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FIELD OF THE INVENTION
The present invention relates to plastic articles and more particularly to colored articles, and to a process for their preparation.
SUMMARY OF THE INVENTION
A process for tinting of articles molded from a polymeric resin is disclosed. Preferably, the article is molded from polycarbonate and the process entails immersing the molded article in a dye bath that contains
(i) at least one leveling agent,
(ii) at least one plasticizing agent and
(iii) water.
The method is especially useful in the manufacture of tinted lenses.
BACKGROUND OF THE INVENTION
Articles molded of polycarbonate are well known. The utility and method for making colored articles that are prepared from pigmented polycarbonate compositions are well known. Also known are processes for dyeing articles molded of resins, including polycarbonates, and including lenses that have been tinted by immersion in special pigmenting mixtures. Among the advantages attained by such tinting of lenses, mention has been made of reduced light transmission and mitigation of glare.
U.S. Pat. No. 4,076,496 disclosed a dye bath composition suitable for dyeing hard-coated polarized lenses. The composition of the bath included a dye and as a solvent, a mixture of glycerol and ethylene glycol, optionally, with a minor proportion of water or other organic solvent.
U.S. Pat. No. 5,453,100 disclosed polycarbonate materials that are dyed by immersion into a mixture of dye or pigment dissolved in a solvent blend. The blend is made up of an impregnating solvent that attacks the polycarbonate and allows the impregnation of the dye or pigment and a moderating solvent that mitigates the attack of the impregnating solvent. The impregnating solvent thus disclosed includes at least one solvent selected from dipropylene glycol monomethyl ether, tripropylene glycol monomethyl ether and propylene glycol monomethyl ether. The moderating organic solvent includes at least one solvent selected from propylene glycol, 1,4-butane diol or ethylene glycol monobutyl ether.
PCT/CA99/00803 (WO 0014325) disclosed tinting plastic articles by immersion in an aqueous dispersion and exposing the dispersion and immersed article to microwave radiation. JP 53035831 B4 disclosed polycarbonate moldings that are dyed in aqueous dispersion containing dispersed dyes and diallyl phthalate, o-phenylphenol or benzylalcohol. Also, JP 55017156 disclosed aliphatic polycarbonate lenses that are colored with liquor containing dyes and water. JP 56031085 (JP-104863) disclosed compositions containing a disperse dye in an aliphatic ketone and polyhydric alcohol said to be useful in coloring polycarbonate films at room temperature. JP2000248476 disclosed a molded polycarbonate bolt that was dyed with a solution containing dyes, an anionic leveling agent and then treated with a solution containing thiourea dioxide.
U.S. Pat. No. 4,812,142 disclosed polycarbonate articles dyed at a temperature of 200° F. or above in a dye solvent having a boiling point of at least 350° F., and U.S. Pat. No. 3,514,246 disclosed immersing molded polycarbonate articles in an emulsified dye liquor which contains a water insoluble dyestuff, an oil-soluble surface active agent dissolved in an aliphatic hydrocarbon solvent and water. The procedure was repeated with similar results where the surfactant was replaced by a poly(oxyethylene) derivative. U.S. Pat. No. 3,532,454 disclosed dyeing of polycarbonate fibers with a dye composition that contains at least one of alkoxyalkylbenzyl ether, alkylene glycol di-benzyl ether, benzoic acid alkoxyalkyl ester or phenoxy acetic acid-alkoxyalkyl ester. U.S. Pat. No. 3,630,664 disclosed a dye bath that required the presence of a carbonate conforming to a specific formula, e.g., ethyl-benzyl-carbonate.
DETAILED DESCRIPTION OF THE INVENTION
The inventive method and the dye bath composition of this invention are useful for dyeing plastic articles molded of a variety of resinous molding compositions. The suitable resins include both thermoplastic and thermosetting compositions. Among the suitable resins, mention may be made of (co)polyesters, (co)polycarbonates (including aromatic and aliphatic polycarbonate such as allyldiglycol carbonate, e.g., trade name CR-39), polyesterpolycarbonate copolymers, styrenic copolymers such as SAN and acrylonitrile-butadiene-styrene (ABS), acrylic polymers such as polymethylmethacrylate and ASA, polyamide, and polyurethane and blends of one or more of these resins. Particularly, the invention is applicable to polycarbonates, and most particularly to thermoplastic aromatic polycarbonates.
The molding compositions useful in molding the articles that are suitable for use in the inventive process may include any of the additives that are known in the art for their function in these compositions and include at least one of mold release agents, fillers, reinforcing agents in the form of fibers or flakes most notably metal flakes such as aluminum flakes, flame retardant agents, pigments and opacifying agents such as titanium dioxide and the like, light-diffusing agents such as polytetrafluoroethylene, zinc oxide, Paraloid EXL-5136 available from Rohm and Haas and crosslinked polymethylmethacrylate minispheres (such as n-licrospheres from Nagase America) UV-stabilizers, hydrolytic stabilizers and thermal stabilizers.
Articles to be dyed in accordance with the inventive process may be produced conventionally by methods that have long been practiced in the plastics arts and include articles molded by compression molding, injection molding, rotational molding, extrusion, injection and extrusion blow molding, and casting, the method of producing the articles is not critical to the practice of the inventive process. The articles may be any of a vast variety of useful items and include computer face-plates, keyboards, bezels and cellular phones, color coded packaging and containers of all types, including ones for industrial components, residential and commercial lighting fixtures and components therefor, such as sheets, used in building and in construction, tableware, including plates, cups and eating utensils, small appliances and their components, optical and sun-wear lenses, as well as decorative films including such films that are intended for use in film insert molding.
Polymer resins particularly suitable in the present context include one or a mixture of two or more resins selected from the group consisting of polyester, polycarbonate, polyesterpolycarbonate copolymer, acrylonitrile-butadiene-styrene (ABS), polyamide, polyurethane, polymethylmethacrylate and styrenic copolymer. While styrenic copolymers, most notable styrene-acrylonitrile copolymers are thus suitable, the inventive process is not applicable for tinting of homopolystyrene.
According to the present invention, the molded article to be tinted, preferably a lens, is immersed in the dyeing bath mixture for a time and at temperature sufficient to facilitate at least some impregnation, or diffusion, of the dye into the bulk of the article thus effecting tinting thereof. For tinting articles made of aromatic polycarbonate, the immersion may be carried out at a temperature of about 90 to 99° C. and the immersion time is typically less than 1 hour, most preferably in the range of 1 to 15 minutes. However, due to the efficiency of dye up-take, thermoplastic resins that have low heat distortion temperature may be dyed at lower temperatures than polycarbonate. For example, polyurethanes and SAN may be readily dyed using the solution composition that is typically used for tinting polycarbonate, heated to only about 60° C. and 90° C., respectively. The tinted article is then withdrawn at a desired rate, including a rate sufficient to effect a tinting gradient, the portion of the article that remains in the mixture longest is impregnated with the most dye so that it exhibits the darkest color tint.
The dyeing bath mixture contains:
(a) water in an amount of 50 to 90, preferably 62.5 to 85, most preferably 70 to 77.5 pbw (percent by weight relative to the weight of the dyeing bath mixture);
(b) an amount of dye sufficient to effect tinting, generally 0.1 to 15, preferably 0.3 to 5, most preferably 0.4 to 2 pbw;
(c) an amount of 2.5 to 20, preferably 5 to 12.5, most preferably 7.5 to 10 pbw of at least one plasticizing agent conforming to
R′—[(O(CH 2 ) m ) n —]OH
where R′ is an ethyl, propyl or butyl radical,
m is 2, 3 or 4, and
n is 1, 2 or 3
with the proviso that where R′ is butyl m is 2 or 4, and
(d) an amount of 5 to 30, preferably 10 to 25, most preferably 15 to 20 pbw of at least one leveling agent conforming structurally to
H—[(O(CH 2 ) m ) n —]OH
where m is 2, 3 or 4 and
n is 1, 2, or 3.
A particularly suitable plasticizing agent is a member selected from the group consisting of ethylene glycol butyl ether, diethylene glycol ethylether, diethylene glycol butylether, propylene glycol propylether, dipropylene glycol propyl ether and tripropylene glycol propylether.
A particularly suitable leveling agent is a member selected from the group consisting of diethylene glycol, triethylene glycol and 1,4 butandiol.
The dyes to be used in accordance with the invention are conventional and include fabric dyes and disperse dyes as well as dyes that are known in the art as being suitable for tinting of polycarbonates.
Examples of suitable disperse dyes include Disperse Blue #3, Disperse Blue #14, Disperse Yellow #3, Disperse Red #13 and Disperse Red #17. The classification and designation of the dyes recited in this specification are in accordance with “The Colour Index”, 3rd Edition published jointly by the Society of Dyes and Colors and the American Association of Textile Chemists and Colorists (1971), incorporated herein by reference. Dyestuffs can generally be used either as a sole dye constituent or as a component of a dye mixture depending upon the color desired. Thus, the term dye as used herein includes dye mixture.
The dye class known as “Solvent Dyes” is useful in the practice of the present invention. This dye class includes the preferred dyes Solvent Blue 35, Solvent Green 3 and Acridine Orange Base. However, Solvent Dyes, in general, do not color as intensely as do Disperse Dyes.
Among the suitable dyes, special mention is made of water-insoluble azo, diphenylamine and anthraquinone compounds. Especially suitable are acetate dyes, dispersed acetate dyes, dispersion dyes and dispersol dyes such as are disclosed in Colour Index, 3 rd Edition, Vol. 2, The Society of Dyers and Colourists, 1971, pp. 2479 and pp. 2187-2743, respectively, all incorporated herein by reference. The preferred dispersed dyes include Dystar's Palanil Blue E-R150 (anthraquinone/Disperse Blue) and DIANIX Orange E-3RN (azo dye/Cl Disperse Orange 25). Note that phenol red and 4-phenylazophenol do not dye polycarbonate in accordance with the inventive process.
The dyes known as “direct dyes” and the ones termed “acid dyes” are not suitable in the practice of the invention for polycarbonate; however, acid dyes are effective with nylon.
The amount of dye used in the mixture can vary; however, only small amounts are typically needed to sufficiently tint an article in accordance with the invention. A typical dye concentration in the bath is 0.4 pbw, but there is considerable latitude in this regard. Generally, dyes may be present in the solvent mixture at a level of about 0.1 to 15 pbw, preferably 0.3 to 0.5 pbw. Where a dye mixture is used and the rates of consumption of the individual components differ one from the others, dye components will have to be added to the bath in such a manner that their proportions in the bath remain substantially constant.
The bath may optionally include an emulsifier in amounts of up to 15 pbw, preferably 0.5 to 5, most preferably 3 to 4 pbw. A suitable emulsifier in the context of the invention is a substance that holds two or more immiscible liquids or solids in suspension (e.g., water and the carrier). Emulsifiers which may be used include ionic, non-ionic, or mixtures thereof. Typical ionic emulsifiers are anionic, including amine salts or alkali salts of carboxylic, sulfamic or phosphoric acids, for example, sodium lauryl sulfate, ammonium lauryl sulfate, lignosulfonic acid salts, ethylene diamine tetra acetic acid (EDTA) sodium salts and acid salts of amines such as laurylamine hydrochloride or poly(oxy-1,2-ethanediyl)alpha-sulfo-omega-hydroxy ether with phenol 1-(methylphenyl)ethyl derivative ammonium salts; or amphoteric, that is, compounds bearing both anionic and cationic groups, for example, lauryl sulfobetaine; dihydroxy ethylalkyl betaine; amido betaine based on coconut acids; disodium N-lauryl amino propionate; or the sodium salts of dicarboxylic acid coconut derivatives. Typical non-ionic emulsifiers include ethoxylated or propoxylated alkyl or aryl phenolic compounds, such as, octylphenoxypolyethyleneoxyethanol or poly(oxy-1,2-ethanediyl)alpha-phenyl-omega-hydroxy, styrenated. The preferred emulsifier is a mixture of C 14 -C 18 and C 16 -C 18 ethoxylated unsaturated fatty acids and poly(oxy-1,2-ethanediyl)alpha-sulfo-omega-hydroxy ether with phenol 1-(methylphenyl)ethyl derivative ammonium salts and poly(oxy-1,2-ethanediyl),alpha-phenyl-omega-hydroxy, styrenated.
Emulsifiers, such as disclosed in “Lens Prep II”, a commercial product of Brain Power International (BPI) may be used.
According to an embodiment of the present invention, an article molded of the resins suitable in accordance with the invention, preferably molded of a polycarbonate composition, is immersed in the inventive dyeing bath. To reduce processing time, while keeping evaporation losses to a minimum, some dyeing baths may be heated to temperatures below 100° C., preferably below 96° C. In the course of dyeing, in accordance with the present invention, it is preferred that the dyeing bath is at a temperature below that at which the bath is at the state of ebullition. The optimum temperature of the bath is to some degree influenced by the molecular weight of the polycarbonate, its additives and the chemical nature of the dye.
In a preferred embodiment in the tinting of parts made of polycarbonate, a dye that is known to be suitable for compounding with polycarbonate composition is mixed with the plasticizer and leveling agent and water and the optional surfactant to form a dye-bath mixture. In accordance with the invention, the article is immersed in the dyeing bath and withdrawn after only a few minutes to provide a color-tinted product. The length of time in which the article should remain immersed in the bath and the process conditions depends upon the desired degree of tint.
Naturally, higher concentrations of dye and higher temperatures will increase the rate of dyeing.
In order to impart a graded tint, the molded article may be immersed in the dyeing bath and then slowly withdrawn therefrom. A graded tint results because the portion of the article that remains in the mixture longest is impregnated with the most dye.
The present invention may be more fully understood with reference to the examples set forth below. The examples are in no way to be considered as limiting, but instead are provided as illustrative of the invention.
EXAMPLES
The process was demonstrated in reference to an article molded of polycarbonate. The components of the dye bath and their relative amounts are noted in the table below that summarizes the results of the several experiments. The bath was maintained at 95° C. and the molded article to be tinted was then dipped. The part was removed from the bath, rinsed with copious quantities of water to remove any traces of excess dye and dried. The dipping time, dye concentration and mix temperature, may be adjusted to yield colors of the desired shades and density. The table below summarizes the results of several experiments that were carried out in accordance with the present invention. The article tinted in accordance with these experiments was molded of polycarbonate, Makrolon 3107 a homopolycarbonate based on bisphenol A having a MFR of 5-7.5 g/10 min. (in accordance with ASTM D 1238) a product of Bayer Corporation. Light transmission, TLT (%) and haze (%) were determined in accordance with ASTM D 1003. All the articles were dipped in the bath for 10 minutes, except for Example 3 where the time was 30 minutes. The contents of the plasticizer and leveling agent in the bath is reported below in percent by weight relative to the weight of the bath, water made up the remainder. The dye used in all the experiments was Palinil Blue and the amount of the dye was 4 grams per liter of bath, except for Example 16 where the amount of dye was 2 g/liter of bath.
TABLE 1
Plasticizer
Leveling
Haze
Example
(%)
agent (%)
TLT (%)
(%)
Remarks
1
EGBE (1)
DEG (9)
5.1
5.2
WD (11)
20%
(10%)
2
EGBE (1)
DEG
8.0
0.9
WD
10%
(5.0%)
3
EGBE (1)
DEG
3.5
1.0
WD
10%
(5.0%)
4
EGBE (1)
DEG
31.0
0.7
WD
5%
(2.5%)
5
DGEE (2)
DEG
77.7
1.3
WD
(20%)
(10%)
6
DGBE (3)
DEG
24.6
0.5
WD
(20%)
(10%)
7
PGEEA (4)
DEG
0.3
97.2
NWD (12)
(20%)
(10%)
8
PGPE (5)
DEG
3.0
2.7
WD
(20%)
(10%)
9
PGPE (5)
DEG
4.6
1.8
WD
(10%)
(5.0%)
10
PGPE (5)
DEG
40.8
0.9
Streaky
(5%)
(2.5%)
11
PGPE (5)
None
7.1
10.5
NWD
(20%)
12
PGPE (5)
Butanediol
2.8
25.6
WD
(20%)
(10%)
13
PGPE (5)
TEG (10)
5.0
38.4
WD
(20%)
(10%)
14
PGBE (6)
DEG
5.6
37.7
NWD
(20%)
(10%)
15
DPGPE (7)
DEG
11.6
10.6
WD
(20%)
(10%)
16
TPGPE (8)
DEG
31.3
1.4
WD
(20%)
(10%)
EGBE (1) -refers to ethylene glycol butyl ether (available commercially as butyl cellusolve, from Union Carbide Corporation, a Subsidiary of The Dow Chemical Company).
DGEE (2) -refers to diethylene glycol ethyl ether.
DGBE (3) -refers to diethylene glycol butyl ether.
PGEEA (4) -refers to propylene glycol ethyl ether acetate.
PGPE (5) -refers to propylene glycol propyl ether.
PGBE (6) -refers to propylene glycol butyl ether.
DPGPE (7) -refers to dipropylene glycol propyl ether.
TPGPE (8) -refers to tripropylene glycol propyl ether.
DEG (9) -refers to diethylene glycol.
TEG (10) -refers to triethylene glycol.
WD (11) -denotes well dispersed.
NWD (12) -denotes “not well dispersed”.
As may readily be seen, the tinting, in accordance with the invention, is sensitive to the makeup of the bath, Examples 7 and 14 where largely similar compounds (PGEEA and PGBE respectively) were used in replacement of the inventive plasticizing agent, resulted in poor dispersion of the dye. Also, in Example 10, where the leveling agent was used in an insufficient amount, the result was deemed streaky, and in Example 11 where no leveling agent was used, the dye was deemed to have been poorly dispersed.
Although the present invention has been described in connection with preferred embodiments, it will be appreciated by those skilled in the art that additions, modifications, substitutions and deletions not specifically described may be made without departing from the spirit and scope of the invention defined in the appended claims. | A process of dyeing a molded article is disclosed. The process entails immersing at least a portion of the article in a dyeing bath, retaining the portion in the bath for a period of time sufficient to allow an amount of dye to diffuse into the article, and removing said article from the bath. The molded article comprises a polymeric resin such as (co)polyester, (co)polycarbonates, acrylonitrile-butadiene-styrene, polyamide, polyurethane, polyalkyl(meth)acrylate, allyldiglycol carbonate and styrene copolymers. The dyeing bath contains in addition to dye, water, a plasticizing agent and a leveling agent. | 3 |
This application claims the benefit of U.S. Provisional application No. 60/028,560, filed Oct. 10, 1996.
BACKGROUND OF THE INVENTION
This invention relates to the field of pharmaceutical and organic chemistry and provides benzo b!thiophene compounds, intermediates, formulations, and methods.
Osteoporosis describes a group of diseases which arises from diverse etiologies, but which are characterized by the net loss of bone mass per unit volume. The consequence of this loss of bone mass and resulting bone fracture is the failure of the skeleton to provide adequate support for the body. One of the most common types of osteoporosis is associated with menopause. Most women lose from about 20% to about 60% of the bone mass in the trabecular compartment of the bone within 3 to 6 years after the cessation of menses. This rapid loss is generally associated with an increase of bone resorption and formation. However, the resorptive cycle is more dominant and the result is a net loss of bone mass. Osteoporosis is a common and serious disease among postmenopausal women.
There are an estimated 25 million women in the U.S. alone who are afflicted with this disease. The results of osteoporosis are personally harmful, and also account for a large economic loss due to its chronicity and the need for extensive and long term support (hospitalization and nursing home care) from the disease sequelae. This is especially true in more elderly patients. Additionally, although osteoporosis is generally not thought of as a life threatening condition, a 20% to 30% mortality rate is related to hip fractures in elderly women. A large percentage of this mortality rate can be directly associated with postmenopausal osteoporosis.
The most generally accepted method for the treatment of postmenopausal osteoporosis is estrogen replacement therapy. Although therapy is generally successful, patient compliance with the therapy is low, primarily because estrogen treatment frequently produces undesirable side effects. An additional method of treatment would be the administration of a bisphosphonate compound, such as, for example, Fosomax® (Merck & Co., Inc.).
Throughout premenopausal time, most women have less incidence of cardiovascular disease than men of the same age. Following menopause, however, the rate of cardiovascular disease in women slowly increases to match the rate seen in men. This loss of protection has been linked to the loss of estrogen and, in particular, to the loss of estrogen's ability to regulate the levels of serum lipids. The nature of estrogen's ability to regulate serum lipids is not well understood, but evidence to date indicates that estrogen can up regulate the low density lipid (LDL) receptors in the liver to remove excess cholesterol.
It has been reported in the literature that serum lipid levels in postmenopausal women having estrogen replacement therapy return to concentrations found in the premenopausal state. Thus, estrogen would appear to be a reasonable treatment for this condition. However, the side effects of estrogen replacement therapy are not acceptable to many women, thus limiting the use of this therapy. An ideal therapy for this condition would be an agent which regulates serum lipid levels in a manner analogous to estrogen, but which is devoid of the side effects and risks associated with estrogen therapy.
Estrogen dependent cancers are major diseases affecting both women and to a lesser extent men. Cancer cells of this type are dependent on a source of estrogen to maintain the original tumor as well as to proliferate and metastasize to other locations. The most common forms of estrogen dependent cancer are breast and uterine carcinomas. Current chemotherapy of these diseases relies primarily on the use of anti-estrogens, predominately tamoxifen. The use of tamoxifen, although efficacious, is not without undesirable side-effects, e.g., estrogen agonist properties, such as uterine hypertrophy and carcinogenic potential. Compounds of the current invention while showing the same or better potential for anti-cancer activity also demonstrate a lower potential for estrogen agonist activity.
Thus, it would be a significant contribution to the art to provide novel compounds useful, for example, in the treatment or prevention of the disease states as indicated herein.
SUMMARY OF THE INVENTION
The present invention relates to compounds of formula I ##STR1## wherein R 1 is --P(O)(OR 6 ) 2 ;
R 2 is --H, --Cl, --F, C 1 -C 4 alkyl, --OH, --O(C 1 -C 4 alkyl), --OCO(C 1 -C 6 alkyl), --O--CO--O(C 1 -C 6 alkyl), --O--CO--AR, --OSO 2 (C 2 -C 6 alkyl), or --O--CO--OAR, where AR is optionally substituted phenyl;
R 3 and R 4 are, independently, R 2 ;
R 5 is 1-piperidinyl, 1-pyrrolidinyl, methyl-1-pyrrolidinyl, dimethyl-1-pyrrolidino, 4-morpholino, dimethylamino, diethylamino, diisopropylamino, or 1-hexamethyleneimino;
R 6 is --H or C 1 -C 4 alkyl;
X is --CO-- or --CH 2 --; and
n is 2 or 3;
or a pharmaceutically acceptable salt or solvate thereof.
The present invention further relates to pharmaceutical compositions containing compounds of formula I and methods for the therapeutic use of such compounds and compositions.
DETAILED DESCRIPTION OF THE INVENTION
The present invention further provides intermediate compounds of formula II which are novel and useful for preparing the pharmaceutically active compounds of the present invention, and are shown below. ##STR2## wherein R 2a , R 3a , and R 4a are, independently, --H, --Cl, --F, C 1 -C 4 alkyl, or --OR 7 , where R 7 is a hydroxyl protecting group; and
R 5 , X and n have their previous meanings.
A preferred compound of formula II is 2- 4-(t-Butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxy benzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl! methanone.
General terms used in the description of compounds herein described bear their usual meanings. For example, "C 1 -C 6 alkyl" refers to straight or branched aliphatic chains of 1 to 6 carbon atoms including moieties such as methyl, ethyl, propyl, isopropyl, butyl, n-butyl, pentyl, isopentyl, hexyl, isohexyl, and the like. Similarly, the term "--OC 1 -C 4 alkyl" represents a C 1 -C 4 alkyl group attached through an oxygen molecule and include moieties such as, for example, methoxy, ethoxy, n-propoxy, isopropoxy, and the like. Of these alkoxy groups, methoxy is highly preferred in most circumstances.
Optionally substituted phenyl includes phenyl and 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 term, "hydroxyl protecting group (R 7 )" contemplates numerous functionalities used in the literature to protect a hydroxyl function during a chemical sequence and which can be removed to yield the phenol. Included within this group would be acyls, mesylates, tosylates, benzyl, alkylsilyloxys, --OC 1 -C 4 alkyls, and the like. Numerous reactions for the formation and removal of such protecting groups are described in a number of standard works including, for example, Protective Groups in Organic Chemistry, Plenum Press (London and New York, 1973); Green, T. W., Protective Groups in Organic Synthesis, Wiley, (New York, 1981); and The Peptides, Vol. I, Schrooder and Lubke, Academic Press (London and New York, 1965). A preferred hydroxyl protecting group for the current invention is tert-butyl-dimethylsilyloxy (TBDMS), (see: examples and preparations, below).
The term "inhibit" includes its generally accepted meaning which includes prohibiting, preventing, restraining, alleviating, ameliorating, and slowing, stopping or reversing progression, severity, or a resultant symptom. As such, the present method includes both medical therapeutic and/or prophylactic administration, as appropriate.
The compounds of the current invention are named as derivatives of centrally located carbon, i.e., the "--CO--" or "--CH 2 --" moiety in formula I, thus derivatives are methanones or methanes, e.g. a compound of A--CO--B, would be named A! B!methanone. Further the compounds of formula I are derivatives of benzo b!thiophene which is named and numbered according to the Ring Index, The American Chemical Society, as follows: ##STR3##
The starting material for preparing compounds of the present invention is a compound of formula III or IIIa. ##STR4## wherein R 2a , R 3a , R 4a , R 5 , and n have their previous meanings.
Compounds of formula III are generally known in the art and are prepared essentially as described by Jones, et al., in U.S. Pat. Nos. 4,400,543 and 4,418,068 each of which is herein incorporated by reference. See also Jones, et al., J. Med. Chem., 27, p. 1057-1066 (1984). The compounds of formula IIIa are prepared as described by Bryant, et al., in U.S. Pat. Nos. 5,484,798 and 5,492,921, each of which is incorporated by reference herein. Compounds of formula III or IIIa, where R 2a-4a are --OR 7 may be prepared by reacting their hydroxy precursors with the proper number of equivalents of protecting reagent which will allow the C 6 hydroxyl group to remain unprotected. This protection synthesis usually results in a statistical distribution of protecting groups on the various hydroxyl functions. These products can be separated by chromatographic techniques to yield the desired compound of III or IIIa, i.e., a compound with an unprotected 6-hydroxyl. An example of this preparation, using the preferred TBDMS protecting group, is given below.
