relational database tables to be employed for the query, (v) a limitation to be imposed on a size of a query result set, a number of rows and/or columns of data to be returned in a query result set, (vi) a cost of a previously-stored query with similar parameters and (vii) a number of function calls employed by the query. Individual query parameters may be evaluated during the screening process performed by the present system. For example, query parameters, such as search terms and logical arguments, may be in a structured query language (SQL) format, or other similar database query formats. The query parameters may be optimized by available third-party query optimization tools known to those of ordinary skill in the art. When multiple tools are available, the system of the present invention may select one of such tools for performing query optimization, based on historical performance of the tools or by intended performance improvements of the tools. The user rights of the user submitting the query may also be evaluated by the present system. The user rights may include an assigned accessibility right of a user, based on a class or category of a user. In addition, user rights may be based on historical system resource requirements of the user's previous queries, and further, upon the historical scores of the user's previously evaluated queries. In various embodiments of the present invention, all such evaluations described above must take place prior to submission of the query to the database engine. In some embodiments, the query is submitted by a user terminal to a database engine, and intercepted and analyzed by a separate screening server prior to receipt by the database engine. In this manner, the screening server may save utilization of the system resources of the database engine by first evaluating the query. Queries that are intercepted and screened in any or all of these manners may be assigned a final impact rating. The rating may be determined, for example, by identifying the various system resources that may be impacted impacted, assigning a weight to each impacted resource, and generating a score reflective of the results. Other useful weighted computational models may also be used. The generated rating is then compared to one or more threshold values set by a database administrator, determined by an analysis of available system resources, or the like. If the rating surpasses the threshold value, the query may be rejected. Alternatively, the screening server may negotiate or assign a limited result set to be provided in response to the query. This limitation is then communicated to the database engine upon submission of the query. If, on the other hand, the rating does not surpass the threshold value, the query may be submitted to the database engine for processing. The result sets generated by the database engine in response to the query may then be communicated to the user by either the database engine or the screening server. In the latter case, the query parameters may nonetheless be optimized by the previously described third-party optimization tools prior to submission to the database engine. In various embodiments, the system of the present invention can optionally prioritize and queue queries for the database engine based on the priority of the query or the user submitting the query. The system may further pause processing of lower priority queries so that higher priority queries may be processed and/or completed first. In FIG. 3 , there is depicted a third exemplary configuration for the network 100 in which a single alternate database server 102 , in conjunction with a single query optimization server 109 , are in operative communication with a plurality of established database engines 104 in a massively parallel architecture. As displayed in FIG. 4 , the network 100 may be configured with a single alternate database server 102 in communication with a plurality of servers 104 , 109 in a massively parallel architecture. Other operative network configurations for network 100 are readily contemplated to be employed by the present invention. Turning now to FIG. 5 , displayed therein are exemplary components of a computing device, such as an alternate database server 102 , for use in any of the configurations described above with respect to FIGS. 1–4 . It should be understood that any computing device described herein may share similar configurations to server 102 . However, for sake of brevity, the discussions of hardware components used by various devices herein will be made in reference to the server 102 only. The primary component of the alternate database server 102 is a central processing unit (CPU) or microprocessor 500 , which may be any commonly available microprocessor, such as the SunSPARC family of processors manufactured by SUN MICROSYSTEMS. The CPU 500 may be operatively connected to further exemplary components, such as random access memory (RAM) 502 , read-only memory (ROM) 504 , a clock 506 , input/output devices such as communication port(s) 508 , and a memory 510 . The memory 510 , in turn, may store one or more application and operating system programs, such as user rights assessment processing instructions 512 , system performance measurement processing instructions 514 , command interpretation processing instructions 516 and alternate database engine process instructions 518 . The memory 510 may further store various system-based database files, used by the server 104 to evaluate and process data commands. Such database files include a user rights table 520 for storing database access rights of a plurality of users, a system performance management table 522 for determining database command impact against parameters stored therein, a language command reference table 524 for converting database commands between various supported formats, a data format parameters table 526 for storing format parameters of stored data and a user command override parameter table 528 used to store any user-specific customizations to language translation processing. The CPU 500 operates in conjunction with RAM 502 and ROM 504 in a manner well known in the art. The RAM 502 may be a suitable number of Single In-line Memory Module (SIMM) chips having a storage capacity (typically measured in kilobytes or megabytes) sufficient to store and transfer, inter alia, processing instructions utilized by the CPU 500 , that in turn may be may be received from the application programs 512 – 518 . The ROM 504 may be any permanent, non-rewritable memory medium capable of storing and transferring, inter alia, processing instructions performed by the CPU 500 during a start-up routine of the alternate database server 102 . The clock 506 may be an on-board component of the CPU 50 which dictates a clock speed (typically measured in MHz) at which the CPU 500 performs and synchronizes, inter alia, communication between the internal components of the alternate database server 102 . The communication port(s) 508 may be one or more commonly known devices used for receiving system operator inputs, network data, and the like and transmitting outputs resulting therefrom. Accordingly, exemplary input devices may include a keyboard, a mouse, a voice recognition unit and the like for receiving inputs from an operator of the alternate database server 102 . Additionally, output devices may include any commonly known devices used to present data to an operator of the alternate database server 102 or to transmit data over the computer network 100 , described further below. Accordingly, suitable output devices may include a display, a printer and a voice synthesizer connected to a speaker. Other output devices may include a telephonic or network connection device, such as a communication port, a telephone modem, a cable modem, a T-1, T-2 or T-3 connection, a digital subscriber line or a network card, or any other device for communicating data to and from other computing devices over the computer network 100 . In an environment in which high numbers of users are involved, it is preferred that the communications devices used as communication ports 508 have capacity to handle high bandwidth traffic in order to accommodate communications with a large number of users. The memory 510 may be an internal or external large capacity device for storing computer processing instructions, computer-readable data, and the like. The storage capacity of the memory 510 is typically measured in megabytes or gigabytes. Accordingly, the memory 510 may be one or more hard disk drives and/or any other computer readable medium that may be encoded with processing instructions in a read-only or read-write format. Further functions of and available devices for memory 510 will be apparent. The memory 510 may further store, inter alia, a plurality of operating system application programs which may be any one or more of UNIX-based system such as LINUX, or one or more personal computer (PC) programs, such as a web hosting program and a database management program of the type manufactured by ORACLE, each of which may be necessary to implement various embodiments of the present invention. In an Internet environment, web hosting software may include functionality sufficient to read JAVASCRIPT, hyper-text markup language (HTML), extensible markup language (XML) and other similar programming languages typically used in conjunction communicating data between clients and servers over the Internet. In any type of network environment, the application programs may also include a database management program, of the type commonly manufactured by ORACLE CORP. to store and maintain various databases as described below at the alternate database server 102 . For example, the database programs may be used to maintain the user rights table 520 , the system performance management table 522 , the language command reference table 524 , the data format parameters table 526 and the user command override parameter table 528 . Further or fewer databases may be used in certain embodiments of the present invention. It should be readily appreciated that any number of database files presented herein may be configured into any number of relational databases. In addition, configurations other than database formats may be used to store the data maintained in these exemplary databases. Turning now to FIG. 6 , therein is depicted an exemplary programming structure 518 for the alternate database engine maintained by the alternate database server 102 . The structure 514 includes a top-most command processing layer 600 , whereby database commands are processed by the alternate database engine. The structure 518 may further include a language emulation layer, by which a plurality of database languages may be recognizable and translatable by the alternate database engine. The structure 518 further includes a database engine kernel 604 for managing native system tables 612 storing system usage parameters and a native transaction log 614 for storing read and write operations to data files maintained by the alternate database server 102 . The structure 518 may also include a data manipulation and transformation processor layer 606 and a query optimizing layer 608 for evaluating and optimizing database commands received by the alternate database engine. Finally, the structure 518 may include a binary file translation processor for converting database commands and received data into a desired format that is compatible with the established database engine, for example, by referencing transaction log files 616 , database files 618 and index files 620 maintained by the established database engine on server 10 . Other software layers, such as network communication layers and the like (not shown), may also readily be employed to implement the present invention. FIGS. 7 A– 7 F 3 depict a general process 700 for intercepting and executing database commands performed by the alternate database engine 500 of FIG. 5 in any of the various network configurations described with respect to FIGS. 1–4 . The process 700 begins when a database command, such as a query, is submitted by a user to the database engine (step 701 ). The input query may be obtained in a transparent manner. That is, the user may not receive an indication that the query intended for the established database engine has been intercepted by the alternate database engine. In other embodiments, queries may be intercepted by batch submission or by providing direct access to the alternate database engine to a plurality of users. The alternate database engine receives an identification of the user and accesses the user rights table 520 to determine the user privileges of the user (step 703 ). The user rights table may store, for example, an identification of the user and user access rights. In various embodiments, it is possible to allow or disallow access to users who are not listed in the user rights table 520 . Based on the user rights table information for the user, the alternate database engine then determines the user's threshold values for query processing (step 703 ), further determines whether any time of day restrictions apply to the user (step 704 ), and also determine the user's query rights (step 705 ). The alternate database engine then determines whether the user is an administrator (step 706 ). If so, the process continues to step 707 where the alternate database engine sets an administrator flag, otherwise, the process 700 continues to step 708 below. At step 708 , the alternate database engine determines whether the user is operating with statement-level exceptions or any command-level overrides intended to alter processing beyond default processing rules established by an administrator or the like. (step 708 ), If, so, step 709 is performed. Otherwise, the process 700 continues to step 710 below, described with respect to FIG. 7B . The alternate database engine next sets a statement level exception flag (step 709 ). The alternate database engine then may set additional appropriate flags which are used later in the process to determine whether to reject, allow or edit a query submitted by the user, based on query parameters. This information may be determined from the access of the user rights table 520 described previously above, or in any other known manner. Continuing now to FIG. 7B , the process 700 next involves the alternate database engine parsing the received query (step 710 ). The query is tokenized into functional commands and query parameters (step 711 ). The alternate database engine then retrieves configuration information from the system performance management table 522 (step 712 ). The system next assesses database management parameters, for example, by accessing the system performance management table 522 which may store, inter alia, performance parameters of the alternate database engine. The system performance management table 522 may accordingly store such parameters as (i) processor speed and usage, (ii) available memory, (iii) available input/output resources, (iv) usage and disk resources and usage, and (v) preferences set by an administrator of the administrator of the alternate database engine. These parameters may be dynamically updated based on the current operating conditions of the alternate database engine or the established database engine. Continuing to step 713 , the alternate database engine then scans the functional command tokens to identify impacted components of the alternate database server 102 . Alternatively or in addition thereto, impacted components of the established database server 104 may be determined and analyzed in this process 700 . The alternate database engine then determines a total number of relevant system components to measure (step 714 ) and further determines whether performance has been measured for all relevant components (step 715 ). If so, the process 700 continues to step 720 of FIG. 7C , otherwise, the process 700 continues to step 716 . The alternate database engine, at step 716 , retrieves a next relevant component to measure and determines whether a third-party tool is required to measure the next system component (step 717 ). If so, the process 700 continues to step 718 . Otherwise, the process 700 continues to step 719 below. At step 718 , the alternate database server measures the current operating performance of system component using third party tools, after which the process returns to step 715 above. At step 719 , the alternate database engine measures the current operating performance of system component using native system (step 719 ), after which the process 700 returns to step 715 above. Continuing now to FIG. 7C , the process 700 next requires that the alternate database engine retrieve operating parameters from the system performance management table 522 (step 720 ) and to determine whether an administrator has set access limits on particular system resources (step 721 ). If so, the process 700 continues to step 722 . Otherwise, the process 700 continues to step 724 below. At step 722 , the alternate database engine determines whether any such limits are relevant to the input command by comparing tokens to the stored limit parameters (step 722 ). If the limits are relevant, the process continues to step 723 . Otherwise, the process 700 continues to step 724 further below. The alternate database engine may then set limit and threshold flags for the relevant resources in accordance with the limits set by the administrator (step 723 ). The alternate database engine next retrieves the operating parameters from user rights table 520 (step 724 ). The alternate database engine next determines if the administrator set limits on operating parameters for the user submitting the query based on the stored user rights (step 725 ). If so, the process 700 continues to step 726 . If not, the process continues to step 728 further below. At step 726 , the alternate database engine determines whether the established limits are relevant to the particular query. If so, the process 700 continues to step 727 . if not, the process 700 continues from step 728 below. The alternate database then set limit and threshold flags as appropriate (step 727 ). At step 728 , the alternate database engine determines whether the established limits prevent use of the alternate database engine to process the query. If so, the process continues to step 729 . If not, the process 700 continues to step 730 described further below with respect to FIG. 7D . At step 729 , the alternate database engine processes the query conventionally by passing it to the established database engine, due to the impact the query would have on the resources of the alternate database server 102 . Continuing to FIG. 7D , the alternate database engine looks up a command token from the parsed query in the language command reference table 524 (step 730 ). The alternate database engine then determines whether the command is indirectly supported (step 731 ). If so, the process 700 continues to step 732 below. Otherwise, the process 700 continues to step 733 . At step 732 , in order to determine if the given user has customized how the alternate database engine should handle specific language commands, the alternate database engine composes a string of directly supported command functions corresponding to the query, and looks up the command in the user command override table 528 (step 733 ). If a user override command is set for the query (step 734 ), the process 700 continues to step 735 . Otherwise, the process 700 continues to step 736 of FIG. 7E . At step 735 , the query is processed conventionally by passing it to the command layer of the established database engine, after which process 700 ends. Continuing to FIG. 7E , the alternate database engine next iterates through language element tokens (step 736 ), compares the language tokens to the language command reference table 524 (step 737 ), assembles a final list of language tokens to emulate (step 738 ), sequences the language tokens to reflect the input format for alternate database engine (step 739 ), translates the query tokens (step 740 ) and processes the query without accessing a command layer of the established database engine (step 741 ). The alternate database engine may also be programmed to execute read-only commands, exclusive of read-write and write commands, in certain embodiments of the present invention. A benefit of performing read-only commands is in using the alternate database server as a low-cost mechanism for increasing overall database system availability and redundancy in an enterprise computing environment. Continuing now to FIGS. 7 F 1 – 7 F 3 , the alternate database engine determines whether the query is a SQL select (or functionally equivalent) statement (step 742 ) If so, the process 700 continues to step 743 . Otherwise, the process 700 continues to step 749 further below. At step 743 , a read only flag is set by the alternate database engine. Tokens are parsed from the select statement (step 744 ) and the alternate database engine then determines whether the query calls for temporally sensitive data by, for example, comparing the tokens to a list of heavily updated data tables (step 745 ). If the query is temporally-sensitive (step 746 ), the process 700 continues to step 747 . Otherwise, the process 700 continues on to step 748 described further below. At step 747 , the alternate database engine sets a transaction log access flag, decomposes the query to a file access sequence (step 748 ) and initiates the binary file access and translation process 800 , described below with respect to FIGS. 8A–8C . Write commands may unduly impact system performance of the alternate or established database servers. Accordingly, any write commands, such as insert commands and delete commands are evaluated. At step 749 , the alternate database engine next determines if the query includes an insert statement. If so, the process continues to step 752 . If not, the process continues at step 750 further below. At step 750 , the alternate database engine next determines if the query includes a delete statement. If so, the process continues to step 752 . If not, the process continues at step 751 below. At step 751 , the alternate database engine next determines if the query includes an update statement. If so, the process 700 continues to step 752 . If not, the process continues at step 755 , described further below. At step 752 , the alternate database engine sets a read-write flag and determines whether the alternate database engine can obtain read-write control over data filein step 753 . If so, the process continues to step 754 . Otherwise, the process continues to step 756 below. At step 754 , the alternate database engine decomposes the query to a file access sequence, after which the binary file access process 800 , described with respect to FIGS. 8A–8C is initiated. Returning to 755 , the alternate database engine determines whether the query is a proprietary data-definition language command (for example, a “create table” command, or an “alter table” command). If so, the process 700 continues to step 756 , and if not, the process 700 ends. At step 756 , the alternate database engine determines whether a corresponding translated query is available in the alternate database engine. If so, the alternate database engine initiates the binary file access process 800 of FIGS. 8A–C . Otherwise, the process 700 ends. Turning to FIGS. 8A–8C , a binary file access process 800 is depicted in which queries and commands that are submitted in a format of the established database engine are translated to a format recognizable by the alternate database engine. The binary translation processor converts proprietary binary data, index, transaction log structures and the like into a standardized internal form suitable for processing with alternate database The process 800 begins by determining whether a read-only flag is set (step 802 ). If so, the process 800 continues to step 804 . Otherwise, the process continues to step 809 , described further below. Next, the alternate database engine determines whether a temporally-sensitive data flag has been set (step 804 ). If so, the process 800 continues to step 806 below. If not, the process 800 continues on to step 808 . The alternate database engine opens transaction log files of the established database server for read only access (step 806 ) and further opens data and index files for the established database engine for read only access (step 808 ). The data files are then scanned (step 810 ) to interpret the data schema of stored data, the alternate database engine further scans index files and interprets data statistics based on the same (step 812 ). From this information, a file access sequence is processed (step 814 ). Continuing now to FIG. 8B , the alternate database engine next determines if a read-only flag is set (step 816 ). If so, the process 800 continues to step 818 . Otherwise, the process 800 continues to step 822 below. At step 818 a query plan is prepared. At step 820 , the query plan may be optimized using the methods described previously, after which the process 800 continues to step 826 , described below with respect to FIG. 8C . At step 822 , a transactional transformation plan is prepared, whereby data that is intended to be determined to be written to the data file is condensed to a series of specific Insert/Update/or Delete command steps. These Insert/Update/or Delete command steps are then first stored in a transaction log file (and then later applied transactionally) to help ensure data integrity. The alternate database server next updates its transactional log through alternate database transaction log 614 (step 824 ). From either step 820 or 824 above, the process 800 continues to step 826 where the alternate database engine determines whether a result set can be generated and outputted to the user in response to the query. If so, the process continues to step 828 . Otherwise, the process continues to step 834 described further below. At step 828 , the alternate database engine looks up data format parameters from the alternate database transaction log 614 , formats the results in a manner similar to results output by the alternate database engine (step 830 ), and transmits the results to user (step 832 ). If a result can not be generated, due to an error in the query or the lack of responsive data in the established database engine, the alternate database engine determines whether a message regarding the failed query is to be output (step 834 ), if not, the process 800 ends. Otherwise, the process 800 continues to step 836 where the alternate database engine retrieves the message format employed by the established database engine. The message is placed in the appropriate format (step 838 ) and which is then transmitted to the to the user (step 840 ), the process 800 then ends. While the processes 700 and 800 have been described above with respect to a single user terminal, a single alternate database server and a single established database engine, it is contemplated that any number of such servers may be employed in an operative embodiment of the present invention, as particularly illustrated in the exemplary network configurations of FIGS. 2–4 . While the data command submitted by a user has been described herein as a database query, other database commands, such as write commands, read/write commands, indexing commands and the like may readily be employed and processed by the system of the present invention. Although the invention has been described in detail in the foregoing embodiments, it is to be understood that the descriptions have been provided for purposes of illustration only and that other variations both in form and detail can be made thereupon by those skilled in the art without departing from the spirit and scope of the invention, which is defined solely by the appended claims.
A computing system provides database access to a plurality of users, for example, over a computer network such as the Internet. The computing system includes an established database engine and accompanying database files containing data that the users may query. The computing system further includes an alternate database engine that may intercept and execute such database commands submitted by the users. The alternate database engine may translate and recognize commands submitted in the format of the established database engine. The alternate database engine may further provide results in the format of the established database engine. In this manner, an alternate database engine can be implemented to provide further or more efficient processing capabilities. At the same time, users may continue to interact with the data maintained by the established database engine in a manner with which they are familiar, and data providers may switch to the alternate database engine without reformatting the data stored in the established database engine.
8
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vibrometer mounting mechanism for securing, in the casing, a vibrometer for measuring, for example, the vibration of a shaft of a rotor of a gas turbine. This application is based on Japanese Unexamined Patent Application, Publication No. 2008-115719, the content of which is incorporated herein by reference. 2. Description of Related Art In the past, a gap adjusting apparatus, disclosed in, for example, Japanese Unexamined Patent Application, Publication No. SHO-58-8824, could be used to adjust the distance (gap) between the tip of a pickup section (measuring section) of a vibrometer and the outer surface of the shaft of a rotor. A known vibrometer mounting mechanism adjusts the distance between the tip of a pickup section and the outer surface of a shaft of the rotor to a predetermined distance by rotating the pickup section and then secures the pickup section in the casing with a locknut. However, with this gap adjusting apparatus and vibrometer mounting mechanism, the member (for example, locknut) securing the pickup section to the casing is disposed at the pickup section and near the shaft, i.e., locations that are difficult for an operator to reach and work on (a location with poor accessibility). Therefore, there are problems in that the pickup section cannot be easily secured at a predetermined location with good precision because the adjustment work of the distance between the tip of the pickup section and the outer surface of the shaft cannot be carried out easily, and, when tightening a member for securing the pickup section in the casing, the pickup section might rotate together with that member. BRIEF SUMMARY OF THE INVENTION The present invention has been conceived in light of the problems described above, and it is an object of the present invention to provide a vibrometer mounting mechanism that enables easy and highly precise adjustment of the distance between the tip of a pickup section and the outer surface of a shaft of the rotor. The present invention provides the following solutions to solve the problems described above. A vibrometer mounting mechanism according to the present invention is a vibrometer mounting mechanism a for securing a measuring section of a vibrometer for measuring vibration of a shaft of a rotary machine to a casing of the rotary machine, the vibrometer mounting mechanism including a case secured to the casing with securing means; an inner cylinder that accommodates the measuring section at one end, that is disposed inside the case, and that slides relative to the case; and an adjustment bolt disposed at one end of the case and capable of moving forward and backward with respect to the case and the inner cylinder, wherein the inner cylinder is made to move in a direction away from or toward the shaft by the adjustment bolt being inserted into the case and the inner cylinder, and wherein the inner cylinder is made to move in a direction toward or away from the shaft by the adjustment bolt being retracted from the case and the inner cylinder. In such a vibrometer mounting mechanism, for example, as the bolt head of the adjustment bolt is turned with a wrench etc. in a direction to tighten the adjustment bolt, the entire adjustment bolt moves toward the case and the inner cylinder, and the inner cylinder moves to the opposite to (moves away from) the shaft. On the other hand, as the bolt head of the adjustment bolt is turned using a wrench etc. in a direction to loosen the adjustment bolt, the entire adjustment bolt moves away from the case and the inner cylinder, and the inner cylinder moves toward (moves close to) the shaft. In other words, by merely turning the adjustment bolt, the distance (gap) between the tip of the measuring section and the outer surface of the shaft can be easily adjusted. Furthermore, the adjustment bolt can be disposed at a location or in a direction away from the measuring section and the shaft at a location where the adjustment work can be easily carried out (a location with good accessibility). In this way, the adjustment of the distance between the tip of the measuring section and the outer surface of the shaft can be easily carried out with good precision, and the design aspects associated with the vibrometer attachment (mounting) position can be simplified (made easy). As the bolt head of the adjustment bolt is turned using a wrench etc. in a direction to tighten the adjustment bolt, the entire adjustment bolt may move toward the case and the inner cylinder, and the inner cylinder may move toward (move close to) the shaft, and as the bolt head of the adjustment bolt is turned using a wrench etc. in a direction to loosen the adjustment bolt, the entire adjustment bolt may move away from the case and the inner cylinder, and the inner cylinder may move to the opposite side of (move away from) the shaft. With the above-described vibrometer mounting mechanism, it is even more preferable that a pyramid section that has a polygonal shape in front view and that is tapered toward the tip be formed at one end of the adjustment bolt, and a bolt hole that receives the pyramid section in a freely rotatable manner and that has an inner circumferential surface be in contact with a side surface of the pyramid section. With such a vibrometer mounting mechanism, when the pyramid section has, for example, a square shape in front view, each time the adjustment bolt moves by ¼ pitch of the thread, the side surface of the pyramid section that contacts the inner circumferential surface of the bolt hole is interchanged with a side surface adjacent to that side surface. In other words, the inner cylinder moves, in small steps, toward the side opposite to the shaft along the inclination angle of the side surface of the pyramid section. On the other hand, each time the adjustment bolt moves by ¼ pitch of the thread, the side surface of the pyramid section that contacts the inner circumferential surface of the bolt hole is interchanged with a side surface adjacent to that side surface. In other words, the inner cylinder moves, in small steps, toward the shaft along the inclination angle of the side surface of the pyramid section. The inner cylinder is placed on the side surface of the pyramid section at the inner circumferential surface of the bolt hole, and, consequently, rotation of the adjustment bolt is prevented, except for when the adjustment work is carried out. The amount of movement of the inner cylinder is Lxtana, where L represents the distance the adjustment bolt moves at a ¼ pitch of the thread, and α represents the inclination angle of a side surface of the pyramid section. With such a vibrometer mounting mechanism, it is even more preferable that a first urging member urging the inner cylinder toward the side of the shaft be provided between the end of the inner cylinder and the case. With such a vibrometer mounting mechanism, since side walls of the pyramid section and the inner circumferential surface of the bolt hole are constantly held in contact with each other by the first urging member, the relative positions of the casing and the measuring section are prevented from changing due to vibration etc., and thus, accurate measurement can be carried out without the influence of vibrations etc. With the above-described vibrometer mounting mechanism, it is even more preferable that a second urging member urging the adjustment bolt in a direction away from the case be provided between the adjustment bolt and the case. With such a vibrometer mounting mechanism, since jolting of the adjustment bolt in the axial direction can be prevented by the second urging member, the relative positions of the casing and the measuring section can be prevented from changing due to vibration, and thus, accurate measurement can be carried out without the influence of vibrations etc. Since a rotary machine according to the present invention includes a vibrometer mounting mechanism capable of easily carrying out adjustment of the distance between the tip of the measuring section and the outer surface of the shaft of the rotor with good precision, the efficiency of installation of a new rotary machine and maintenance can be increased, and the number of working hours can be decreased. The present invention is advantageous in that the adjustment of the distance between the tip of a pickup section and the outer surface of a shaft of a rotor can be easily carried out with good precision. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS FIG. 1 is a partial schematic diagram of a gas turbine in which a vibrometer mounting mechanism according to an embodiment of the present invention is employed. FIG. 2A is a sectional view illustrating the vibrometer mounting mechanism according to an embodiment of the present invention. FIG. 2B is a front view taken along arrow A in FIG. 2A . FIG. 3 is a plan view taken along arrow B in FIG. 2A . DETAILED DESCRIPTION OF THE INVENTION An embodiment of a vibrometer mounting mechanism according to the present invention will be described below with reference to FIGS. 1 to 3 . FIG. 1 is a partial schematic diagram of a turbine (hereinafter referred to as “gas turbine”) 100 in which a vibrometer mounting mechanism 1 according to this embodiment is employed; FIG. 2A is a sectional view illustrating the vibrometer mounting mechanism 1 according to this embodiment; FIG. 2B is a front view taken along arrow A in FIG. 2A ; and FIG. 3 is a plan view taken along arrow B in FIG. 2B . As shown in FIG. 1 , the gas turbine (rotary machine) 100 is mainly constructed of a compressor 102 for compressing air taken in through an intake manifold 101 , a combustor (not shown) for generating combustion gas by receiving air compressed at the compressor 102 and fuel, and a turbine (not shown) rotated by the combustion gas generated at the combustor. The gas turbine 100 includes a rotor 103 having rotor blades 102 a protruding radially on the outer circumference, a journal bearing 104 for supporting the rotor 103 by a bearing, and a casing (casing) 105 in which stator blades 102 b are vertically disposed on the inner circumference. The vibrometer mounting mechanism 1 according to this embodiment secures (attaches), in the casing 105 , a pickup section (measurement unit) 2 (see FIGS. 2A and 3 ) of a vibrometer (distance sensor) that is disposed near the journal bearing 104 and that constantly measures the shaft vibration of a shaft 103 a of the rotor 103 . As shown in FIG. 2A , the vibrometer mounting mechanism 1 is mainly constructed of a case 4 secured (attached) to the casing 105 (see FIG. 1 ) with attachment bolts (securing means) 3 (see FIG. 3 ), an inner cylinder 5 disposed on the inner side of the case 4 , a spring (first urging member) 6 disposed between the case 4 and the inner cylinder 5 , and an adjustment bolt 7 for adjusting the relative positions of the case 4 and the inner cylinder 5 . As shown in FIGS. 2A and 3 , the case 4 is a box-shaped member that externally appears as a substantially cubic shape (a substantially rectangular solid). At substantially the center of the case 4 in plan view, a first through-hole 10 is formed to connect a front surface 4 a and a back surface 4 b of the case 4 in the height direction (a direction orthogonal to the rotary axis of the shaft 103 a and the up-and-down direction in FIG. 2A ). At one end of the case 4 in a front view, a second through-hole 11 is formed to connect a side surface 4 c of the case 4 and the first through-hole 10 in the width direction (a direction parallel to the rotary axis of the shaft 103 a and the left-to-right direction in FIG. 2A ). Furthermore, at substantially the center of the case 4 in a back view, a third through-hole 12 is formed to connect another side surface of the case 4 (the side surface opposite to the side surface 4 c ) 4 d and the first through-hole 10 in the width direction (a direction parallel to the rotary axis of the shaft 103 a and the left-to-right direction in FIG. 2A ). The cross-sections of the first through-hole 10 , the second through-hole 11 , and the third through-hole 12 are circular. The first through-hole 10 is formed such that its inner diameter is substantially the same as the outer diameter of the inner cylinder 5 ; the second through-hole 11 is formed such that its inner diameter is substantially the same as the outer diameter of the adjustment bolt 7 ; and the third through-hole 12 is formed such that its inner diameter is substantially the same as the outer diameter of a rotation-prevention pin 13 . The inner circumferential surface of the first through-hole 10 is a smooth surface; a thread (not shown) that engages with a thread 7 a provided on the outer circumferential surface of the shaft of the adjustment bolt 7 is provided on the inner circumferential surface of the second through-hole 11 ; and a thread (not shown) that engages with a thread 13 a provided on the outer circumferential surface of the shaft of the rotation-prevention pin 13 is provided on the inner circumferential surface of the third through-hole 12 . The rotation-prevention pin 13 is a member for preventing rotation of the inner cylinder 5 relative to the case 4 . The adjustment bolt 7 has a bolt head 7 b on one of its ends and has a pyramid section 7 c on the other end; and a shaft having the thread 7 a on the outer circumferential surface is provided between the bolt head 7 b and the pyramid section 7 c . A flange section 7 d is provided between the adjustment bolt 7 and the shaft; and a spring (second urging member) 14 is disposed between the back side (the surface opposite to the side surface 4 c of the case 4 ) of the flange section 7 d and the side surface 4 c of the case 4 . The spring 14 is a member for urging the adjustment bolt 7 away from (separating from) the side surface 4 c of the case 4 . As shown in FIG. 2B , the pyramid section 7 c is a member that has a polygonal shape (square in this embodiment) in front view (sectional view) and is tapered toward the tip (side opposite to the bolt head 7 b ). In other words, each side surface of the pyramid section 7 c (four side surfaces in this embodiment) is a flat surface inclined such that the side surfaces become closer to each other from the shaft side to the tip. The inner cylinder 5 is a hollow member having an attachment hole 15 for attaching the pickup section 2 to one of the ends and being open at the other end. The attachment hole 15 is formed with an inner diameter is substantially the same as the outer diameter of the pickup section 2 ; and a thread (not shown) that engages with a thread 2 a provided on the outer circumferential surface of the pickup section 2 is provided on the inner circumferential surface of the attachment hole 15 . Furthermore, the pickup section 2 , which is attached at a predetermined position in the attachment hole 15 , is secured to the inner cylinder 5 with a locknut 16 . The wall of the outer circumferential surface of the inner cylinder 5 is a smooth surface; and a pin hole 17 in which a pin section 13 b provided at the tip section of the rotation-prevention pin 13 is inserted and a bolt hole 18 in which the pyramid section 7 c of the adjustment bolt 7 is inserted are formed in the wall 5 a of the inner cylinder 5 . The pin hole 17 is an elongated hole that extends in the length direction of the inner cylinder 5 and has a rectangular shape in front view (plan view), formed such that the width substantially aligns with the outer diameter of the pin section 13 b . The inner circumferential surface of the pin hole 17 is a smooth surface. The bolt hole 18 is provided on a wall 5 a opposite to the wall 5 a where the pin hole 17 is formed (i.e., the wall 5 a opposing the pin hole 17 ), extends in the length direction of the inner cylinder 5 , and is a elongated hole formed as a rectangular shape in front view (plan view) and larger than the outer diameter of the pyramid section 7 c of the adjustment bolt 7 (in order that the pyramid section 7 c is capable of rotate in the bolt hole 18 ); one surface (the surface opposite to the side on which the pickup section 2 is located) on the inner circumferential surface of the bolt hole 18 is a flat surface having an inclination angle substantially the same as the inclination angle of the side surface of the pyramid section 7 c. A spring 6 is disposed between the back surface 4 b of the case 4 and the back surface (the surface opposing the back surface 4 b of the case 4 ) of a flange 19 provided at one end of the inner cylinder 5 and is a member for urging the inner cylinder 5 toward the shaft 103 a. Reference numeral 20 in FIGS. 2A and 3 represents wires for transmitting data (electrical signals) measured at the pickup section 2 to the main body (or control unit) of the vibrometer. Next, the process of adjusting the distance (gap) between the tip of the pickup section 2 and the outer surface of the shaft 103 a will be described. First, as the bolt head 7 b is turned with a wrench etc. in a direction to tighten the adjustment bolt 7 , the entire adjustment bolt 7 moves toward the back surface 4 d of the case 4 . At this time, each time the adjustment bolt 7 moves by ¼ pitch of the thread 7 a , the side surface of the pyramid section 7 c that contacts the inner circumferential surface of the bolt hole 18 is interchanged with a side surface adjacent to that side surface. In other words, the inner cylinder 5 moves, in small steps, toward the side opposite to the shaft 103 a along the inclination angle of the side surface of the pyramid section 7 c. On the other hand, as the bolt head 7 b is turned using a wrench etc. in a direction to loosen the adjustment bolt 7 , the entire adjustment bolt 7 moves away from the back surface 4 d of the case 4 . At this time, each time the adjustment bolt 7 moves by ¼ pitch of the thread 7 a , the side surface of the pyramid section 7 c that contacts the inner circumferential surface of the bolt hole 18 is interchanged with a side surface adjacent to that side surface. In other words, the inner cylinder 5 moves, in small steps, toward the shaft 103 a along the inclination angle of the side surface of the pyramid section 7 c. Then, the inner cylinder 5 is placed on the side surface of the pyramid section 7 c at the inner circumferential surface of the bolt hole 18 . When the adjustment bolt 7 is to be rotated from this position, regardless of the direction, it has to move over the corner section of the pyramid section 7 c once, and to do so, it has to move against the load of the spring 6 , which is equivalent to the lifted height. Since such a state does not occur naturally, as a result, the adjustment bolt 7 is prevented from rotating, and rotation of the adjustment bolt 7 is prevented, except for when the adjustment work is carried out. The amount of movement of the inner cylinder 5 is L×tan α, where L represents the distance the adjustment bolt 7 moves at a ¼ pitch of the thread 7 a , and α represents the inclination angle of the side surfaces of the pyramid section 7 c . Therefore, even finer adjustment of the inner cylinder 5 is possible by decreasing the pitch of the thread 7 a and reducing the inclination angle α. The amount of movement of the inner cylinder 5 can be reduced by setting the front view (sectional view) shape of the pyramid section 7 c to a regular polygon with five or more sides. When the gap with respect to the shaft 103 a is adjusted, the inner cylinder 5 is always lifted at the corner sections of the pyramid section 7 c to increase the gap, allowing the gap to be adjusted freely. With the vibrometer mounting mechanism 1 according to this embodiment, an adjustment member (adjustment bolt 7 ) for adjusting the distance (the gap) between the tip of the pickup section 2 and the outer surface of the shaft 103 a can be disposed away from the pickup section 2 and the shaft 103 a at a location where the adjustment work can be easily carried out (a location with good accessibility). In this way, adjustment of the distance between the tip of the pickup section 2 and the outer surface of the shaft 103 a can be carried out easily and with good precision, and the design aspect associated with the vibrometer attachment (mounting) position can be simplified (made easy). Since the rotation prevention operation of the adjustment bolt 7 does not have to be carried out in a small area, the possibility of the adjustment bolt 7 becoming loose and causing the vibrometer to become inoperable can be eliminated. With the vibrometer mounting mechanism 1 according to this embodiment, since jolting of the adjustment bolt 7 in the axial direction can be prevented by the spring 14 and since side walls of the pyramid section 7 c and the inner circumferential surface of the bolt hole 18 are constantly held in contact with each other by the spring 6 , the relative positions of the casing 105 and the pickup section 2 are prevented from changing due to vibration etc., and thus, accurate measurement can be carried out without the influence of vibrations etc.