The compounds of formula III or IIIa are converted into their triflate analogs, i.e., the compounds of formula II, by reaction of the phenol with a trifluoromethylsulfonoylating agent in the presence of an acid scavenger. Commonly used sulfonoylating reagents would be halides, e.g., trifluoromethylsulfonoyl-chloride, -bromide, or -iodide, anhydrides mixed or homogeneous, e.g,. triflic anhydride, or imides, e.g., N-alkyl or aryl trifluoromethylsulfonylimide. A preferred reagent is N-phenyltrifluoromethanesulfonimide.
Acid scavengers used in the synthesis of the compounds of formula II include alkali metal base, e.g., Na 2 CO 3 , K 2 CO 3 , etc. or organic tertiary amines, e.g., trimethylamine, pyridine, lutidine, triethylamine, etc. A preferred acid scavenger is triethylamine.
This reaction may be run in a variety of inert solvents, such ether, THF, dioxane, methylene chloride, and the like. Of these, THF is preferred and especially preferred is the anhydrous form of THF.
The sulfonoylation reaction may be run at temperatures between 0-50° C., with ambient temperature adequate and most convenient. Under these reaction conditions, the reaction is usually complete within one to twenty hours. The optimal time can be determined by monitoring the progress of the reaction via conventional chromatographic techniques, such as tlc.
Application of the chemistry described, supra, enables the preparation of the compounds of formula II. Examples of the compounds of formula II include, but are not limited to:
2- 4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2- 4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methane
2- 3-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2- 2-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2- 4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-pyrrolidinyl)ethoxy!phenyl!methanone
2- 4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 3-(1-piperidinyl)propoxy!phenyl!methanone
2- 3-chloro-4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2- 3-(t-butyldimethylsilyloxy)-4-fluorophenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methane
2- 2-methyl-4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2- 4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-hexamethyleneimino)ethoxy!phenyl!methanone
2- 4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(N,N-dimethylamino)ethoxy!phenyl!methane
2- 3-fluoro-4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 3-(1-piperidinyl)propoxy!phenyl!methanone
2- 3,4-di-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2- 2,4-di-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methane
2- 2,3-di-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-pyrrolidinyl)ethoxy!phenyl!methanone
2- 2,3-di-chlorophenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-pyrrolidinyl)ethoxy!phenyl!methanone
2- 4-fluorophenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-pyrridinyl)ethoxy!phenyl!methanone
2- 2-methyl-3-fluorophenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-pyrridinyl)ethoxy!phenyl!methanone
2- 3-methyl-4-chlorophenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2- 3,4-di-methoxyphenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl!4- 2-(1-pyrridinyl)ethoxy!phenyl!methanone
2- 4-methoxyphenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2- 4-methoxyphenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methane
The triflate compounds of formula II are converted to the compounds of formula Ia by a transition metal coupling reaction. Transition metals such as, but not limited to, palladium and nickel, in various oxidation states, are generally employed. Typically, these reactions are run in inert solvents which would include toluene, DMF, acetonitrile, and the like. Catalytic amounts of phosphorous-bearing ligands are used to facilitation these reactions, e.g., triarylphosphines, bis-diphenylphosphoalkanes, bis-diphenylphosphinoferrocenes and the like. A preferred phospho-ligand/transition metal catalyst is Pd(0)(PPh 3 ) 4 . Organic bases are also employed to facilitate the reaction, e.g., trialkylamines, pyridine, etc. A preferred base is triethylamine. The temperature employed in this coupling is that which is sufficient to effect completion of the reaction, generally, in the range from 50-100° C. The length of time required for the reaction to run to completion is typically from four to seventy-two hours. However, the optimal time can be determined by monitoring the progress of the reaction via conventional chromatographic techniques.
When the preferred hydroxyl protecting group (R 7 ), i.e., TBDMS, is present in a compound of formula II, this protecting group is cleaved during the coupling reaction and subsequent workup. Thus, the products (Ia) are isolated as the free hydroxyl derivatives. This chemistry is illustrated in Scheme I, below. ##STR5## wherein R 2b , R 3b , and R 4b are, independently, --H, --Cl, --F, C 1 -C 4 alkyl, or --OH; R 6a is C 1 -C 4 alkyl; and R 2a ,R 3a , R 4a ,R 5 , n, and X have their previous meanings.
The compounds of formula Ia, where the triflate has been replaced by a phosphonate (ester or acid), are prepared by running the metal coupling reaction in the presence of a phosphite, (R 6a O) 2 P(O)H. A specific example of this reaction enabling the preparation of the compounds of formula Ia, is given below. Further information regarding this chemistry may be found in Thurieau, et al., J. Med. Chem., 37, 625-629 (1994). Application of the chemical synthesis described, supra, enables the preparation of the compounds of formula Ia. Compounds of formula Ia include, but are not limited to:
2-(4-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methane
2-(4-hydroxyphenyl)-6-di-methylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-chlorophenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-fluorophenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(3-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(2-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-pyrrolidinyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-di-propylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-di-i-butylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(2-methyl-4-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 3-(1-piperidinyl)propoxy!phenyl!methanone
2-(3,4-di-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(N,N-diethyl)ethoxy!phenyl!methanone
and the like.
The compounds of formula Ia are used to synthesize the phosphonic acids, formula Ib, i.e., where R 6 is --OH. This conversion is accomplished by hydrolyzing the ester moieties of a Ia compound. This chemistry is well known in the art and is usually done under basic conditions. Bases commonly employed for this hydrolysis are NaOH, KOH, Na 2 CO 3 , and the like. Such reactions are carried out in a mixed aqueous solvent, e.g., aqueous alcohol mixtures, biphasic water-organic systems, and the like. The reaction are usually run at temperature between 50-100° C. for two to twenty-four hours. Application of the chemical synthesis described, supra, enables the preparation of the compounds of formula Ib. Compounds of formula Ib include, but are not limited to:
2-(4-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methane
2-(3-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(2-methyl-4-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-pyrrolidinyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-N,N-di-methyl)ethoxy!phenyl!methanone
2-(4-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 3-(1-piperidinyl)propoxy!phenyl!methanone
2-(3-chloro-4-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(3,4-di-hydroxyphenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-fluorophenyl)-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-phenyl-6-phosphonatobenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
Other compounds of formula I, i.e., those of formula Ic, where the hydroxyl functions (R 2b-4b ), when present, are substituted with acyl or sulfonoyl moieties, are also apart of the current invention. Compounds of formula Ic are prepared by replacing the 2', 3', and/or 4'-position hydroxy moieties of Ia or Ib compounds, when present, with a moiety of the formula --O--CO--(C 1 -C 6 alkyl), --O--CO--Ar, or --O--SO 2 --(C 2 -C 6 alkyl) via well known procedures. See, e.g., U.S. Pat. Nos. 5,393,763 or 5,482,949, each of which is included by reference herein.
For example, when an --O--CO(C 1 -C 6 alkyl) or --O--CO-phenyl group is desired, a mono-, di-, trihydroxy compound of formula Ia or Ib is reacted with an agent such as acyl chloride, bromide, cyanide, or azide, or with an appropriate anhydride or mixed anhydride. The reactions are conveniently carried out in a basic solvent such as pyridine, lutidine, quinoline or isoquinoline, or in a tertiary amine solvent such as triethylamine, tributylamine, methylpiperidine, and the like. The reaction also may be carried out in an inert solvent such as ethyl acetate, dimethylformamide, dimethylsulfoxide, dioxane, dimethoxyethane, acetonitrile, acetone, methyl ethyl ketone, and the like, to which at least one equivalent of an acid scavenger, such as a tertiary amine, has been added. If desired, acylation catalysts such as 4-dimethylaminopyridine or 4-pyrrolidinopyridine may be used. See, e.g., Haslam, et al., Tetrahedron, 36:2409-2433 (1980).
The present reactions are carried out at moderate temperatures, in the range from about -25° C. to about 100° C., frequently under an inert atmosphere such as nitrogen gas. However, ambient temperature is usually adequate for the reaction to run.
Acylation of a 2', 3', and/or 4'-position hydroxy group also may be performed by acid-catalyzed reactions of the appropriate carboxylic acids in inert organic solvents. Acid catalysts such as sulfuric acid, polyphosphoric acid, methanesulfonic acid, and the like are used.
When a formula I compound is desired in which the 2',3', and/or 4'-position hydroxy group of a formula Ia or Ib compound is converted to a group of the formula --O--SO 2 --(C 2 -C 6 alkyl), the mono-, di-, or trihydroxy compound is reacted with, for example, a sulfonic anhydride or a derivative of the appropriate sulfonic acid such as a sulfonyl chloride, bromide, or sulfonyl ammonium salt, as taught by King and Monoir, J. Am. Chem. Soc., 97:2566-2567 (1975). The hydroxy compounds also can be reacted with the appropriate sulfonic anhydride or mixed sulfonic anhydrides. Such reactions are carried out under conditions such as were explained above in the discussion of reaction with acid halides and the like.
Applying the chemical synthetic schemes, supra, compounds of formula Ic may be prepared, and such compounds include, but are not limited to:
2-(4-acetoxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-benzoyloxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-butanoyloxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-hexanoyloxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methane
2-(4-benzoyloxyphenyl)-6-di-methylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(2-acetoxy-4-chlorophenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(3-benzoyloxy-4-fluorophenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(3-benzoyloxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(2-butanoyloxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-pyrrolidinyl)ethoxy!phenyl!methanone
2-(4-n-butylsulfonoyloxyphenyl)-6-di-propylphosphonoylbenzo b!thien-3-yl!4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-n-butylsulfonoyloxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-acetoxyphenyl)-6-di-i-butylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(2-methyl-3-acetyl-4-hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
2-(4-benzoyloxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 3-(1-piperidinyl)propoxy!phenyl!methanone
2-(3,4-di-acetoxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
and the like.
A preferred embodiment of the current invention is 2-(4-hydroxyphenyl)-6-diethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone.
Together, the compounds of formulae Ia, Ib, and Ic comprise the genus of the compounds of formula I, are novel, and useful for the pharmacologic methods described herein.
Although the free-base form of formula I compounds can be used in the methods of the present invention, it is preferred to prepare and use a pharmaceutically acceptable salt form. Thus, the compounds used in the methods of this invention primarily form pharmaceutically acceptable acid addition salts with a wide variety of organic and inorganic acids, 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, terephthalate, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, propiolate, propionate, phenylpropionate, salicylate, sebacate, succinate, suberate, sulfate, bisulfate, pyrosulfate, sulfite, bisulfite, sulfonate, benzenesulfonate, p-bromophenylsulfonate, chlorobenzenesulfonate, ethanesulfonate, 2-hydroxyethanesulfonate, methanesulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate, p-toluenesulfonate, xylenesulfonate, tartarate, and the like. Preferred salts are the hydrochloride and oxalate salts.
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 ethyl acetate. 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.
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.
The term "solvate" represents an aggregate that comprises one or more molecules of the solute, such as a formula I compound, with one or more molecules of solvent.
The following examples are presented to further illustrate the preparation of compounds of the present invention. It is not intended that the invention be limited in scope by reason of any of the following examples.
NMR data for the following Examples were generated on a GE 300 MHz NMR instrument, and anhydrous d-6 DMSO was used as the solvent unless otherwise indicated.
PREPARATION 1
2- 4-(t-Butyldimethylsilyloxy)phenyl!-6-hydroxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
A solution was prepared consisting of 10 g (21.1 mmol) of 2-(4-hydroxyphenyl)-6-hydroxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone and 6 g (49.1 mmol) of dimethylaminopyridine in 700 mL of THF-DMF (6:1)(v/v). This solution was stirred for one hour at ambient temperature and then cooled to 0° C. in an ice bath. To this solution was added 2.9 g (19.3 mmol) of tert-butyl-dimethylsilylchloride. The reaction mixture was stirred under a nitrogen atmosphere and allowed to warm to ambient temperature. After seventy-two hours, the reaction was quenched with the addition of a saturated solution of aqueous NH 4 Cl. The organic layer was separated and washed with water, brine, and finally dried by filtration through anhydrous Na 2 SO 4 and evaporated to dryness. The crude product was triturated with CH 2 Cl 2 , allowed to stand for three hours, and filtered to remove unreacted starting material. This resulting product is a mixture of isomers, which are separated by chromatography on a silica gel column eluted with a linear gradient beginning with CHCl 3 and ending with CHCl 3 --MeOH (19:1)(v/v). The desired fractions were determined by tlc, combined, and evaporated to dryness. This yielded 5.1 g of the title compound, isolated as a yellow crystalline solid.
PMR: δ0.12(s,6H); 0.92(s,9H); 1.46(m,2H); 1.67(m,4H); 2.56(m,5H); 2.79(t, J=5.6 Hz, 2H); 4.07(t, J=5.7 Hz, 2H); 6.55(d, J=8.9 Hz, 2H); 6.66(d, J=8.5 Hz, 2H); 6.77(dd, J 1 =8.7 Hz, J 2 =2.2 Hz, 1H); 7.17(d, J=2.2 Hz, 1H); 7.20(d, J=8.6 Hz, 3H); 7.44 (d, J=8.8 Hz, 1H); 7.63(d, J=8.9 Hz, 2H)
MS: m/e=587 (M) FD
EA: Calc. for C 34 H 41 NO 4 SSi: C, 69.47; H, 7.03; N, 2.38 Found: C, 69.19; H, 6.98; N, 2.57.
PREPARATION 2
2- 4-(t-Butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
A solution was prepared of 10 g (17.5 mmol) of 2- 4-(t-butyldimethylsilyloxy)phenyl!-6-hydroxybenzo b! thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone in 100 mL of CH 2 Cl 2 , which was placed under a nitrogen atmosphere and cooled to 0° C. in an ice bath. Triethylamine (5 mL, 3.6 g, 35.9 mmol) was added followed by the addition of 7 g (19.5 mmol) of N-phenyltrifluoromethanesulfonimide. The reaction was allowed to warm slowly to ambient temperature over a period of sixteen hours. The reaction mixture was filtered and evaporated to a red oil. The crude product was chromatographed on a silica gel column eluted with CH 2 Cl 2 . This yielded 11 g of the title compound isolated as a tan amorphous solid.
PMR: (CDCl 3 ) δ0.05 (s, 6H); 0.85(s, 9H); 1.35(m, 2H); 1.55(m, 4H); 2.40(m, 4H); 2.65(t, J=7 Hz, 2H); 4.00(t, J=7 Hz, 2H); 6.65(m, 4H); 7.20(m, 3H); 7.65(d, J=10 Hz, 2H); 7.75(m,2H)
MS: m/e=720 (M) FD
EXAMPLE 1
2-(4-Hydroxyphenyl)-6-di-ethylphosphonoylbenzo b!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone
A solution was prepared of 2 g (2.8 mmol) of 2- 4-(t-butyldimethylsilyloxy)phenyl!-6-trifluoromethylsulfonoyloxybenzob!thien-3-yl! 4- 2-(1-piperidinyl)ethoxy!phenyl!methanone, 0.58 g (0.54 mL, 4.2 mmol) of diethylphosphite, and 5 mL of triethylamine in 15 mL of MeCN. The reaction was purged with nitrogen for fifteen minutes and 100 mg of Pd(0)(Ph 3 P) 4 was added. The reaction mixture turned a bright yellow color. The reaction mixture was heated to 75° C. for thirty-six hours. The reaction was allowed to cool, evaporated to dryness in vacuo, the residue resuspended in 100 mL of THF, and filtered. The crude product was partitioned between 100 mL of EtOAc and 100 mL of 1N HCl and stirred, vigorously, for two hours at ambient temperature. The organic layer was separated and dried by filteration through anhydrous Na 2 SO 4 and evaporated to dryness. This yielded 800 mg of the title compound as yellow solid, mp: 75-78° C.
PMR: δ1.25 (t, J=4 Hz,6H); 1.40 (s br, 2H); 1.50 (s br, 4H); 2.45 (s br, 4H); 2.70 (t, J=3 Hz, 2H); 4.05-4.25 (m, 6H); 6.80 (d, J=8 Hz, 2H); 7.00 (d, J=8 Hz, 2H); 7.35 (d, J=8 Hz, 2H); 7.65-7.70 (m, 2H); 7.75 (d, J=8 Hz, 2H); 8.55 (d, J=15 Hz, 1H); 10.05 (s br, 1H)
MS: m/e=594 FD
EA: Calc. for C 32 H 36 NO 6 PS-3/2H 2 O: C, 63.47; H, 6.21; N, 2.31 Found: C, 63.10; H, 6.08; N, 2.20.
TEST PROCEDURE
General Preparation Procedure
In the examples illustrating the methods, a post-menopausal model was used in which effects of different treatments upon circulating lipids were determined.
Seventy-five day old female Sprague Dawley rats (weight range of 200 to 225 g) are obtained from Charles River Laboratories (Portage, Mich.). The animals are either bilaterally ovariectomized (OVX) or exposed to a Sham surgical procedure at Charles River Laboratories, and then shipped after one week. Upon arrival, they are housed in metal hanging cages in groups of 3 or 4 per cage and have ad libitum access to food (calcium content approximately 0.5%) and water for one week. Room temperature is maintained at 22.2°±1.7° C. with a minimum relative humidity of 40%. The photoperiod in the room is 12 hours light and 12 hours dark.
Dosing Regimen Tissue Collection. After a one week acclimation period (therefore, two weeks post-OVX) daily dosing with test compound is initiated. 17α-ethynyl estradiol or the test compound are given orally, unless otherwise stated, as a suspension in 1% carboxymethylcellulose or dissolved in 20% cyclodextrin. Animals are dosed daily for 4 days. Following the dosing regimen, animals are weighed and anesthetized with a ketamine: Xylazine (2:1, V:V) mixture and a blood sample is collected by cardiac puncture. The animals are then sacrificed by asphyxiation with CO 2 , the uterus is removed through a midline incision, and a wet uterine weight is determined.
Cholesterol Analysis. Blood samples are allowed to clot at ambient temperature for 2 hours, and serum is obtained following centrifugation for 10 minutes at 3000 rpm. Serum cholesterol is determined using a Boehringer Mannheim Diagnostics high performance cholesterol assay. Briefly, the cholesterol is oxidized to cholest-4-en-3-one and hydrogen peroxide. The hydrogen peroxide is then reacted with phenol and 4-aminophenazone in the presence of peroxidase to produce a p-quinone imine dye, which is read spectrophotemetrically at 500 nm. Cholesterol concentration is then calculated against a standard curve.
Uterine Eosinophil Peroxidase (EPO) Assay. Uteri are kept at 4° C. until time of enzymatic analysis. The uteri are then homogenized in 50 volumes of 50 mM Tris buffer (pH-8.0) containing 0.005% Triton X-100. Upon addition of 0.01% hydrogen peroxide and 10 mM o-phenylenediamine (final concentrations) in Tris buffer, increase in absorbance is monitored for one minute at 450 nm. The presence of eosonophils in the uterus is an indication of estrogenic activity of a compound. The maximal velocity of a 15 second interval is determined over the initial, linear portion of the reaction curve.
Source of Compound: 17α-ethynyl estradiol was obtained from Sigma Chemical Co., St. Louis, Mo.
The pharmacologic activity for the methods of the current invention, i.e., the compounds of formula I, are illustrate in Table 1, below.
Osteoporosis Test Procedure
Following the General Preparation Procedure, infra, the rats are treated daily for 35 days (6 rats per treatment group) and sacrificed by carbon dioxide asphyxiation on the 36th day. The 35 day time period is sufficient to allow maximal reduction in bone density, measured as described herein. At the time of sacrifice, the uteri are removed, dissected free of extraneous tissue, and the fluid contents are expelled before determination of wet weight in order to confirm estrogen deficiency associated with complete ovariectomy. Uterine weight is routinely reduced about 75% in response to ovariectomy. The uteri are then placed in 10% neutral buffered formalin to allow for subsequent histological analysis.
The right femurs are excised and digitized x-rays generated and analyzed by an image analysis program (NIH image) at the distal metaphysis. The proximal aspect of the tibiae from these animals are also scanned by quantitative computed tomography.
In accordance with the above procedures, compounds of the present invention and ethynyl estradiol (EE 2 ) in 20% hydroxypropyl β-cyclodextrin are orally administered to test animals.
TABLE 1______________________________________ Serum Dose Uterine Wt. Uterine EPO CholesterolCompound mg/kg).sup.a (% Inc.).sup.b (Vmax).sup.c (% Dec.).sup.d______________________________________EE.sub.2.sup.e 0. 171.2* 142.4* 85.1*Example 1 0.1 -.08 3.9 -20.4 1 0.9 2.7 6.3 10 36.6* 7.2 48.9*______________________________________ *p < 0.05 .sup.a mg/kg PO .sup.b Uterine Weight, % increase versus the ovariectomized controls .sup.c Eosinophil peroxidase, .sup.V maximum .sup.d Serum cholesterol decrease versus ovariectomized controls .sup.e 17Ethynyl-estradiol
As evidence of the current invention treat estrogen dependent cancer, the following assay was performed.
MCF-7 Proliferation Assay
MCF-7 breast adenocarcinoma cells (ATCC HTB 22) were maintained in MEM (minimal essential medium, phenol red-free, Sigma, St. Louis, Mo.) supplemented with 10% fetal bovine serum (FBS) (V/V), L-glutamine (2 mM), sodium pyruvate (1 mM), HEPES {(N- 2-hydroxyethyl!piperazine-N'- 2-ethanesulfonic acid! 10 mM}, non-essential amino acids and bovine insulin (1 ug/mL) (maintenance medium). Ten days prior to assay, MCF-7 cells were switched to maintenance medium supplemented with 10% dextran coated charcoal stripped fetal bovine serum (DCC-FBS) assay medium) in place of 10% FBS to deplete internal stores of steroids. MCF-7 cells were removed from maintenance flasks using cell dissociation medium Ca++/Mg++ free HBSS (phenol red-free) supplemented with 10 mM HEPES and 2 mM EDTA!. Cells were washed twice with assay medium and adjusted to 80,000 cells/mL. Approximately 100 mL (8,000 cells) were added to flat-bottom microculture wells (Costar 3596) and incubated at 37° C. in a 5% CO 2 humidified incubator for 48 hours to allow for cell adherence and equilibration after transfer. Serial dilutions of drugs or DMSO as a diluent control were prepared in assay medium and 50 mL transferred to triplicate microcultures followed by 50 mL assay medium for a final volume of 200 mL. After an additional 48 hours at 37° C. in a 5% CO 2 humidified incubator, microcultures were pulsed with tritiated thymidine (1 μCi/well) for 4 hours. Cultures were terminated by freezing at -70° C. for 24 hours followed by thawing and harvesting of microcultures using a Skatron Semiautomatic Cell Harvester. Samples were counted by liquid scintillation using a Wallac BetaPlace β counter. The compounds of formula I are active and potent in inhibiting the tumor cell growth.
The Example 1 compound has an IC 50 of 100 nM for the inhibition of the MCF-7 tumor cell line.
As used herein, the term "effective amount" means an amount of compound of the present invention which is capable of inhibiting the symptoms of the various pathological conditions herein described. The specific dose of a compound administered according to this invention will, of course, be determined by the particular circumstances surrounding the case including, for example, the compound administered, the route of administration, the state of being of the patient, and the pathological condition being treated.
The compounds of this invention can be administered by a variety of routes including oral, rectal, transdermal, subcutaneous, intravenous, intramuscular, and intranasal. These compounds preferably are formulated prior to administration, the selection of which will be decided by the attending physician. Thus, another aspect of the present invention is a pharmaceutical composition comprising an effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
The total active ingredients in such formulations comprises from 0.1% to 99.9% by weight of the formulation. By "pharmaceutically acceptable" it is meant the carrier, diluent, excipients and salt must be compatible with the other ingredients of the formulation, and not deleterious to the recipient thereof.
Pharmaceutical formulations of the present invention can be prepared by procedures known in the art using well known and readily available ingredients. For example, the compounds of formula I, with or without an estrogen or progestin compound, 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 also can be formulated as elixirs or solutions for convenient oral administration or as solutions appropriate for parenteral administration, for example, 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 physiological location, possibly over a period of time. The coatings, envelopes, and protective matrices may be made, for example, from polymeric substances or waxes.
Compounds of formula I, alone or in combination with another pharmaceutical agent, generally will be administered in a convenient formulation. A typical dosage amount is from about 5 mg to about 600 mg, 1 to 3 times a day. More typically, the dose will be about 15 mg to 80 mg/day. The term of administration will be for a period of at least 2 months. More typically, administration will be at least 6 months, or chronically. The following formulation examples only are illustrative and are not intended to limit the scope of the present invention.
FORMULATIONS
In the formulations which follow, "active ingredient" means a compound of formula I, or a salt or solvate thereof.
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 formulation above may be changed in compliance with the reasonable variations provided.
A tablet formulation is prepared using the ingredients below:
Formulation 2: Tablets
______________________________________Ingredient Quantity (mg/tablet)______________________________________Active ingredient 2.5-1000Cellulose, microcrystalline 200-650Silicon dioxide, fumed 10-650Stearate acid 5-15______________________________________
The components are blended and compressed to form tablets.
Alternatively, tablets each containing 2.5-1000 mg of active ingredient are made up as follows:
Formulation 3: Tablets
______________________________________Ingredient Quantity (mg/tablet)______________________________________Active ingredient 25-1000Starch 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 4: 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.
An aerosol solution is prepared containing the following ingredients:
Formulation 5: Aerosol
______________________________________ Quantity (% byIngredient weight)______________________________________Active ingredient 0.25Ethanol 25.75Propellant 22 (Chlorodifluoromethane) 70.00______________________________________
The active ingredient is mixed with ethanol and the mixture added to a portion of the propellant 22, cooled to 30° C., and transferred to a filling device. The required amount is then fed to a stainless steel container and diluted with the remaining propellant. The valve units are then fitted to the container.
Suppositories are prepared as follows:
Formulation 6: Suppositories
______________________________________Ingredient Quantity (mg/suppository)______________________________________Active ingredient 250Saturated fatty acid 2,000glycerides______________________________________
The active ingredient is passed through a No. 60 mesh U.S. sieve and suspended in the saturated fatty acid glycerides previously melted using the minimal necessary heat. The mixture is then poured into a suppository mold of nominal 2 g capacity and allowed to cool.