Adjustment of the distance between the tip of a pickup section and the outer surface of a shaft of a rotor can be carried out easily and with high precision. In a vibrometer mounting mechanism securing a measuring section of a vibrometer for measuring vibration of a shaft of a rotary machine to a casing of the rotary machine, the vibrometer mounting mechanism includes a case secured to the casing with fixing means; an inner cylinder that accommodate the measuring section at one end, that is disposed in the inside of the case, and that slides relative to the case; and an adjustment bolt disposed at one end of the case and capable of moving forward and backward with respect to the case and the inner cylinder, wherein the inner cylinder is made to move in a direction away from the shaft by the adjustment bolt being inserted into the case and the inner cylinder, and wherein the inner cylinder is made to move in a direction toward the shaft by the adjustment bolt being retracted from the case and the inner cylinder.
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REFERENCE TO PRIOR FIELD APPLICATIONS [0001] This application relies for priority on previously filed provisional application 61/070,978 filed Mar. 25, 2008 by Kenneth W. Cowans et al and entitled “Thermal Control System with Advanced Temperature Capabilities”. BACKGROUND OF THE INVENTION [0002] U.S. Pat. No. 7,178,353, issued Feb. 20, 2007 and entitled “Thermal Control System and Method”, inventor Kenneth W. Cowans et al and assigned to Advanced Thermal Sciences Corporation, teaches a novel and widely applicable concept for precise and changeable temperature control of a thermal load. Among its departures from other known systems, the system circulates a two-phase refrigerant in direct thermal transfer relation to the load that is being controlled. To do this at different temperatures, it uses a controllable mix of pressurized refrigerant gas at high temperature together with a flow of the same refrigerant, after it has been condensed, then cooled by controlled expansion to provide a flow that is at least partially vapor. The mix then provides a refrigerant flow of predetermined pressure and temperature so that thermal exchange can be effected directly with the load, at a target temperature that can be adjusted up or down. This thermal control is directly effected with refrigerant alone and is therefore more efficient and responsive than most temperature control units, since both pressure and temperature can be controlled with facility, and no intermediate temperature stable media is required. [0003] Consequently, this thermal control technique, which has been descriptively called Transfer Direct of Saturated Fluid (TDSF) is of immediate benefit in a number of demanding applications and also of potentially general capability for a wide variety of temperature control systems. It is of particular promise for applications which require precision control of thermal loads at different temperature levels, along with capability for rapidly varying the temperature levels. [0004] When rapidly shifting between selected temperature levels, however, instabilities and offsets can be encountered since no significant time delays or averaging effects exist in the temperature loop. In systems using TDSF technology, the flow of hot gas controlled by a proportional valve is to be mixed with liquid refrigerant, partially expanded for cooling. While the proportional valve setting can be changed rapidly, imprecision and instability may be encountered because of delays in flow rate variations and system demands. The response times and amplitudes of changes have to be considered in system terms, which factors can be accounted for in accordance with the present invention. [0005] The above referenced patent to Cowans et al, U.S. Pat. No. 7,178,353, also discloses a number of advantageous features within the system, which enhance the ability to separately control pressurized hot gas in one flow path and cold expanding refrigerant in another, before mixing. The patent consequently also discloses a number of techniques for interrupting or modifying flows to increase or decrease temperature particularly rapidly under specified conditions. However, there is often a need for assuring that temperature changes take place at controlled transitional rates that limit overshoot or otherwise provide assurance that a new target has been reached at the thermal load. SUMMARY OF THE INVENTION [0006] A TDSF system in accordance with the invention generally incorporates, as previously disclosed, separate flow paths for high temperature two-phase refrigerant and condensed, pressurized, partially expanded refrigerant at a lower temperature. Flow remainder in the high temperature path is controlled with a proportional valve and the temperature of the flow in the second path is controlled with a thermal expansion valve. A refrigerant mix of chosen pressure and temperature is thus provided for temperature control of a thermal load, the cycle being completed by recirculation of the two-phase refrigerant to the compressor. In accordance with the present invention, however, the rate of change of the hot gas flow as well as the final setting, are selectively varied by using access to stored control algorithms. This means that shifts of varying amounts from one flow rate to another can be effected stably, with due regard to system needs for response times varying the rate of change of the hot gas constituent. In one example, the proportioning valve is driven at a selectively variable frequency by a stepper motor that is responsive to the control algorithms. In a second example the control signals are varied in analog form, and an algorithm chosen signal amplitude controls the rate of change. [0007] A further feature of this invention is the introduction of a flow control circuit including a fast acting control valve between the hot gas line subsequent to the proportioning valve and a return line to the compressor input, but before processor elements in that input line. When it is desired to cool the load virtually immediately, a valve in this bypass line, which may be a solenoid expansion valve, is opened to shunt all the hot gas flow back to the input of the compressor, so that only the cooling flow is applied to the load. BRIEF DESCRIPTION OF THE DRAWINGS [0008] A better understanding of the invention may be had by reference to the following description, taken in conjunction with the accompanying drawings, in which: [0009] FIG. 1 is a block diagram of a TDSF system with flow rate control in accordance with the invention that uses a digital control scheme; [0010] FIG. 2 is a block diagram of a part of a TDSF system that presents an alternative control scheme for use in the system of FIG. 1 , and [0011] FIG. 3 comprises timing diagrams labeled A, B and C showing variations in response rates in systems in accordance with the invention. DETAILED DESCRIPTION OF THE INVENTION [0012] Referring now to FIG. 1 , a TDSF system 10 includes, as described in the above-identified Cowans et al '353 patent, a refrigeration loop for a two-phase refrigerant which loop includes a compressor 12 feeding a first part of its pressurized output to a first high pressure gas path 32 and a second remaining part of its output 26 to a condenser 14 . The condenser 14 is cooled with a flow of ambient temperature water from a facility 18 . The water for cooling is fed to a heat exchanger 16 disposed in thermal contact relation to the condenser 14 , the flow is further controllable by a control valve 20 . Other fluid systems, or gas, may be used for cooling the condenser 14 to ambient temperature. The output from the condenser 14 is directed as one input to mixing circuits 22 that include a thermal expansion valve 28 , hereafter TXV, for receiving and modulating the second flow. The output of the TXV 28 within the mixing circuits 22 is propagated through a pressure dropping (ΔP) valve 30 for reasons previously expanded in the Cowans patent which need not be repeated here. The first flow path 32 from the output of the compressor 12 is directed first to a shut off valve 34 , which feeds a separate input to the mixing circuits 22 . However the first flow is modulated at a variable rate by a valve 42 whose setting in this example is controlled by a stepper control circuit 44 commanded by a system controller 40 . The valve 42 is of the type known as a proportioning valve and provides a variable flow of pressurized hot gas to the mixing circuits 22 . To change its setting, the controller 40 provides commands to the stepper control circuits 44 that generate a sequence of pulses supplied at a predetermined rate by a variable frequency control 48 to drive the proportioning valve 42 open or closed. In the controller system 40 stored programs 46 contain suitable control algorithms supplying any of a variety of integrating and/or differential functions, as described in the Antoniou and Christofferson patent entitled “Systems and Methods for Controlling Temperatures of Process Tools”, U.S. Pat. No. 6,783,080. The chosen algorithm determines the rate at which the variable frequency control 48 feeds pulses to operate the proportioning valve 42 . This actuation varies the response rate of the valve 42 , consequently the mass of hot gas that is supplied in response. [0013] The flows in the first flow path 26 and second flow path 32 , after modulation are subsequently combined in a mixing tee 50 within the mixing circuits 22 , after the hot gas flow has been passed through a check valve 52 . The output from the mixing circuits 22 is then applied to the load 54 , and its output is returned, via other circuits to the input to the compressor 12 . [0014] The TXV 28 is a well known device and is externally equalized by pressure communicated from a bulb 56 in operative relation (thermal interchange) with the return line 57 from the load 54 . The bulb 56 generates a pressure level in the gas it contains that is applied via a coupling line 58 to the TXV 28 , for equalization of the TXV setting to the load 54 output. The return line 57 from the load 54 passes serially through a Close-on-Rise (COR) regulator valve 70 , toward the compressor 12 input. Before that input, however, it branches off at a shunt line 76 including a desuperheater valve (DSV) 72 of conventional purpose, that is externally equalized by pressure in a conduit 74 ′ from a bulb 74 responsive the input temperature to the compressor 12 . The shunt line 76 that includes the DSV 72 couples from the output of the condenser 14 to the return line 57 that leads to the compressor 12 . A separate shunt line 77 couples the output of the compressor 12 back to the compressor input line 57 , to a hot gas bypass valve (HGBV) 78 which responds to temperature levels at the compressor 12 input as detected by a temperature sensor 79 in that region of the shunt line 76 . A temperature sensor 79 input is provided to the controller 40 , which also provides a control output to a heater 82 in the compressor input line 57 , the heater 82 serving to insure that the compressor 12 receives gaseous input only. [0015] For purposes of rapid cooling, when operating independently of typical load temperature changes, the system 10 also includes a bypass line 60 starting at between the hot gas flow path after the proportioning valve 42 and extending to the return line 57 (the input to the compressor 12 ), the junction being made at a point prior to the COR regulator valve 70 . This bypass line 60 includes a solenoid expansion valve (SXV) 62 , followed by an orifice 63 so that when the SXV 62 is abruptly closed no hot gas is supplied to the mixing circuit 22 , the SXV 62 is controlled by the stored program circuits 64 responsive to the controller 40 . The hot gas flow path 32 can also be closed by the shut off valve 34 before the proportioning valve 42 . [0016] Inasmuch as the general operation of the TDSF system is adequately described in U.S. Pat. No. 7,178,353, those portions which are not essential to the inventive features herein will only be briefly described. The flow of pressurized hot gas from the compressor 12 is fed into the hot gas pressurized flow line via the first flow path 32 . The proportioning valve 42 is operated by the controller 40 , usually in relation to any cooled expanded flow in the second flow path 26 so as to provide, from the mixing circuit 22 , a predetermined output to the load 34 for the temperature and pressure conditions specified by the controller 40 . Consequently, in the mixing circuit 22 , the second flow in the second path 26 has been controllably expanded by the TXV 28 and applied to the separate input to the mixing tee 50 after passing the ΔP valve 30 . Consequently, a combined flow at a predetermined pressure and temperature is available at the input to the load 54 . Because the concept facilitates rapid pressure and temperature changes, and because the two-phase refrigerant is used directly in thermal exchange with the load 54 , the system has unique operative capabilities and cost advantages. [0017] Further uniqueness is now provided via the controller 40 in relation to the operation of the proportioning valve 42 , and also the bypass line 60 , in relation to the operation of the SXV 62 . The controller 40 includes what may be called a variable frequency control board 48 that with stored PLC algorithms to operate the stepper circuits 44 for control of the degree of opening of the proportioning valve 42 . The hard wired stored programs supply the controller 40 with instructions for commanding the stepper 44 to move the proportioning valve 42 open or closed at a selected rate to a desired final position. [0018] Consequently, when a change in the setting of the proportioning valve 42 is indicated, as a new temperature level is chosen for the system 10 , the controller 40 accesses the stored PLC algorithms in the storage 46 indicate the rate of change as well as the limit position to be reached. The necessary number of stepper increments are supplied at a chosen rate, and the stepper control circuits impulse the proportioning valve 42 accordingly. This consequently adapts the proportion and the rate of change of the hot gas flow to assure that the new setting is both precise and achieved with stability. [0019] The advantages of this approach can perhaps better be appreciated by referring to the operative diagram of FIG. 3 , illustrating in curve (A) sharp transition commands, as when fully off to fully on. The dotted line curve shows the resulting flow changes, with delay in response on opening and overshoot on reaching target flow. This may be followed by oscillations about the target level. In waveform (B), illustrating by a solid line a sudden nominal change from full open to fully closed, a reciprocal instability condition occurs for a period of time as the valve is fully closed, as seen in the dotted line waveform which depicts typical actual flow conditions in response to sudden change. In contrast, in waveform (C) the incrementally changing slope of the valve change in opening (solid line) is very closely followed by the flow change (dotted line) and there is no overshoot. With the modulated stepper motor approach the angle of the slope can be varied arbitrarily. [0020] There are some operating conditions in which it is desired or necessary to transition to a cooler temperature as quickly as possible, by passing the rate control. For this purpose, the SXV 62 in the bypass line 60 is driven by the PLC algorithm in the stored programs 61 to close virtually instantaneously, enabling the expanded coolant in the first flow line 26 to be operatively effective without delay. This line, which includes an orifice 63 , coupled to the return line 57 which goes into the compressor 12 input, at a point prior to the COR regulator valve 70 . Consequently, this feature provides a rapid response characteristic that supplements those already mentioned in the aforementioned Cowans et al patent. [0021] In some systems it may be desired or necessary to use an analog system for changing the opening of the proportioning valve 42 , and FIG. 2 , to which reference is made, shows only the signal generating and motor driving parts of such a system, the remainder of the system of FIG. 1 being applicable and therefore not shown. Here the controller 40 ′ provides a variable amplitude signal indicating a new target position for the proportioning valve 42 , and selects one of a number of timing circuits 90 to supply a drive signal of the needed slope to actuate the analog drive circuit 92 which moves the proportioning valve 42 . Again, a controlled rate of transition between the prior and new flow set points is achieved. [0022] Although various forms and alternatives have been shown or described, utilizing the teachings of the invention, it should be appreciated that the invention is not limited thereto but encompasses all expedients and variations within the scope of the appended claims.
In a thermal control system of the type employing a two phase refrigerant that is first compressed and then is divided into a variable mass flow of refrigerant into a hot pressurized gas form and a differential remainder flow of cooled vapor derived from condensation and then thermal expansion, transitions between different temperature levels are enhanced by incremental variations of the mass flow at different control rates.