An intravenous formulation is prepared as follows:
Formulation 7: Intravenous Solution
______________________________________Ingredient Quantity______________________________________Active ingredient 50 mgIsotonic saline 1,000 mL______________________________________
The solution of the above ingredients is intravenously administered to a patient at a rate of about 1 mL per minute.
Formulation 8: Combination Capsule I
______________________________________Ingredient Quantity (mg/capsule)______________________________________Active ingredient 50Premarin 1Avicel pH 101 50Starch 1500 117.50Silicon Oil 2Tween 80 0.50Cab-O-Sil 0.25______________________________________
Formulation 9: Combination Capsule II
______________________________________Ingredient Quantity (mg/capsule)______________________________________Active ingredient 50Norethylnodrel 5Ayicel pH 101 82.50Starch 1500 90Silicon Oil 2Tween 80 0.50______________________________________
Formulation 10: Combination Tablet
______________________________________Ingredient Quantity (mg/capsule)______________________________________Active ingredient 50Premarin 1Corn Starch NF 50Povidone, K29-32 6Avicel pH 101 41.50Avicel pH 102 136.50Crospovidone XL10 2.50Magnesium Stearate 0.50Cab-O-Sil 0.50______________________________________ | This invention relates to the field of pharmaceutical and organic chemistry and provides benzothiophene compounds, intermediates, formulations, and methods. | 2 |
Specification
This invention relates to percussion drilling apparatus; and more particularly relates to a novel and improved downhole drilling apparatus for boring earth, rock or other hard substances in a reliable and highly efficient manner.
BACKGROUND AND FIELD OF INVENTION
Numerous approaches have been taken in the design and construction of percussive drilling apparatus and particularly in the design of bits which employ multiple drilling teeth or drills for downhole drilling operations. Representative of approaches taken in the past is that disclosed in U.S. Letters Pat. No. 2,815,932 to Wolfram wherein a pneumatic hammer drives a generally fan-shaped arrangement of plungers with a pilot cutter positioned centrally of the plungers. Spring return members are employed in association with the plungers but are not in and of themselves capable of fully retracting the plungers after each blow. In U.S. Letter Pat. No. 2,595,126 to Causey, vertically adjustable inner and outer concentric drilling units are employed where one unit works ahead of the other to facilitate drilling a well. U.S. Letters Pat. No. 1,932,891 to Harner employs teeth arranged in fan-shaped rings which are successively reciprocated by pneumatic drive which operate cylinder heads. The arrangement is such that the teeth in one ring are driven between the teeth of another adjacent ring. In U.S. Letters Pat. No. 1,419,980 to Palma, fish-tail type cutting teeth are activated by divergently extending cylinders in cutting across a vertically extending arc. Similarly, in U.S. Letters Pat. No. 1,970,113 to Slawson, pressurized air is employed to drive a series of axially directed teeth; and in U.S. Letters Pat. No. 2,400,853 to Stilly, spring-loaded cutting tools are operated by fluid pressure.
It is proposed in accordance with the present invention to employ combustion chambers concentrically arranged to successively drive a series of teeth at the lower ends of concentric rings of pistons to deliver the necessary force to a series of teeth. The teeth are disposed in circumferentially spaced relation to one another in a series of concentric rows and are successively driven from the innermost to outermost row by sequential firing of the combustion chambers for each row or ring of teeth. Individual teeth are constructed so as to afford optimum wear and efficiency in operation.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide for a novel and improved combustion operated drilling assembly and which is specifically designed for downhole drilling applications.
Another object of the present invention is to employ internal combustion for driving concentric rings of movable teeth in radially outward succession to progressively enlarge a hole to the desired size.
A further object of the present invention is to provide for a novel method and means for sequentially firing successive rings of teeth to chip off portions of a substance to be penetrated into the space evacuated by the chipping action of the teeth of each next adjacent inner ring, the inside to outside chipping action improving the efficiency and speed at which hard substances can be penetrated.
Another object of the present invention is to provide for a novel and improved combustion operated mechanism which is capable of delivering substantial impact force via concentric or annular pistons to successive rings of movable teeth.
A still further object of the present invention is to provide a novel and improved percussive drilling apparatus in which a series of movable teeth are concentrically arranged in a fan-shaped arrangement and set at different predetermined angles to the longitudinal axis of the assembly for most efficient cutting and chipping action; and further wherein a series of combustion chambers are employed in combination with pistons which are successively fired to drive the teeth in such a way as to effect optimum efficiency and speed of penetration of the bit into different substances to be drilled.
A preferred form of the present invention resides in a percussion drill bit apparatus for drilling into subterranean formations and which comprises a drill bit housing mounted at the lower end of a drill string, the housing provided with a central opening therethrough and a plurality of drill rods are concentrically arranged in the housing to extend downwardly through the lower end of the housing, each rod having an impact tooth at its lower end and means for mounting the drill rod for slidable lengthwise reciprocal movement along the longitudinal axes of the drill rods. A series of combustion chambers are arranged in concentric relation to one another above the drill rods, each chamber having at least one fuel intake valve and one exhaust valve, means for delivering a combustible fuel mixture into each of the combustion chambers and igniter means for igniting the mixture when introduced into each chamber. Sequential control means for sequentially opening and closing each of the intake and exhaust valves in a chamber and having firing means which are correlated with the opening of the intake valves to activate the igniter means in coordination with the opening of each valve to sequentially advance the drill rods downwardly from the lower end of the housing into the subterranean formation. Preferably, each combustion chamber has a piston mounted at the lower end and which is operative to drive each drill rod downwardly into the formation, and the drill rods are arranged at different angles of extension away from the housing so as to vary the angle of attack with respect to the formation. In this relation, the lower end of each drill rod is tapered and fitted with an impact tooth which will most effectively penetrate the formation and particularly in regard to hard substances impart a chipping or cutting action. By sequentially firing the rows of drill rods and impact teeth progressively from the innermost to outermost row, cutting progresses in a radial outward direction away from the center to progressively enlarge the hole to the desired size.
The above and other objects, advantages and features of the present invention will become more readily understood and appreciated from a consideration of the following detailed description of a preferred embodiment when taken together with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view partially in section of a preferred form of drilling apparatus employed in an earth-boring operation and representing typical controls utilized at the surface for operation of the apparatus;
FIG. 2 a sectional view enlarged of a preferred form of drilling apparatus in accordance with the present invention;
FIG. 3 is a sectional view illustrating in more detail one the movable teeth assemblies employed in the of the present invention;
FIG. 4 is a cross-sectional view taken about lines 4--4 of FIG. 3;
FIG. 5 is a fragmentary sectional view illustrating a portion of adjacent valve disks, combustion chambers and pistons employed in driving successive movable teeth, in accordance with the present invention;
FIG. 6 is a cross-sectional view taken about lines 6--6 of FIG. 2 and schematically illustrating the fuel intake and exhaust lines;
FIG. 7 is a perspective view of a preferred form of intake valve;
FIG. 8 is another perspective view illustrating a preferred form of intake valve with respect to a combustion chamber and cam track; and;
FIG. 9 illustrates a preferred form of exhaust valve and cam track.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2 of the drawings, a preferred form of drilling apparatus 10 is illustrated in operative position in forming a bore hole B in a subsurface formation, for instance, in the drilling of a gas or oil well, the drilling apparatus 10 being suspended from a conventional drill string 12. The drill string 12 is of tubular construction and in a well-known manner permits circulation of a drilling fluid through hollow interior 14, and an umbilical cord 16 extends downwardly through the hollow interior 14 of the drill string 12. The umbilical cord may be multi-chambered and of the type commonly used in turbo drilling and similar operations for the purpose of carrying a plurality of electrical cables and circulating lines as indicated from the surface down to the drilling apparatus 10. Typically, the controls at the surface necessary for operation of the drilling operation may for the purpose of illustration consist of a fuel tank 20 and fuel pump 22 with a rheostat control 23 to pump fuel via line 24 to the drilling apparatus. Electrical controls include a suitable power source 26 and rheostat 27 both for driving an electric motor M (see FIG. 5) and for sequentially firing spark plugs S in a manner to be described. A compressor 28 supplies air under pressure via line 29 to the combustion chambers, and an exhaust line 30 is provided as a means of removing spent gases from the combustion chambers.
As noted from FIG. 2, the preferred form of drilling apparatus 10 takes the form of a bit having a tooth housing or body 34 and an upper threaded end or sub 32 for threaded connection to the lower end of the drill stem 12, and the hollow interior 14 of the drill stem extends continuously throughout the length of the body 34 to communicate with the bore hole at its lower exit end 14'.
The housing or body 34 preferably is a solid block of steel or other durable material provided with a series of bores 35 at its lower end arranged to accommodate concentric rows of movable drilling teeth 36 inserted into individual sleeves or liners 37 in each bore 35. In the embodiment shown in FIG. 2, four concentric rows of teeth 36 are provided with an inner row 40 having a series of teeth 36 in circumferentially spaced relation to one another and slanted or cocked radially and inwardly at a low gradual angle with respect to the center axis of the body 34. A second row 41 is provided with teeth arranged along individual axes parallel to the longitudinal axis. In row 42, the teeth 36 are arranged to diverge in a radially downward and outward direction at a low gradual angle away from the longitudinal axis of the body while an outer row 43 of teeth 36 fan outwardly at a slightly greater angle than that of the next outer row 42. For the purpose of illustration but not limitation, the inner row 40 has teeth inclined inwardly at an angle on the order of 10° while in the outer rows 42 and 43 the teeth angle outwardly at angles of 10° and 20°, respectively. Further by way of example, the number of teeth in each row proceeding in a radial outward direction from the inner row 40 is progressively increased so that for example in row 40 there are a series of eight teeth, in row 41 a series of sixteen teeth, in row 42 a series of twenty-four teeth, and in the outermost row 43 a series of thirty-two teeth; however, it will be evident that the number of teeth in each row will vary according to the size of the bit and nature of the formation into which a hole or bore is to be formed.
The upper end of the body 34 has an outer cylindrical wall 44 terminating in an upper reduced end 45 which is connected to a socket end 46 of the sub 32 by lock screws 47. An inner cylindrical wall 48 of the body is held in sealed engagement with the lower surface 33 of the sub 32 as indicated at 49. A plurality of concentric rings 50, 51 and 52 are arranged in equally spaced relationship proceeding outwardly from the inner wall 48 to the outer wall 44 and which define annular combustion chambers to house the activating pistons 54 for each of the rings of movable drilling teeth 36. It will be noted that the outer wall 44 is divided into two sections with an upper section 44' interconnected to the lower section 44" by locking screws 55; and the lower section 44' includes an outwardly divergent extension or skirt 56 at its lower end which forms a part of the wall surrounding the outermost series of bores 43. Inner wall 48 similarly is divided into upper section 48' and lower section 49' sealed together in end-to-end relation at 58, and the lower end of the wall 49' being tapered to form a part of the housing for the innermost series of bores 40.
Referring to FIGS. 2 to 4 and the construction and arrangement of each movable drilling tooth 36, a tooth shaft 60 of generally cylindrical configuration has a lower inclined end surface 61 to which is affixed a tooth plate 62, the plate 62 being made of a tungsten carbide or other wear resistant substance and which can be removed and replaced when worn or broken. The plate may be of a variety of shapes and sizes although preferably is of a generally elliptical configuration to conform to the inclined face of the lower end 61 and also may suitably vary in construction or composition according to the hardness or ductility of the substance to be penetrated. The shaft 60 has diametrically opposed tooth guides 64 which travel in radial grooves or longitudinal slots 65 in the tooth sleeve 37 so as to prevent each tooth from rotating and enable the tooth to be aligned in the desired orientation; also the guides limit the downward stroke of the tooth by virtue of the shoulder 65' at the lower end of the grooves or longitudinal slots 65.
A return spring 66 is mounted on the tooth shaft 60 between an upper retainer flange 68 and shoulder 69 and is mounted under compression so as to normally urge the tooth in a direction retracting it upwardly toward the activating piston 72. A pair of seals 70 are disposed at the lower end of the housing or sleeve 37 for each tooth. At the upper end of each tooth shaft 60 is a removable impact plate 67 of a substance similar to that employed on the tooth plate 62 and which is disposed at an angle with respect to the tooth shaft such that it is aligned with the axially extending lower end of the activating piston 54.
Referring to FIGS. 2 and 5, a combustion operated drive assembly is located at the upper end of the body 34 and is comprised of combustion chambers in the form of the concentric annular or ring-like areas 50, 51, 52 aligned above the rows 40 to 43 of the tooth drilling assembly. Each piston 54 is in the form of a generally ring-like member disposed in each respective chamber area 50-52 and which when fired will impact a single ring, or portion of a ring, of the movable drilling teeth 36. In a manner to be described, the individual pistons 54 can be fired as often as necessary to effect optimum efficiency in driving the teeth 36, and the firing of the pistons 54 can be retarded or speeded up depending upon the nature of the material to be penetrated. Essentially, however, the pistons 54 and their activating mechanisms to be described are fired sequentially from the inner circle 40 outwardly to the outermost circle 43 in succession so that the drilling teeth 36 are sequentially driven from the center to the outside of the hole. In this way, the chipped off portions of the substance to be penetrated will tend to advance into the space evacuated by the chipping action of the teeth of the next inner adjacent ring. In particular, the inside/out chipping action has been found to improve the efficiency and speed at which the substances can be penetrated. Moreover, the impact force may be varied according to the amount of fuel or fuel/air mixture supplied thus enabling accurate control of the penetration rate in substances of different hardness. Again, referring to FIGS. 2, 3, and 5, each piston impact block 72 is aligned in end-to-end relation to the lower end of piston 54, and impact plates 73 and 74 are removably attached to the confronting end surfaces of the piston 54 and impact block 72, respectively. Each piston 54 may assume various different configurations and, as illustrated in FIG. 5, includes an upper body portion 75 with axially spaced sealing rings 76, 77 extending around the internal and external side surfaces for sealing with respect to the wall of the cylinder. Upper body portion 75 tapers downwardly through a narrow cross section intermediate portion 78 and terminates in enlarged lower body portion 79 with the impact plate 73 removably attached to the lower end of the body portion 79. Corresponding sealing rings 76, 77 are disposed in axially spaced relation to one another between the lower body 79 and wall surfaces of the cylinder. Each piston impact block 72 is of annular configuration and arranged to extend downwardly from the piston 54 to terminate in a lower impact plate 80 in confronting relation to upper impact plates 67 of each tooth assembly.
The upper end of each combustion chamber is closed by a cylinder wall 82, there being a series of fuel injection valves 84 and exhaust valves 86 located in each concentric ring or row of chambers 50 to 52. Each injection valve 84 includes a valve stem 88 provided with an enlarged valve member 89 movable toward and away from a valve seat 90, the valve member having a conical surface 89' to correspond with the valve seat and movable between an open position as shown in FIG. 5 and a closed position bearing against the seat 90. An arcuate leaf spring member 81 extends through the valve stem and is curved downwardly into press fit engagement with grooves 91 in the upper surface of the cylinder wall 82 to normally urge the valve upwardly in a direction forcing it into the closed position. The upper end of the valve stem 88 bears against a valve control cam 85 in the form of a downwardly projecting rib on a ring or annular cam member 92, and upwardly projecting gear teeth 93 intermesh with teeth on a gear 94. A spark plug S is mounted in the cylinder wall 82 adjacent to each injection valve and is electrically connected to a contact block 98 which is spaced beneath contact block 99 electrically connected by line 100 to power source 26. Another contact block 102 on the surface of the valve disk will complete the circuit between the contact blocks 99 and 98 when the cam 92 is rotated in a manner to be hereinafter described so as to generate a spark within the combustion chamber directly beneath the valve member 89. Fuel is injected into each chamber via a fuel injection port 104 which communicates via fuel line 24 with the fuel pump 22 at the surface. As illustrated in FIGS. 2 and 8, the fuel injection port 104 for the inner concentric chamber extends radially through the cylinder wall 80 into communication with the seat 90. Additional fuel injection ports or lines are directed radially outwardly through the combustion chambers and concentric rings 50, 51 and 52 to each of the concentrically located valves 84, as schematically illustrated in FIG. 6.
Referring to the exhaust valve 86, although illustrated in side-by-side relation to an injection valve 84 in adjacent combustion chambers in FIG. 5, as further represented in FIG. 6, the exhaust valves 86 alternate with the injection valves 84 in each row. The valves 86 are spaced such that upon ignition of fuel in the chamber the exhaust valves 86 are advanced by a drive gear 94 to an open position in order to exhaust the combustion gases via ports 87 into line 30 after each ignition cycle and thereafter are returned to a closed position in preparation for the next ignition or firing sequence. As seen from FIG. 5, each exhaust valve 86 is of generally "Y" shaped configuration having upper bifurcated ends 106 and a lower valve member 108 having a conical surface normally urged against valve seat 109 in the cylinder wall 80. An arcuate leaf spring 110 is mounted with respect to the exhaust valve in the same manner as the leaf spring 81 for the injection valve and causes the valve stem to be normally urged in a direction closing the valve by urging the valve 108 into engagement with the seat 109. The cam ring 92 includes downwardly projecting ribs or cams 112 and 113 which are radially spaced with respect to one another, as best seen from FIG. 9. The ribs 112, 113 incline in a circumferential direction so as to form ramps of gradually increasing depth causing the exhaust valve 86 to be moved gradually into an open position and then gradually returned to a closed position during and after each firing sequence. Similarly, as illustrated in FIG. 8, the single rib or cam 85 is a ramp of generally increasing depth which is located centrally of the ring 92 and, as the ring 92 is rotated by the drive gear 94, will move into engagement with an injection valve stem 84 to overcome the urging of the leaf spring 81 and open the valve for introduction of fuel via the fuel line 24 as a preliminary to each firing sequence. The valve then returns to the closed position during each firing cycle under the urging of the leaf spring 81. The exhaust line 30 permits removal of the spent gases when uncovered by an exhaust valve 86 at the end of each firing sequence. Specifically, exhaust ports 87 radiate outwardly from the exhaust line through the combustion chambers, as illustrated in FIG. 6, for extension through a cylinder wall 82 into communication with a valve seat 109. Bearings 115 are disposed between the sides of the valve rings 92 and cylinder walls. Preferably the drive gear 94 is driven by a turbo electric motor M which is energized by the electrical lines 100 from the power source 26.
In operation, drilling fluid is circulated in a conventional manner through bore 14 and lower end 14' along the cutting face. The drilling fluid in a well known manner operates as a coolant as well as to aid in circulating and removing chipped particles upwardly for removal into a separate collection basin or reservoir at the surface. Compressed air is delivered by compressor 28 via circulating line 29 and into the combustion chambers via ports 104. Fuel is injected via lines 24 from the fuel tank 20 through fuel injection ports 104 into each of the combustion chambers. The rheostat control 27 is operative to regulate the downhole motor M for driving the cam rings 92 at a predetermined rate of speed. When the cam rings rotate, the contact block 102 completes the circuit between the outer contact blocks 98 and 99 causing a spark which fires each chamber in turn. The injection valve 84 is depressed as a preliminary to ignition to inject fuel into the chamber; and as the cam ring 92 rotates further the valve 84 is caused to retract into a closed position and electrical contact is made to ignite the fuel/air mixture. When ignited, the pressure buildup in the combustion chamber drives each piston 78 in succession downwardly against impact blocks 54 so as to impart a driving force to the upper impact plate 71 on each tooth drilling assembly in that circle. The firing frequency is controlled by the speed of rotation of the cam rings 92 when the motor M is energized, and the power of the stroke is regulated for the most part by the fuel injection pressure as determined by the fuel pump 22.
At the conclusion of the firing sequence, the cam rings 92 are advanced into engagement with the exhaust valves 86 to cause the valves to be depressed or opened and permit the spent gases to be exhausted as described. As each chamber is fired and the cam ring 92 is rotated, ribs 112 and 113 on the cam disk 92 move into a position to open the exhaust valve 86. Simultaneously, tooth springs 66 return the impacted teeth 62 to their original positions, thereby forcing the pistons upward into firing position causing exhaust gases to be expelled through the open exhaust valve 86. The firing sequence is established such that the drilling or cutting action proceeds from the inner row outwardly to the outermost row so that each row in succession is caused to fire and exert a penetrating action via the teeth. This sequential firing is created simply by appropriate arrangement of contact points 98, 99 and 100 on the cylinder walls and cam rings as illustrated.
As noted, the teeth 62 are of generally circular configuration although oval or other shapes of teeth are possible as long as they can be sealed to prevent the entry of drilling fluid and debris into the individual guideways for the tooth drilling assembly. It should be further noted that the fan-shaped arrangement of the teeth within the tooth housings are such that the inner rows are progressively lower than the outer rows so that the overall bit housing 34 is of generally convex configuration along the bottom. In the illustrative embodiment shown in FIG. 6, the number of injection/exhaust valves consists of one pair for each piston segment. The inner chamber ring may be one continuous ring, and the next ring comprised of two semi-circular chambers; the next outer concentric ring may be comprised of three chambers; and the next and subsequent rings may be comprised of three chamber sections. The number of separate firing chambers generally will depend on the hardness or ductility of material to be penetrated, and in certain cases can employ single chambers in each ring or annulus depending upon the hardness of material. Further, it is apparent that the number of teeth in a given housing may be varied as well as the particular angular disposition of the teeth 62. The return springs 60 as described exert sufficient force to retract the teeth at the completion of each firing sequence although it will be apparent that compressed air may be employed as a supplement to the return springs. By way of illustration, each ring of teeth may be fired every four seconds with the rate of rotation of each ring being on the order of one to two revolutions per minute. Rate of penetration can be increased with more rapid rotation but the main factor is the rate of the stroke.
It is therefore to be understood that various modifications and changes may be made in the specific construction and arrangement of parts as well as composition of materials comprising the alternate forms of the present invention without departing from the spirit and scope thereof as defined by the appended claims. | A percussion drilling apparatus for drilling bore holes into subterranean formation in which a plurality of drill rods are arranged in concentric rows in a drill bit housing, each rod having an impact tooth at its lower ends and the rods arranged either to converge inwardly adjacent to the center of the housing or to diverge outwardly at progressively increased angles in each row toward the outermost row. The impact teeth are fired sequentially by concentric combustion chambers arranged above the drill rods and where the pattern and rate of firing can be controlled by cam operated intake and exhaust valves associated with the combustion chambers. The drill bit housing is arranged at the lower end of the drill string with an umbilical cord which carries all necessary cables and lines between the surface controls and the drill bit housing for the purpose of controlling combustion in each chamber and of carrying away the cuttings as the drilling operation proceeds. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to a process for preparing mono-alkyl acid phosphates, and particularly concerns an improved process for preparing said phosphates with a high mono-content and light color.
2. The Prior Art
Mono-alkyl acid phosphates are well-known, and are generally prepared by reacting alcohols with phosphorus pentoxide. The nature of the chemical reaction between alcohols and phosphorus pentoxide is very nondiscreet. The result, therefore, is a mixture of products including monoalkyl acid phosphate, di-alkyl acid phosphate, free phosphoric acid, variously substituted pyrophosphate, and possibly even triphosphate. The situation is further complicated in the case wherein stearyl alcohol is used as it is a solid at room temperature and relatively unreactive. Phosphorus pentoxide is also a solid. Therefore, the reaction between stearyl alcohol and phosphorus pentoxide must be run at a temperature above the melting point of stearyl alcohol (mp 58° C.).
It is particularly advantageous to obtain a product according to the present invention that is high in monocontent. The high mono-content product is more effective than low mono-content products as a surfactant and as an agent for removal of blood stains, egg yolk, and the like from cloth and other materials.
Another advantage of the present invention is the light color of the product. Light color is advantageous because it makes the product more desirable for marketing purposes.
Various methods have been described in the prior art for improving the mono-content in the synthesis of mono-alkyl acid phosphates. In U.S. Pat. No. 2,586,897, for example, water is added to the reaction mixture of lauryl alcohol and phosphorus pentoxide to hydrolyze any acid phosphate esters. This enhances the production of monolauryl phosphate. This technique is also described in U.S. Pat. No. 3,318,982.
It is also known in the prior art to add hydrogen peroxide to the reaction mixture to improve the color of the product. See, for example, U.S. application Ser. No. 791,625, filed Apr. 27, 1977.
SUMMARY OF THE INVENTION
In accordance with the present invention, production of mono-alkyl acid phosphates with high mono-content and light color is achieved by following a specific reaction sequence.
The sequence is generally outlined as follows:
Step 1. -- Alcohol is introduced into a reaction vessel followed by mixing with tetrasodium pyrosphosphate.
Step 2. -- An approximately stoichiometric amount of P 2 O 5 is introduced into the reaction vessel.
Step 3. -- Water and hydrogen peroxide, P 2 O 5 and alcohol are introduced sequentially or continuously into the reaction vessel. The P 2 O 5 added at this time is in slight stoichiometric excess over the alcohol.
Step 4. -- Hydrogen peroxide is introduced into the reaction vessel.
The product is a mixture of mono- and di-alkyl acid phosphate having light color and a mono-content of over about 70 percent by weight.
The products of the present invention have the general formula: ##STR2## wherein R is straight or branched alkyl having from 1 to about 25 carbon atoms.
An idealized reaction scheme for the present invention is: ##STR3## wherein R is as defined above.
DETAILED DESCRIPTION OF THE INVENTION
In the mono-alkyl acid phosphates of the present invention having the structural formula: ##STR4## wherein R is as defined above, exemplary R groups include but are not limited to methyl, ethyl, propyl, isopropyl, butyl, tert-butyl, pentyl, heptyl, octyl, decyl, dodecyl, hexadecyl, nonadecyl, lauryl, palmityl and stearyl.
The process of the present invention is carried out by following a specific reaction sequence. Said sequence can be defined by four sequential steps as follows:
Step. 1. -- Alcohol having the structural formula:
ROH (11)
wherein R is as defined above, is introduced into a reaction vessel. Tetrasodium pyrophosphate (Na 4 P 2 O 7 ) is admixed with the alcohol, prior to or following introduction of the alcohol into the reaction vessel, in an amount from about 0.1 percent to about 0.5 percent by weight of the alcohol.
Step 2. -- An approximately stoichiometric amount of phosphorus pentoxide (P 2 O 5 ) is introduced into the reaction vessel.
Step 3. -- Water and hydrogen peroxide, the hydrogen peroxide having a concentration from about 5 percent to about 10 percent by weight of the water, P 2 O 5 and the alcohol are introduced sequentially or continuously into the reaction vessel.
The P 2 O 5 added in this step is in stoichiometric excess from about 2 percent to about 15 percent over the alcohol.
Step 4. -- Hydrogen peroxide in an amount from about 0.2 percent to about 0.5 percent by weight of the alcohol is introduced into the reaction vessel.
The following reaction scheme (2) is representative of the process: ##STR5## wherein R is defined above.
Step 1 can be modified by utilizing a heel from a previous preparation of mono-alkyl acid phosphate rather than the initial charge of alcohol. The heel generally consists of mono-alkyl acid phosphate, di-alkyl acid phosphate and free H 3 PO 4 . This modification has the disadvantage that the product is darker than the product produced with an initial charge of alcohol to the reaction vessel.
A stoichiometric excess of P 2 O 5 is utilized in Step 3 to limit the quantity of di-alkyl acid phosphate formed.
The final step of adding hydrogen peroxide results in a lighter colored product.
Products of the process can be removed from the reaction vessel by, for example, pumping the product to a flaker followed by discharging the resultant flakes into a storage or shipping container.
During Steps 1 and 2, the temperature of the reactants in the reaction vessel is maintained from about 20° to about 180° C., and preferably from about 50° to about 100° C. The preferred temperature range is selected because excess thermal energy will promote undesirable side reactions such as dehydration which results in the formation of pyro-compounds and other reactions which are deleterious to the color of the mono-alkyl acid phosphate product. Inadequate thermal energy, however, can result in crystallization or solidification of the alcohol. Process temperatures that will provide good product distribution and color can easily be determined by one skilled in the art.
In Steps 3 and 4, the reaction mixture is maintained at a temperature from about 40° to about 200° C., and preferably from about 60° to about 140° C. The reason for the preference is to minimize thermal catalyzed degradation which is accompanied by lower yields, undesired product color even with the addition of hydrogen peroxide, and possible loss of desired product selectivity. The optimum temperature can easily be determined by one skilled in the art. In the case of a process utilizing stearyl alcohol, for example, the optimum temperature is in the range from about 80° to about 85° C.
The product is a mixture of mono-alkyl acid phosphate and di-alkyl acid phosphate having a mono-content of over about 70 percent by weight.
The reaction can be conducted in a continuous or batchwise process.
Reaction times can vary over relatively wide ranges and can easily be determined by one skilled in the art. Factors affecting reaction time include reaction temperature, viscosity, efficiency of mixing, rate of addition of reactants and rate of heat input.
Typical reaction times are from about 1 to about 10 hours. Times from about 3 to about 6 hours are preferred, however, to prevent product degradation and color formation.
The products of the present invention can be purified if desired by conventional means. These include crystallization and chromatography among others.
The identification of the products can be achieved by infrared spectroscopy, hydrogen and phosphorus nuclear magnetic resonance spectroscopy, titration, and elemental analysis.
Typical yields of the desired mono-alkyl acid phosphates of the present invention are from about 70 percent to about 95 percent.
Illustrative of the mono-alkyl acid phosphate compounds of the present invention are: ##STR6##
Isomers of the foregoing illustrative compounds are also illustrative of the mono-alkyl acid phosphate compounds of the present invention.
The mono-alkyl acid phosphates of the present invention are useful as surface active agents for use in cleaning systems such as detergents utilized in dish-washing and industrial bottle-cleaning formulations, food grade lubricants and flotation and suspending agents.
One aspect of the present invention involves the preparation of monostearyl acid phosphate. The reaction to produce this product requires the use of molten stearyl alcohol in the process described above, or use of solid stearyl alcohol flakes added to the reaction mixture.
The present invention will be more fully illustrated in the example which follows:
EXAMPLE
Pilot plant scale equipment was utilized to prepare monostearyl acid phosphate. The equipment was as follows:
1. a jacketed, 300 gallon, stainless steel reactor provided with a turbine agitator, baffles and a thermocouple;
2. a 20 gallon per minute stainless steel centrifugal pump provided on a recycling line for the reactor, the pump and line having steam coils;
3. a variable speed, stainless steel, screw feeder provided with a 30 cubic foot hopper and placed on a scale;
4. a variable feed, single drum, flaker having a 12 inch diameter and an 18 inch length; and
5. an open, 50 gallon, stainless steel container provided with a steam coil.
Raw materials utilized were as follows:
1. stearyl alcohol flakes;
2. phosphoric anhydride (P 2 O 5 );
3. food grade tetrasodium pyrophosphate;
4. 30% hydrogen peroxide; and
5. deionized water.
The process was conducted stepwise as follows:
1. Two hundred pounds of stearyl alcohol flakes were added to the 50 gallon container. The system was turned on to melt the alcohol flakes while maintaining temperature below 90° C. Melting time was two hours.
2. The liquid stearyl alcohol was then transferred to the 300 gallon reactor and the turbine agitator was turned on. The steam was then turned off.
3. Two pounds of tetrasodium pyrophosphate were added to the reactor.
4. The steam was turned on or the steam coils in the recycling line and pump. After the coils heated up, the bottom valve on the reactor was opened and the pump turned on.
5. The steam was then turned off and cold water was circulated through the jacket to bring the stearyl alcohol temperature down to 80° C.
6. Fifty-five pounds of P 2 O 5 was then added to the reactor at a rate of 1 to 1.5 pounds per minute. The temperature was maintained at 80° to 85° C. throughout the addition. When the temperature reached 85° C., 3600 cubic centimeters of water mixed with 360 cubic centimeters of H 2 O 2 was added in small portions over a span of about 20 minutes. This helped to keep the temperature of the reaction mixture below 85° C.
7. After the water addition, the P 2 O 5 feeding was stopped as soon as the reaction temperature reached 85° C. Small increments of P 2 O 5 were then added as the temperature went down until the entire 55 pounds of P 2 O 5 was added.
8. The jacket temperature was then adjusted to 85° C. with warm water and the following series of operations were performed twelve times.
(a) The reaction temperature was maintained at 80°-85° C.
(b) 900 cubic centimeters of water mixed with 90 cubic centimeters of 30% H 2 O 2 were added to the reactor and at the same time 14 pounds of P 2 O 5 were added at a rate of 1 pound per minute.
(c) As soon as 1-2 pounds of P 2 O 5 had been added, the addition of 50 pounds of stearyl alcohol was begun. The addition of P 2 O 5 was kept proportionally ahead of the stearyl alcohol addition.
Steps (a) - (c) took a total of about 20 minutes. Over the entire reaction period, the mass of reaction looked like a tan to light brown fluid slurry. No foaming occurred.
9. Once all of the raw materials had been added, the reactor contents were agitated for 2 more hours and kept at 80° to 85° C. The slurry became a clear brown liquid.
10. Bleaching was then effected by adding 2000 cubic centimeters of 30 percent H 2 O 2 . Agitating was then continued for 2 hours and the liquid became a tan color.
11. The product was removed from the reactor by the following procedures:
(a) The pipe from the reactor was heated with a steam coil.
(b) The flaker pan was heated with a steam coil and an electrical heater.
(c) The flaker drum was cooled with cool water and the drum speed was set at 4 revolutions per minute.
(d) Flow through the reactor pipe was begun and maintained at a rate of about 120 pounds per hour.
Easily breakable sheets of product were obtained from the flaker drum. During the flaking procedure, 30 percent H 2 O 2 was added to the reactor every two hours in an H 2 O 2 equivalent of about 0.1 percent of the product still left in the reactor.
The major components of the product had the following specifications:
78 percent monostearyl acid phosphate (1050 pounds)
8.8 percent distearyl acid phosphate
7.0 percent phosphoric acid
color -- off-white flakes
Having set forth the general nature and an example of the present invention, the scope is now particularly set forth in the appended claims. | Mono-alkyl acid phosphates having the formula: ##STR1## wherein R is straight or branched alkyl having from 1 to about 25 carbon atoms, are prepared by reacting alcohol with P 2 O 5 in the presence of tetrasodium pyrophosphate and hydrogen peroxide. The process involves initially adding P 2 O 5 to a mixture of alcohol and tetrasodium pyrophosphate followed by continuous or sequential addition of water and hydrogen peroxide, P 2 O 5 (in stoichiometic excess) and then alcohol. Additional hydrogen peroxide is added at the end of the reaction. A mixture of mono- and di-alkyl acid phsophate is obtained with a mono-content of over about 70 percent by weight. | 2 |
BACKGROUND
[0001] 1. Field of Invention
[0002] The invention relates generally to a system and method for locking together tubulars in a wellhead assembly.
[0003] 2. Description of Prior Art
[0004] Wellheads used in the production of hydrocarbons extracted from subterranean formations typically comprise a wellhead assembly attached at the upper end of a wellbore formed into a hydrocarbon producing formation. Wellhead assemblies usually provide support hangers for suspending production tubing and casing into the wellbore. The casing lines the wellbore, thereby isolating the wellbore from the surrounding formation. The tubing typically lies concentric within the casing and provides a conduit therein for producing the hydrocarbons entrained within the formation.
[0005] Wellhead assemblies also typically include a wellhead housing adjacent where the casing and tubing enter the wellbore, and a production tree atop the wellhead housing. The production tree is commonly used to control and distribute the fluids produced from the wellbore and selectively provide fluid communication or access to the tubing, casing, and/or annuluses between the tubing and casing. Valves assemblies are typically provided within wellhead production trees for controlling fluid flow across a wellhead, such as production flow from the borehole or circulating fluid flow in and out of a wellhead.
[0006] Seals are used between inner and outer wellhead tubular members to contain internal well pressure. The inner wellhead member may be a tubing hanger that supports a string of tubing extending into the well for the flow of production fluid. The tubing hanger lands in an outer wellhead member, which may be a wellhead housing, a production tree, or a tubing head. A packoff or seal seals between the tubing hanger and the outer wellhead member. Alternately, the inner wellhead member might be an isolation sleeve secured to a production tree. A seal or packoff seals between the isolation sleeve and a casing hanger located within the wellhead housing.
[0007] A variety of seals of this nature have been employed in the prior art. Prior art seals include elastomeric and partially metal and elastomeric rings. Prior art seal rings made entirely of metal for forming metal-to-metal seals are also employed. The seals may be set by a running tool, or they may be set in response to the weight of the string of casing or tubing. One type of prior art metal-to-metal seal has inner and outer walls separated by a conical slot. An energizing ring is pushed into the slot to deform the inner and outer walls apart into sealing engagement with the inner and outer wellhead members. The deformation of the inner and outer walls exceeds the yield strength of the material of the seal ring, making the deformation permanent. Sometimes a lockdown ring is provided in the annular space between the tubulars, which is put into a position that locks the tubulars to one another when the seal is set.
SUMMARY OF THE INVENTION
[0008] Provided herein is an example of a wellhead assembly. In one example, a wellhead assembly includes an axis, an outer tubular, an inner tubular inserted into the outer tubular and defining an annular space between the inner tubular and outer tubular, and a lock ring in the annular space that is moveable from an unlocked position into a locked position. The wellhead assembly of this embodiment also includes an activation ring having a profiled surface that is axially slidable against and in contact with the lock ring to define a contact interface that is offset an angle from the axis when the lock ring is in the locked position, and to define a contact interface that is offset an angle from the axis when the lock ring is in the unlocked position, so that the angle when the lock ring is in the locked position is less than the angle when the lock ring is in the unlocked position. Optionally, a portion of the profiled surface is curved that is in contact with the lock ring when the lock ring is in the unlocked position, and a portion of the profiled surface that is in contact with the lock ring when the lock ring is in the locked position is substantially linear. In one example embodiment, the lock ring is set radially inward from the outer tubular when in the unlocked position, and the lock ring comprises a protrusion that engages a depression formed in an inner radial surface of the outer tubular. Alternatively, the lock ring is set radially outward from the inner tubular when in the unlocked position, and the lock ring has a protrusion that engages a depression formed in an outer radial surface of the inner tubular. In an alternate embodiment, the wellhead further includes a seal assembly that transfers a downward axial force to an upper end of the activation ring and that is energized by an energizing force. The force applied to the activation ring that slides the activation ring along the lock ring may urge the lock ring from the unlocked position to the locked position, and the energizing force can be greater than the force applied to the activation ring. In one example, the outer tubular is a wellhead housing and the inner tubular is a tubing hanger.
[0009] Also provided herein is a system for locking together tubulars that are disposed in a wellhead assembly. In this example the system includes a lock ring that axially rests on one of the tubulars and selectively engages an adjacent tubular thereby axially locking together the one of the tubulars and the adjacent tubular. Also included is an activation ring axially moveable to between the lock ring and the one of the tubulars and having a surface in sliding contact with the lock ring that transitions from a curved profile to a linear profile as the activation ring moves to between the lock ring and the one of the tubulars. In an example embodiment of the system, the activation ring contacts the lock ring along an interface that is offset from an axis of the wellhead assembly by an angle up to about 5 degrees when the lock ring is engagement with the adjacent tubular. Optionally, the activation ring contacts the lock ring along an interface that is offset from an axis of the wellhead assembly by an angle that ranges from at least about 5 degrees to about 30 degrees when the curved profile is in contact with the lock ring. The one of the tubulars can be a tubing hanger and the adjacent tubular can be a wellhead housing. In an alternate example, the one of the tubulars can be a wellhead housing and the adjacent tubular can be a tubing hanger. Optionally, an upper end of the activation ring is in axial contact with a seal assembly, where the seal assembly is energized with an axial force that exceeds a force applied to slide the activation ring from a position above the lock ring to a position adjacent the lock ring.
[0010] Yet further provided herein is a method of locking together tubulars in a wellhead assembly. One example embodiment of the method includes providing a lock ring on a lateral surface of one of the tubulars, applying a force onto the lock ring in a direction oblique with an axis of the wellhead assembly to radially urge the lock ring towards an adjacent tubular, changing the direction of the force to be substantially perpendicular to the axis and engaging the lock ring with the adjacent tubular, and retaining the lock ring in engagement with the adjacent tubular by continuing to apply the force in a direction substantially perpendicular to the axis. The method may further include providing an activation ring having a contact surface that transitions from a curved portion to a linear portion. In one example, the step of applying a force onto the lock ring in a direction oblique with an axis of the wellhead assembly involves axially urging the activation ring so the curved portion slides against a side of the lock ring. In an optional embodiment, the step of applying a force onto the lock ring in a direction perpendicular to an axis of the wellhead assembly includes axially urging the activation ring so the linear portion slides against a side of the lock ring. In an example, the step of continuing to apply the force in a direction substantially perpendicular to the axis includes retaining the activation ring adjacent the lock ring so the linear portion is in contact with a side of the lock ring.
BRIEF DESCRIPTION OF DRAWINGS
[0011] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0012] FIGS. 1A and 1B are side sectional views of an example of coupling together tubulars in a wellhead assembly in accordance with the present invention.
[0013] FIGS. 2A-2C are side sectional detailed views of operation of a locking mechanism of FIGS. 1A and 1B in accordance with the present invention.
[0014] FIG. 3 is a side partial sectional view of an example embodiment of the wellhead assembly of FIGS. 1A and 1B set over a wellbore in accordance with the present invention.
[0015] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0016] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
[0017] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the improvements herein described are therefore to be limited only by the scope of the appended claims.
[0018] FIG. 1A is a side sectional view of one example embodiment of a wellhead assembly 10 that includes a portion of a wellhead housing 12 adjacent a tubing hanger 14 . The wellhead housing 12 and tubing hanger 14 are generally tubular members that are spaced apart. An example of a seal assembly 16 is illustrated set within an annulus 18 that is between the tubing hanger 14 and wellhead housing 12 . The embodiment of the seal assembly 16 includes an annular seal ring 20 insertable into the annulus 18 . The seal ring 20 of FIG. 1A has an inner leg 22 , which as provided in the sectional view is an elongate member that extends generally parallel with an axis A X of the wellhead assembly 10 . The example of the seal ring 20 also includes an outer leg 24 ; which also extends substantially parallel with the axis A X and is longer than the inner leg 22 . The outer leg 24 is set radially outward from the inner leg 22 to define an annular space 26 set between the inner and outer legs 22 , 24 . The inner and outer legs 22 , 24 are connected to one another on their respective lower ends by a cross piece that also defines a lower surface of the space 26 . An energizing ring 28 is shown having a lower end inserted into an upper end of the space 26 . In an example, axially urging the seal assembly 20 into annulus 18 then inserting energizing ring 28 into space 26 urges legs 22 , 24 radially outward from one another thereby creating a pressure barrier in the annulus 18 . A ring-like collar 30 is shown circumscribing a portion of the energizing ring 28 and threadingly engaged with an upper end of the outer leg 24 .
[0019] Further illustrated in the example of the wellhead assembly 10 of FIG. 1A is an annular activation ring 32 , which is set in the annulus 18 below the seal assembly 20 . In the example of FIG. 1A , the lower end of the seal assembly 20 rests on an upper end of the activation ring 32 . Below the activation ring 32 is a lock ring 34 for axially locking together the wellhead housing 12 and tubing hanger 14 . Referring now to FIG. 2A , illustrated in detailed sectional view is an example of the activation ring 32 and lock ring 34 . In the example of FIGS. 1A and 2A , the lock ring 34 is in an unlocked configuration, thus the wellhead housing 12 and tubing hanger 14 may move axially with respect to one another. As shown in FIG. 2A , a surface of the activation ring 32 facing axis A X defines an inner surface 36 that is shown having a transition 38 where a radius of the surface 36 changes. Opposite the inner surface 36 is an outer surface 40 shown having a lower portion 42 that transitions into an upper portion 44 . The transition 46 at the upper end of upper portion 44 defines where a change in length of radius of the outer surface 40 takes place.
[0020] Profiles 48 are shown formed on the outer surface 40 and above transition 46 to define a handle 50 for raising and lowering the activation ring 32 within the annulus 18 ( FIG. 1A ). In the example of FIG. 2A , a line L 1 is shown extending tangentially across upper portion 44 illustrating in the example of FIG. 2A that the outer surface 40 is generally linear along upper portion in the axial direction. In contrast, outer surface 40 along lower portion 42 is curved and in some portions thereof maintains a consistent radius. A line L 2 is shown tangentially across a portion of an inner surface of the lock ring 34 . In one example embodiment, the line L 2 is at about 20 degrees to about 35 degrees offset from axis A X .
[0021] Still referring to FIG. 2A , an outer surface 54 of the lock ring 34 is shown having protrusions 56 that extend radially outward and away from inner surface 52 . Referring back to FIG. 1A , the protrusions 56 are profiled to correspond to depressions 58 shown formed along an inner surface 60 of the wellhead housing 12 and adjacent lock ring 34 . Further illustrated in FIG. 1A are wickers 62 , 64 shown respectively formed on the inner surface 60 of the wellhead housing 12 and an outer surface 66 of the tubing hanger 14 . In an embodiment, the wickers 62 , 64 are ridge-like members formed in the surfaces 60 , 66 , so that when the seal 20 is set in the annulus 18 , the wickers 62 , 64 deform respective outer surfaces of the inner leg 22 and outer leg for enhancing the sealing function of the seal assembly 20 .
[0022] FIG. 1B illustrates in side sectional view an example of the lock ring 34 set in a locked position and in engagement with the depressions 58 on the wellhead housing 12 . Further illustrated in FIG. 1B is that a lower end of the lock ring 34 rests on a shoulder 67 defined where the outer surface 66 of the tubing hanger 14 juts radially outward and away from axis A X . Engaging the protrusions 56 with the depressions 58 axially retains the lock ring 34 in place. Also, by contacting the shoulder 67 with lower end of the block ring 34 , the tubing hanger 14 is prevented from moving axially upward with respect to the wellhead housing 12 by the axially static lock ring 34 . Further in the example of FIG. 1B , the lock ring 34 engages the profiles 58 by being moved radially outward from axis A X by downward axial movement of the activation ring 32 . Thus, retaining the activation ring 32 in the position of FIG. 1B , the tubing hanger 14 is axially constrained to the wellhead housing 12 .
[0023] A detailed example of interaction between the activation ring 32 and lock ring 34 in the locked position is illustrated in side sectional view in FIGS. 2B and 2C . In FIG. 2B , shown is an example of the activation ring 32 having a force F applied to its upper end thereby slidingly urging the activation ring 32 to a position adjacent the lock ring 34 ( FIG. 2C ). In one example, the activation ring 32 and lock ring 34 are substantially coaxial when the lock ring 34 is in the locked position. In the example of FIG. 2B , the lower curved portion 42 of the activation ring 32 is in contact with the inner surface 52 of the lock ring 34 . As such, a resultant force F R is exerted against the lock ring 34 and shown being in a direction generally oblique to the axis A X . With further downward movement of the activation ring 32 , the direction of resultant force F R rotates from its oblique orientation and to one that is close to being substantially perpendicular to axis A X ( FIG. 2 ). In the example of FIG. 2B , a portion of line L 3 extends along a contact interface between the activation ring 32 and lock ring 34 . Similarly, line L 4 in FIG. 2C is drawn along a contact interface between the activation ring 32 and lock ring 34 when the activation ring 32 is substantially adjacent lock ring 34 . As shown, line L 4 is at an offset angle from axis A X that is less than an offset angle between L 3 and axis A X ( FIG. 2B ).
[0024] An advantage of the curved lower surface 42 is that the lock ring 34 may be urged radially outward into its locked configuration with the wellhead housing 12 by a stroke distance of the activation ring 32 that is shorter than a corresponding stroke distance in instances where the lower portion 42 is linear. Moreover, by transitioning the outer surface 40 of the activation ring 32 from a curved lower portion 44 to a linear upper portion 44 , the resultant force F R has a reduced axial component exerted from the lock ring 34 onto the activation ring 32 . As such, more force from the lockdown system may be distributed towards retaining the tubing hanger 14 rather than maintaining the lock ring 34 in its locked position.
[0025] FIG. 3 is a side partial sectional view of one example of the wellhead assembly 10 shown set over a wellbore 68 , where the wellbore 68 extends through a formation 70 . In the example of FIG. 3 , an example of a lockdown assembly 71 is schematically illustrated for locking the tubing hanger 14 to the wellhead housing 12 . In the example of FIG. 3 , the lockdown assembly 71 includes examples of the activation ring and lockdown ring as described above. Further illustrated in FIG. 3 is a string of tubing 72 that depends downward into the bore hole 68 from the tubing hanger 14 .
[0026] An additional advantage of the lockdown assembly illustrated herein is that by transitioning the outer surface of the retaining ring 32 , axial forces required for retaining the lockdown ring 34 in its locked position are reduced that in turn allows for higher preloads on a seal assembly 20 ( FIG. 1A ). Thus, the lock ring 34 can be set at an axial force below that which may initiate energizing of a seal set in the annulus 18 .
[0027] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | A wellhead assembly having an outer tubular, an inner tubular inserted into the outer tubular, an annular space between the inner and outer tubulars, a lock ring in the annular space, and an activation ring that axially strokes between the lock ring and one of the tubulars. The lock ring selectively locks together the inner and outer tubulars when the activation ring slides between the lock ring and the one of the tubulars. The surface of the activation ring that contacts lock ring is contoured so that an interface surface between the activation ring and lock ring when the lock ring is in its locked position, is offset an angle from an axis of the wellhead that is less than an offset between the axis of the wellhead and an interface surface between the activation ring and lock ring when the activation ring is stroking downward. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation (and claims the benefit of priority under 35 USC 120) of U.S. application Ser. No. 13/153,331, filed Jun. 3, 2011, now allowed, which is incorporated by reference in its entirety.
TECHNICAL FIELD
This disclosure relates generally to creating custom vibration patterns for playback by a mobile electronic device, for example, in response to receiving a notification event.
BACKGROUND
Mobile devices are currently capable of providing unique audible indications in response to receiving notifications or alerts at the mobile device, for example, the receipt of a phone call, email message, or text message. For example, a user of a mobile device may assign unique ringtones to associated contacts in the user's contact address book. When the mobile device detects that one of these unique contacts is calling, or otherwise attempting to communicate with, the user, the mobile device can provide audible playback of the unique ringtone assigned to the calling contact.
In addition, a user of a mobile device can assign unique sounds to essentially any notification event associated with a mobile device. For example, phone calls, SMS/MMS messages, email receipt, calendar alerts, and the like may be assigned to corresponding sounds that can audibly inform the user of the underlying notification event or alert.
SUMMARY
This disclosure describes technology, which can be implemented as a method, apparatus, and/or computer software embodied in a computer-readable medium, and which, among other things, be used to create custom vibration patterns in response to user input, for example, in response to the user tapping out a desired pattern on the display of a mobile device.
In general, in one aspect, a method performed by one or more processes executing on a computer system includes receiving tactile input from a user of an electronic device specifying a custom vibration pattern, in concert with receiving tactile input, providing visual feedback to the user corresponding to the received tactile input, and storing the specified custom vibration pattern for use by the electronic device to actuate haptic feedback signaling a predetermined notification event. Other implementations of this aspect include corresponding systems, apparatus, and computer program products.
This, and other aspects, can include one or more of the following features. The tactile input may comprise a cadence of tap-down and tap-up events received on a touch-sensitive surface of the electronic device. The visual feedback may comprise a progress bar illustrating the custom vibration pattern over time. The progress bar may include an indication of vibration segments within the custom vibration pattern, the vibration segments corresponding to tap-down events. The indication of each vibration segment in the progress bar may include a length, wherein the length of each vibration segment corresponds to a duration of a tap-down event. The visual feedback may visually accentuate an origin of a tap-down event. The visual feedback may vary in relation to at least one of intensity and duration of the tap-down event. The visual feedback may be noticeably lesser regarding at least one of color intensity, size, and speed for a shorter duration tap-down event as compared to a longer duration tap-down event. The method can further include, in concert with receiving the tactile input, providing haptic feedback to the user corresponding to the received tactile input specifying the custom vibration pattern. The haptic feedback may vary in relation to at least one of intensity and duration of a tap-down event. The haptic feedback may be noticeably lesser regarding at least one of duration and intensity for a shorter duration tap-down event as compared to a longer duration tap-down event. The method may further include replaying the custom vibration pattern, where the replaying further includes providing the visual feedback to the user corresponding to the tactile input and actuating haptic feedback corresponding to the custom vibration pattern. The method may further include assigning the custom vibration pattern to a notification event and upon detection of the notification event by the electronic device, actuating haptic feedback in accordance with custom vibration pattern.