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BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The invention relates to a portable mechanism for actuating a pneumatically-driven artificial heart. [0003] 2. Description of the Prior Art [0004] The heart is the muscle that drives the cardiovascular system in living beings. Acting as a pump, the heart moves blood throughout the body to provide oxygen, nutrients, hormones, and to remove waste products. The blood follows two separate pathways in the human body, the so-called pulmonary and systemic circulatory circuits. In the pulmonary circuit, the heart pumps blood first to the lungs to release carbon dioxide and bind oxygen, and then back to the heart. Thus, oxygenated blood is constantly being supplied to the heart. In the systemic circuit, the longer of the two, the heart pumps oxygenated blood through the rest of the body to supply oxygen and remove carbon dioxide, the byproduct of metabolic functions carried out throughout the body. The heart supplies blood to the two circuits with pulses generated by the orderly muscular contraction of its walls. [0005] In order to keep blood moving through these two separate circulatory circuits, the human heart has four distinct chambers that work in pairs. As illustrated in FIG. 1 , the heart 10 includes a right atrium 12 , a right ventricle 14 , a left atrium 16 , and a left ventricle 18 . One pair of chambers, the right ventricle and left atrium, is connected directly to the pulmonary circuit. In it, de-oxygenated blood from the body is pumped from the right ventricle 14 to the lungs, where it is oxygenated, and then back to the left atrium 16 . [0006] In the systemic circuit, the other pair of chambers pumps the oxygenated blood through body organs, tissues and bones. The blood moves from the left atrium 16 , where it flows from the lungs, to the left ventricle 18 , which in turn pumps the blood throughout the body and all the way back to the right atrium 12 . The blood then moves to the right ventricle 14 where the cycle is repeated. In each circuit, the blood enters the heart through an atrium and leaves the heart through a ventricle. [0007] Thus, the ventricles 14 , 18 are essentially two separate pumps that work together to move the blood through the two circulatory circuits. Four check valves control the flow of blood within the heart and prevent flow in the wrong direction. A tricuspid valve 20 controls the blood flowing from the right atrium 12 into the right ventricle 14 . Similarly, a bicuspid valve 22 controls the blood flowing from the left atrium 16 into the left ventricle 18 . Two semilunar valves (pulmonary 24 and aortic 26 ) control the blood flow leaving the heart toward the pulmonary and systemic circuits, respectively. Thus, in each complete cycle, the blood is pumped by the right ventricle 14 through the pulmonary semilunar valve 24 to the lungs and back to the left atrium 16 . The blood then flows through the bicuspid valve 22 to the left ventricle 18 , which in turn pumps it through the aortic semilunar valve 26 throughout the body and back to the right atrium 12 . Finally, the blood flows back to the right ventricle 14 through the tricuspid valve 20 and the cycle is repeated. [0008] When the heart muscle squeezes each ventricle, it acts as a pump that exerts pressure on the blood, thereby pushing it out of the heart and through the body. The blood pressure, an indicator of heart function, is measured when the heart muscle contracts as well as when it relaxes. The so-called systolic pressure is the maximum pressure exerted by the blood on the arterial walls when the left ventricle of the heart contracts forcing blood through the arteries in the systemic circulatory circuit. The so-called diastolic pressure is the lowest pressure on the blood vessel walls when the left ventricle relaxes and refills with blood. Healthy blood pressure is considered to be about 120 millimeters of mercury systolic and 80 millimeters of mercury diastolic (usually presented as 120/80). [0009] Inasmuch as the function of the circulatory system is to service the biological needs of all body tissues (i.e., to transport nutrients to the tissues, transport waste products away, distribute hormones from one part of the body to another, and, in general, to maintain an appropriate environment for optimal function and survival of tissue cells), the rate at which blood is circulated by the heart is a critical aspect of its function. The heart has a built-in mechanism (the so-called Frank-Starling mechanism) that allows it to pump automatically whatever amount of blood flows into it. Such cardiac output in a healthy human body may vary from about 4 to about 15 liters per minute (LPM), according to the activity being undertaken by the person, at a heart rate that can vary from about 50 to about 180 beats per minute. [0010] Several artificial devices have been developed over the years to supplement or replace the function of a failing heart in patients. These include devices developed by companies as well as research institutions such as the Berlin Heart Institute, the Pennsylvania State University, the University of Utah, the Cleveland Clinic Foundation, the University of Perkinje (in Bruno, Czechoslovakia), the University of Tokyo, the Thoratec Corporation, Abiomed Inc., Novacor, and Symbion Inc. Typically, these artificial devices consist of pumps that aim at duplicating the required pumping functions of the left and right human ventricles. One method of actuation for these pumps has been through the pneumatic action of an external mechanism. See, for example, U.S. Pat. Nos. 4,611,578 and 5,766,207. Periodic pulses of compressed air drive the pumps at the desired pressure and rate of cardiac output. A moderate vacuum may be applied between pulses to allow more rapid refilling of the ventricles with blood flowing from the respective atrium. [0011] One notable artificial heart currently in use as an implant for patients waiting for a heart transplant is the Total Artificial Heart manufactured by SynCardia Systems, Inc., of Tucson, Ariz. Designed to operate much the same way as a human heart, this artificial heart replaces the two active chambers (i.e., the ventricles) of the human heart with corresponding artificial components. As illustrated in FIG. 2 , such artificial heart 30 includes two separate chambers or ventricles 32 and 34 that replace the right and left ventricles of the human heart, respectively. Each chamber is equipped with a respective diaphragm ( 36 and 38 in the right and left chamber, respectively) that has an air contact side and a blood contact side. Each diaphragm is designed as a spherical hemisphere. As shown in FIG. 3 , the artificial heart 30 is implanted by connecting the top of the right chamber 32 to the right atrium 12 and the top of the left chamber 34 to the left atrium 16 . The bottom of each chamber is provided with an air line ( 40 and 42 in the right and left chamber, respectively) that is embedded in the patient's body but extends outside for connection to a pneumatic driver. [0012] When driven by a supply of pressurized air from the pneumatic driver, each diaphragm 36 , 38 discharges blood from the respective chamber 32 , 34 simulating the function of a ventricle. This phase is referred to in the art as systole or equivalently as the ejection phase. When the pressurized air is removed from the diaphragm, known as diastole or the filling phase, blood can enter the ventricle from the connected atrium. The rate at which blood enters the ventricle depends on the difference between the atrial pressure and the pressure on the air-side of the diaphragm. To increase this filling rate, a slight vacuum of about 10 mm Hg is normally applied to the air-side of the diaphragm during diastole. Artificial valves 44 a (tricuspid), 46 a (bicuspid) and 44 b (pulmonary), 46 b (aortic) control the flow from the respective atrium into each artificial ventricle and out to the circulatory systems, respectively. [0013] The pneumatic drivers used to date for driving all artificial hearts have been cumbersome and inadequate for affording patients any degree of independent mobility. They employ compressors, vacuum pumps, and air tanks coupled to electrically actuated valves, all of which amounts to a large and heavy apparatus that can only be transported on wheels and with considerable effort. Therefore, many attempts have been made during the last two decades to produce a portable driver for these devices. However, because of the complexity of the required functionality and the hardware necessary to produce it, pneumatic heart drivers continue to be bulky, require frequent maintenance, and often provide air pulses that do not match the performance of the larger drivers they are meant to replace. Even at the approximate weight of 20 pounds and size of about 0.7 cubic feet achieved so far, pneumatic drivers remain unwieldy and substantially not portable for a patient who is kept alive by an artificial heart. [0014] In essence, a portable driver needs to be reliable, durable, easy to use, and sufficiently simple in design to be affordable. Unfortunately, each of these requirements contributes to the complexity of the design, which in turn has produced devices that are not sufficiently small and light-weight to be manageable in the hands of a patient. Furthermore, it is essential that the pneumatic driver be able to provide the correct pressure balance between the left and right ventricles of the artificial heart to ensure the proper operating pressure to the pulmonary and systemic circuits regardless of the speed of operation. Typically, this requires that the driver be able to operate so as maintain, on average, a right atrial pressure of about 9 mmHg, a mean pulmonary artery pressure of about 35 mmHg, a left atrial pressure of about 10 mmHg, and a mean aortic pressure of about 95 mmHg. [0015] This need to provide different operating pressures to the right and left chambers (ventricles) of the artificial-heart device has not been met heretofore with a simple design suitable for a portable driver. For example, the blood pump described in U.S. Pat. No. 4,611,578 includes a configuration wherein two reciprocating pistons in a common cylinder may be operated alternatively to provide redundancy or independently to actuate two separate pneumatically driven blood pumps. This issue is not addressed in the patent, but it describes a sophisticated control system that arguably could be used to provide the correct operating pressure to each chamber of the artificial heart. However, the complex and multi-component structure of the device necessarily requires a relatively heavy and large apparatus, though described as portable. The commercially available module weighs about 25 pounds and is approximately 0.6 cubic feet in volume. [0016] U.S. Pat. No. 5,766,207 describes another portable pneumatic driver for ventricular assist devices that could also be adapted for an artificial heart. The single pump of the invention could be used to drive both ventricles of an artificial heart, but only at the same pressure and volume rate. Thus, this device, even if modified to meet the other requirements of a portable artificial-heart driver, would not be suitable as an alternative to the stationary modules currently in use. [0017] Therefore, there remains a strong need for an artificial-heart pneumatic driver that provides the detailed functions of stationary modules, is highly reliable, light-weight and manageable in size, so as to be easily portable for a patient in the normal condition of a person in need of a heart transplant. The present invention provides an extremely simple and elegant solution to this problem in a configuration designed particularly to meet the specifications of the SynCardia artificial heart. SUMMARY OF THE INVENTION [0018] The major concerns in designing a portable driver relate to size, weight, reliability, durability, extended battery life, ease of use, and simplicity of design (which in turn affects cost). With these constraints in mind, the present invention is directed at providing coordinated and independent periodic actuation pressure to each ventricle of the artificial heart, limiting peak pressures and peak vacuums to provide a safe and efficient cycle of operation, allowing only partial filling of each ventricle of the cardiac device to ensure redundancy of capacity, providing sufficient pneumatic stroke to completely eject the blood from the ventricles at each beat, readily adjusting the rate at which the artificial heart is actuated, and minimizing overall size and weight to enable portability. [0019] In view of the foregoing, the preferred embodiment of the pump of the invention comprises two coaxial cylindrical pumping chambers, each enclosing a disk-shaped piston incorporating seals to eliminate leakage. The pistons are connected to one another through a partition by a tube, thereby forming a monolithic piston assembly that is driven axially by a common electrical actuator providing reciprocating motion through a rod connected to the top piston. The tube travels through a seal in the partition that separates the two chambers and, by defining the boundary between the pistons, also acts as a bulkhead for the top chamber. [0020] The volume in the bottom chamber is selected as needed to provide the desired pressure in the left ventricle of the artificial heart driven by the pump. According to one aspect of the invention, the diameter of the tube connecting the pistons is selected such that the stroke volume (i.e., the displacement) of the top chamber is reduced with respect to that of the bottom chamber as needed to match the reduced pressure requirements of the right ventricle of the artificial heart. Namely, the maximum pressure achieved in each chamber should be as needed to fully eject blood from each ventricle of the artificial heart substantially at the operating pressures of the human pulmonary and systemic circulatory circuits. A limit check valve is preferably used in each chamber to ensure venting of excess pressure during the compression stroke. A limit check valve is also preferably used in each chamber to limit the vacuum generated during the reverse, aspiration stroke. [0021] In an alternative embodiment of the invention, the top and bottom pistons may have different diameters and travel with the same stroke length along cylindrical housings of correspondingly different volumes, thereby achieving the same effect of producing different pressures in the ventricles of the artificial heart. In a third embodiment, the height of one of the piston housings may be greater than the stroke length, so as to provide a buffer zone to reduce the operating pressure of that piston. The same result may be achieved with an external buffer zone that may consist of an additional chamber or in an additional volume in the air line to the artificial ventricle. [0022] Additional features and advantages of the invention will be forthcoming from the following detailed description of certain specific embodiments when read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0023] FIG. 1 is a representation of a human heart. [0024] FIG. 2 is a schematic view of the SynCardia artificial heart for which the present invention has been developed. [0025] FIG. 3 is a representation of the artificial heart of FIG. 2 connected to the heart atria of a human body. [0026] FIG. 4 is a schematic view of a pneumatic driver according to the preferred embodiment of the invention. [0027] FIG. 5 is a sectioned view of the actual pneumatic driver that incorporates the concepts of the invention. [0028] FIG. 6 is an illustration of the portable driver of the invention connected to an artificial heart implanted in a human body. [0029] FIG. 7 is a view of an alternative embodiment of the invention wherein the pneumatic driver features a single housing with two piston/cylinder combinations of different diameter. [0030] FIG. 8 is a view of a third embodiment wherein the upper-pressure cylinder incorporates a buffer zone to increase the working volume of gas compressed by that cylinder. [0031] FIG. 9 is a view of another embodiment of the invention wherein the additional working volume is implemented with a buffer chamber connected to the upper-pressure cylinder. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0032] With reference to the schematic representation of FIG. 4 , the preferred embodiment of a pneumatic pump 50 according to the invention includes a single cylinder housing 52 wherein two parallel pistons 54 , 56 are mounted for axial reciprocating motion. A partition or bulkhead 58 between the two pistons defines two separate pumping chambers or cylinders 60 and 62 for actuating, respectively, the right and left ventricles of the artificial heart driven by the pump 50 . The pistons 54 , 56 are rigidly connected to one another by means of a rod or tube 64 that is slidably mounted through the partition 58 . Seals 66 are provided on all sliding surfaces to prevent leakage. A piston actuator 68 is connected to one of the pistons for periodic reciprocating translation along the longitudinal axis of the cylinder 52 . [0033] For ease of description, the terms right and left are used in describing the pump 50 with reference to the right and left ventricles (or chambers) of the artificial heart to which the chambers 60 , 62 are connected. Similarly, the terms top or upper and bottom or lower are used to refer to the upper and lower chambers 60 and 62 and to their respective components, as illustrated in the figures, but it is understood that this relative position has not significance in relation to the invention. A driveline (seen in FIG. 6 ) connects the right drive port 70 of the upper chamber 60 to the air line 40 of the pneumatically-driven right ventricle of the artificial heart (see FIG. 3 ). Similarly, a separate driveline (also shown in FIG. 6 ) connects the left drive port 72 of the lower chamber 62 to the air line 42 of the pneumatically-driven left ventricle of the artificial heart. [0034] As the piston assembly is pushed down by the actuator 68 , the working gas in each of the upper and lower chambers 60 , 62 is exhausted through their respective ports 70 , 72 to pressurize and actuate the diaphragms 36 , 38 in the right and left ventricles of the artificial heart in the patient. The pressure exerted on each diaphragm forces blood to flow from the blood-side of the ventricles to the patient's body (the eject phase). The upper chamber 60 is equipped with a right-drive pressure relief valve 74 to ensure that air is expelled from the chamber if the right-drive pressure exceeds a predetermined level (the cracking pressure of the pressure relief valve), thereby providing a safety pressure limit. Similarly, air is expelled from lower chamber through a left-drive pressure relief valve 76 if the left-drive pressure exceeds the cracking pressure of the relief valve. Because the chambers operate at different maximum pressures, the cracking pressures of the relief valves are set at correspondingly different levels, typically at 103 mmHg and 212 mmHg for the right- and left-drive pressures, respectively. [0035] As the piston assembly is pulled up by the reciprocating motion of the actuator 68 , the working gas in each of the upper and lower chambers 60 , 62 is drawn back through their respective ports 70 , 72 and a vacuum (relative to atmospheric pressure) is generated to aid the reverse motion of the diaphragms 36 , 38 in the right and left ventricles of the artificial heart. The negative pressure exerted on each diaphragm creates a suction that helps the flow of blood from each atrium of the patient's heart to the blood-side of the ventricles of the artificial heart (the fill phase). In order to also ensure against excessive vacuum levels, the upper chamber is equipped with a right-drive vacuum relief valve 78 that allows air to be drawn from the atmosphere if the right-drive vacuum exceeds a predetermined level (the cracking pressure of the vacuum relief valve). Similarly, air is drawn into the lower chamber through a left-drive vacuum relief valve 80 if the left-drive vacuum exceeds the cracking pressure of the vacuum relief valve. These limiting cracking pressures are optimally set to achieve sufficient vacuum, namely about 10 mmHg, at each ventricle to ensure matching fill volumes. [0036] According to a critical aspect of the invention, the diameter of the connecting tube 64 is sized so as to provide an output flow rate from the upper chamber 60 designed to match the pressure requirements of the right ventricle 32 of the artificial heart. Once the stroke and volume of the lower chamber 62 are set to provide the desired pressure to the left ventricle 34 of the artificial heart at the nominal rate of operation of the pump, the pressure provided by the upper chamber can be adjusted as necessary simply by calculating the diameter of the tube 64 that produces the output rate required for the target pressure. As one skilled in the art will readily understand, the maximum pressures exerted on the diaphragms 36 , 38 are a function of the overall changes in volume produced by the stroke of each piston 54 , 56 . That is, if the total volume of the chamber, the artificial heart ventricle, and the air line connecting them is halved during a compression stroke under substantially isothermal conditions, the pressure will approximately double. Therefore, the sizing of the displacement in each chamber 60 , 62 , including the diameter of the tube 60 according to the invention, to meet the pressure requirements of each ventricle 32 , 34 is a matter of simple calculation. [0037] The reciprocating actuator 68 for the piston assembly of the invention is preferably based on a mechanism (detailed in a separate disclosure) that produces a sinusoidal motion of the pistons. Such rate of compression and aspiration has been found to produce the required pressure profiles during the compression stroke to completely empty each ventricle 32 , 34 of the blood accumulated during the aspiration stroke. Similarly, the vacuum generated during the aspiration stroke, together with the natural flow of blood from the atria, produces the required filling of the ventricles. Operation of the artificial heart is engineered such that the ventricles are only partially filled during normal conditions in order to provide redundant capacity when the blood flow in the body of the patient is increased as a result of physical activity. [0038] In the specific embodiment of the invention designed for the SynCardia artificial heart, the air side of each ventricle has a volume of approximately 4.27 cubic inches and the diaphragms 36 , 38 have an approximate area of 6.37 inch square each. The diameter and the stroke length of the pistons 54 , 56 are 3.0 and 0.943 inches, respectively, and the diameter of the tube 64 is 1.1 inches, producing displacements of 5.77 and 6.67 cubic inches in the upper and lower chambers 60 , 62 , respectively. The total air volume of the pump chamber, the ventricle and the air line connecting them under uncompressed conditions is 16.51 and 17.41 cubic inches in the right and left ventricle systems, respectively. Operating at 125 cycles (beats) per minute, the pump of the invention produces operating pressures of 103 and 212 mmHg in the right and left ventricles, respectively, causing each ventricle to fill with about 55 cc of blood and completely ejecting it at each stroke. The compactness of the design of the pump of the invention, together with the novel reciprocating mechanism actuating it (described separately), has enabled the manufacture of a portable driver prototype weighing less than 12 pounds and sized like a small purse. FIG. 6 illustrates its size and portability as a patient's accessory. [0039] In a different embodiment 90 of the invention illustrated schematically in FIG. 7 , two pistons 92 , 94 are also connected by a rod 96 through a partition 58 defining two separate cylinder chambers 98 , 100 . The pistons are similarly actuated by a common reciprocating mechanism 68 . However, the lower pressure in the upper (right ventricle) chamber 100 is obtained by decreasing its diameter and the corresponding displacement associated with each piston stroke. [0040] The same result may be obtained with a housing of constant diameter, as in the pump 50 of FIG. 4 , but with the upper chamber 60 lengthened beyond the stroke of the piston 54 , thereby providing an additional cylinder volume 102 , illustrated in FIG. 8 by the phantom line delineation 104 . This additional volume provides a buffer zone that reduces the pressure exerted by the stroke of the piston 54 . In an equivalent embodiment, illustrated in FIG. 9 , this additional volume is provided by a buffer chamber 106 placed along the air line 40 to the low-pressure artificial ventricle 32 . The same result could be achieved simply by sizing the lines 40 and 42 as necessary to provide the required volume difference for the two ventricle systems. As in the case of the preferred embodiment of the invention, the sizing of the relative dimensions of the various chambers and buffer volumes of these alternative embodiments are simply a matter of calculation based on the desired pressure delivered at each artificial ventricle. [0041] While the invention has been shown and described herein with reference to what is believed to be the most practical embodiment, it is recognized that departures can be made within the scope of the invention. For example, the pistons of the invention could be substituted with diaphragms connected by a tube or rod sized to produce the same effect described herein. Similarly, the cylindrical housing wherein the pistons are housed and the connecting tube need not be of circular cross-section, any shape being suitable so long as capable of producing the different pressures required for the operation of the right and left ventricle with the same stroke of the pistons. Further, a single valve that performs both pressure and vacuum limiting functions could be used. Such a valve could be a force-actuated valve that opened and closed as required by the system either through electrical means or as a function of a mechanical connection between the valve and the piston actuator. The pressure relief valve could also be implemented as a seal-break feature in the cylinder that would allow air to bypass the air seal between the piston and the cylinder wall at a predetermined point in the stroke. The pressure and vacuum limiting valves can also be placed in the chamber boundaries, as seen in FIG. 5 , rather than in the pistons.
A pneumatic pump comprises two coaxial cylindrical pumping chambers, each enclosing a piston connected to the other through a partition by a tube, thereby forming a monolithic piston assembly that is driven axially by a common electrical actuator providing reciprocating motion. The volume in the bottom chamber is selected as needed to provide the desired pressure in the left ventricle of an artificial heart driven by the pump. The diameter of the tube connecting the pistons is selected such that the stroke volume of the top chamber is reduced with respect to that of the bottom chamber as needed to match the reduced pressure requirements of the right ventricle of the artificial heart. Check valves are used in each chamber to ensure venting of excess pressure during the blood ejection phase and to limit the vacuum during the fill phase.
0
This application claims priority from U.S. Patent Application No. 60/507,127 filed on Oct. 1, 2003. FIELD OF THE INVENTION The present invention relates to methods and apparatus for distributing heat to or removing heat from remote locations. DESCRIPTION OF THE PRIOR ART It is often necessary to distribute heat to or remove heat from remote locations to inhibit freezing at that location. For example, in a fluid conveying system such as a water supply system, there is a danger during cold weather that fluid in the conduit will freeze. There are many proposals to supply heat to such a conduit such as by wrapping an electric heating cable about the conduit but these have tended to be used in locations close to. an electrical power source. Moreover, such installations tend to be used intermittently due to their relative inefficiency and power consumption. An alternate form of heating apparatus is shown in Canadian Patent 2019590 in which a self-regulating heating cable is inserted within a fluid conduit. With this arrangement it is possible to insulate the conduit to conserve energy and to regulate the power consumption due to the self-regulating nature of the cable. This arrangement has found wide-spread use, particularly in domestic water supplies in remote areas. The heating effect obtained from this installation is however limited to the available length of the heating cable which becomes a limiting factor in some installations. Moreover, the electrical system is prohibited in some environments such as sewers or drains that may contain methane because of the possibility of ignition of sewer gas. There is also a reticence to use electric heating cables in some environments where the cable may be exposed, such as roof and gutter de-icing, where damaged cables may come in contact with water and can result in fire when breakdown occurs. Proper electrical installation ensures the safe operation of such devices but nevertheless there is always a risk of improper installation. It will also be appreciated that such cables cannot function to extract heat from the fluid. It is therefore an object to the present invention to provide a method and apparatus for providing heat to remote locations in which the above disadvantages are obviated or mitigated. SUMMARY OF THE INVENTION According to one aspect of the present invention there is provided a fluid conduit having a peripheral wall to define a flow passage and a pair of fluid capillaries extending along the wall. The capillaries are connected in series and secured to the wall. Fluid may then flow along one of the capillaries in one-axial direction and be returned through the other capillary in the opposite direction. The capillaries are connected to a source of heat exchange fluid and thereby transfer heat through the wall of the conduit between the heat exchange fluid and fluid within the conduit. In an alternative embodiment, the capillaries may be contained within the peripheral wall defining the conduit. In both embodiments an external jacket may be applied to provide insulation to the conduit. In an alternative aspect of the invention there is provided a heating apparatus comprising a pair of concentric conduits and an end-cap at one end of said conduits to direct fluid flowing in one of the conduits to the other. At the opposite end, the conduits are connectable to a source of heat exchange fluid. In a further aspect, the present invention provides a heat distribution system having a source of heat exchange fluid, a manifold having a fluid supply and a fluid return, a pump to circulate fluid between the supply and return through the heat exchange fluid source and a conduit connected to each of the supplies and returns with said conduits being connected in series. The conduits transfer heat along their path. BRIEF DESCRIPTION OF THE DRAWINGS These and other features of the preferred embodiments of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings wherein: FIG. 1 is a schematic representation of a heat distribution system. FIG. 2 is a perspective view of a heat distribution apparatus used in the system of FIG. 1 . FIG. 3 is a view on the line III of FIG. 2 . FIG. 4 is a view partly in section of an alternative embodiment of heating apparatus used in the system of FIG. 1 . FIG. 5 is a view on the line V—V of FIG. 4 . DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring therefore to FIG. 1 , a heat distribution system 10 includes a fluid heater 12 , a central manifold 14 and a pair of heat distribution apparatus 16 , 18 connected at respective locations to the manifold 14 . It will be appreciated that a cooling effect can be obtained using a fluid cooler rather than a heater but for ease of description reference will be made to the apparatus functioning as a heater. The fluid heater 12 is connected to the manifold 14 through a supply line 20 and a return line 22 . The lines 20 , 22 are connected through an inlet 21 and outlet 23 to a coil 24 within the heater 12 . A heating source, such as a gas or electric heater, is supplied to the coil 24 so that fluid within the coil 24 is heated as it passes through the coil between the inlet 21 and outlet 23 . Fluid is circulated through the coil 24 by a pump 26 located within the manifold 24 and connected to the supply line 20 . The lines 20 , 22 are connected to each of a series of outlets 30 , 32 , 34 provided on the manifold 14 . Each of the outlets 30 , 32 , 34 has a pair of pipes 36 , 38 , one of which is connected to the supply line 20 and the other of which is connected to the return line 22 . The pipe 36 is connected to the supply line 20 through a check valve 40 and the return line 22 is connected to the pipe 38 through a selector valve 42 . The valve 42 may be moved between an open and closed position to permit fluid to flow from the pump 26 through the coil 24 to be discharged in the supply conduit 22 and to the outlet 30 . The manifold therefore permits selective distribution of fluid to one or more of the outlets 30 , 32 , 34 . The heat distribution apparatus 16 is connected to the outlet 30 and is shown in greater detail in FIG. 2 . The apparatus 16 includes a conduit 50 having a peripheral wall 52 defining an interior channel 54 through which a fluid to be heated, for example water, flows. A pair of capillary tubes 56 , 58 are located on the exterior of the peripheral wall 52 and extend axially parallel to the axis of the conduit 50 . A metallic tape 60 is interposed between the capillary tubes and the wall 52 and an outer sleeve 62 is located over the conduit 50 . The sleeve 62 is preferably made from heat shrinkable plastics material and retains the capillary tubes 56 , 58 in location. A tracer wire 64 extends parallel to the capillary tubes 56 , 58 to assist in locating the apparatus 16 at a later date if it is buried or hidden. At one end of the conduit 52 , the capillary tubes 56 , 58 are interconnected by a connector 66 . The connector 66 is a press fit on the exterior of the capillary tubes 56 , 58 and may be secured by a suitable cement. The connector 66 also includes a wire loop 68 that may be used to indicate the end of the capillaries during a subsequent inspection. The opposite end of the capillaries 56 , 58 are split from the conduit 52 and connected at the port 30 to the lines 36 , 38 respectively. A continuous loop is therefore provided from the pump 26 through the heater 12 and the capillaries 56 , 58 for fluid that is heated within the coil 24 . The conduit 52 is used to convey fluid, such as a water supply line and the heat supplied from fluid flowing through the capillaries 56 , 58 flows through the wall 52 to maintain the fluid above the freezing point or other predetermined temperature. The supply of heat may be regulated by varying the temperature of the fluid or by varying the flow rate through modulation of the pump 26 . An alternative heat distribution apparatus 18 is shown in greater detail in FIGS. 4 and 5 and is intended for the direct application of heat to remote areas such as an eavestrough or roof or to be located internally within a fluid conduit, such as a water pipeline sewer. The heat distribution apparatus 18 includes a pair of concentric ducts 70 , 72 defined by annular walls 71 , 73 respectively with an end-cap 76 bridging the termination of the ducts 70 , 72 . At the opposite end, an end-cap 78 provides a spigot 80 for connection to the line 36 . The conduit 70 extends through the end-cap 78 where it is sealed by an o-ring 82 and terminates in an end-cap 84 with a connecting spigot 86 for connection to the line 38 . Again, therefore, the heated fluid is discharged through the spigot 86 into the duct 70 and is re-directed by end-cap 76 into the exterior duct 72 . Heat is transferred across the wall of the duct 72 to provide distributed heating to the surrounding environment. Each of the heat distribution apparatus 16 , 18 has one or more temperature sensors 80 , 82 , along the axis to sense either the temperature of fluid in conduit 52 or the ambient temperature. The sensor 80 , 82 control the valves 42 to direct fluid to the outlet at which heat is required. The heating apparatus 16 may be co-extruded as a unitary moulding and sized to meet the requirements of the fluid within the conduit 52 . The heating apparatus 18 is likewise sized to provide a flexible pliant heater that may be entrained along the edge of a roof or within an eavestrough. Typically the fluid conduit is a extruded polyethylene pipe or similar extrudeable material. A cross linked polyethylene pipe, such as that known by the trade name PEX or KITEC is suitable. For a conduit of nominal 50 mm diameter the capillary tubes 56 , 58 have a diameter of 5 mm to 10 mm for the apparatus 18 , the ducts 70 , 72 have a diameter of 12 mm to 16 mm, although it will be appreciated that other dimensions may be used to suit different applications. In the embodiment of FIGS. 2 and 3 , the number of capillary tubes 56 , 58 may be increased to 4, 6, or more if required to meet the heating needs for particular environments. The pair of capillary tubes 56 , 58 may then be connected in parallel and supplied through a common manifold or may be controlled independently so that the heating effect can be regulated according to the ambient temperature. Thus, as the temperature drops below a given level, an additional pair of capillaries are connected to the heat source and additional heat supplied to the conduit by multiple flow paths. It will also be appreciated that the capillaries may be wound about the exterior of the conduit in a spiral pattern if so desired to distribute the heating effect uniformly over the wall 52 of the conduit. The capillaries may be co-extruded with the conduit 50 and may be secured with adhesive if preferred. Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention as outlined in the claims appended hereto.
A heat distribution apparatus comprising a fluid conduit having a peripheral wall defining a flow passage and a pair of fluid capillaries extending along the wall and secured thereto. The capillaries being connected to one another in series to provide a fluid flow path along one of the capillaries and a return path along another of said capillaries to convey heat exchange fluid to transfer heat between the flow passage and the heat exchange fluid.
5
BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to compressed gas guns. More particularly, the present invention relates to compressed gas guns that employ a cocking mechanism, which yields a mechanical advantage for the compression of a main spring. Description of the Related Art Compressed gas guns operate to release a quantity of compressed gas into the breech of a barrel, which has been pre-loaded with a projectile, thereby propelling the projectile out of the barrel at high velocity. In practice, such a gun must provide a source of compressed gas in order to function. Typically, this source of gas is an air tank that is pre-charged prior to being coupled with the gun, or a fixed tank that is charged in place while coupled to the gun. As such, these are referred to as pneumatic pre-charged (PCP) guns. In either case, the tank holds a finite quantity of compressed gas. Upon discharging the gun one or more times, the reserve of compressed gas is ultimately depleted and must be replenished. Air is used as the compressed gas in the majority of PCP guns, but other suitable gases can be employed as well. In the case of a manually loaded compressed gas gun, the breech of the barrel must be accessible for manual insertion of a projectile into the breech of the barrel. It is desirable to provide a readily accessible breech, which can be conveniently loaded by the fingers of the user. In the case of an auto-loading gun, the breech still must be accessible to the loading mechanism, yet sealable so as to coupled the compressed gas to the breech without undue gas leakage. A valve mechanism is commonly provided which acts to discharge a quantity of compressed gas as a result of actuation of a trigger mechanism. However, prior to discharging the gun, the valve assembly must be coupled to the breech of the barrel in order to seal the gas port between the tank and the breech of the barrel. It is desirable to provide a pressure-tight seal, which serves to conserve the amount of gas consumed upon discharging the gun and also to conserve the pressure of the gas so as to maximize the amount of energy transferred from the compressed gas to the projectile. Furthermore, a tight gas seal reduces the sound level of the gun upon discharging, which is desirable in compressed gas guns. The inventor of the present disclosure has been granted two prior patents, which are U.S. Pat. No. 5,586,545 issued on Dec. 24, 1996 for COMPRESSED GAS GUN, and U.S. Pat. No. 5,813,392 issued on Sep. 29, 1998 for COMPRESSED GAS GUN, which together disclose several embodiments of compressed gas guns. The entire disclosures of these two patents are hereby incorporated by reference. A review of those patents will reveal that the loading, cocking, and discharging mechanisms, collectively referred to as the operating assembly, incorporate a hammer and a mainspring where the compressed energy of the mainspring drives the hammer rearward in the receiver, and this energy is ultimately driven against a pneumatic valve to release a surge of compressed gas into the breech of a barrel to discharge the gun. It will also be noted that these designs were intended for lighter caliber projectiles, generally ranging from 0.17 inch to 0.25 inch calibers. The force of the main spring, weight of the hammer, and pneumatic valve actuation force are all related to the caliber and mass of the projectile. Since the forces required for lighter calibers are reasonable with respect to the force an operator must exert to compress the main spring, these prior design utilized a cocking lever that was directly coupled to the mechanism such that actuation of the cocking lever opened the breech seal, moved the hammer forward, and compressed the main spring in preparation of a subsequent discharge of the gun. A growing trend in compressed gas guns is toward heavier caliber projectiles. Today, 0.30 inch caliber guns are known, and recently 0.45 inch caliber guns are entering the market. While the prior loading, cocking, and discharging mechanisms have performed well with lighter caliber guns, the higher forces required to discharge heavier calibers has correspondingly increased mainspring compressive forces, and the size and weight of related components, such that the operator applied cocking forces have become challenging for some operators. Thus it can be appreciated that there is a need in the art for a compressed gas gun that functions with heavier calibers, yet is manageable to operate. SUMMARY OF THE INVENTION The need in the art is addressed by the apparatuses of the present invention. The present disclosure teaches a compressed gas gun for discharging a projectile. In an illustrative embodiment, the compressed gas gun includes a barrel with a muzzle and breech, which is fixed to a receiver that supports a cocking pawl and a gas valve located adjacent to the breech. A cocking member slides in parallel with the barrel, and has a spring stop fixed thereto. A cocking lever is rotatably coupled to the receiver at a first end and coupled to the cocking member by a cocking link, and provides a mechanical advantage in sliding the cocking member. Opposing directions of rotation of the cocking lever urge the cocking member towards the muzzle or toward the breech. A breech seal slides together with the cocking member, and seals to the barrel adjacent to the breech. A hammer and a main spring are located between the breech seal and the spring stop. Rotation of the cocking lever to urge the cocking member toward the muzzle slides the breech seal away from the gas valve to facilitate insertion of the projectile into the breech, and also urges the hammer to engage the cocking pawl, thereby retaining the hammer. Further, rotation of the cocking lever to urge the cocking member toward the breech compresses the main spring between the hammer and the spring stop, and further slides the breech seal to seal to engage the gas valve. Actuation of the cocking pawl releases the hammer, which is driven by the main spring to impact the breech seal, which impacts the gas valve to release compressed gas and discharge the projectile from the muzzle. In a specific embodiment, the foregoing apparatus further includes a trigger assembly coupled to the cocking pawl, which is disabled from releasing the cocking pawl unless the cocking member has been urged toward the breech to sealably engage the breech seal with the gas valve. In a specific embodiment of the foregoing apparatus, the breech seal is slidably coupled to the cocking member, and further includes a seal spring disposed between the cocking member and the breech seal, which urges the breech seal against the gas valve. In a refinement to this embodiment, an elastomeric seal is placed between the breech seal and the gas valve. In a specific embodiment of the foregoing apparatus, the spring stop position with respect to the cocking tube is adjustable, which enables adjustment of the main spring compression. In a specific embodiment, the foregoing apparatus further includes a magnet disposed on the receiver, and the cocking lever is held in place by the magnet while the cocking member is urged toward the breech. In another specific embodiment of the foregoing apparatus, the cocking member has a tubular form and is positioned concentric with the barrel. In a refinement to this embodiment, the hammer has a tubular form and is positioned to slide along the barrel exterior and the cocking member interior together with the main spring. In another specific embodiment, the breech seal has a substantially tubular form with a cylindrical interior that is sealed to the barrel with an elastomeric seal. The present disclosure also teaches a compressed gas gun apparatus for discharging a projectile, which includes a barrel with a muzzle and a breech that is fixed to a receiver that has a breech opening adjacent to the breech. A gas valve is located adjacent to the breech opening and aligned with the barrel. A trigger with a cocking pawl is fixed to the receiver. A cocking member slides in parallel with the barrel, and has a spring stop fixed thereto. A cocking lever is rotatably coupled to the receiver at a first end and is coupled to the cocking member by a cocking link to provide a mechanical advantage to slide the cocking member. Opposing directions of rotation of the cocking lever selectively urges the cocking member towards the muzzle or toward the breech. A breech seal slides together with the cocking member, and sealably engages the barrel adjacent to the breech. A hammer and a main spring are located between the breech seal and the spring stop. Urging the cocking member toward the muzzle slides the breech seal away from the gas valve and exposes the breech within the breech opening, to facilitate insertion of the projectile into the breech, and also slides the hammer toward the muzzle to engage the cocking pawl and retain the hammer. Urging the cocking member toward the breech compresses the main spring between the hammer and the spring stop, and also slides the breech seal to seal the gas valve. Actuation of the trigger releases the hammer from the cocking pawl, which is driven by the main spring to impact the breech seal to further impact the gas valve, to thereby release compressed gas and discharge the projectile from the muzzle. In a specific embodiment of the foregoing apparatus, the trigger assembly is disabled from releasing the cocking pawl unless the cocking member has been urged toward the breech to seal the breech seal with the gas valve. In a specific embodiment of the foregoing apparatus, the breech seal is slidably coupled to the cocking member, and the apparatus further includes a seal spring between the cocking member and the breech seal, which urges the breech seal against the gas valve. In a specific embodiment of the foregoing apparatus, the spring stop position with respect to the cocking tube is adjustable, which enables adjustment of compression of the main spring. In a specific embodiment, the foregoing apparatus further includes a magnet disposed on the receiver, and the cocking lever location while the cocking member is urged toward the breech is maintained by magnetic attraction. In a specific embodiment of the foregoing apparatus, the cocking member has a tubular form and is positioned concentric with the barrel. In a refinement to this embodiment, the hammer has a tubular form and is positioned to slide along the barrel exterior and the cocking member interior together with the main spring. In a specific embodiment of the foregoing apparatus, the breech seal has a substantially tubular form with a cylindrical interior that is sealed to the barrel with an elastomeric seal. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view drawing of an air gun according to an illustrative embodiment of the present invention. FIG. 2 is a perspective view drawing of an air gun with a breech seal in a closed position according to an illustrative embodiment of the present invention. FIG. 3 is a perspective view drawing of an air gun with a breech seal in an open position according to an illustrative embodiment of the present invention. FIG. 4 is a section view drawing of an air gun according to an illustrative embodiment of the present invention. FIG. 5 is a detailed section view drawing of an air gun according to an illustrative embodiment of the present invention. FIG. 6 is a detailed section view drawing of an air gun according to an illustrative embodiment of the present invention. FIG. 7 is a cross section view drawing of an air gun according to an illustrative embodiment of the present invention. FIGS. 8A, 8B, 8C, and 8D are a bottom view drawing, an end view drawing, a right side view drawing, and a left side view drawing, respectively, of an air gun cocking tube according to an illustrative embodiment of the present invention. FIGS. 9A and 9B are a side view drawing and an end view drawing, respectively, of an air gun spring stop according to an illustrative embodiment of the present invention. FIG. 10 is drawing of an air gun main spring according to an illustrative embodiment of the present invention. FIGS. 11A and 11B are a side view drawing and an end view drawing, respectively, of an air gun hammer according to an illustrative embodiment of the present invention. FIG. 12 is a drawing of an air gun breech seal spring according to an illustrative embodiment of the present invention. FIGS. 13A, 13B, and 13C are a side view drawing, a breech end view drawing, and a muzzle end view drawing, respectively, of an air gun breech seal according to an illustrative embodiment of the present invention. FIGS. 14A, 14B, and 14C are section view drawings of an air gun in the loading position, cocked position, and fired position, respectively, according to an illustrative embodiment of the present invention. DESCRIPTION OF THE INVENTION Illustrative embodiments and exemplary applications will now be described with reference to the accompanying drawings to disclose the advantageous teachings of the present invention. While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope hereof and additional fields in which the present invention would be of significant utility. In considering the detailed embodiments of the present invention, it will be observed that the present invention resides primarily in combinations of steps to accomplish various methods or components to form various apparatus and systems. Accordingly, the apparatus and system components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the disclosures contained herein. In this disclosure, relational terms such as first and second, top and bottom, upper and lower, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. As was discussed in the Background section of this disclosure, the inventor hereof has been granted two prior art US patents, U.S. Pat. No. 5,586,545 issued on Dec. 24, 1996 for COMPRESSED GAS GUN, and U.S. Pat. No. 5,813,392 issued on Sep. 29, 1998 for COMPRESSED GAS GUN. These patents disclose compressed gas guns that employ loading, cocking and discharging mechanisms that perform well with light caliber projectiles, typically ranging from 0.17 inch to 0.25 inch calibers. In use, the operator of the gun follows a sequence of steps to load and discharge the gun, which generally proceeds as follows. Beginning from the condition where the gun as previously been discharged, the operator grasps a cocking handle and pushes a breech seal forward toward the muzzle, which exposes the breech end of barrel and pushes a hammer forward to compress a main spring until a cocking pawl engages the hammer in cocked position. Next, the operator inserts a projectile into breech end of barrel, and then pushes the breech seal rearward toward the breech end of the gun while the cocking pawl retains the hammer in the cocked position. The breech seal seals a gas release valve to the breech of barrel. Finally, the operator pulls a trigger, which releases the cocking pawl to allow the main spring to drive hammer rearward to impact the breech seal, which in-turn impacts the air release valve expelling air into the breech seal and barrel breech, thereby driving the projectile out of the muzzle of the barrel. Note that this configuration requires the operator to directly compress the main spring with the cocking handle. The present disclosure provides novel loading, cocking, and discharging mechanisms for compressed gas guns that are particularly suitable for heavier calibers, although they are quite suitable for light calibers as well. According to certain illustrative embodiments of the present disclosure, the gun mechanism enables the operator to more easily and conveniently operate the compressed gas gun. In one embodiment, the operator grasps a cocking lever and pulls it away from the gun's receiver, which pushes an internal cocking tube forward toward the muzzle that also carries a breech seal and hammer forward to engage a cocking pawl of a trigger mechanism. Then, the operator closes the cocking lever and that pushes the cocking tube and breech seal rearward while the cocking pawl holds the hammer in forward position such that main string is compressed between a spring stop in cocking tube and the cocking pawl in trigger mechanism. The trigger is pulled to release cocking pawl, thereby allowing the hammer to be driven rearward into the breech seal, actuating an air valve and discharging a projectile. Another embodiment follows this sequence of events, which also begins with the gun in a previously discharged condition. The operator rotates a cocking lever that moves a cocking member within the gun's receiver. This action opens a breech seal to expose the barrel breech, and also urges a hammer and main spring forward until a coking pawl engages the hammer in forward position. The operator then inserts a projectile into breech end of barrel. Then, the operator rotates the cocking lever in the opposite direction to move the cocking tube rearward, which compresses the spring between a spring stop on the cocking member and a cocking pawl, and this action also closes that breech seal to seal an air release valve with barrel breech. Finally, the operator pulls a trigger to release the cocking pawl, which allows the main spring to drive hammer rearward to impact breech seal, which in-turn impacts the air release valve expelling air into the breech seal and barrel breech, thereby driving the projectile out of barrel and muzzle. Reference is directed to FIG. 1 , which is a perspective view drawing of a compressed gas gun 2 according to an illustrative embodiment of the present invention. The gun 2 is built about a receiver 4 , which is an aluminum extrusion that is further machined in the illustrative embodiment. A barrel 18 is fixed to the receiver 4 with its muzzle 19 at the forward end of the gun 2 . A pistol grip 10 and fore stock 12 are attached to the receiver 4 and are provided for operator convenience. A compressed gas cylinder 6 provides the energy source for the gun 2 , and also functions as a shoulder stock, and further includes shoulder rest 8 , also for operator convenience. A gas fill port 20 is provided so that the compressed gas cylinder can be refilled without disconnecting it from the receiver 4 . A breech opening 14 is cut into the receiver, which provides operator access to the barrel breech (not shown) to facilitate loading of projectiles (not shown). A cocking lever 16 is rotatably connected to the receiver 4 , and is also connected to a cocking link 24 , which engages a cocking member (not shown) inside the receiver 4 through a cocking slot 26 . The cocking lever 16 , cocking link 24 , and the cocking member (not shown) operate cooperatively to yield a mechanical advantage for the operator. A mechanical advantage is a measure of the force amplification achieved by using the cocking mechanism as a system. The cocking mechanism preserves the input power and trades off forces against movement to obtain a desired amplification in the output force. This is essentially the law of the lever, as will be appreciated by those skilled in the art. Machine components designed to manage forces and movement in this way are called mechanisms. Reference is directed to FIG. 2 and FIG. 3 , which are partial perspective view drawings of a compressed gas gun with a breech seal in a closed position and opened position, respectively, according to an illustrative embodiment of the present invention. FIG. 2 corresponds to FIG. 1 , but provides a closer view to facilitate the presentation of further details. Note that the receiver 4 , pistol grip 10 , fore stock 12 and gas cylinder 6 are presented. FIG. 2 presents a breech seal 30 in the closed position, and engaged with a gas valve 32 . The breech seal 30 slides together with a cocking member 34 , which is partially visible within the breech opening 14 in this condition. Note that the cocking handle 16 is positioned close to the receiver 4 , which is a convenient location for carrying, discharging, and storing the gun. The cocking handle 16 is maintained in the closed position using a magnet (not shown) that is fixed to the receiver. The cocking link 24 is also held close to the receiver 4 . The cocking link 24 engages a cocking member (not shown) through a cocking slot 26 formed in the receiver 4 . The cocking handle 16 is rotatably coupled to the receiver 4 using a pivot mount 28 . FIG. 3 corresponds with FIG. 2 , however FIG. 3 presents the gun with the cocking lever 16 rotated forward so as to urge the cocking member (not shown) and breech seal 30 toward the muzzle (not shown) to thereby expose the barrel breech 22 within the breech opening 14 . The gas valve 32 is also more clearly visible in this condition. Note that the magnet 15 is fixed to the pivot mount 28 , which serves to hold the cocking lever 16 in place against the receiver 4 , as illustrated in FIG. 2 . The cocking link 24 follows the cocking lever 16 as it is rotated toward the muzzle end the gun, and the distal end slides within the cocking slot 26 to advance the cocking member (not shown) inside the receiver 4 . In the condition illustrated in FIG. 3 , the operator has access to the breech 22 for insertion of a projectile. Note that the breech end 22 of the barrel is cut-away so that a projectile may rest thereupon as it is inserted into the breech 22 . The projectile need not be fully inserted into the breech, rather just sufficiently to enable the compressed gas to force it into the barrel upon discharging the gun. Once a projectile is inserted, the operator rotates the charging handle 16 toward the breech end of the gun to return the gun to the same condition illustrate in FIG. 2 . Further operations of the mechanisms will be more fully discussed hereinafter. Reference is directed to FIG. 4 , which is a section view drawing of a compressed gas gun 2 according to an illustrative embodiment of the present invention. This view is a section taken through the centerline of an illustrative embodiment compressed gas gun 2 , and serves to further orient the viewer with respect to other drawing figures and descriptive materials. The receiver 4 is an aluminum extrusion that is further machined to accommodate the various other components of the gun. The barrel 18 is fixed to the receiver 4 . A breech opening 14 is formed into the receiver 4 to provided access to the breech 22 of the barrel. The pistol grip 10 and fore stock 12 are presented. The compressed gas cylinder 6 and shoulder stock 8 are also presented. The gas valve 32 is fixed to the gas cylinder 6 for expelling compressed gas into the breech 22 of the barrel 18 . Note that a trigger assembly 48 is disposed in the lower portion of the receiver 4 . The trigger assembly 48 includes a safety function in addition to the triggering function. Reference is directed to FIG. 5 , which is a detailed section view drawing of a compressed gas gun according to an illustrative embodiment of the present invention. FIG. 4 corresponds with FIG. 5 and is also a section view along the centerline, but is a closer view to reveal further details. In FIG. 4 , the receiver 4 , barrel 18 , fore stock 12 , pistol grip 10 , and gas cylinder 6 are again presented. The gas valve 32 is fixed to the gas cylinder, and couples from the interior of the gas cylinder to a location within the breech opening 14 , and is aligned with the breech 22 of the barrel 18 , but spaced away so that there is sufficient space available to insert a projectile (not shown) into the breech 22 . A number of components are located in the annual gap between the exterior of the barrel 18 and the interior of the receiver 4 . Among these are, the cocking member 34 , the breech seal 30 , the breech spring 44 , the hammer 42 , and the main spring 40 . All of these items are of cylindrical form and concentric with one another in the illustrative embodiment. This facilitates mutual support and location of these various components, and also yields a compact and lightweight design. However, the cylindrical and concentric arrangement is not required to implement a gun under the teachings of the present disclosure. Other configurations could be employed, and it is not required for all these components to be located within the receiver. For example, the hammer could be a pivoting member driven by a leaf spring, and the cocking member could be a bar located parallel to the barrel and outside of the receiver. Continuing in FIG. 5 , the trigger assembly 48 , which is located in a lower recess of the receiver 4 , further includes a trigger actuator 44 and a safety actuator 46 for implementing the convention functions of discharging the gun and interlocking against the discharge of the gun. A cocking pawl 43 engages the hammer 42 to retain the hammer 42 in position against the compressive force of the main spring 40 while the gun is cocked. When the trigger 44 is pressed, the cocking pawl 43 moves downward and releases the hammer 42 to be driven rearward toward the breech end of the gun by the main spring 40 . The hammer 42 accelerates and impacts the breech seal 30 , which functions as an energy communicating member to impact the gas valve 32 to release a pulse of compressed gas. The breech seal 30 sealably engages both the gas valve 32 and the barrel 18 so as to coupled the compressed gas energy to the barrel 18 , rather than leaking away. Although, a small amount of leakage away from the intended pneumatic path is not problematic. Note that the cocking member 34 , which is tubular in this embodiment, serves the function of carrying the moving components toward the muzzle or toward the breech as the cocking mechanism (not shown) is actuated. The moving members include the breech seal 30 , the seal spring 44 , the hammer 42 , and the main spring 40 , among certain other components that will be discussed hereinafter. Reference is directed to FIG. 6 , which is a detailed section view drawing of a compressed gas gun according to an illustrative embodiment of the present invention. This view of the illustrative embodiment gun 2 is presented with several of the internal components removed so that the location and arrangement of others is more readily discernable. The receiver 4 supports the barrel 18 in a fixed relationship. Note that the barrel is supported from the receiver 4 near the muzzle end using concentric collars (not shown) and sets screws (not shown), although other support arrangements could be employed. The fixed relationship is useful for aiming and accuracy of the gun 2 since the sights or scope are fixed to the receiver 4 . The compressed gas cylinder 6 is fixed to the receiver 4 and presents the gas valve 32 in the breech opening 14 of the receiver 4 . Note that an annular groove 33 is provided in the gas valve 32 for retaining an O-ring (not shown), which provides an elastomeric seal with the breech seal (not shown) when the two are sealably engaged. The gas valve 32 is concentrically aligned with the barrel 18 so that the breech seal (not shown) may slidable and sealably engage both of the barrel 18 and gas valve 32 . The barrel breech 22 is visible in FIG. 6 , and note the cut-away barrel extension 23 that extends rearward toward the gas valve 32 . This extension 23 provides a trough into which the operator can rest a projectile (not shown) as it is pressed into the breech 22 . Another significant aspect of the illustrative embodiment of FIG. 6 is the location of the cocking slot 26 in the receiver 4 . In this view, the cocking slot 26 is illustrated by phantom line because it is physically located on the portion of the receiver 4 removed for this section view. However, the position is correct with respect to the receiver 4 and cocking member 34 . Also note the two mounting holes 36 that of formed in the cocking member 34 for engaging the cocking link (not shown) through the cocking slot 26 . The mount holes 36 are illustrated in phantom line for the same reason. The cocking member 34 is tubular in this embodiment and it is enabled to slide fore and aft in the direction of the muzzle or breech ends of the barrel 18 as allowed by the length of the cocking slot 26 and urged by the cocking link (not shown). In this view, the cocking member 34 is illustrated at mid-travel between the two extremes. Note also the location of the cocking pawl 43 , which passes through suitable apertures formed in both the receiver 4 and cocking member 34 . The cocking pawl 43 is illustrated without the remaining components of the trigger assembly for the sake clarity. Reference is directed to FIG. 7 , which is a cross section view drawing of a compressed gas gun according to an illustrative embodiment of the present invention. This section view labeled “A-A” is taken from FIG. 6 , at the location illustrated. In FIG. 7 , the receiver 4 extrusion profile is visible with the barrel 18 at the center of the receiver 4 . The cocking member 34 slides along the interior of the receiver 4 , which serves as a guide for the sliding action. The cocking pawl 43 extends upwardly into the interior of the receiver 4 thought a suitable hole 5 in the receiver 4 , and further through a suitable slot 52 in the cocking member 34 . In this manner, the cocking pawl may be positioned within the interior of the cocking member 34 even thought the cocking member is slid for and aft. The annular space between the exterior of the barrel 18 and the interior of the cocking member 34 is provided to accommodate the breech seal (not shown), hammer (not shown) and the main spring (not shown). Reference is directed to FIGS. 8A, 8B, 8C, and 8D , which are a bottom view drawing, an end view drawing, a right side view drawing, and a left side view drawing, respectively, of a compressed gas gun cocking member 34 according to an illustrative embodiment of the present invention. The cocking member 34 is in the form of a tube in this embodiment, which is open at both ends and slides along the interior of the receiver (not shown). The cocking member 34 has a slot 52 formed along its bottom, which provides access for the cocking pawl (not shown) to reach into its interior and engage the hammer (not shown). The cocking member includes a pair of opposing slots 54 on either side, and adjacent to the breech end, to facilitate connection of the breech seal (not shown). The cocking member 34 further includes a pair of mounting holes 36 on one side for connecting the cocking link (not shown), which drives the cocking member fore and aft during cycling of the gun. The interior of the muzzle end of the cocking member 34 is threaded 58 to engage and retain the spring stop (not shown). A spring stop adjustment port 50 is provided so that the spring stop (not shown) may be rotated to adjust its position, and thereby change the degree to which the main spring (not shown) is compressed during the cocking operation. The receiver 4 (not shown) has a corresponding spring stop adjustment opening for access by the operator. Reference is directed to FIGS. 9A and 9B , which are a side view drawing and an end view drawing, respectively, of a compressed gas gun spring stop 38 according to an illustrative embodiment of the present