Potential advantages that may arise from the described subject matter may include enhanced visualization feedback during the recording and replay phases of a custom vibration pattern. For example, while recording a custom vibration pattern, a user may tap out a pattern on the display of a mobile device. Upon detecting a tap-down event, the mobile device can provide visualizations in the display corresponding to the tap-down event. For example, a progress bar may be displayed that contains indications of the length of a tap-down event and/or periods between tap-down events. In addition, other visual feedback may be provided simultaneously in another portion of the display. For example, a pebble-in-pond ripple effect may be displayed in which ripples visually appear on the display screen to be emanating from the origin of the tap-down event. The ripple effect may vary in intensity and color corresponding to the force and duration of the tap-down event.
Another potential advantage may include a method for vibrating a mobile device in a customized way so as to provide recognizable vibration feedback for a notification event or alert. For example, a unique vibration pattern can be assigned to a particular contact in an address book, a SMS/MMS notification, a calendar alert, email receipt, and the like. Upon detecting a notification event or alert, if the notification event or alert is assigned to a vibration pattern, the mobile device can actuate haptic feedback corresponding to the vibration pattern to inform a user of the mobile device of the underlying notification event or alert.
Details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, aspects, and potential advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a flowchart of an example method for creating a custom vibration pattern for a notification event.
FIGS. 2 a -2 d are exemplary user interfaces for creating custom vibration patterns on a mobile device.
FIGS. 3 a -3 b are exemplary user interfaces for replaying custom vibration patterns on a mobile device.
FIG. 4 is an exemplary user interface for naming and storing a custom vibration.
FIG. 5 is an exemplary user interface for assigning a vibration pattern to a notification event.
FIG. 6 is a block diagram of exemplary architecture of a mobile device.
FIG. 7 is a block diagram of an exemplary network operating environment for mobile devices.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 is a flowchart of an example method for creating a custom vibration pattern and assigning the custom vibration pattern to a notification event. In step 110 , a user of a mobile device may initiate recording of a custom vibration pattern. For example, the user may select a record button in the user interface of an application for creating a custom vibration pattern. Upon initiation of the record phase, the mobile device can detect and capture input received from the user and create a custom vibration pattern in response to the input. In step 112 , user input can be received at the mobile device. For example, a user may physically tap out a cadence (e.g., a series of tap-down events of varying duration and potentially having varying delays between them) on a touch-sensitive surface associated with the mobile device. Input may also be received from any other suitable input mechanism, e.g., a motion capture sensor or a physical button on the mobile device. For each tap-down event, a particular vibration segment within a vibration pattern can be created. In some implementations, the duration of a vibration segment may be related to a respective duration of a tap-down event. Additionally, the duration of a tap-up event, e.g., an arbitrarily long duration during which no tap-down events are detected, may be related to a respective duration between tap-down events. For example, if a mobile device detects a one second tap-down event (e.g., the user's finger or stylus remains in contact with the touch sensitive surface) followed by two seconds of a tap-up event followed by three seconds of a second tap-down event, the vibration pattern can be one second of vibration followed by two seconds of no vibration followed by three seconds of vibration.
A measure of intensity (e.g., a detected force with which the user asserted a finger or stylus against the touch sensitive surface) may be detected with each tap-down event and translated into variable intensity (e.g., varying levels of vibration) for a corresponding vibration segment in the vibration pattern. In some implementations, intensity of a vibration segment may be variable based on the duration of a tap-down event. For example, at the start of a tap-down event, a vibration segment may be associated with a particular intensity. As the duration of the tap-down event increases, the intensity associated with the vibration segment may increase or decrease as a function of the duration of the tap-down event, e.g., proportionally to the duration of the tap-down event or inversely to the duration of the tap down event. In some implementations, the intensity associated with a vibration segment may reach a maximum intensity based on the capabilities of the haptic mechanisms in a mobile device.
In another implementation, intensity may be determined based on an amount of force applied to a touch-sensitive surface or the location on a touch-sensitive surface of a tap-down event. For example, varying forces (e.g., a finger or stylus applying different amounts of force) can be detected on a touch-sensitive surface during a single tap-down event. Such varying forces can be translated to varying vibrations in the vibration segment corresponding to the tap-down event. Additionally, specific regions of a touch-sensitive surface may be associated with varying levels of intensity such that when a tap-down event occurs in a specific region, a specific intensity is assigned to the corresponding vibration segment. For example, a tap-down event sensed in one specific region of the touch sensitive surface, for example, the center, may correspond to a higher intensity vibration whereas a tap-down sensed in another specific region of the touch sensitive surface, for example, a corner, may correspond to a lower intensity vibration. In some implementations, intensity may be determined based on a particular tap-down and drag pattern across a touch-sensitive surface. For example, a tap-down event may start in one portion of a touch-sensitive surface and end in another. An intensity may be assigned to a corresponding vibration segment based on the direction of travel for the tap-down event. For example, a tap-down event that starts near the bottom and ends near the top of the touch sensitive surface may correspond to a high, or increasing, intensity, while a tap-down event detected moving in the opposite direction may correspond to a low, or decreasing, intensity. Tap-down events moving left-to-right, right-to-left, or diagonally similarly may correspond to predetermined intensity levels and/or patterns of varying intensities.
User input received in step 112 may also be detected by a motion sensing component of a mobile device. For example, a user can make a physical gesture with the mobile device (e.g., accelerate the device in a direction such as up, down, left, or right) which can be translated into a corresponding vibration segment in a vibration pattern.
In step 114 , feedback may be provided in response to the user input received in step 112 . Feedback may be provided visually, tactilely, audibly, or through any other suitable means for providing feedback. In some implementations, the duration of a tap-down event may correspond to the duration of a particular vibration segment in a vibration pattern. Visual feedback may be provided depicting the duration of the vibration segment based on the duration of the tap-down event. For example, a progress bar may be displayed that indicates the duration of a vibration pattern over time and the duration of the vibration segments within the vibration pattern over time. In some implementations, a shorter duration tap-down event, e.g., a tap-down without a tap-down hold, may be represented by a dot whereas a longer duration tap-down event, e.g., a tap-down with a tap-down hold, may be represented by a growing rectangle of variable length in the progress bar.
Other visual feedback may be provided on the display of a mobile device in step 114 in response to receiving user input to create a vibration pattern, e.g., a “pebble-in-pond” effect such as shown in FIG. 4 b . In some implementations, a pebble-in-pond effect can be visualized as a rippling wave or waves emanating from the origin on the touch-sensitive surface where a tap-down event was detected, similar to waves emanating from the origin of a pebble entering a pond. If the tap-down event is shorter in duration or has weaker intensity, the ripples emanating from the tap-down event can appear to be smaller as if a small pebble were thrown into a pond. On the other hand, if the tap-down event is longer in duration or has a stronger intensity, the ripples emanating from the origin of the tap-down event can appear to be larger as if a large pebble were thrown into a pond. Additionally, fewer ripples may be used for a shorter tap-down event and a greater number of ripples may be used for a longer tap-down event. In some implementations, color may be associated with the ripples such that certain colors are associated with varying intensities of a tap-down event. For example, a shorter duration or weaker in intensity tap-down event may result in green ripples whereas a longer duration or stronger intensity tap-down event may result in red ripples.
Other visual feedback may be provided on the display of a mobile device in step 114 in response to receiving user input to create a vibration pattern, e.g., a circle emanating from the origin of a tap-down event that grows and shrinks based on the duration and/or intensity of the tap-down event. In some implementations, a circle can expand indefinitely from the origin of the tap-down event as a solid circle until a threshold circular size is reached, at which point the circle may start pulsating to provide the visualization that the circle has reached a maximum bound and continues to bump up against that maximum bound. Upon release of the tap-down event, i.e., a tap-up event, the circle can begin to shrink. Additionally, colors may be associated with the circle to indicate intensity for a vibration segment in a vibration pattern. For example, a circle could start emanating from the origin of the tap-down event in one color, e.g., green, indicating that the vibration segment may have a low intensity. The circle may then transition to a different color, e.g., red, as the circle expands to indicate that the vibration segment may have a stronger intensity.
In addition, in step 114 haptic feedback may be provided during the recording phase of a vibration pattern. For example, during a tap-down event, a mobile device can provide haptic feedback, or vibrations, corresponding to the tap-down event. The haptic feedback may vary in intensity and duration depending on the detected duration and intensity of the tap-down event. In some implementations, the haptic feedback tracks or relates to the vibration segments in the custom vibration pattern being created by the user input. For example, the haptic feedback provided in step 114 in response to the user input received in step 112 may correspond to vibration in the vibration pattern. That is, the haptic feedback provided in step 114 may be the same haptic feedback or vibrations actuated in step 118 to notify a user of a mobile device that a notification event has been received, where the vibration pattern corresponding to the haptic feedback has been assigned to the notification event in step 116 .
Feedback provided in step 114 in response to receiving user input may be provided in a real-time manner. For example, although the mobile device may not know how long a tap-down event will last, visualization and haptic feedback can be provided in real-time for an indefinite amount of time by providing instructions to the mobile device to start and stop the feedback based on the received user input.
In step 114 , in addition to providing real-time feedback during the recording phase of a vibration pattern, visual and haptic feedback can be provided during a replay portion of the recording phase. For example, after recording has ended, a user of the mobile device may desire to preview the vibration pattern before assigning it to a notification event. In some implementations, the user can select to replay the vibration pattern just recorded. During replay, any of the visualizations discussed in this disclosure can be displayed and haptic feedback can be provided corresponding to the recorded vibration pattern.
In step 116 , the custom vibration pattern created in step 112 can be assigned to a notification event. For example, the custom vibration pattern may be assigned to a particular contact in an address book, universally for all phone calls, SMS/MMS messages, email receipts, calendar alerts, and the like. In step 118 , upon detection of a notification event by a mobile device, e.g., a call from a contact with an assigned vibration pattern, the mobile device can actuate haptic feedback at the mobile device corresponding to the vibration pattern.
In addition to or in place of assigning a custom vibration pattern to a notification event, preset or stock vibration patterns may be assigned to a notification event in step 116 . For example, a number of preset and stock vibration patterns may be provided to a mobile device. A user of the mobile device may assign any of such preset or stock vibration patterns to a notification event.
FIGS. 2 a -2 d are exemplary user interfaces for creating a custom vibration pattern on a mobile device. In FIG. 2 a an application running on a mobile device can prompt a user to physically tap display screen 212 of the mobile device to begin a vibration pattern recording phase. Upon detecting a tap, or tap-down event, and beginning the recording phase, the user may physically tap the screen in a series of taps to create vibration segments for a corresponding vibration pattern. Each tap-down event may correspond to an individual vibration segment and vary in duration and intensity. In FIG. 2 b , in response to detecting tap-down event 224 , the mobile device may provide visual feedback on display 212 and haptic feedback using a haptic mechanism of the mobile device. For example, progress view bar 214 can represent a vibration pattern over time and vibration segment 226 corresponding to tap-down event 224 can be used to indicate a shorter vibration in the vibration pattern. Ripple effect 222 can be presented in display 212 in response to detecting tap-down event 224 . In some implementations, ripple effect 222 has the visual effect of emanating from the origin of tap-down event 224 and increases in intensity proportionally to the duration and/or force of tap-down event 224 . At any time during the recording of a vibration pattern, a user may select the stop button 228 to end the recording phase.
In FIG. 2 c , in response to detecting tap-down event 232 , the mobile device may provide visual feedback 230 and 236 as well as haptic feedback. For example, in progress bar 214 , vibration segment 236 can correspond to tap-down event 232 and can be depicted by a growing rectangle in progress bar 214 to indicate a longer duration tap-down event. Ripple effect 230 can be displayed in display 212 in response to detecting tap-down event 232 and can correspond to vibration segment 236 . For example, ripple effect 230 can have multiple ripples close together to indicate a longer tap-down event or a tap-down event with a stronger intensity. In FIG. 2 d , recording of the vibration pattern has ended. For example, a user may select button 228 in FIG. 2 c to end a vibration recording phase. An indication of the custom vibration pattern can be seen in progress bar 214 in FIG. 2 d . For example, vibration segment 226 can correspond to tap-down event 224 in FIG. 2 b , vibration segment 236 can correspond to tap-down event 232 shown in FIG. 2 c , and vibration segments 260 and 262 can correspond to other tap-down events that were detected during the recording of the custom vibration pattern. In FIG. 2 d , after recording of a vibration pattern has ended, a user may select the play button 240 to replay the previously created vibration pattern or the record button 242 to record a new vibration pattern. Additionally, the user may select save button 250 to assign a name to the vibration pattern and save the vibration pattern to memory.
FIGS. 3 a -3 b are exemplary user interfaces for replaying a custom vibration pattern on a mobile device. For example, FIGS. 3 a -3 b can be used to replay the custom vibration pattern created in FIGS. 2 a -2 d . In FIG. 3 a , if a user selects play button 240 in FIG. 2 d to replay the previously created vibration pattern, the vibration pattern represented by progress bar 214 can be replayed on the mobile device. Replay of a vibration pattern may involve both haptic and visual feedback. For example, during playback the visualizations and haptic feedback created during the recording of a vibration pattern may be conveyed to a user of the mobile device. As an example, the vibration pattern created in FIGS. 2 a -2 d can be used in FIGS. 3 a -3 b . Playback may be indicated by a playback position on progress bar 214 . When vibration segment 226 is encountered during playback, visual and haptic feedback can be provided corresponding to vibration segment 226 . For example, haptic feedback corresponding to the duration and/or intensity of the tap-down event used to create vibration segment 226 can be actuated and ripple effect 222 displayed during the recording of vibration segment 226 can be presented in display 212 . When playback encounters vibration segment 236 , haptic feedback corresponding to the duration and/or intensity of the tap-down event used to create vibration segment 236 can be actuated and ripple effect 230 displayed during the recording of vibration segment 236 can be presented in display 212 . Similarly, when playback encounters vibration segments 260 and 262 , haptic feedback corresponding to the duration and/or intensity of the tap-down events used to create vibration segments 260 and 262 can be actuated and ripple effects displayed during the recording of vibration segments 260 and 262 can be presented in display 212 .
FIG. 4 is an exemplary user interface for naming and saving a custom vibration pattern. For example, a user may enter a name for a custom vibration pattern in text box 402 , e.g., “Test”, using keyboard 404 and then save the name by clicking save button 406 .
FIG. 5 is an exemplary user interface for assigning a vibration pattern to a notification event. For example, the custom vibration pattern “Test” may be selected in vibration selection 508 to correspond to the contact “John” in 502 . When a mobile device detects that John is calling by detecting the number in mobile number box 504 is calling, the mobile device can actuate haptic feedback in accordance with vibration pattern “Test” and/or play audible sounds in accordance with ringtone “Default” in box 506 .
FIG. 6 is a block diagram of exemplary architecture 600 of a mobile device configured to perform motion-based operations. A mobile device can include memory interface 602 , one or more data processors, image processors and/or processors 604 , and peripherals interface 606 . Memory interface 602 , one or more processors 604 and/or peripherals interface 606 can be separate components or can be integrated in one or more integrated circuits. Processors 604 can include one or more application processors (APs) and one or more baseband processors (BPs). The application processors and baseband processors can be integrated in one single process chip. The various components in mobile device 600 , for example, can be coupled by one or more communication buses or signal lines.
Sensors, devices, and subsystems can be coupled to peripherals interface 606 to facilitate multiple functionalities. For example, motion sensor 610 , light sensor 612 , and proximity sensor 614 can be coupled to peripherals interface 606 to facilitate orientation, lighting, and proximity functions of the mobile device. Motion sensor 610 can include one or more accelerometers configured to determine change of speed and direction of movement of the mobile device. Location processor 615 (e.g., GPS receiver) can be connected to peripherals interface 606 to provide geopositioning. Electronic magnetometer 616 (e.g., an integrated circuit chip) can also be connected to peripherals interface 606 to provide data that can be used to determine the direction of magnetic North. Thus, electronic magnetometer 616 can be used as an electronic compass. Gravimeter 617 can be coupled to peripherals interface 606 to facilitate measurement of a local gravitational field of Earth.
Camera subsystem 620 and an optical sensor 622 , e.g., a charged coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS) optical sensor, can be utilized to facilitate camera functions, such as recording photographs and video clips.
Communication functions can be facilitated through one or more wireless communication subsystems 624 , which can include radio frequency receivers and transmitters and/or optical (e.g., infrared) receivers and transmitters. The specific design and implementation of the communication subsystem 624 can depend on the communication network(s) over which a mobile device is intended to operate. For example, a mobile device can include communication subsystems 624 designed to operate over a CDMA system, a WiFi™ or WiMax™ network, and a Bluetooth™ network. In particular, the wireless communication subsystems 624 can include hosting protocols such that the mobile device can be configured as a base station for other wireless devices.
Audio subsystem 626 can be coupled to a speaker 628 and a microphone 630 to facilitate voice-enabled functions, such as voice recognition, voice replication, digital recording, and telephony functions. In addition, microphone 630 may detect ambient noise and other audible frequencies.
Haptic subsystem 680 and haptic mechanism 682 , e.g., spinning motor, servo motor, or piezoelectric motor, can be utilized to facilitate haptic feedback, such as vibration, force, and/or motions.
I/O subsystem 640 can include touch screen controller 642 and/or other input controller(s) 644 . Touch-screen controller 642 can be coupled to a touch screen 646 or pad. Touch screen 646 and touch screen controller 642 can, for example, detect contact and movement or break thereof using any of a plurality of touch sensitivity technologies, including but not limited to capacitive, resistive, infrared, and surface acoustic wave technologies, as well as other proximity sensor arrays or other elements for determining one or more points of contact with touch screen 646 .
Other input controller(s) 644 can be coupled to other input/control devices 648 , such as one or more buttons, rocker switches, thumb-wheel, infrared port, USB port, and/or a pointer device such as a stylus. The one or more buttons (not shown) can include an up/down button for volume control of speaker 628 and/or microphone 630 .
In one implementation, a pressing of the button for a first duration may disengage a lock of the touch screen 646 ; and a pressing of the button for a second duration that is longer than the first duration may turn power to mobile device 600 on or off. The user may be able to customize a functionality of one or more of the buttons. The touch screen 646 can, for example, also be used to implement virtual or soft buttons and/or a keyboard.
In some implementations, mobile device 600 can present recorded audio and/or video files, such as MP3, AAC, and MPEG files. In some implementations, mobile device 600 can include the functionality of an MP3 player. Mobile device 600 may, therefore, include a pin connector that is compatible with the iPod. Other input/output and control devices can also be used.
Memory interface 602 can be coupled to memory 650 . Memory 650 can include high-speed random access memory and/or non-volatile memory, such as one or more magnetic disk storage devices, one or more optical storage devices, and/or flash memory (e.g., NAND, NOR). Memory 650 can store operating system 652 , such as Darwin, RTXC, LINUX, UNIX, OS X, WINDOWS, or an embedded operating system such as VxWorks. Operating system 652 may include instructions for handling basic system services and for performing hardware dependent tasks. In some implementations, operating system 652 can include a kernel (e.g., UNIX kernel).
Memory 650 may also store communication instructions 654 to facilitate communicating with one or more additional devices, one or more computers and/or one or more servers. Memory 650 may include graphical user interface instructions 656 to facilitate graphic user interface processing; sensor processing instructions 658 to facilitate sensor-related processing and functions; phone instructions 660 to facilitate phone-related processes and functions; electronic messaging instructions 662 to facilitate electronic-messaging related processes and functions; web browsing instructions 664 to facilitate web browsing-related processes and functions; media processing instructions 666 to facilitate media processing-related processes and functions; GPS/Navigation instructions 668 to facilitate GPS and navigation-related processes and instructions; camera instructions 670 to facilitate camera-related processes and functions; magnetometer data 672 and calibration instructions 674 to facilitate magnetometer calibration. The memory 650 may also store other software instructions (not shown), such as security instructions, web video instructions to facilitate web video-related processes and functions, and/or web shopping instructions to facilitate web shopping-related processes and functions. In some implementations, the media processing instructions 666 are divided into audio processing instructions and video processing instructions to facilitate audio processing-related processes and functions and video processing-related processes and functions, respectively. An activation record and International Mobile Equipment Identity (IMEI) or similar hardware identifier can also be stored in memory 650 . Memory 650 can include haptic instructions 676 . Haptic instructions 676 can be configured to cause the mobile device to perform haptic-based operations, for example providing haptic feedback to a user of the mobile device as described in reference to FIGS. 1-5 .
Each of the above identified instructions and applications can correspond to a set of instructions for performing one or more functions described above. These instructions need not be implemented as separate software programs, procedures, or modules. Memory 650 can include additional instructions or fewer instructions. Furthermore, various functions of the mobile device may be implemented in hardware and/or in software, including in one or more signal processing and/or application specific integrated circuits.
FIG. 7 is a block diagram of exemplary network operating environment 700 for the mobile devices configured to perform motion-based operations. Mobile devices 702 a and 702 b can, for example, communicate over one or more wired and/or wireless networks 710 in data communication. For example, a wireless network 712 , e.g., a cellular network, can communicate with a wide area network (WAN) 714 , such as the Internet, by use of a gateway 716 . Likewise, an access device 718 , such as an 802.11g wireless access device, can provide communication access to the wide area network 714 .
In some implementations, both voice and data communications can be established over wireless network 712 and the access device 718 . For example, mobile device 702 a can place and receive phone calls (e.g., using voice over Internet Protocol (VoIP) protocols), send and receive e-mail messages (e.g., using Post Office Protocol 3 (POP3)), and retrieve electronic documents and/or streams, such as web pages, photographs, and videos, over wireless network 712 , gateway 716 , and wide area network 714 (e.g., using Transmission Control Protocol/Internet Protocol (TCP/IP) or User Datagram Protocol (UDP)). Likewise, in some implementations, the mobile device 702 b can place and receive phone calls, send and receive e-mail messages, and retrieve electronic documents over the access device 718 and the wide area network 714 . In some implementations, mobile device 702 a or 702 b can be physically connected to the access device 718 using one or more cables and the access device 718 can be a personal computer. In this configuration, mobile device 702 a or 702 b can be referred to as a “tethered” device.
Mobile devices 702 a and 702 b can also establish communications by other means. For example, wireless mobile device 702 a can communicate with other wireless devices, e.g., other mobile devices 702 a or 702 b , cell phones, etc., over the wireless network 712 . Likewise, mobile devices 702 a and 702 b can establish peer-to-peer communications 720 , e.g., a personal area network, by use of one or more communication subsystems, such as the Bluetooth™ communication devices. Other communication protocols and topologies can also be implemented.
The mobile device 702 a or 702 b can, for example, communicate with one or more services 730 over the one or more wired and/or wireless networks. For example, one or more vibration pattern delivery services 730 can be used to deliver one or more vibration patterns. In some implementations, a vibration pattern delivery service may be a virtual store to buy and download vibration patterns. A vibration pattern delivery service may also be part of a push notification delivery service. For example, a vibration pattern associated with a particular push notification may be pushed to a mobile device to inform a user of the mobile device of the particular notification, e.g., a distinctive vibration pattern may be associated with a team scoring in a sports game, when the team scores, the distinct vibration pattern can be pushed to the mobile device to notify the user of the mobile device of the score.
Mobile device 702 a or 702 b can also access other data and content over the one or more wired and/or wireless networks. For example, content publishers, such as news sites, Really Simple Syndication (RSS) feeds, web sites, blogs, social networking sites, developer networks, etc., can be accessed by mobile device 702 a or 702 b . Such access can be provided by invocation of a web browsing function or application (e.g., a browser) in response to a user touching, for example, a Web object.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the following claims. | The present disclosure describes technology, which can be implemented as a method, apparatus, and/or computer software embodied in a computer-readable medium, and which, among other things, be used to create custom feedback patterns in response to user input, for example, in response to the user inputting a desired pattern of tactile events detected on a mobile device. For example, one or more aspects of the subject matter described in this disclosure can be embodied in one or more methods that include receiving tactile input from a user of an electronic device specifying a custom feedback pattern, in concert with receiving tactile input, providing feedback to the user corresponding to the received tactile input, and storing the specified custom feedback pattern for use by the electronic device to actuate feedback signaling a predetermined notification event. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to visors, sun shields, caps and the like having headbands which can be adjusted to the size of the wearer's head.
It is common to provide visors and the like with some type of headband, such as shown for example in U.S. Pat. Nos. 2,988,743 and 3,271,778. One of the problems associated with such headbands, however, is that in order to provide for substantially positive locking at at particular head size, locking mechanisms have been provided which require significant manipulation and conscious effort on the part of the wearer. Such manipulation is made all the more difficult by the fact that the headband is best adjusted while on the head, so that the mechanism must be adjusted by feed alone.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of this invention to provide a visor having a headband whose length can be easily adjusted while the visor is on one's head.
Another object of the invention is to provide a visor with a mechanism that locks positively, and with which tension on the headband increases the locking force.
These and other objects are attained by a visor formed from sheet material, including an arcuate bill and integrally connected thereto a first strap, including a distal end having a slot extending obliquely across the strap, and a second strap bounded by serrated edges. The slot is wider than the second strap to permit insertion of the latter, and each of the serrated edges comprises a series of triangular teeth which engage the ends of the slot to provide a positive locking action.
In a preferred construction, the slot is angled obliquely across its strap in such a way that if extended, its point of intersection with the outer edge of the strap would be closer to the bill than its point of intersection with the inner edge of the strap.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing, FIG. 1 is a perspective view, looking obliquely downward at the front of a visor embodying the invention;
FIG. 2 is a perspective view of the visor taken from the rear thereof; and
FIG. 3 is a detailed view of a connecting mechanism of the headband.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A visor embodying the invention is cut from a stiff, resilient sheet material, preferably a paper product such as bristol board or cardboard. As shown in FIGS. 1 and 2, the visor includes a broad bill 10 defined between arcuate peripheral and interior edges 12 and 14, which draw nearer to one another at the sides of the bill, and extend therefrom generally parallel to each other to define a first strap 16 and a second strap 18 at opposite sides of the bill.
Referring to FIG. 2, the first strap 16 has an outer edge 20 and an inner edge 22, and terminates at an enlarged rounded distal end 24. A slot 26 is cut in the end 24, between but not extending to the edges 20 and 22, along a slightly oblique line that, if extended to meet the edges of the strap, would intersect the outer edge of the strap at a point closer to the bill than the point at which it would intersect the inner edge of the strap. That is, the slot inclines rearwardly in the direction of the opposite strap. A first portion of the distal end 24 is defined adjacent one end of slot 26 and a second portion of the distal end is defined adjacent the other end of the slot.
The second strap 18 has inner and outer edges 28 and 30 respectively, both of which are serrated for most of their length. The serrations comprise a series of teeth 32, each of which has the form of an isoceles triangle (approximately a right isoceles triangle), the equal legs of the triangle forming forward and rearward tooth edges 34 and 36 respectively (FIG. 3). Tooth edges 34 and 36 may be referred to as first and second legs, respectively. The teeth are preferably equidistant, having a pitch of about three eighths of an inch. The strap 18 ends at a rounded tab 38.
As shown in FIG. 3, an imaginary line 40 colinear with the rearward edge of a tooth on one side of the second strap intersects the opposite side of the strap at a trough 42 between adjacent teeth 32. The trough-to-trough distance measured along this line (45° oblique to the length of the strap in the preferred configuration) should substantially equal or be just slightly less than the width of the slot 26, since the slot becomes aligned parallel to such a line when the visor is being worn so that said first portion of the distal end engages one of said second legs and said second portion of the distal end engages one of said first legs. (See FIGS. 2 and 3.)
In use, the wearer places the tab 38 of the second strap 18 orthogonally through the slot 26, to form a visor as shown in FIGS. 1 and 2. The natural stiffness of the bill, which is drawn from a planar shape to a conical configuration as the straps are joined, tends to rotate the second strap within the slot to an oblique alignment as shown in FIGS. 1 and 2. In this alignment, the trough-to-trough distance equals the slot length, with the teeth firmly engaging the ends of the slot, so as to provide positive locking and prevent inadvertant undoing or relaxing of the visor. Any strap tension occasioned by use increases the locking force. However, the visor can be easily readjusted or removed by grasping the end of the serrated second strap and aligning it orthogonally with the first strap so as to disengage the teeth from the ends of the slot.
The invention is subject to variations and modifications. For example, a material other than a paper product may be used, e.g., in some instances plastic may be preferred. Furthermore, the dimensions and proportions of the visor may vary, and accordingly, the foregoing should be regarded as merely illustrative of the invention defined by the following claims. | A visor formed from sheet material includes a bill formed with integral straps, one of which has a slot near its end extending obliquely across the strap. The other strap has a series of triangular teeth on both of its edges, which provide positive locking within the slot, and yet easy adjustment of the visor for head size. | 0 |
BACKGROUND OF THE INVENTION
This invention relates generally to lighting fixtures and more particularly concerns the use of LED light bands in creating lighting effects.
LED technology can be used to facilitate simulation of natural phenomena. The shapes of the LED housings, the reflective and refractive qualities of the lenses and the configurations of the arrays, colors and diffusion patterns of the LEDs can be coordinated to produce a wide variety of effects. But the use of such coordination to produce, for example, attractive “twinkling starlight” or “licking flames” simulations, often comes with a high price tag.
One of the problems in some applications is that sheets of polycarbonate material, unlike metal sheets, cannot be economically, if at all, cold pressed. Polycarbonate LED lighting lenses are economical and, using presently known technology, crests and nadirs can, in some applications, be shaped into a sheet of polycarbonate material using a “wavy” roller. However, the rollers are limited in length so the nadirs and crests must run parallel to the length of the material. Thus, known technology cannot be used to create an elongated lens of polycarbonate with transverse crests and nadirs. But an elongated lens of polycarbonate with transverse crests and nadirs could be useful in the creation of attractive LED effects in long bands without any visual interruption of the simulated phenomena.
It is, therefore, an object of this invention to provide a relatively inexpensive elongated lens of polycarbonate with transverse crests and nadirs. It is also an object of this invention to provide a relatively inexpensive lens of polycarbonate capable of contributing to the attractive simulation of certain visual phenomena and images. A further object of this invention is to provide an LED light band which is capable of simulation of certain visual phenomena and images, such as “licking flames.”
SUMMARY OF THE INVENTION
In accordance with the invention, an LED light band has a thin elongated housing with an open front face covered by an elongated polycarbonate lens. The lens has transverse corrugations with crests and nadirs at a first predetermined interval and a linear array of LEDs extending behind and along the bottom edge of the lens. The LEDs of the array are spaced at a second predetermined interval. The first and second predetermined intervals are different so that the lens display appears to be random.
The first predetermined interval is preferably greater than the second. The ratio of the first to second predetermined intervals is preferably approximately ⅔. Preferably, the first predetermined interval is approximately 2½″ and the second predetermined interval is approximately 1⅔″ with the depth of the corrugation from crest to nadir being approximately ½″, the height of the lens being approximately 15″ and the depth of the housing being approximately 2½″.
The housing has a rear wall with a lower vertical portion and a forwardly tilted upper portion. The base of the housing extends forwardly from the bottom of the lower vertical portion. Upper and lower opposed channels are attached to the top of the forwardly tilted upper portion and to the forward edge of the lower vertical portion, respectively, for sliding reception of the lens therebetween.
The linear array of LEDs are mounted on an elongated LED circuit board pitched toward the lens by a bracket extending lengthwise in the housing behind the lens and along the junction of the rear wall and base of the housing. The angle of the pitch is approximately 12°.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a perspective view of the LED light band;
FIG. 2 is a front plan view of the LED light band of FIG. 1 ;
FIG. 3 is a cross-sectional view taken along the line 3 - 3 of FIG. 2 ;
FIG. 4 is a cross-sectional view taken along the line 4 - 4 of FIG. 2 ;
FIG. 5 is a cross-sectional view taken along the line 5 - 5 of FIG. 4 ;
FIG. 6 is a perspective view of a typical end cap for the LED light band of FIG. 1 ;
FIG. 7 is a perspective view of an outside corner for the LED light band of FIG. 1 ;
FIG. 8 is a perspective view of an inside corner for the LED light band of FIG. 1 ; and
FIG. 9 is a cross-sectional view of the LED light band of FIG. 1 mounted on a parapet.
While the invention will be described in connection with a preferred embodiment thereof, it will be understood that it is not intended to limit the invention to that embodiment or to the details of the construction or arrangement of parts illustrated in the accompanying drawings.
DETAILED DESCRIPTION
Looking first at FIGS. 1-3 , an LED light band 10 includes a thin, elongated housing 11 with an open front face covered by an elongated polycarbonate lens 13 . The lens 13 is transversely corrugated to provide vertically aligned crests 15 or nadirs 17 spaced at a first predetermined interval 19 , respectively.
Turning to FIGS. 4-5 , a linear array of LEDs 21 extends behind and along the bottom edge of the lens 13 . The LEDs 21 of the array are spaced at a second predetermined interval 23 . As best seen in FIG. 5 , the first and second predetermined intervals 21 and 23 are different. Therefore, the angles of reflection between consecutive LEDs 21 and the corrugated lens 13 are different and the dispersion of light through the lens 13 varies accordingly along the length of the lens 13 .
This variation of dispersion results in a random appearance of light to a passing observer such that, as the observer moves in relation to the light band 10 , the light seems to flicker. The effect may be accentuated by external conditions, such as wind striking the face of the lens 13 and causing slight and irregular distortions of the polycarbonate material of the lens 13 . If, for example, the lens 13 were red in color, the lens 13 would take on the appearance of a flickering flame.
As seen in FIG. 5 , the first predetermined interval 19 is preferably greater than the second predetermined interval 23 . The ratio of the first to second predetermined intervals 19 to 23 is preferably approximately ⅔. Preferably, the first predetermined interval 19 is approximately 2½″ and the second predetermined interval 23 is approximately 1⅔″ with the depth 25 of the corrugation from crest 15 to nadir 17 being approximately ½″. Also preferably, as seen in FIG. 4 , the height 27 of the lens 13 is approximately 15″ and the depth 29 of the housing 11 is approximately 2½″.
Continuing to look at FIGS. 4-5 , the housing 11 has a rear wall 31 with a lower vertical portion 33 and a forwardly tilted upper portion 35 . The base 37 of the housing 11 extends forwardly from the bottom of the lower vertical portion 33 of the rear wall 31 and is turned upward, rearward and upward to form a seat 39 on and against which the lower edge and rear face of the lens 13 rests. The forwardly tilted upper portion 35 of the rear wall 31 extends to an upper channel 41 opposed to the seat 39 . The channel 41 has an internal flange 43 which secures the lens 13 in, and against the back inside face of, the channel 41 . As can be understood by reference to FIG. 4 , the lens 13 can be mounted by sliding longitudinally onto the seat 39 and into the channel 41 or by vertical insertion into the channel 41 and rotation onto the seat 39 . The lower portion of the lens 13 is secured against the back of the seat 39 by the upper flange 45 of a facia 47 extending across the front of the upward portion of the base 37 .
The linear array of LEDs 21 are mounted on an elongated LED circuit board 51 pitched toward the lens 13 by clips 53 spaced lengthwise in the housing 11 behind the lens 13 and along the junction of the lower portion 33 of the rear wall 31 and the base 37 of the housing 11 . The angle 55 of the pitch is approximately 12°.
Turning to FIGS. 6, 7 and 8 , accessories for the light band 10 include end caps 60 , outside corners 70 and inside corners 80 , respectively. The left end cap 60 shown has left end, top, bottom, front and rear walls 61 , 63 65 , 67 and 69 , respectively, contoured to enclose and conform to the left end of a light band 10 inserted into its open right face. The right end cap, not shown, is an opposite hand configuration of the left hand cap 60 shown. The outside corner 70 and inside corner 80 are right angle corners having frames 71 / 81 identical in cross-sectional configuration, each with a top, a bottom and a side wall 73 / 83 , 75 / 85 and 77 / 87 , respectively, contoured for insertion into and conformance with the left and right ends of two light bands 10 . For the outside corner 70 , an outside piece of corner trim 79 completes the junction of the frames 71 and, for the inside corner 80 , an outside piece of corner trim 89 completes the junction of the frames 81 .
Looking at FIG. 9 , one manner of mounting the light band 10 on a parapet P is illustrated. A base plate 91 is secured atop the parapet P, perhaps as shown by an anchor bolt 93 . A generally S-shaped mounting bracket 95 has a base portion 97 , an upward angled leg 99 , a horizontal top 101 and a downward vertical leg 103 . The base 37 of the light band 10 is positioned on the horizontal top 101 of the mounting bracket 95 with the front face of the base 37 and the front face of the leg 103 are in a common plane. Nested identical angle irons 105 and 107 are telescoped to a generally desired length adjustable by use of screws 109 . The distal ends of the nested angle irons 105 and 107 have flat extensions 111 and 113 , respectively. The upper flat extension 111 will be secured to the angled portion 35 of the housing 11 , as shown by screws 115 . The lower flat extension 113 will be secured to the mounting bracket 95 , the parapet P, the mounting plate 91 or such other structure as may be available, depending on the building/parapet structure. As shown, the lower flat extension 113 will be secured between the base portion 97 of the mounting bracket 95 and the base plate 91 . This is accomplished by bending the upper flat extension 111 at a point 117 below the screws 115 to generally position the lower flat extension 113 to be secured to the selected support structure. As shown, the lower flat extension 113 is bent at points 119 and 121 as required to accommodate the support structure and, once positioned between the base plate 91 and the mounting bracket 95 , is secured by an anchor bolt 123 , as shown extending into the parapet P. The bends 117 , 119 and 121 and the positions of the screws 109 can then be adjusted to provide a most stable mount for the light band 10 . To finish the installation, the facia 47 can be selected to extending across the front of the upward portion of the base 37 and also across the leg 103 of the mounting bracket 95 to the base plate 91 on the parapet P.
A lens 10 suitable for the purposes of this disclosure has been made by starting with a roll, perhaps 450 ′ or more in length, of 15.5″ wide×⅛″ thick flat polycarbonate stock. The stock is rolled off its drum 7.5′ to 8.0′ at a time into a sheet metal die press where the desired corrugation is pressed into the unrolled polycarbonate. A 230 T hydraulic press has been found suitable to the purpose. After each 7.5′ to 8.0′ length is pressed, the press is relaxed to receive the next unrolled 7.5′ to 8.0′ length of polycarbonate. Preferably, each next length is rolled out only so far as will permit the die to overlap the trailing end of the previous length. As the pressed polycarbonate exits the press it is wound onto a coiler from which it can later be unwound and cut into any length desired.
Thus, it is apparent that there has been provided, in accordance with the invention, a corrugated lens LED light band that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with a specific embodiment thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art and in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit of the appended claims. | An LED light band has a thin elongated housing with an open front face covered by an elongated transversely corrugated polycarbonate lens having crests and nadirs spaced at a first predetermined interval. A linear array of LEDs extending behind and along the bottom edge of the lens are spaced at a second predetermined interval different from the first. Because of the difference in the intervals, the light dispersion from the lens appears to the eye to be random so that, for example, a red lens can be used to suggest the presence of licking flames. The polycarbonate lens can be made by pressing long narrow lengths of flat polycarbonate in a sheet metal press. | 1 |
This application claims priority under 35 U.S.C. § 119 of Korean Patent Application No. 2003-10761, which was filed on Feb. 20, 2003, in the Korean Intellectual Property Office, the disclosure of which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor package and method for fabricating. More particularly, the present invention relates to a method for stacking semiconductor chips and forming a stacked semiconductor package including a plurality of semiconductor chips in one semiconductor package.
2. Description of the Related Art
While semiconductor manufacturing technologies have improved the integrity and decreased the size of semiconductor devices, fabricating a semiconductor package can still be expensive and burdensome. In particular, in a wafer fabricating process, a large financial investment must be made for upgraded facilities and new equipment in addition to research costs. In the case of semiconductor memory devices, the process of upgrading from 64-megabit Dynamic Random Access Memory (DRAM) to 256-megabit DRAM can be costly when requiring a new wafer fabricating process.
Semiconductor manufacturers have introduced a method for fabricating a semiconductor package by placing a plurality of semiconductor chips into one semiconductor package. The process of a stacked semiconductor package includes stacking at least two semiconductor chips. The stacking of the semiconductor chips provides a solution to improving the integrity and performance of the semiconductor package without the need for fabricating an entirely new wafer. For example, the 256-megabit DRAM can be fabricated by assembling the semiconductor package with four 64-megabit DRAM semiconductor chips.
In previous methods for fabricating a multi-chip semiconductor package, the semiconductor package is made by stacking multiple unit semiconductor chips on top of one another. One such method for fabricating a stacked semiconductor package is disclosed in U.S. Pat. No. 6,239,496 entitled “Package Having Very Thin Semiconductor Chip, Multichip Module Assembled By The Package And Method For Manufacturing The Same.”
However, this type of multi-chip semiconductor package requires a new assembly method, new materials, and complex fabrication processes.
SUMMARY OF THE INVENTION
The present invention provides a stacked semiconductor package and method of fabricating the same using conventional equipment and processes that allow for fabrication with reduced cost.
In one exemplary embodiment of the stacked semiconductor package, on a first semiconductor chip, a second semiconductor chip is stacked offset such that a portion of the first semiconductor chip is exposed. At least one first conductor electrically connects the exposed portion of the first semiconductor chip to the second semiconductor chip.
In one exemplary embodiment, the first conductor does not extend beyond a periphery of the first semiconductor chip.
In another exemplary embodiment, the first conductor electrically connects at least one bond pad on the first semiconductor chip with at least one bond pad on the second semiconductor chip, and a redistribution pattern electrically connects the bond pad on the second semiconductor chip to a differently positioned bond pad on the second semiconductor chip. This embodiment may further include a frame supporting a chip package structure formed of at least the first and second semiconductor chips. And at least one second conductor may electrically connect the differently positioned bond pad to the frame. In other embodiments, a plurality of first conductors and/or a plurality of second conductors exist.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and other advantages of the present invention will become more apparent by describing exemplary embodiments in detail with reference to the accompanying drawings, in which:
FIG. 1 is a top view of a redistribution pattern on a semiconductor chip in a semiconductor chip package according to an embodiment of the present invention;
FIG. 2 is a side view of a stacked semiconductor package according to an embodiment of the present invention;
FIG. 3 is another side view of stacked semiconductor package according to an embodiment of the present invention; and
FIG. 4 is a top view of stacked semiconductor package according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following drawings, like reference numerals identify similar or identical elements.
FIG. 1 is a top view of a redistribution pattern 206 on an upper surface of a semiconductor chip according to an embodiment of the present invention. The redistribution pattern 206 may be formed on any of the semiconductor chips within a stacked semiconductor package of an exemplary embodiment of the invention. As shown, a plurality of first bond pads 202 are formed along an edge of the semiconductor chip 200 , 300 , 400 . A plurality of second bond pads 204 are formed along opposite edges of the semiconductor chip 200 , 300 , 400 . The redistribution pattern 206 is a pattern of wires that electrically connects respective first bond pads 202 to respective second bond pads 204 . In the exemplary embodiment of FIG. 1 , a one-to-one correspondence exists between the first and second bond pads 202 and 204 , but the present invention is not limited to this arrangement. Also, the redistribution pattern 206 may be changed to accommodate any location of the first or second bond pad 202 and 204 . Namely, the present invention is not limited to the positions of the first and second bond pads 202 and 204 shown in FIG. 1 . In one exemplary embodiment, the first bond pad 202 is formed by a flexible wire bonding process that is based on the location of the second bond pad 204 . In creating the first bond pads 202 , the redistribution pattern 206 and the second bond pads 204 are formed on a film located at the uppermost part of a semiconductor chip. Next, an insulating film, for example a polyimide film, is coated on the semiconductor chip on which the redistribution pattern 206 and the second bond pad 204 are formed. After that, the portion of the semiconductor chip where the bond pads are to be etched 208 is etched to expose the first 202 and second 204 sets of bond pads.
Referring to FIG. 2 , the stacked semiconductor package 100 according to an exemplary embodiment of the present invention includes a frame 110 , which may be a printed circuit board used for a Ball Grid Array (BGA) package or a flexible substrate (the flexible substrate is also referred to as an insulated wiring board). In an example of the present invention the stacked semiconductor package is a Chip Scale Package (CSP) or a Quad-Flat No-lead (QFN) semiconductor package. As shown, in an exemplary embodiment, the stacked semiconductor package 100 is mounted to the die pad 112 using an insulating adhesive tape 120 . Here, the insulating adhesive tape 120 is attached to a rear surface of a wafer from which the first semiconductor chip 200 is formed before a sawing process of the stacked semiconductor package 100 fabrication process.
The frame 110 used in the QFN semiconductor package includes a die pad 112 and an inner lead 114 . The die pad 112 represents a portion where a first semiconductor chip 200 , middle semiconductor chips 300 A, 300 B and a fourth semiconductor chip 400 of the QFN semiconductor package are mounted within the package 100 fabrication process. The inner lead 114 represents a portion where the stacked semiconductor chip package 100 is electrically connected to the frame 110 .
The stacked semiconductor package 100 according to an exemplary embodiment of the present invention comprises first wires 130 , for example, bonding wires, for electrically connecting respective first bond pads of the lower semiconductor chip 200 , the middle semiconductor chips 300 A and 300 B, and the upper semiconductor chip 400 to each other. A ball bonding process is used to bond the first wires 130 to the first bond pads 202 on the exposed portion of the lower semiconductor chip 200 , and a stitch bonding process is used to bond the first wires 130 to the first bond pads 202 of the middle and upper semiconductor chips 300 A, 300 B and 400 .
The stacked semiconductor package 100 according to an exemplary embodiment of the present invention includes second wires 140 , for example, bonding wires for electrically connecting the inner lead 114 of the frame 110 with respective second bond pads of the upper semiconductor chip 400 .
Also the stacked semiconductor package 100 includes a sealing resin 150 for sealing the semiconductor chips 200 , 300 A, 300 B, and 400 , the wires 130 and 140 , and a part of the frame 110 . The sealing resin 150 may be an Epoxy Mold Compound (EMC).
As described in detail below with respect to FIGS. 3 and 4 , the semiconductor chips of FIG. 2 are stacked in an offset fashion in order to expose the first bond pads 202 on one edge of the first and middle semiconductor chips 200 , 300 A and 300 B. The offset stacking of the semiconductor chips in the QFN configuration exposes the first bond pads 202 , the semiconductor chips 200 , 300 A and 300 B such that the conductors 130 may electrically connect the respective first bond pads 202 of the chips.
FIG. 3 is a side view of the stacked semiconductor package illustrated in FIG. 2 , and FIG. 4 is a top view of the stacked semiconductor chip package in FIG. 2 .
Referring to FIG. 3 , in an exemplary embodiment of the present invention the lower, middle, and upper semiconductor chips 200 , 300 A, 300 B, and 400 are mounted on the die pad 112 of the frame in a offset or stepped shape. This exposes an edge portion of the first and middle semiconductor chips 200 , 300 A and 300 B such that the first bond pads 202 on one edge of each chip are exposed. As such, the first conductors 130 may electrically connect, for example by wirebonding, respective first bond pads 202 of the first, middle and upper semiconductor chips 200 , 300 A, 300 B and 400 together. When, in an exemplary embodiment the first conductors 130 are wires, the connecting portion 132 of the first wires 130 on the middle and upper semiconductor chips 300 A, 300 B, and 400 are formed by performing a ball-bonding process or a stitch-bonding process.
As further shown in FIGS. 3 and 4 , the second conductors 140 electrically connect respective second bond pads 204 of the upper semiconductor chip 400 to the connection unit of the frame 110 , for example, the inner lead 114 . Thus, the first wires 130 and the second wires 140 may be wire-bonded in different directions and location to use space efficiently. Also, the second bond pads 204 of upper semiconductor chip 400 and the first bond pads 202 of the lower, middle, and upper semiconductor chips 200 , 300 A, 300 B, and 400 respectively, are exposed for the connection of the first and second wires 130 and 140 .
To fabricate the stacked semiconductor package according to the present invention, the frame 110 is prepared along with the lower, middle, and upper semiconductor chips 200 , 300 A, 300 B, and 400 by assuring the proper bond pad distribution prior to the process of stacking the semiconductor chips. Following these preparations, the lower, middle, and upper semiconductor chips 200 , 300 A, 300 B, and 400 are mounted on the die pad 112 of the frame 110 in a stepped shape so that the first bond pads 202 are exposed as shown in FIGS. 3 and 4 . The semiconductor chips are attached by insulating adhesive tape 120 attached on the bottom surfaces of the semiconductor chips 200 , 300 A, 300 B, and 400 .
Then, the second bond pads of the lower, middle, and upper semiconductor chips 200 , 300 A, 300 B, and 400 are wire-bonded with each other by the first wires 130 . The wire bonding process includes the ball-bonding process, which is generally performed on the first bond pads on an exposed portion of a lower semiconductor chip 200 and a stitch-bonding process, which is usually performed on the first bond pads 202 on the middle and upper semiconductor chips 300 A, 300 B and 400 . In addition, the second bond pad's 204 of the upper semiconductor chip 400 and the connection unit such as the inner lead 114 of the frame 110 are wired-bonded by the second wires 140 . The resultant bonded wires are sealed with a sealing resin 150 , for example, an EMC as shown in FIG. 2 . In the case where the frame 110 is a printed circuit board or an insulating wiring board, solder balls may be selectively attached thereto.
In an exemplary embodiment of the present invention the lower, middle and upper semiconductor chips 200 , 300 A, 300 B, and 400 are semiconductor devices of the same kind, for example, dynamic random access memories (DRAMs). However, different types of semiconductor devices can be used if necessary as well as a variable number of semiconductor chips within the package.
According to the present invention, the stacked semiconductor package is capable of performing with improved functionality within a minimal area. This can be realized by improving the stacking method of semiconductor chips and the wire-bonding method. Further, the stacked semiconductor package can be made with relative ease and the cost of equipment investment can be reduced since conventional equipment and processes are used.
While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention. | In the stacked semiconductor package, on a first semiconductor chip, a second semiconductor chip is stacked offset such that a portion of the first semiconductor chip is exposed. At least one first conductor electrically connects the exposed portion of the first semiconductor chip to the second semiconductor chip. The first conductor may be formed such that the first conductor does not extend beyond a periphery of the first semiconductor chip. The first conductor electrically connects at least one bond pad on the first semiconductor chip with at least one bond pad on the second semiconductor chip, and a redistribution pattern electrically connects the bond pad on the second semiconductor chip to a differently positioned bond pad on the second semiconductor chip. | 7 |
FIELD OF THE INVENTION
The present invention is a helical locking mechanism for doors.
BACKGROUND OF THE INVENTION
Helix-driven door mechanisms are widely used. Such mechanisms are used, for example, in vehicle doors, shielding doors, and civil doors. The helix-driven door mechanisms usually have problems on locking and unlocking of the door. At present, both home and abroad, helix-driven door mechanisms usually adopt various locks formed by brakes and clutches or the locks with electromagnetic, hydraulic and pneumatic driving modes for locking and unlocking. Most door locking mechanisms mentioned above have disadvantages of complicated mechanism and low reliability, and that their unlocking usually requires additional power sources.
SUMMARY OF THE INVENTION
The present invention is aimed to solve the defects mentioned above, to put forward a simple and reliable helical locking mechanism for doors, and to realize the locking and powerless self-unlocking of helix-driven door mechanism.
The present invention provides a powerless helical locking mechanism for door, comprised of a screw with variable lead angle, and a self-adaptive nut.
The screw is connected with a power source, and the self-adaptive nut is connected with the door. The screw slot is divided into three sections: a working section with the lead angle more than the friction angle, a locking section with the lead angle less than the friction angle, and a transition section therebetween. The power source can drive the screw to rotate bidirectionally. The self-adaptive nut comprises a connected shaft sleeve and pin shaft. The self-adaptive nut is assembled with the screw to form a screw kinematic pair.
The pin shaft in the self-adaptive nut is kept deep in the screw slot and realizes linear contact with the screw slot so that the pin shaft and a screw slot form a matched screw pair to realize power and motion transfer from the power source to the self-adaptive nut.
The inventive mechanism is powerless in that both the locking and unlocking of machine does not require an additional power source.
The inventive mechanism offers high reliability in that the locking section of the screw, with a lead angle of screw pair being less than the friction angle causes self-locking and thus lets the screw with variable lead angle lockup the self-adaptive nut; that is, securely lock the door. No unlocking problems are caused by vibration, etc. While the power source drives the clockwise (CW) and counter-clockwise (CCW) rotations of the screw with variable lead angle, it also drives the self-adaptive nut and door to move synchronously in parallel with the axis of the screw, with the self-adaptive nut entering and exiting the locking section of the screw to realize the locking and powerless self-unlocking of door.
The inventive door lock mechanism has less parts and a simple structure as compared to the prior art. The present invention is suitable for various helix-driven door locks.