invention. Generally speaking, the spring stop is a fitment coupled to the cocking member, which engages the mainspring. The main spring is compressed between the spring stop and the hammer as the gun is cocked. The hammer is, in turn, retained by the cocking pawl. Thusly, release of the cocking pawl releases the hammer, which is accelerated under force of the mainspring. The cocking action is effected by the urging the cocking member against the main spring. The spring stop 38 of the illustrative embodiment in FIGS. 9A and 9B is generally tubular with exterior threads 41 to engage the corresponding threads in the cocking member (not shown). A series of holes 39 are formed around the circumference of the spring stop 38 . These holes 39 are presented within the aforementioned spring stop adjustment ports (not shown) on the receiver (not shown) and cocking member (not shown). A suitable tool (not shown) can be used to engage the holes 39 to incrementally rotate the spring stop 38 on its threads 41 to vary its position with respect to the cocking member (not shown). Reference is directed to FIG. 10 , which is drawing of a compressed gas gun main spring 40 according to an illustrative embodiment of the present invention. The main spring configuration is a coiled spring with tubular form that is specified according to the diameter, length, compressive force, and dimensions required for the gun caliber, hammer weight, and travel required, as will be appreciated by those skilled in the art. Other spring configurations can also be adapted to the teachings of the present invention. Reference is directed to FIGS. 11A and 11B , which are a side view drawing and an end view drawing, respectively, of a compressed gas gun hammer 42 according to an illustrative embodiment of the present invention. The hammer 42 of the illustrative embodiment is tubular in form having a length, diameter, and weight required for the physical configuration of the cocking assembly and driving force required for the air valve. Other hammer configurations could be adapted to the teachings of the present invention, as will be appreciated by those skilled in the art. The requisite functions of the hammer are that it can be retained by the cocking pawl and urged against the main spring. Reference is directed to FIG. 12 , which is a drawing of a compressed gas gun breech seal spring 12 according to an illustrative embodiment of the present invention. The breech seal spring 44 is slid over the breech seal (not shown) and engages the cocking member (not shown) so at to urge the breech seal away from the cocking member. In operation, as the cocking member is urged toward the gas valve, the breech seal engages the gas valve and is urges there against by the compressive force of the breech seal spring 44 . Refer to the FIG. 5 for a graphical depiction of this arrangement. Reference is directed to FIGS. 13A, 13B, and 13C , which are a side view drawing, a breech end view drawing, and a muzzle end view drawing, respectively, of a compressed gas gun breech seal 30 according to an illustrative embodiment of the present invention. The breech seal 30 functions to sealably engage the barrel (not shown) and the gas valve (not shown) to provide a pneumatic path for compressed gas to be forced into the barrel breech (not shown) and drive the projectile (not shown). Since the breach seal 30 must be moved away to facilitate loading a projectile, it is coupled to the cocking member (not shown) and slides together therewith. This coupling is facilitated using a pair of pin fasteners (not shown) inserted into a pair of holes 31 on either side of the breech seal 30 . These pins slidable engage a pair of corresponding slot in the cocking member (see items 54 in FIG. 8C and FIG. 8D ). The play inherent in aligning a pin with a slot is addressed through the use of the breech seal spring (see FIG. 12 ), which is disposed between the breech seal 30 and the cocking member (not shown). The breech end face 56 of the breach seal 30 engages the gas valve (not shown) and acts to transfer the force of the hammer (not shown) through the breech seal to the gas valve. Note that the breech seal includes a clearance chamfer 33 to clear the location of the cocking pawl (not shown). Details of the physical arrangement are presented in FIGS. 14A, 14B, and 14C , and are hereinafter described. Reference is directed to FIGS. 14A, 14B, and 14C , which are section view drawings of a compressed gas gun in a loading position, a cocked position, and a fired position, respectively, according to an illustrative embodiment of the present invention. These drawings will assist the in understanding the sequence of actions in operating the gun and the interrelation of the various component parts. The receiver 4 with barrel 18 fixed thereto, barrel breech 22 , breech opening 14 , gas cylinder 6 , and gas valve 32 are again presented. The cocking pawl 43 portion of the trigger assembly location is shown. Note the cocking slot 26 in the receiver 4 is again illustrated in phantom line since it is actually removed by virtue of the section view geometry. So too are the cocking assembly mounting holes 36 in the cocking member 34 shown in phantom. It is important to understand that the actuation of the mechanisms presented herein are effected by operation of the cocking mechanism (not shown), which are presented in FIG. 2 and FIG. 3 . Thus, the driving force in the operation of the cocking mechanisms is input through the cocking mechanism holes 36 in the cocking member 34 , which may be urged either toward the muzzle end of the gun or toward the breech end of the gun. There are several components slidably located along the length of the barrel 18 . These include, beginning from the muzzle end of the barrel 18 , the spring stop 38 , the main spring 40 , the hammer 42 , and the breech seal 30 . The cocking member 34 is slidably disposed between these several items, excepting the spring stop 38 , and the interior of the receiver 4 . The spring stop 38 is threadably engaged with the cocking member 34 . Note also that the breech seal 32 movement with respect to the cocking member 34 is limited to the length of the opposing slots (items 54 in FIG. 8C and FIG. 8D ). Thusly, as the cocking tube us urged between the muzzle end position and the breach end position by the cocking mechanism (not shown), the breach seal 32 , hammer 40 , main spring 42 , and spring stop 38 are also urged to slide together therewith, subject to the spacing between each of them and their connection to the cocking member 34 . In the sequence discussion to follow, note that the cocking pawl 43 is enabled to selectively retain an release the hammer 40 under control of the trigger mechanism (not shown). FIG. 14A illustrates the gun in a condition where it has been loaded by the operator, but not yet cocked. Note that the cocking mechanism (not shown) has urged the cocking member 34 toward the muzzle end of the gun and the cocking pawl 43 has been urged inward by the trigger mechanism (not shown). Note that the cocking mechanism holes 36 in the cocking member 34 are advanced as far as possible toward the muzzle end of the cocking slot 26 in the receiver 34 . Also note that the operator has inserted a projective 60 into the breech of the barrel 18 . In this condition, the cocking pawl blocks the reward movement of the hammer 42 , but the main spring is relaxed due the extended distance between the spring stop 38 and the hammer 42 . FIG. 14B illustrates the gun in the cocked position. The gun is cocked by actuation of the cocking mechanism (not shown), which urges the cocking member 34 toward the breech end of the gun. Note that the cocking mechanism holes 36 in the cocking member 34 are advanced as far as possible towards the breech end of the cocking slot 26 in the receiver 34 . As the cocking member 34 is advanced toward the breech end, the spring stop 38 applies force against the mains spring 40 , which applies force against the hammer 42 . However, since the hammer 42 is retained by the cocking pawl 43 , the main spring 40 must compress to accommodate movement of the spring stop 38 . Thusly, the energy applied to the cocking mechanism (not shown) is stored in the main spring 40 by compression. The mechanical advantage, discussed hereinbefore, of the cocking mechanism (not shown) aides the operator in compressing the main spring 40 . Also note that the movement of the cocking mechanism 34 toward the breech carries the breech seal 30 rearward such that it sealably engages the gas valve 32 . This sealing action is assisted by compression of the breech seal spring 44 . Elastomeric seals disposed between the barrel 18 and the breech seal 30 , and disposed between the breech seal 30 and the gas valve 32 perfect a pneumatic pathway from the gas valve 32 to the breech of the barrel 18 . The gun is now ready to be discharged. FIG. 14C illustrates the gun as it is discharged by actuation of the trigger mechanism (not shown), which drops the cocking pawl 43 away from the hammer 42 . As this occurs, the energy stored in the main spring 40 is released and applied against the hammer 42 , urging it toward the breech end of the gun. The hammer 42 accelerates and impacts the breech seal 30 . Since the breech seal 30 is already engaged with the gas valve 32 , the hammer 42 energy is immediately transferred to the gas valve, thereby “popping” the gas valve 32 and releasing a burst of compressed gas into the breech seal 30 and barrel 18 . Of course, the gas pressure applies force against the projectile 60 , and discharges it from the muzzle. The gas valve 32 immediately closes as soon as the spring forces and pressures balance between the interior of the gas cylinder 6 and the burst of gas behind the projectile 60 . Thus, the present invention has been described herein with reference to a particular embodiment for a particular application. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof. It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention.
A compressed gas gun with a cocking mechanism that provides a mechanical advantage in compressing a mainspring, while providing a two stage loading and cocking action that accesses and seals a breech through utilization of an intermediate cocking member.
5
CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/314,065, filed Mar. 15, 2010, entitled “TIRE BEAD SEATING,” the disclosure of which is incorporated herein by reference. RELATED ART 1. Field of the Invention The present disclosure is directed to machines for seating a tire bead on a wheel, and related methods for bead seating. 2. Brief Discussion of Related Art Various methods and machines have been devised for seating the bead of a tire on a wheel. Generally, it may be desirable to ensure that the bead, or inner rim, of the tire aligns with and/or seats within the bead seat on the wheel to permit proper functioning of the wheel/tire assembly. Due to the substantial friction between the tire (which may be made of rubber) and the wheel (which may be made of metal), lubrication may be used to aid in mounting a tire on a wheel. For example, some methods may include soaping the tire and wheel, installing the tire on the wheel, inflating the tire at least partially, and manipulating the tire in some manner to get the tire bead to seat on the wheel completely around the diameter of the wheel. U.S. Pat. No. 6,557,610, which is incorporated by reference into this Background section, may be related to tire bead seating. INTRODUCTION TO THE INVENTION The present invention is directed to machines for seating a tire bead on a wheel, and related methods for bead seating. It is a first aspect of the present invention to provide a tire bead seating apparatus for seating tire beads on a vehicle wheel, the apparatus comprising: (a) a repositionable arm operatively coupled to a rotatable drum, the repositionable arm directing the rotatable drum into selective engagement with an inflated tire mounted to a vehicle wheel, the rotatable drum operative to rotate when engaging the inflated tire to rotate the inflated tire and the vehicle wheel; (b) a first set of rollers selectively contacting a first peripheral surface of the inflated tire, the first peripheral surface bridging between a first sidewall and a treaded surface of the inflated tire; (c) a first set of rollers selectively contacting a second peripheral surface of the inflated tire, the second peripheral surface bridging between a second sidewall and the treaded surface of the inflated tire, the first sidewall being generally opposite the second sidewall; (d) a first bead roller selectively contacting the first sidewall proximate a first bead of the inflated tire; and, (e) a second bead roller selectively contacting the second sidewall proximate a second bead of the inflated tire. In a more detailed embodiment of the first aspect, the repositionable arm comprises a plurality of repositionable arms, and each of the repositionable arms is coupled to a rotatable drum. In yet another more detailed embodiment, at least two of the rotatable drums selectively engage the inflated tire to rotate the inflated tire. In a further detailed embodiment, the apparatus farther comprises a repositionable rail conveyor that extends between the first set of rollers, the repositionable rail conveyor operative to deliver the inflated tire and vehicle wheel where both can be engaged by the rotatable drum, the repositionable rail conveyor repositionable between an elevated position that positions the inflated tire and vehicle wheel above the first set of rollers, and a retracted position that positions the inflated tire and vehicle wheel into contact with the first set of rollers. In still a further detailed embodiment, the first bead roller is rotationally mounted to a first repositionable shaft, the first repositionable shaft being pivotally mounted to a first chassis, and the second bead roller is rotationally mounted to a second repositionable shaft, the second repositionable shaft being pivotally mounted to a second chassis. In a more detailed embodiment, the first chassis is operatively coupled to a first pneumatic cylinder that repositions the first chassis within a first plane in a first direction and a second direction opposite the first direction, the second chassis is operatively coupled to a second pneumatic cylinder that repositions the second chassis within a second plane in a first direction and a second direction opposite the first direction, and the first plane is generally parallel to the second plane. In a more detailed embodiment, a first rotational axis extending axially through the first bead roller is acutely angled with respect to a first radial plane extending through the first sidewall at a location where the first bead roller contacts the first sidewall, and a second rotational axis extending axially through the second bead roller is acutely angled with respect to a second radial plane extending through the second sidewall at a location where the second bead roller contacts the second sidewall. It is a second aspect of the present invention to provide a tire bead seating apparatus for seating tire beads on a vehicle wheel, the apparatus comprising: (a) a first bead roller selectively contacting a first sidewall of an inflated tire proximate a first bead, the inflated tire mounted to a vehicle wheel; (b) a second bead roller selectively contacting a second sidewall of the inflated tire proximate a second bead, the second sidewall and the first sidewall interposed by a tread section; and, (c) a tire rotator operative to rotate the inflated tire and vehicle wheel, where a contact area of the first bead roller is acutely angled with respect to a radius that extends through a first contact area of the inflated tire when the first bead roller contacts the first sidewall, and where a contact area of the second bead roller is acutely angled with respect to a radius that extends through a second contact area of the inflated tire when the second bead roller contacts the second sidewall. In yet another more detailed embodiment of the second aspect, the first bead roller is rotationally mounted to a first repositionable shaft, the first repositionable shaft being pivotally mounted to a first chassis, and the second bead roller is rotationally mounted to a second repositionable shaft, the second repositionable shaft being pivotally mounted to a second chassis. In still another more detailed embodiment, the first chassis is operatively coupled to a first pneumatic cylinder that repositions the first chassis within a first plane in a first direction and a second direction opposite the first direction, the second chassis is operatively coupled to a second pneumatic cylinder that repositions the second chassis within a second plane in a first direction and a second direction opposite the first direction, and the first plane is generally parallel to the second plane. In a further detailed embodiment, a first rotational axis extending axially through the first bead roller is acutely angled with respect to a first radial plane extending through the first sidewall at a location where the first bead roller contacts the first sidewall, and a second rotational axis extending axially through the second bead roller is acutely angled with respect to a second radial plane extending through the second sidewall at a location where the second bead roller contacts the second sidewall. In still a further detailed embodiment, the first bead roller contacts the first sidewall at a first location, the second bead roller contacts the second sidewall at a second location, and the first location is positioned directly above the second location. In a more detailed embodiment, the apparatus further comprises a plurality of inclined rollers cooperating to form a tire bed, and a plurality of inclined roller cooperating to form a tire ceiling. It is a third aspect of the present invention to provide a method of seating tire beads on a vehicle wheel, the method comprising: (a) rotating a vehicle wheel and a tire, the tire being mounted to the vehicle wheel and inflated; (b) applying pressure on a first sidewall of the tire proximate a first bead while the vehicle wheel and tire are rotating, where applying pressure on the first sidewall creates a gap between the first sidewall and the vehicle wheel and pulls the first sidewall radially outward with respect to the vehicle wheel; and, (c) applying pressure on a second sidewall of the tire proximate a second bead while the vehicle wheel and tire are rotating, where applying pressure on the second sidewall creates a gap between the second sidewall and the vehicle wheel and pulls the second sidewall radially outward with respect to the vehicle wheel. It is a fourth aspect of the present invention to provide a method of seating tire beads on a vehicle wheel, the method comprising: (a) rotating a vehicle wheel and a tire, the tire being mounted to the vehicle wheel and inflated; (b) applying pressure on a first sidewall of the tire proximate a first bead while the vehicle wheel and tire are rotating; and, (c) applying pressure on a second side wall of the tire proximate a second bead while the vehicle wheel and tire are rotating. In yet another more detailed embodiment of the fourth aspect, the pressure applied to the first sidewall of the tire proximate the first bead occurs simultaneously with the pressure applied to the second sidewall of the tire proximate the second bead. In still another more detailed embodiment, a first roller is used to apply the pressure to the first sidewall of the tire proximate the first bead, and a second roller is used to apply the pressure to the second sidewall of the tire proximate the second bead. In a further detailed embodiment, at least one of the first roller and the second roller is acutely angled with respect to at least one of the first bead and the second bead. In still a further detailed embodiment, the first roller is acutely angled with respect to the first bead, and the second roller is acutely angled with respect to the second bead. In a more detailed embodiment, the first bead roller contacts the first sidewall at a first location, the second bead roller contacts the second sidewall at a second location, and the first location is positioned directly above the second location. In a more detailed embodiment, the vehicle wheel and tire are horizontally rotated, the pressure applied on the first sidewall of the tire proximate the first bead comes from a first roller positioned above the vehicle wheel and tire, and the pressure applied on the second sidewall of the tire proximate the second bead comes from a second roller positioned below the vehicle wheel and tire. In another more detailed embodiment, the vehicle wheel and tire are rotated in excess of four hundred rotations per minute while the pressure is applied to the first and second sidewalls, the first roller is acutely angled with respect to the first bead, and the second roller is acutely angled with respect to the second bead. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an elevated perspective view of a tire assembly. FIG. 2 is a horizontal cross-section of the exemplary tire assembly of FIG. 1 . FIG. 3 is a profile view of an exemplary tire inflation station, showing a cross-section of the tire and how air is provided to inflate the tire. FIG. 4 is a frontal view of an exemplary tire bead seating machine in accordance with the instant disclosure. FIG. 5 is a frontal view of the exemplary tire bead seating machine of FIG. 4 , shown with a tire positioned within the working area. FIG. 6 is a right side profile view of the exemplary tire bead seating machine of FIG. 4 . FIG. 7 is a frontal view of the exemplary tire bead seating machine of FIG. 4 , shown with a tire positioned within the working area and the bead seating rollers contacting respective sidewalls of the tire. FIG. 8 is a right side profile view of the exemplary tire bead seating machine of FIG. 4 , shown with a tire positioned within the working area and the bead seating rollers contacting respective sidewalls of the tire. FIG. 9 is a right side profile view of the hold-down assembly and upper bead seating assembly shown in FIG. 8 . FIG. 10 is a bottom view of the hold-down assembly and upper bead seating assembly shown in FIG. 9 . FIG. 11 is an elevated perspective view of the lower bead seating assembly shown in FIG. 4 . FIG. 12 is a right side profile view of the lower bead seating assembly shown in FIG. 11 . FIG. 13 is a first part of a process flow diagram. FIG. 14 is a second part of the process flow diagram of FIG. 13 . FIG. 15 is a graphical representation of an exemplary bead seat roller positioned with respect to a radius of a tire. FIG. 16 is a graphical representation of an exemplary bead seat roller angled at an angle θ with respect to the radius of the tire. DETAILED DESCRIPTION The exemplary embodiments of the present invention are described and illustrated below to encompass machines for seating a tire bead on a wheel, and related methods for bead seating. Of course, it will be apparent to those of ordinary skill in the art that the preferred embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present invention. However, for clarity and precision, the exemplary embodiments as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present invention. Referencing FIGS. 1 and 2 , an exemplary wheel assembly 100 includes a rubber tire 102 mounted to a vehicle wheel 104 . In exemplary form, the tire 102 is inflated with air or nitrogen to a pressurized state well above atmospheric pressure to provide resistance to collapsing of the tire under a load. The tire 102 includes a tread section 106 that interposes right and left sidewalls 108 , 110 . An exposed circumferential edge of each sidewall 108 , 110 includes a bead 112 that is correspondingly received by circumferential bead seats 114 of the vehicle wheel 104 . Referring to FIG. 3 , as is understood by those skilled in the art, a typical tire inflation station 140 conveys the wheel assembly 100 onto a stationary position beneath an overhead tire inflation head 150 . Centering arms (not shown) may thereafter engage the tire 102 and center it with respect to the inflation head 150 . The inflation head is then moved downwardly into engagement with one of the sidewalls 108 , thereby displacing the bead 112 from the bead seat 114 , and high pressure air is injected between the bead and bead seat 114 to inflate the tire 102 . A more detailed explanation of this process and equipment is found in U.S. Pat. No. 4,947,919, the disclosure of which is incorporated herein by reference. Referring to FIGS. 2 , 4 and 5 , an exemplary tire bead seating machine 200 is utilized to seat the tire 102 bead 112 of each sidewall 108 , 110 with respect to the bead seat 114 of the vehicle wheel 104 after the tire has been inflated by the tire inflation station. By seating the bead 112 , the machine 200 ensures that an adequate seal is formed between the bead 112 and bead seat 114 that may have otherwise been compromised by soap or other debris interposing the bead and bead seat resulting from the tire inflation process and mounting the tire 102 onto the wheel 104 . The machine 200 includes a conveyor 202 utilized to reposition the wheel assembly 100 into and out of a working area 204 . In this exemplary embodiment, the conveyor 202 comprising a pair of spaced apart, parallel tracks 206 that each include a series of raised studs 208 . The tracks 206 ride upon a guide wheels (not shown) and are operative to move forward or rearward. The raised studs 208 operate to engage the wheel assembly 100 and retain the wheel assembly on the conveyor 202 as the wheel assembly is moved into or out of the working area 204 . Within the working area 204 , the machine 200 includes a lower wheel bed assembly 220 , which includes a plurality of rollers 222 arranged to horizontally support the wheel assembly 100 . In exemplary form, the rollers 222 comprise cylindrical rollers that are mounted to corresponding supports 224 that angle the rollers approximately five degrees from vertical and orient the rollers within a circular footprint of the wheel assembly 100 . More specifically, the rollers 222 are generally oriented in parallel to respective radius of the wheel assembly 100 . In this manner, the rollers 222 are adapted to contact an end of the lower sidewall 110 proximate the tread section 106 . The machine 200 also includes a plurality of drive roller assemblies 230 operative to selectively contact the tread section 102 of the wheel assembly 100 in order to rotate the wheel assembly while within the working area 204 . In this circumstance, there are four drive roller assemblies 230 A, 230 B, 230 C, 230 D, with two on each side of the machine 200 . It should be noted that each drive roller assembly 230 is substantially identical and accordingly only one drive roller assembly will be described in detail, with it being understood that the other assemblies are substantially identical in terms of construction and operation as described. An exemplary drive roller assembly 230 includes a cylindrical roller 232 mounted at opposing ends to a repositionable frame 234 . The repositionable frame 234 includes a block C-shaped section 236 with corresponding ends that receive corresponding ends of the cylindrical roller 232 . A spindle (not shown) mounted to and extending through the roller 232 is received within respective ends of the C-shaped section 236 . An end of the spindle is operatively coupled to a motor, such as an electric or hydraulic motor, that is operative to rotate the spindle thus rotate the roller 232 . In particular, the motor drives the spindle, thus rotating the roller 232 that is in contact with the tread portion 106 of the tire 102 . This rotation of the roller 232 causes the tire 102 to rotate about a central axis while being seated upon the drive roller assemblies 230 . In order to hold down the tire 102 while it is rotated by the drive roller assemblies 230 , the machine also includes a hold-down assembly 250 that includes a plurality of hold-down rollers 252 . In this exemplary embodiment, the hold-down assembly includes a pair of rollers 252 that are positioned opposite one another. It should be noted, however, that one or more than two rollers 252 may be utilized and oriented in any particular orientation. The hold-down assembly 250 is vertically repositionable to allow the hold-down rollers 252 to selectively engage an opposing sidewall 108 of the tire 102 . In exemplary form, the hold-down rollers 252 comprise frustoconical rollers that are mounted to corresponding supports 254 that angle the rollers approximately fifteen degrees from vertical and orient the rollers within a circular footprint of the wheel assembly 100 . More specifically, the rollers 252 are generally oriented in parallel to respective radius of the wheel assembly 100 . In this manner, the rollers 252 are adapted to contact an end of the upper sidewall 108 proximate the tread section 106 and maintain engagement with the wheel assembly 100 while the wheel assembly is rotated. Referring to FIGS. 4-10 , in order to vertically reposition the hold-down rollers 252 and supports 254 , a repositionable platform 260 is mounted to the supports. In exemplary form, the platform 260 comprises an elongated plate having a cross-member 262 to which the corresponding supports 254 and hold-down rollers 252 are mounted. A predominant dimension of the platform 260 runs perpendicular to the direction of the cross-member, with the cross member being offset from the center of the platform. In order to vertically reposition the platform 260 , a pair of hydraulic or pneumatic cylinders 264 is mounted to a top side 266 . The hydraulic cylinders 264 are operative to reposition the platform 260 between a retracted position (see FIG. 4 ) and a working (i.e., extended) position (see FIG. 7 ). In the retracted position, the hold-down rollers 252 are elevated above the working area 204 . In contrast, when in the working position, the hold-down rollers 252 occupy a portion of the working area 204 . Referring specifically to FIGS. 4 , 9 , and 10 , an upper bead seating assembly 270 is also mounted to the repositionable platform 260 . The upper bead seating assembly 270 is mounted on a bottom side 272 , opposite the top side 266 . In exemplary form, the upper bead seating assembly 270 includes a pair of pneumatic actuators 274 , 276 operative to reposition an upper bead seating roller 280 . Specifically, the first actuator 274 is mounted to the platform 260 and concurrently mounted to a repositionable carriage 282 . The carriage 282 is laterally repositionable along a track 284 extending parallel to the dominant dimension of the platform 260 . In other words, the mounting position of the first actuator 274 is fixed with respect to the platform and only a piston 286 of the first actuator is repositionable with respect to the platform. The piston is mounted to the repositionable carriage 282 and, thus, as the piston is repositioned (extended or contracted) laterally, so too is the carriage repositioned laterally. The carriage 282 includes a block 288 having a through passage occupied partially by an L-shaped bracket 290 and a pin 292 that concurrently extends through the L-shaped bracket and a portion of the block. Specifically, the L-shaped bracket 290 is pivotally mounted to the block 288 and pivots around the pin 292 . In contrast, the block 288 is mounted to the carriage 282 in a fixed orientation. A first end 294 of the L-shaped bracket 290 is mounted to a piston 296 of the second actuator 276 , while a second end 298 of the L-shaped bracket is mounted to a spindle 302 . As will be discussed in more detail hereafter, the spindle 302 is mounted to the second end 298 of the L-shaped bracket 290 in a non-perpendicular orientation. Specifically, the spindle 302 is angled at approximately five degrees with respect to a centerline 306 extending through the L-shaped bracket 290 . It should be noted that the centerline 306 extending through the L-shaped bracket 290 is parallel to radius extending from the center of the tire 102 when the platform 260 is lowered to a working position. The other aspect of the second actuator 276 is fixedly mounted to the carriage 282 , but the piston 296 is repositionable with respect to the carriage. In sum, the first actuator 274 is operative to laterally reposition the carriage 282 , while the second actuator 276 is operative to reposition the L-shaped bracket 290 . Repositioning of the L-shaped bracket 290 is operative to reposition the upper bead seating roller 280 , which is mounted to the spindle 302 , between a retracted position (see FIG. 6 ) and a seating position (see FIG. 8 ). As will be discussed in more detail hereafter, in operation, the upper bead seating assembly 270 is operative to seat the bead 112 with respect to the bead seat 114 on one side of the wheel assembly 100 . In order to seat the bead 112 with respect to the bead seat 114 on the opposite side of the wheel assembly 100 , the machine 200 includes a lower bead seating assembly 320 . Referring specifically to FIGS. 4 , 11 , and 12 , the lower bead seating assembly 320 is mounted to a frame of the machine laterally in-between the rollers 222 . In exemplary form, the lower bead seating assembly 320 includes a pair of pneumatic actuators 324 , 326 operative to reposition a lower bead seating roller 328 . Specifically, the first actuator 324 is mounted to a fixed position platform 330 and concurrently mounted to a repositionable carriage 332 . The carriage 332 is laterally repositionable along a track 334 extending parallel to the dominant dimension of the platform 330 . In other words, the mounting position of the first actuator 324 is fixed with respect to the platform 330 and only a piston 336 of the first actuator is repositionable with respect to the platform. The piston 336 is mounted to the repositionable carriage 332 and, thus, as the piston is repositioned (extended or contracted) laterally, so too is the carriage repositioned laterally. The carriage 332 includes a block 338 having a through passage occupied partially by an L-shaped bracket 340 and a pin 342 that concurrently extends through the L-shaped bracket and a portion of the block. Specifically, the L-shaped bracket 340 is pivotally mounted to the block 338 and pivots around the pin 342 . In contrast, the block 338 is mounted to the carriage 332 in a fixed orientation. A first end 344 of the L-shaped bracket 340 is mounted to a piston 346 of the second actuator 326 , while a second end 348 of the L-shaped bracket is mounted to a spindle 352 . As will be discussed in more detail hereafter, the spindle 352 is mounted to the second end 348 of the L-shaped bracket 340 in a non-perpendicular orientation. Specifically, the spindle 352 is angled at approximately five degrees with respect to a centerline 356 extending through the L-shaped bracket 340 . It should be noted that the centerline 356 extending through the L-shaped bracket 340 is parallel to radius extending from the center of the tire 102 when the L-shaped bracket 340 repositioned to a working position. The other aspect of the second actuator 326 is fixedly mounted to the carriage 332 , but the piston 346 is repositionable with respect to the carriage. In sum, the first actuator 324 is operative to laterally reposition the carriage 332 , while the second actuator 326 is operative to reposition L-shaped bracket 340 . Repositioning of the L-shaped bracket 340 is operative to reposition the lower bead seating roller 328 , which is mounted to the spindle 352 , between a retracted position (see FIG. 6 ) and a seating position (see FIG. 8 ). As will be discussed in more detail hereafter, in operation, the lower bead seating assembly 320 is operative to seat the bead 112 with respect to the bead seat 114 on the opposite side of the wheel assembly 100 . Referring generally to FIGS. 13 and 14 , an example method of seating a bead using the tire bead seating machine 200 of the instant disclosure includes transferring a single wheel assembly 100 into the machine at step 400 . As discussed briefly beforehand, the tire assembly 100 is positioned within the working area 204 of the machine 200 using the conveyor 202 . Specifically, the wheel assembly 100 is positioned on a portion of the conveyor 202 and conveyed toward the working area 204 . Referring to FIGS. 5 and 13 , just before reaching the edge of the forward most rollers 222 , the studs 208 of the conveyor 202 are raised to elevate the wheel assembly 100 above the rollers 222 , while continuing to move the wheel assembly into the working area 204 . In this manner the wheel assembly 100 is elevated above the rollers and generally centered with respect to the rollers. Thereafter, the studs 208 of the conveyor 202 are lowered, resulting in one side of the tire 102 sitting upon the rollers 222 . At step 402 , the drive roller assemblies 230 A, 230 B, 230 C, 230 D are repositioned from a non-contact position (see FIG. 4 ) to a contact position where the rollers 232 contact the tread portion 106 of the tire 102 . In this exemplary embodiment, the drive roller assemblies 230 A, 230 B, 230 C, 230 D are equidistantly positioned about the circumference of the tire 102 . Referencing FIGS. 6 and 13 , at step 404 , while the rollers 230 contact the circumference of the tire 102 , the hold-down assembly 250 is lowered from a retracted position (see FIG. 4 ) to a working position (see FIG. 7 ) so that the hold-down rollers 252 contact the top circumferential edge between the sidewall 108 and the tread section 106 . At step 406 , the drive roller assemblies 230 A, 230 B, 230 C, 230 D are engaged so that the rollers 232 rotate and correspondingly rotate the tire 102 . Referring to FIGS. 7 , 8 , and 13 , at step 408 one or both of the bead seating assemblies 270 , 320 are repositioned so that one or both bead seating rollers 280 , 328 contacts a corresponding sidewall 1008 , 110 of the tire 102 . In this exemplary process, the bead seating assemblies 270 , 320 are concurrently repositioned so that both bead seating rollers 280 , 328 contact respective sidewalls 108 , 110 of the tire 102 at the same time. Referring to FIG. 15 , an exemplary diagram shows the bead seating roller 280 , 328 oriented coaxially with a radius 450 of the tire 102 . Referring to FIG. 16 , the exemplary method includes angling the bead seating roller 280 , 328 with respect to the radius 450 of the tire 102 between an angle θ of two degrees to an angle of approximately forty-five degrees. In exemplary form, the bead seating roller 280 , 328 is shown angled at approximately five degrees with respect to the radius 450 . Referring back to FIGS. 7 , 8 , and 13 , by applying a positive force to a portion of the sidewalls 108 , 110 in contact with the bead seating rollers 280 , 328 , a gap is temporarily created between the bead 112 and the bead seat 114 . In this exemplary embodiment, the bead seating rollers 280 , 328 engage respective sidewalls 108 , 110 at about ¾″ from the wheel flange and apply a pressure of about 150-265.10 lbf/sq. in. It should be noted, however, that other pressures may be used without departing from the scope of the disclosure. This gap is sufficiently large to allow trapped air in between the bead 112 and bead seat 114 to escape through the gap and displace any debris between the bead and the bead seat as a result of the rotational forces acting on the debris. But the gap is sufficiently small to inhibit significant deflation of the tire 102 . After any debris is displaced, and the bead 112 again contacts the bead seat 114 . This contact occurs after the respective portion of the sidewall is no longer in contact with the bead seating rollers 280 , 328 . In this exemplary process, the wheel assembly 100 is rotated between approximately 200-1000 revolutions per minute for between approximately one to ten seconds. It should be noted, however, that other rates of rotation may be used and other durations of time may be utilized without departing from the scope of the disclosure. Referring to FIGS. 5 and 13 , at step 410 , one or both of the bead seating assemblies 270 , 320 are repositioned to discontinue contact between the one or both bead seating rollers 280 , 328 and a corresponding sidewall 108 , 110 of the tire 102 . In sum, at the end of step 410 , both bead seating assemblies 270 , 320 no longer contact the tire 102 . Referring to FIGS. 5 and 14 , at step 412 , the drive roller assemblies 230 A, 230 B, 230 C, 230 D are disengaged. This includes first stopping the rotation of the rollers 232 , followed by repositioning of the rollers to no longer contact any portion of the tire 102 . At step 414 , the hold-down assembly 250 is raised from the working position (see FIG. 7 ) to the retracted position (see FIG. 4 ) to so that the hold-down rollers 252 no longer contact the top circumferential edge between the sidewall 108 and the tread section 106 . At step 416 , the studs 208 of the conveyor 202 are raised to elevate the wheel assembly 100 above the rollers 222 . Thereafter, the conveyor 202 removes the wheel assembly 100 from the working area 204 and conveys it along the conveyor. At this time, while the wheel assembly is positioned on the conveyor outside of the working area, a worker may exchange one wheel assembly 100 having completed the process for another wheel assembly needing to undergo the process. Thereafter, the foregoing process is repeated using steps 400 - 416 . While the machine has been described as a stand-alone piece of equipment, it should be understood that the machine 200 and components thereof may be utilized in an assembly line and/or may perform some or all of the operations discussed above in an automatic manner. Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, the invention contained herein is not limited to this precise embodiment and that changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein.
A tire bead seating apparatus for seating tire beads on a vehicle wheel, the apparatus comprising: (a) a repositionable arm operatively coupled to a rotatable drum, the repositionable arm directing the rotatable drum into selective engagement with an inflated tire mounted to a vehicle wheel, the rotatable drum operative to rotate when engaging the inflated tire to rotate the inflated tire and the vehicle wheel; (b) a first set of rollers selectively contacting a first peripheral surface of the inflated tire, the first peripheral surface bridging between a first sidewall and a treaded surface of the inflated tire; (c) a first set of rollers selectively contacting a second peripheral surface of the inflated tire, the second peripheral surface bridging between a second sidewall and the treaded surface of the inflated tire, the first sidewall being generally opposite the second sidewall; (d) a first bead roller selectively contacting the first sidewall proximate a first bead of the inflated tire; and, (e) a second bead roller selectively contacting the second sidewall proximate a second bead of the inflated tire.
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