Working Principles of the present invention are explained below.
When the power source closes the door, the screw with variable lead angle makes the clockwise (CW) rotation and drives the self-adaptive nut to move from a working section to a locking section of the screw. Once the self-adaptive nut enters the locking section of the screw, the closing of the door is realized, and then the automatic locking of the door is realized.
When the power source opens the door, the screw with variable lead angle makes the counter-clockwise (CCW) rotation and drives the self-adaptive nut to move from the locking section to the working section of the screw. Once the self-adaptive nut withdraws from the locking section of the screw, the automatic unlocking of door is realized, and then the opening of the door is realized.
When closing the door with hands, the difference from closing the door with power source is that the self-adaptive nut may drive the screw to rotate and let the self-adaptive nut enter the locking section of the screw to realize the automatic locking of the door and fulfill the closing of the door.
When opening the door with hands, with a device to let the screw make the counter-clockwise (CCW) rotation of a specific angle, the self-adaptive nut withdraws from the locking section of the screw and unlocking is realized. Then, the opening of the door is realized by the counter-clockwise (CCW) motion of the self-adaptive nut. A shift lever, a gear, a clutch unlocking device, and many other devices may be applied for this purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a working principle drawing of the present invention.
FIG. 2 is a partial enlargement view of a typical section of the screw 1 .
FIG. 3 is the perspective cross-sectional view of a pin shaft of a self-adaptive nut at the working section of the screw.
FIG. 4 is the perspective cross-sectional view of the pin shaft of the self-adaptive nut at the locking section of the screw.
FIG. 5 is the working principle schematic diagram of a manual unlocking device.
FIG. 6 is the 3D illustration of FIG. 5 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
Identification of elements illustrated in FIG. 1-6 :
1 —screw with variable lead angle, 2 —nut, 3 —retainer ring, 4 —torsion spring, 5 —pin shaft, 6 —rolling bearing, 7 —spindle sleeve, 8 —bearing cap, 9 —nut sleeve, 10 —door, 11 —power source, 12 —pull-wire wheel, 13 —left shift lever, 14 —right shift lever, 15 —right connecting plate, 16 —pull-wire, 17 —torsion spring, 18 —middle strut, 19 —self-adaptive nut, 20 —screw slot
The invention provides a helical locking mechanism for a door. The locking mechanism comprises a screw 1 with a variable lead angle ( FIG. 2 ) and a self-adaptive nut 19 . The screw 1 is connected with a power source 11 . The power source 11 can drive the screw to rotate bi-directionally.
The self-adaptive nut 19 is connected with the door 10 so that the self-adaptive nut 19 and the door 10 move synchronously.
With reference to FIG. 2 , the slot 20 of the screw 1 is divided into three sections: i) a working section C with the lead angle more than the friction angle, ii) a locking section A with the lead angle less than the friction angle, and iii) a transition section B located between the working section C and the locking section A.
The screw slot 20 has rectangle or trapezoid threaded end face. The screw slot 20 may have a single head or multiple heads.
With reference to FIG. 1 , the self-adaptive nut 19 comprises a spindle sleeve 7 , a pin shaft 5 , a nut sleeve 9 , a nut 2 , a rolling bearing 6 with a bearing cap 8 , a retainer ring 3 , and a torsion spring 4 .
The nut 2 and the nut sleeve 9 have a circumference rotary connection, and have a rigid connection through the retainer ring 3 in an axis of the screw 1 . One end of the torsion spring 4 is connected with the nut sleeve 9 . The other end of the torsion spring 4 is connected with the nut 2 .
The pin shaft 5 and the spindle sleeve 7 are connected in rigid connection or rotary connection. When the pin shaft 5 and the spindle sleeve 7 are in rigid connection, a screw pair in sliding friction is form. When the pin shaft 5 and the spindle sleeve 7 are in rotary connection, a screw pair is in rolling friction is formed.
When the power source 11 closes the door, the screw 1 makes a clockwise (CW) rotation to drive the self-adaptive nut 19 to move from the working section C of the screw to the locking section A of the screw, until the self-adaptive nut 19 enters the locking section A and the door is locked.
When the power source 11 opens the door, the screw 1 makes a counter-clockwise (CCW) rotation to drive the self-adaptive nut 19 to leave the locking section A and move reversely to open the door.
When manually closing the door, the movement of self-adaptive nut 19 drives the screw 1 to make the clockwise (CW) rotation. This clockwise (CW) rotation lets the self-adaptive nut 19 enter the locking section A of the screw 1 to manually close the door and lock the door.
The manual opening mechanism of the door is shown in FIG. 5 .
The right shift lever 14 is connected with the nut 2 of the self-adaptive nut 19 through the right connecting plate 15 . The left shift lever 13 is connected with the pull wire wheel 12 . The pull wire wheel 12 is idly set on the screw 1 . The pull wire 16 is connected with the pull wire wheel 12 . One end of the torsion spring 17 is connected with the pull wire 16 . The other end of the torsion spring 17 is connected with the middle strut 18 .
The pull wire 16 drives the pull wire wheel 12 and the left shift lever 13 to rotate. Through the right shift lever 14 , the right connecting plate 15 drives the nut 2 to rotate to thereby realize the rotation of the screw 1 to a specific angle. After the manual unlock is completed, the door may be opened by hands with the counter-clockwise (CCW) rotation of the self-adaptive nut 19 . After unlocking, under the torsion of the torsion spring 17 , the pull wire wheel 12 and the pull wire 16 reset to be ready for the next manual unlocking.
FIG. 2 is a partial enlarged view of a typical section of the screw slot 20 . Part A is the locking section, with the lead angle less than the friction angle. Part C is the working section, with the lead angle more than the friction angle. Part B is the transition section located between parts A and C. In part B the lead angle varies continuously.
FIG. 3 is an illustration of the pin shaft 5 of the self-adaptive nut 19 at the working section C of the screw 1 . The self-adaptive nut 19 and the screw 1 are assembled into a screw kinematic pair. The pin shaft 5 is deep in the screw slot 20 and is in linear contact with the screw slot 20 . The pin shaft 5 and the screw slot 20 , with any lead angles, can form the matched screw pair to transfer power and motion, to realize opening and closing of the door.
FIG. 4 is an illustration of the pin shaft 5 of the self-adaptive nut 19 at the locking section A of the screw 1 . The self-locking is caused by the lead angle of the screw pair being less than the friction angle. The screw slot 20 can lockup the pin shaft 5 so that the self-adaptive nut 19 is unable to move. This reliably locks the door. | A powerless helical locking mechanism for a door includes a screw with a variable lead angle connected with a power source, and a self-adaptive nut connected to the door. The helical slot of the screw is divided into a working segment with the helical lead angle greater than the friction angle, a closing segment with the helical lead angle smaller than the friction angle, and a transition segment between the closing and working segments. The power source actuates the screw to rotate bidirectionally. | 4 |
FIELD
The present invention relates to mechanisms for capturing spacecraft, and more particularly the present invention relates to a capture device for capturing and rigidising a bracket mounted on a spacecraft.
BACKGROUND
Grappling free flying target objects in space involves systems which possess the following capabilities: acquiring the location of the target object's position relative to the capture mechanism, establishing and tracking the relative motion of the target and capture mechanism, effecting a timely reduction in the relative separation between the two objects and then acting to capture the target object fast enough that it is grasped by the capture mechanism before the target moves out of the way on its own or is knocked away by the capture mechanism (an event known as “tip off”). The methods by which the relative positions and motions of the capture mechanism and the target object are established and tracked and the methods by which the capture mechanism is moved into position to capture are not part of this description. In general these may be accomplished through the orbital and attitude control of the captured spacecraft and in some cases augmented with manipulator arms which provide further dexterity and speed in the final stage of approach and positioning of the capture device with respect to the spacecraft which is to be captured. All these techniques are well known to those skilled in the art.
Capture mechanisms do, however, play a part in how large the relative movement can be between the target object and the capture mechanism. The faster the capture mechanism can perform an initial capture, the greater the relative motion can be between the two objects. This is because if the mechanism acts quickly enough, the target will have less time to move out of the way. For a given mechanism, the faster it works, the faster the relative motions can be between target object and capture mechanism. Providing a capture mechanism that permits a greater relative motion between the capture mechanism and the target object has significant benefits in potentially simplifying the design of the capture spacecraft if not the client spacecraft.
SUMMARY
The capture mechanism disclosed herein is designed with a view to capturing several of the standard spacecraft Marman clamp flange interfaces (see attached interface documents for specific variations), frequently called Launch Adapter Rings. The vast majority of satellites launched for Western customers, both commercial and military, use this interface due to its heritage and reliability. That said, the capture mechanism disclosed herein can be used to quickly capture other client spacecraft protrusions, the key criteria being the ability of the mechanism jaws to close on the protrusion from both sides and that, when closed, at least one side of the target protrusion has an extended profile that at least one part of the two sets of jaws can get behind with which to contain the target. Examples of potentially suitable target profiles would include, but not be limited to, personnel handles and grab rails, I-beams and C-channels, T-fittings, pipes, structural members, etc. As used herein the word “profile” refers to the cross sectional shape of the capture feature.
An embodiment of a system for system for capturing a capture feature on a free flying spacecraft comprises:
a capture mechanism including
i) a quick grasp mechanism mounted for movement in a housing, said quick grasp mechanism including at least two spaced pairs of grasping jaws and a closing/opening mechanism connected to said at least two pairs of grasping jaws for closing/opening each pair of grasping jaws, said quick grasp mechanism being configured for forcing said at least two pairs of spaced grasping jaws together around said capture feature to grasp the capture feature when the capture feature is in close proximity to, and triggers, said quick gasp mechanism to soft capture the capture feature; ii) said at least two pairs of grasping jaws including structural features configured to accommodate local variations in size and shape of the capture feature at at least two locations on the capture feature being grasped by said at least two pairs grasping jaws; and ii) a rigidizing mechanism including a rigidizing contact feature, said rigidizing mechanism being configured to force said at least two spaced grasping jaws further together to a closed position and at the same time driving said rigidizing contact feature into contact with said capture feature within said at least two grasping jaws to secure said capture feature within said closed grasping jaws between said rigidizing contact and said closed grasping jaws, to rigidize the capture feature and the spacecraft.
In another embodiment there is provided a capture mechanism for capturing a capture feature on a free flying spacecraft, comprising:
i) a quick grasp mechanism mounted for movement in a housing, said quick grasp mechanism including a pair of opposed grasping jaws and a closing/closing mechanism connected to said opposed grasping jaws for closing/opening said pair of grasping jaws, said quick grasp mechanism being configured for forcing said pair of grasping jaws together around said capture feature to grasp the capture feature; ii) at least one grasping jaw of said pair of grasping jaws including one or more distal end portions which are flexibly mounted to a remainder of the at least one grasping jaw, and are shaped and sized to accept a range of capture feature shape profiles; iii) a rigidizing mechanism including a rigidizing contact feature, said rigidizing mechanism being configured to force said pair of grasping jaws further together to a closed position and at the same time driving said rigidizing contact feature into contact with said capture feature within said at least two grasping jaws to secure said capture feature within said closed grasping jaws between said rigidizing contact and said closed grasping jaws, to rigidize the capture feature and the spacecraft.
The system may include
a) a positioning device attached to the capture mechanism capable of positioning the capture mechanism into close proximity to the feature to trigger the quick grasp mechanism; and b) a sensing system for ascertaining a relative position and motion of the capture mechanism and the feature to be captured c) a sensing system for ascertaining the relative or absolute positions of various elements within the capture mechanism.
In addition, the system may include a computer control system connected to said sensing system and programmed to position the capture mechanism in close proximity to said feature to be captured to trigger said quick grasp mechanism.
There is also disclosed herein a servicer satellite for capturing a capture feature on a free flying client satellite, comprising:
a) propulsion and guidance systems; b) a capture mechanism, the capture mechanism comprising
ii) said at least two pairs of grasping jaws including structural features configured to accommodate local variations in size and shape of the capture feature at at least two locations on the capture feature being grasped by said at least two pairs grasping jaws; and ii) a rigidizing mechanism including a rigidizing contact feature, said rigidizing mechanism being configured to force said at least two spaced grasping jaws further together to a closed position and at the same time driving said rigidizing contact feature into contact with said capture feature within said at least two grasping jaws to secure said capture feature within said closed grasping jaws between said rigidizing contact and said closed grasping jaws, to rigidize the capture feature and the spacecraft
c) a positioning mechanism releasably attached to the capture mechanism capable of positioning the capture mechanism to a desired proximity to the capture feature to trigger the quick grasp mechanism; d) a sensing system for ascertaining a relative position of the capture mechanism and the capture feature; and e) a communication system configured to provide communication between a command and control system and a remote operator for remote teleoperator control, supervised autonomous control, or fully autonomous control of all servicer satellite operations and operation of said capture mechanism between the servicer spacecraft and the client satellite.
In an embodiment there is provided a method for capturing a capture feature on a free flying spacecraft, comprising:
a) maneuvering a servicer satellite in proximity to a free flying spacecraft; b) positioning a capture mechanism mounted on the servicer satellite into proximity to a capture feature located on the free flying spacecraft, the capture mechanism including
i) a quick grasp mechanism mounted for movement in a housing, said quick grasp mechanism including at least two spaced pairs of grasping jaws and a closing/closing mechanism connected to said at least two pairs of grasping jaws for closing/opening each pair of grasping jaws, said quick grasp mechanism being configured for forcing said at least two spaced grasping jaws together around said capture feature to grasp the capture feature; ii) said at least two pairs of grasping jaws including structural features configured to accommodate local variations in size and shape of the capture feature at at least two locations on the capture feature being grasped by said at least two pairs grasping jaws; and ii) a rigidizing mechanism including a rigidizing contact feature, said rigidizing mechanism being configured to force said at least two spaced grasping jaws further together to a closed position and at the same time driving said rigidizing contact feature into contact with said capture feature within said at least two grasping jaws to secure said capture feature within said closed grasping jaws between said rigidizing contact and said closed grasping jaws, to rigidize the capture feature and the spacecraft;
c) once the capture mechanism is in proximity to said capture feature, advancing the capture mechanism until quick grasp mechanism is in position and triggering the quick grasp mechanism to close said at least two pairs of grasping jaws to soft capture the capture feature, activating the rigidizing mechanism to rigidize the capture feature and the free flying spacecraft; and d) after servicing the free flying spacecraft, disengaging the capture mechanism from the capture feature and maneuvering a servicer satellite away from the free flying spacecraft.
A further understanding of the functional and advantageous aspects of the disclosure can be realized by reference to the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will now be described, by way of example only, with reference to the drawings, in which:
FIG. 1 shows a perspective view of the capture mechanism of the present invention in the open position as if approaching a bracket located on a spacecraft;
FIG. 2 is a side view of the capture mechanism of FIG. 1A in the open position;
FIG. 3 shows a perspective view of the capture mechanism of FIG. 1 but from a different perspective than shown in FIG. 1 ;
FIG. 4 is a perspective view similar to FIG. 1 but with the bracket being grasped by the capture mechanism which is in the closed position;
FIG. 5 is a partial cross sectional of the capture mechanism in the open position taken along line 5 - 5 of FIG. 8 ;
FIG. 6 is a partial cross sectional of the capture mechanism in the closed position taken along line 5 - 5 of FIG. 8 except the jaws are in the closed position;
FIG. 7 is a top view of the capture mechanism taken along arrow 4 of FIG. 3 ;
FIG. 8 is a view of the front of the capture mechanism with the clamping jaws in the open position;
FIG. 9 is a view of the back of the capture mechanism with the clamping jaws in the open position;
FIG. 10 is a section view of the capture mechanism taken along the line 10 - 10 in FIG. 9 ;
FIG. 11 is a perspective view of the cross sectional view in FIG. 10 ;
FIG. 12 is a close up of FIG. 11 showing the gear box drive for the lead screw.
FIG. 13 is a close up of the trigger mechanism in the armed condition with several structural elements of the capture mechanism not shown for clarity;
FIG. 14 is a repeat of FIG. 13 except showing a partial cross section of the trigger reset pawl and how it interacts with the trigger reset cam rod
FIG. 15 is a repeat of FIG. 13 except showing a partial cross section of the trigger reset arrangement showing how the trigger reset cam transfers motion to the trigger reset rod.
FIG. 16 is a repeat of FIG. 13 except showing a partial cross section of the trigger mechanism showing how the trigger bar rests upon the trigger cam and how the trigger roller holds the trigger cam in place;
FIG. 17 is a close up of the electromagnetic solenoid trigger actuator and how it interacts with the trigger mechanism;
FIG. 18 is a sectional view through the lines 18 - 18 in FIG. 9 showing the guide shaft, carriage, trigger and how the ball screw interacts with the carriage to force the jaw rods forwards;
FIGS. 19A to 19E are partial sectional views similar to FIG. 5 illustrating the bracket capture sequence, FIG. 19A shows the mechanism at the moment the trigger mechanism is activated, FIG. 19B shows the jaws closed to the soft capture position just as the rigidisation starts, FIG. 19C shows the bracket fully captured and seated within the jaws but without any preload applied, FIG. 19D shows the mechanism fully preloaded within the mechanism, FIG. 19E shows the optional locking latch engaged to restrain the bracket within the jaws.
FIG. 20 is a partial sectional view along the line 11 - 11 of FIG. 9 showing the installation of the shock absorbers within the carriage.
FIG. 21 is a partial exploded view of the main housing showing installation of the shaft 111 and ball screw 120 .
FIG. 22 showing details of the shuttle 114 and the trigger bar 130 .
FIG. 23 showing details of the trigger mechanism.
FIG. 24 is a partial exploded view showing elements of the vision system 602 .
FIG. 25 showing details of the trigger-actuating solenoid 161 .
FIG. 26 is a partial exploded view showing installation of the shuttle plungers 170 .
FIG. 27 showing details of the actuator 180 and associated gearing.
FIG. 28 showing details of the draw bars 116 .
FIG. 29 showing details of the clamp jaw assembly 200 .
FIG. 30 showing details of the variable clamp jaw assembly 210 .
FIG. 31 showing details of how the clamp jaw assembly 200 is free to move within the main housing 110 .
FIG. 32 showing details of the mechanism that restrains rotary motion of the clamp jaw assembly 200 .
FIG. 33 showing details of the cam follower assembly 240 .
FIG. 34 showing details of the locking jaw assembly 230 .
FIG. 35 is a block diagram showing a servicing satellite equipped with the present capture mechanism for capturing a satellite.
FIG. 36 is a block diagram showing constituent parts of an exemplary computer control system which may be used for controlling the process of capturing the client satellite.
FIG. 37 is an overall view of an alternate embodiment of the tool that has been fitted with a mechanical trigger for the mechanism in addition to the solenoid trigger method shown in FIGS. 13 and 17 .
FIG. 38 is a sectional view taken in the same plane as the section for FIG. 18 as shown in FIG. 9 . It shows how the pusher plate 650 is connected by rod 653 to the trigger pin 670 which then contacts the Trigger 140 .
FIG. 39 is a detail showing how the trigger pin 670 acts to contact the trigger 140 and release the sear 141 to activate the mechanism.
FIG. 40 is an overall view of an alternate embodiment of the tool showing the general arrangement of the shock absorber system from the front of the tool.
FIG. 41 is an overall view of an alternate embodiment of the tool showing the general arrangement of the shock absorber system from the back of the tool.
FIG. 42 is a section showing the arrangement of the shock absorber system taken along the line 42 - 42 of FIG. 9 .
FIG. 43 is a general arrangement an alternate embodiment of the tool equipped with a jaw adjustment system 800 that both coordinates the motion of the two clamp jaw assemblies 200 and allows the clamp jaw assemblies 200 to be adjusted to capture launch adapter rings 502 or other features of varying diameters.
FIG. 44 is a detail view showing how a linear actuator 801 is integrated within the jaw adjustment system 800
FIG. 45 is a detail that shows how the jaw compliance mechanism 810 is integrated within the jay adjustment system 800
FIG. 46 is a section through the jaw compliance mechanism 810 .
DETAILED DESCRIPTION
Various embodiments and aspects of the disclosure will be described with reference to details discussed below. The following description and drawings are illustrative of the disclosure and are not to be construed as limiting the disclosure. The drawings are not necessarily to scale. Numerous specific details are described to provide a thorough understanding of various embodiments of the present disclosure. However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present disclosure.
As used herein, the terms, “comprises” and “comprising” are to be construed as being inclusive and open ended, and not exclusive. Specifically, when used in this specification including claims, the terms, “comprises” and “comprising” and variations thereof mean the specified features, steps or components are included. These terms are not to be interpreted to exclude the presence of other features, steps or components.
As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not be construed as preferred or advantageous over other configurations disclosed herein.
As used herein, the terms “about” and “approximately”, when used in conjunction with ranges of dimensions of particles, compositions of mixtures or other physical properties or characteristics, are meant to cover slight variations that may exist in the upper and lower limits of the ranges of dimensions so as to not exclude embodiments where on average most of the dimensions are satisfied but where statistically dimensions may exist outside this region. It is not the intention to exclude embodiments such as these from the present disclosure.
As used herein, the phrase “rigidized” refers to a joint, union or contact between two items where a predetermined amount of stiffness has been achieved between the two items. The term “rigidizing” refers to the process of achieving this condition.
The capture device disclosed herein has been conceived to address two types of spacecraft/space object capture. In general, it is for capturing “non-prepared” objects. This refers to a class of client spacecraft which were not designed with purpose-made features that would be used for later capture by a servicing spacecraft once the client spacecraft was in orbit. The capture device has been designed to capture through a grasping action of natural features like launch adapter rings which are present on most spacecraft for the purposes of attachment to the launch vehicle prior to release on-orbit. Other natural features such as rails would also be applicable.
A secondary feature of these non-prepared spacecraft for which this proposed capture device is intended is non-cooperative spacecraft. These are client spacecraft which are no longer under standard attitude control with the spacecraft no longer held in a stable attitude, but are instead are tumbling, i.e. rotating in one or more axis with respect to their desired pointing direction. In non-tumbling capture, the rendezvousing servicer spacecraft generally is moving relative to the client on a single axis of motion. In capturing a tumbling spacecraft, the servicer spacecraft and/or its manipulator arm must close the separation between it and the client in a number of axes. This puts a premium on the capture device being able to quickly grasp the tumbling spacecraft in what is a much narrower capture zone time, generally limited by the responsiveness of the spacecraft attitude and orbital control system and the responsiveness and peak rates of the manipulator arm.
The pool of viable clients will increase with the capture mechanism's ability to more quickly capture a mechanical feature on the client over a larger range of relative motion. In addition, the spacecraft carrying the capture mechanism will not have to control its own position as precisely, which will result in less propellant being needed and less complex avionics being required resulting in lower overall mission costs.
This premium on quickly grasping the client which is potentially tumbling presents a challenge for typical robotic grippers. They first must quickly close trapping or soft capturing the mechanical feature, and then very quickly produce a sufficiently high applied gripping load to ensure that the captured spacecraft remains grasped while resisting the forces and moments that develop at the interface as the servicer spacecraft and manipulator arrest the relative motion of the client. This presents a challenge for typical single action gripping devices which generally use some sort of gearing or transmission in the clamping action. In space systems, this gearing is needed because there is a need for lightweight actuators. As the gearing is increased to compensate for the low torque of the actuator, the penalty is a lower closure rate. This design trade-off in single action robotic grippers is a primary motivation for the two-stage, capture device disclosed.
As discussed above, the spacecraft being captured are generally moving relative to one another and the physical grasping of one spacecraft by another is a principle method of cancelling out the relative motions between the two spacecraft. Once a rigid grasp has been obtained upon the client spacecraft it is then necessary that the grasp between the two spacecraft be strong enough to absorb the forces and moment generated as the disparate motions between the two spacecraft are absorbed by the positioning mechanism and capture mechanisms now connecting the vehicles. Even with small relative motions between spacecraft, significant forces can be generated at the grasp points and within the capture mechanism. Spreading out the stance of the grasp reduces many of the internal forces permitting the mechanism to be lighter and achieve a better grasp with lower forces.
Broadly speaking, there is disclosed herein a system for capturing a rail and or flange feature (herein all referred to as a “capture feature”) on a free flying spacecraft. The system includes a capture mechanism which includes what may be characterized as a quick grasp mechanism mounted for movement in a housing with the quick grasp mechanism including at least one pair of grasping jaws. The quick grasp mechanism is configured to grasp the capture feature when the capture feature is in sufficiently close proximity, the trigger mechanism is initiated causing the the at least one pair of grasping jaws to quickly close to soft capture the capture feature. The capture mechanism includes an opening/closing mechanism which force the grasping jaws of the quick grasp mechanism further together to a closed position. The capture mechanism also includes a rigidizing contact. After the grasping jaws have been quickly closed to soft capture the capture feature, the rigidizing contact is driven into contact with the capture feature within the grasping jaws to secure the capture feature between the rigidizing contact and the closed grasping jaws, thereby to rigidize the capture feature and hence spacecraft within the capture mechanism.
Parts List
This embodiment of the capture mechanism tool is comprised of the following parts:
Number
Part Description
100
Capture Mechanism
110
Main Housing
111
Guide Shaft
112
Guide Shaft Bearing
113
Guide shaft Bearing Spacer
114
Shuttle
115
Guide Shaft Retainer
116
Draw Bar
117
Microswitch
120
Ball Screw Shaft
121
Ball Screw Thrust Bearing
122
Ball Screw Tail Bearing
123
Bearing Cover
124
Ball Screw Nut
125
Shock Absorber
126
Shock Absorber Mount Plate
127
Nut Plate
130
Trigger Bar
131
Trigger Bar Support
132
Trigger Housing
133
Trigger Guide Rod
134
Sear Support Rod
135
Trigger Reset Pawl
136
Trigger Reset Lever
137
Spring Retaining Pin
138
Spring Retaining Pin
139
Sear Spring
140
Trigger
141
Sear
142
Trigger Spring
143
Sear Reset Rod
144
Trigger Roller Axle
145
Trigger Roller
146
Trigger Lever Return Spring
147
Trigger Lever Stop
150
Camera
151
Line-Producing Laser
152
Situational Camera Assembly
153
Light Curtain Support
154
Forward Light
155
Aft Light
156
Forward Receiver
157
Aft Receiver
160
Solenoid Mounting Plate
161
Solenoid
162
Solenoid Lever
163
Solenoid Pin
164
Lever Pin
165
Trigger Striker
170
Plunger
171
Plunger Spring
172
Spring Housing
173
Plunger Retaining Nut
180
Actuator
181
Idler Axle
182
Actuator Mounting
183
Gearbox Cover
184
Motor Output Gear
185
Idler Gear
186
Ball Screw Input Gear
200
Clamp Jaw Assembly
201
Clamp Housing
202
Bearing Cover Plate
203
Clamp Housing Bearing
204
Hinge Pin
205
Jaw Bearing Plate
206
Journal Bearing
207
Jaw Hinge Springs
210
Variable Jaw Assembly
211
Jaw Hinge
212
Clamp Hinge Plate
213
Spring Mount
214
Variable Jaw
215
Clamp Hinge Pin
216
Spring
217
Contact Plunger
218
Contact Spring
219
Spring Housing
220
Plunger Retaining Nut
221
Plunger Mounting Plate
230
Locking Jaw Assembly
231
Jaw Hinge
232
Contact Rods
233
Clamp Plate
234
Lock Hinge Pin
235
Lock
236
Lock Spring
240
Cam Follower Assembly
241
Housing
242
Contact Shaft
243
Guide Pin
244
Shaft Retaining Nut
245
Contact Spring
246
Contact
247
Contact Housing
248
Cam Roller
249
Spacer
250
Roller Axle
251
Link
252
Lock Roller
260
Compliance Spring
261
Clamp Retainer
262
Journal Bearing
263
Shaft Retainer Nut
281
Bracket
282
Link
283
Spring
284
Torque Rod
285
Rod Retainer Nut
286
Link Pin
287
Link Pin Nut
300
Forward Light Beam
301
Aft Light Beam
302
Jaw Cam Surface
303
Lock Cam Surface
304
Trigger Pawl Surface
305
Lever Slot
306
Trigger Surface
307
Trigger Bar Surface
308
Ball Screw Nut Slot
500
Servicer Spacecraft
501
Robotic Arm
502
Launch Adapter Ring
503
Client Spacecraft
504
Communication Signal
505
Earth
506
Communications Antenna
600
Computer System
601
Computer Control System
602
Vision System
603
Central Processor
604
Internal Storage
605
Communications Interface
606
Power Supply
607
Memory
608
Input/Output Devices and Interfaces
609
Data Network
The structure of the capture mechanism will first be described and particular reference is made to a feature on most spacecraft named a Marman flange which is used as a launch adapter ring between the launching booster and the client spacecraft but it will be understood the present capture mechanism can be configured to capture any available similar feature on a spacecraft not necessarily intended to be grasped.
Referring to FIGS. 35 and 36 , using known methods not part of this disclosure the servicer spacecraft 500 approaches the client spacecraft 503 and manoeuvres within the reach of the robotic arm 501 attached to the client spacecraft 500 . The robotic arm 501 manoeuvres the capture device to within a prescribed distance from the launch adapter ring 502 on the client spacecraft 503 either by autonomous control from the computer system 600 or with partial or full control by human operators located either on the servicer spacecraft or at a remote location. Once the capture mechanism 100 is at the prescribed distance, the computer system 600 assumes automatic control of the final grasping and rigidisation actions. Providing position information to the computer system 600 , the vision system 602 receives input from the cameras 150 within the mechanism as well as other sensors on the servicer spacecraft 500 . The computer system 600 uses these inputs to calculate requited motions needed to manoeuvre the robotic arm 501 and the capture mechanism 100 into the final positions near the launch adapter ring 502 while tracking any motions of the client spacecraft 503 . At the proper moment, the computer system 600 directs the robotic arm 501 to advance the capture mechanism 100 into contact with the launch adapter ring 502 . It will be appreciated that if the servicer spacecraft is particularly maneuverable, an arm may not be required or needed at all and the spacecraft attitude and orbital control system (AOCS) could be used to manoeuvre the capture tool 100 into the proper relative position with respect to the client spacecraft launch adapter ring 502 .
FIG. 1 shows a perspective view of the capture mechanism 100 of the present invention in the open position as if approaching a bracket such as a rail and or a flange feature on a free flying spacecraft, or any other part that can be grasped, collectively referred to as a capture feature located on a free flying spacecraft to be captured.
FIG. 2 is a side view of the capture mechanism of FIG. 1 in the open position. FIG. 3 shows a perspective view of the capture mechanism 100 of FIG. 1 but from a different perspective than shown in FIG. 1 . FIG. 4 is a perspective view similar to FIG. 1 but with a capture feature (in this case a bracket, rail or launch adapter ring 502 located on the free flying spacecraft) being grasped by two clamp jaw assemblies 200 forming part of the capture mechanism 100 , which is shown in the closed position. While FIGS. 1, 3 and 4 show a pair of clamp jaw assemblies 200 pivotally mounted on the main housing 110 , it will be appreciated that the capture mechanism 100 may have only one clamp jaw assembly 200 or may have more than two clamp jaw assemblies 200 .
As best seen in FIGS. 1 and 4 , forward and rear light sources 154 and 155 respectively are mounted on one end of a light curtain support 153 and produce front and rear light beams 300 and 301 respectively. Front and rear detectors 156 and 157 are mounted on the other end of light curtain support 153 and located to receive the beams 300 and 301 respectively. The light sources 154 and 155 and their associated detectors 156 and 157 are positioned on light curtain supports 153 with respect to the clamp jaw assemblies 200 so that when capture feature 502 on the free flying spacecraft is in close proximity to the clamp jaw assemblies 200 the beams of light 300 and 301 are broken which triggers the clamp jaw assembly 200 to close around capture feature 502 , discussed in more detail below. The collection of light sources and receivers and the appropriate circuitry (including in this embodiment the computer 600 ) comprise the optical initiator.
Each clamp jaw assembly 200 includes a variable jaw assembly 210 pivotally mounted with respect to a locking jaw assembly 230 which will be discussed in great detail hereinafter.
FIG. 5 is a partial cross sectional view of the clamp jaw assembly 200 in the open position taken along line 5 - 5 of FIG. 8 . The combination of the local shape of the jaw cam surfaces 302 and the location of the cam rollers 248 allow the variable jaw assembly 210 and the locking jaw assembly 230 , rotating about hinge pins 204 to be biased apart by the jaw hinge springs 207 .
FIG. 6 is a partial cross sectional view of the capture mechanism in the closed and locked position taken along line 5 - 5 of FIG. 8 except the jaws are in the closed position. In this view the cam follower assembly 240 has been moved forward (to the left in the figure) and as the cam rollers 248 move along the contours of the jaw cam surfaces 302 , they force the variable jaw assembly 210 and the locking jaw assembly 230 together against the forces of the jaw hinge springs 207 (see also FIG. 5 ). The capture feature 502 has been pressed down into the contact plunger 217 compressing the contact spring 218 which is within the spring housing 219 . At the same time, the contact feature 246 has been pressed into the face of the capture flange 502 compressing the contact spring 245 contained within the contact housing 247 . The combination of compressed spring 245 and compressed contract spring 218 act together to hold the capture flange 502 against the fixed elements of the clamp jaw assembly 200 with the desired level of security or contact stiffness. The cam follower assembly 240 has advanced to its furthest forward limit and the lock roller 252 has forced the lock 235 inwards against the capture feature 502 thereby mechanically securing the capture flange 502 in place.
FIG. 7 is a top view of the capture mechanism 100 taken along arrow 7 of FIG. 2 . This view shows how the shuttle 114 is linked to the draw bars 116 which are flexibly connected to associated contact shafts 242 that serve to advance their associated cam follower assemblies 240 .
FIG. 8 is a view of the front of the capture mechanism 100 with the clamping jaw assemblies 200 in the open position and illustrates the relative positions of the cameras 150 , line-producing lasers 151 and the clamp jaw assemblies 200 . It also shows how the situational camera assembly 152 can be positioned to oversee the operation of the capture mechanism 100 .
FIG. 9 is a view of the back of the capture mechanism 100 with the clamping jaw assemblies 200 in the open position.
FIG. 10 is a section view of the capture mechanism taken along the line 10 - 10 in FIG. 9 and shows how the guide shaft bearings 112 and guide shaft bearing spacer 113 act to support the guide shaft 111 . It also shows how the shuttle 114 is connected to the draw bars 116 .
FIG. 11 is a perspective view of the cross sectional view in FIG. 10 . It shows how the plunger springs 171 acts upon the spring housings 172 and the plungers 170 to force the draw bars 116 forward. The spring housings 172 are attached to the main housing 110 .
FIG. 12 is a close up of FIG. 11 with gearbox cover 183 removed showing the arrangement of gears 184 , 185 and 186 that transmit torque from the actuator 180 to the ball screw shaft 120 .
FIG. 13 is a close up of the trigger mechanism in the armed condition with several structural elements of the capture mechanism not shown for clarity.
FIG. 14 is a repeat of FIG. 13 except showing a partial cross section of the trigger reset pawl 135 and how it is mounted to the trigger reset lever 136 and how the trigger reset pawl relates to the trigger pawl surface 304 on the trigger bar support 131 . It also shows how the trigger bar 130 sits within the trigger bar support 131 and how the sear 141 is biased by the sear spring 139 acting upon the spring retaining pin 138 .
FIG. 15 is a repeat of FIG. 13 except showing a further partial cross section of the trigger reset arrangement showing how, when the trigger reset lever 136 is rotated when the trigger pawl surface 304 moves the trigger reset pawl 135 it causes the sear reset rod 143 to rotate the sear 141 . It also shows how the motion of the trigger reset lever 135 is limited in the aft direction by the trigger lever stop 147 and how the motion of the trigger bar 130 is restrained by the contact with the sear 141 along the trigger bar surface 307 .
FIG. 16 is a repeat of FIG. 13 except showing a further partial cross section of the trigger mechanism showing how the trigger bar 130 rests upon the sear 141 and how the trigger roller 145 holds the sear 141 in place.
FIG. 17 is a close up of the solenoid 160 and how it interacts with the trigger mechanism with the reciprocating motion of the solenoid 160 being transmitted and the force amplified by the solenoid lever 162 which forces the trigger striker 165 into contact with the trigger 140 forcing it to rotate.
FIG. 18 is a sectional view through the lines 18 - 18 in FIG. 9 showing the guide shaft 111 , shuttle 114 , and how the ball screw shaft 120 interacts with the shuttle 114 via the ball screw nut 124 and shock absorber mount plate 126 to force the shuttle 114 and therefore the draw bars 116 and the contact shaft 242 forwards.
FIGS. 19A to 19E are partial sectional views similar to FIG. 5 illustrating the bracket 502 capture sequence when viewed in alphabetical order. FIG. 19A shows the capture mechanism 200 at the moment the trigger 140 is struck and the sear 141 is free to rotate releasing the trigger bar 130 allowing the shuttle 114 to move. FIG. 19B shows the jaw assembly 200 closed to the soft capture position just as the rigidisation starts. The plunger springs 171 are at minimum compression and, via the plungers 170 , have driven the draw bars 116 and contact shafts 242 as far forward as they can. FIG. 19C shows the cam follower assembly 240 having been pushed further forward by the action of the ball screw shaft 120 on the ball screw nut 124 with the bracket 502 fully captured and seated within the jaws 210 and 230 but without any preload applied, FIG. 19D shows the clamp jaw assembly 200 fully preloaded with the forward motion of the cam rollers 248 forcing the jaw cam surfaces 302 together forcing the bracket 502 into the contact plunger 217 and the contact 246 . This motion is resisted by spring 216 and contact spring 245 creating a connection of known rigidity between the bracket 502 and the capture mechanism 100 . FIG. 19E shows the cam follower assembly 240 even further forward where the lock roller 252 has pushed the optional lock 235 into position against the bracket 502 to restrain the bracket 502 within the jaws 210 and 230 .
FIG. 20 is a partial sectional view along the line 21 - 21 of FIG. 2 showing the installation of the shock absorbers 125 attached to the shock absorber mount plate 126 which is then attached to the nut plate 127 capturing the ball screw nut 124 between them. The three assembled items 125 , 126 and 127 are then free to move within the ball screw nut slot 308 in the shuttle 114 .
FIG. 21 is a partial exploded view of the main housing 110 showing installation of the shaft 111 and ball screw 120 . The shock absorbers 125 are attached to the shock absorber mount plate 126 which is then attached to the nut plate 127 capturing the ball screw nut 124 between them. The shuttle 114 moves back and forth guided by the guide shaft 111 with friction being reduced by the guide shaft bearings 112 that are spaced appropriately by the guide shaft bearing spacer 113 . The ball screw shaft 120 is secured to the main housing 110 by the ball screw thrust bearing 121 and stabilised by the ball screw tail bearing 122 which is secured by the bearing cover 123 .
FIG. 22 shows details of the shuttle 114 , the trigger bar 130 and the trigger bar supports 131 that secure the trigger bar 130 to the shuttle 114 . The ball screw nut slot 308 is sized such that with the ball screw nut 124 in the ready-to-latch position as shown in FIG. 20 , the free play in the slot permits the shuttle 114 to advance very rapidly under the influence of the plunger springs 171 without requiring the ball screw shaft 120 to rotate. This permits the rapid soft capture action of the capture mechanism 100 .
FIG. 23 shows details of the trigger mechanism. The trigger mechanism is comprised of three parts, the trigger reset lever 136 , the sear 141 and the trigger 140 all mounted such that they are free to rotate and yet biased into preferred positions by the trigger lever return spring 146 , the sear spring 139 and the trigger spring 142 , respectively. The trigger reset pawl 135 transmits motion from the trigger bar support 131 to the trigger reset lever 136 , which then moves the trigger reset rod 143 which rotates the sear 141 out of the way permitting the trigger 140 to return to the armed position driven by the trigger spring 140 .
FIG. 24 is a partial exploded view showing the optical elements of the vision system 602 showing the positions of the cameras 150 , and the line-producing lasers 151 mounted on the main housing 110 .
FIG. 25 showing details of the trigger-actuating solenoid subassembly. The solenoid 161 , mounted to the solenoid mounting plate 160 , acts when commanded by the computing system 600 . The shaft of the solenoid retracts into the body of the solenoid 161 when activated, which causes the solenoid lever 162 to rotate. This solenoid lever 162 is connected to the solenoid 161 by the solenoid pin 163 and to the solenoid mounting plate 160 by the lever pin 164 . The trigger striker 165 is mounted to the solenoid lever 162 such that it forces the trigger 140 to rotate sufficiently to activate the capture mechanism 100 .
FIG. 26 is a partial exploded view showing installation of the shuttle plungers 170 . Microswitches 117 are mounted to the main housing 110 such that as they open or close, they provide desired information on the location of the shuttle 114 to the computer system 600 . Guide shaft retainer 115 secures the guide shaft 111 to the main housing 110 . The plungers 170 are free to move reciprocally within the spring housings 172 which are secured to the main housing 110 . The forward end of the plungers 170 butt against the aft face of the draw bars 116 (not shown). The aft motion of the plungers 170 is constrained by the plunger springs 171 , which in the armed condition, are compressed sufficiently to propel the plungers 170 forward forcing the draw bars 116 and cam roller assemblies 240 to complete the soft capture action. The plungers 170 are contained within the spring housings 172 by the retainer nuts 173 .
FIG. 27 shows details of the actuator 180 and associated gearing. The actuator 180 is secured to the motor output gear 184 which rotates the idler gear 185 , secured by the idler axle 181 to the actuator mounting 182 which is attached to the main housing 110 . The idler gear 185 rotates the ball screw input gear 186 which is secured to the ball nut shaft 120 rotating the ball nut shaft 120 and transmitting the actuator 180 torque to the ball nut shaft 120 .
FIG. 28 shows how the draw bars 116 assemble into the shuttle 114 and how the plungers 170 interfaces with the draw bars 114 . It also shows the relationship between the stereo pair of cameras 150 , situational cameras 152 , the solenoid mounting plate 160 , the microswitches 117 and the main housing 110 .
FIG. 29 is an exploded view showing details of the clamp jaw assembly 200 . The variable jaw assembly 210 and the locking jaw assembly 230 are flexibly mounted to the clamp housing 201 by hinge pins 204 and biased to a preferred position by jaw hinge springs 207 . Bearing cover plate 202 secures the clamp housing bearing 202 to the clamp jaw assembly 200 . The cam rollers 248 and lock roller 252 are secured to the cam follower assembly 240 but free to rotate by the roller axles 250 and located by the spacers 249 . The links 251 maintain the correct spacing between the cam rollers 248 when under load during the rigidising action. The jaw bearing plate 205 , in conjunction with the clamp housing bearing 203 , permits the clamp jaw assembly 200 to rotate with respect to the main housing 110 while being axially and laterally supported in the main housing 110 . The journal bearing 206 permits the cam follower assembly to move axially with respect to the rest of the clamp jaw assembly 200 .
FIG. 30 showing details of the variable clamp jaw assembly 210 . The clamp hinge plate 212 is secured to the jaw hinge 211 . The spring mounts 213 permit jaw hinge springs 207 (not shown) to be mounted to the assembly. The variable jaw 214 is attached to the clamp hinge plate 212 by the clamp hinge pin 215 , but is free to rotate. The position of the variable jaw 214 is biased to a preferred position by the spring 216 . The contact plungers 217 are secured to the spring housing 219 by the plunger retaining nuts 220 such that they may move axially and trap the contact springs 218 . The spring housings 219 are attached to the variable jaws 214 by the plunger mounting plate 221 .
FIG. 31 shows details of how the clamp jaw assembly 200 is free to move within the main housing 110 . The jaw bearing plate 205 is fastened to the main housing 110 which, in concert with the clamp housing bearing 203 permits the clamp jaw assembly 200 to rotate with respect to the main housing 110 . The contact shaft 242 is secured to the draw bar 116 using the clamp retainer 261 . The compliance spring 260 and the journal bearing 262 permit the draw bar 116 to move axially with respect to the clamp jaw assembly 200 reducing the chances of damage at the end of draw bar 116 travel.
FIG. 32 shows details of the mechanism that restrains rotary motion of the clamp jaw assembly 200 . With the brackets 281 secured to the main housing 110 , the torque rod 284 is placed with a slot in the bracket 281 . A spring 283 is placed over each end of the torque rod 284 such that the bracket 281 is sandwiched between them. The springs 283 are secured by a rod retainer nut 285 on the interior end and by a link 282 on the external end. The hole in the link 282 is secured to a clevis in the clamp housing 201 by a link pin 286 and a link pin nut 287 . The torque rod 284 is free to move within the slot in the bracket 281 yet is centred by the opposing actions of the springs 283 thus centring the position of the clamp jaw assembly 200 with respect to the main housing 110 .
FIG. 33 shows details of the cam follower assembly 240 . The contact shaft 242 is attached to the housing 241 by the shaft retaining nut 244 . The contact housing 247 is fastened to the housing 241 permitting the contact 246 to move axially within it constrained by the contact spring 245 . Guide pins 243 are fastened to the housing 241 and engage axial slots on the clamp housing 201 to prevent the cam follower assembly 240 from rotating about the axis of the clamp shaft 242 while permitting it to move freely axially with respect to the clamp housing 201 .
FIG. 34 showing details of the locking jaw assembly 230 . The clamp plate 233 is secured to the jaw hinge 231 . The spring mounts 213 permit jaw hinge springs 207 to be mounted to the assembly. The lack 235 is attached to the clamp plate 233 by the lock hinge pin 234 , but is free to rotate. The position of the lock 235 is biased to a preferred position by the lock spring 236 . Contact rods 232 are secured to the clamp plate 233 and the jaw hinge 231 and provides a hard contact surface that the feature 502 can abut to.
FIG. 37 is an overall view of an alternate embodiment of the tool 900 that has been fitted with a mechanical trigger for the mechanism in addition to the solenoid trigger method shown in FIGS. 13 and 17 . In this embodiment a pusher plate 650 has been arranged such that it is a back-up activating method and thus is not engaged unless the electronic triggering method fails. It will be understood that should it be required, this arrangement can be reversed so that the mechanical trigger is the primary method and the electronic triggering method is the back-up method.
The pusher plate 650 is connected to a rod 653 that transmits the contact force via the trigger pin 670 to the trigger 140 (best seen in FIG. 39 ). The rod 653 is supported at the front by support 652 and at the rear by bushing block 656 which is fastened to the main housing 110 . The rod 653 is guided by bushings 651 and terminates in a pin support 671 .
FIG. 38 is a sectional view taken in the same plane as the section for FIG. 18 as shown in FIG. 9 . It shows how the pusher plate 650 is connected by rod 653 to the trigger pin 670 which then contacts the trigger 140 . The motion of the pusher plate 650 and rod 653 are controlled by spring 655 , the effect of which is adjusted by securing collar 654 at various points along the rod 653 . A second collar 654 prevents the rod 653 from extending too far out of the tool 900 . Depending upon the final purpose to which the tool 900 will be put, the adjustability of the securing collar 654 may be limited to establishing the correct performance of the tool 900 by being adjusted only during manufacture or, in an alternate embodiment not shown, by the use of an additional actuator(s) to vary the position of the securing collar 654 on the rod 653 thus varying the performance of the spring 655 and the performance of the mechanical triggering portion of the tool 900 as a whole.
A slot 658 in rod 653 is engaged by a pin 657 that is secured within the bushing block 656 and keeps the trigger pin 670 properly aligned by preventing the rod 653 from rotating around its long axis.
FIG. 39 is a detailed view showing how the trigger pin 670 acts in parallel with and independently of the trigger striker 165 to contact the trigger 140 and release the sear 141 to activate the mechanism. Aftward motion of the rod 653 forces the trigger pin 670 against the surface of trigger 140 . Pin support 671 is threaded for trigger pin 670 and the exact timing of when the trigger pin 670 strikes the trigger 140 is set by advancing or retarding the position of the trigger pin 670 within the pin support 671 .
An alternate embodiment of the tool, as shown generally at 940 in FIG. 40 , includes a shock absorber system to reduce the internal forces generated by the powerful plunger spring 171 when the mechanism is activated. These forces can cause damage to tool or impose shock loads on the servicer spacecraft 500 or the client spacecraft 503 .
FIG. 41 is an overall view of the alternate embodiment of the tool 940 fitted with a shock absorber system 702 showing the general arrangement from the back of the tool. When the mechanism is activated the draw bars 116 are forced forward by the plunger springs 171 acting upon the plungers 170 . In this embodiment the plungers 171 are connected together by the connector plate 700 which transfers some of the plunger spring 171 forces to the shock absorbers 702 through the pistons 701 (best seen in FIG. 42 ). The shock absorbers 702 slow the motion of the draw bars 116 and reduce the internal forces acting upon the housing 110 to decelerate the mechanism at the end of its stroke. The drag caused by the shock absorbers 702 and the spacing 707 (shown in FIG. 42 ) between the connector plate 700 and the pistons 701 can be varied to fine tune the timing and forces required by the tool 100 to perform successfully.
FIG. 42 is a section showing the arrangement of the shock absorber system taken along the line 42 - 42 of FIG. 9 . The shock absorber 702 is secured to the housing 110 by mounting plate 704 . Both mounting plate 704 and the exterior of the shock absorbers 702 are threaded such that the axial position of the shock absorber 702 can be varied to set the spacing 707 . Once located correctly, nut 703 is tightened securing the shock absorber 702 in the correct position. Bumper 706 acts to spread the load from plunger 170 to the draw bars 116 .
An additional alternate embodiment of the tool 980 equipped with a jaw adjustment mechanism 800 for altering the angular position, also known as the pose, of the clamp jaw assemblies 200 is shown in FIG. 43 . The jaw adjustment system 800 both coordinates the motion of the two clamp jaw assemblies 200 and allows the clamp jaw assemblies 200 to be adjusted to capture launch adapter rings 502 , or other features, of varying diameters. The jaw adjustment system 800 also incorporates features that provide compliance to the individual clamp jaw assemblies 200 to accommodate small misalignments and client satellite 503 movements.
The coordinated motion function is accomplished by the combination of components, drive gear 809 , idler gear 805 and bell crank 807 . A rotational input, in this case affected by the linear actuator 801 , to one clamp jaw assembly 200 (the left side, for example) will cause the clamp jaw assembly 200 to rotate about the clamp housing bearing 203 (best seen in FIG. 5 ). This will move the arm securing the link 282 (best seen in FIG. 32 ) or jaw compliance mechanism 810 to the link pin 286 . The jaw compliance mechanisms 810 are free to rotate about either the link pin 286 or the pin 806 at either end. Movement of the jaw compliance mechanism 810 moves the moment arm 803 connected to the idler 805 . Rotation of the idler 805 rotates the drive gear 804 , but in the opposite direction, which then moves the connected moment arm 803 . That moment arm 803 is connected to the shaft 802 and the linear actuator 801 each of which has a pin that is free to rotate at the end. For embodiments where varying the nominal capture radius of the tool is unnecessary, the linear actuator 801 and shaft 802 may be replaced with a single rigid component fitted with free rotating pins on either end (not shown in this embodiment). Rigid motion of the linear actuator 801 causes the bell crank 807 to rotate about axle 809 causing the second jaw compliance mechanism or link to be rotated and then transfer the rotation to the sending clamp jaw assembly 200 , but with an opposite and coordinated rotation.
FIG. 44 is a detail view showing how a linear actuator 801 is integrated within the jaw adjustment system 800 of FIG. 43 . When it is desired to vary the radius of curvature that the clamp jaw assemblies 200 can accommodate the linear actuator 801 can extend or contract the shaft 802 . As configured in FIG. 43 , extending the shaft 802 will enable the clamp jaw assemblies 200 to grasp a smaller radius feature through the motion of the gears 804 and 805 , bell crank 807 and compliance mechanisms 810 as described above. Retracting the shaft 802 will enable the clamp jaw mechanisms to grasp a larger radius feature, adjusting their pose or rotational position relative to their link pin axes 286 on the main housing 110 . The axles 809 are mounted rigidly to the bracket 808 which is rigidly mounted to the housing 110 . Different arrangements of gears 804 and 805 and bell cranks 807 can be created to change the motion parameters of the system.
In addition, as an alternate method of adjusting the grasp radius, the linear actuator 801 can be replaced by a rigid shaft and a rotary actuator or motor connected rigidly to the axle 809 of either gear 804 or 805 .
FIG. 45 is a detail that shows how the jaw compliance mechanism 810 ( FIG. 43 ) is integrated within the jaw adjustment system 800 ( FIG. 43 ). Undesirable motion variances of the individual clamp jaw assemblies 200 can be accommodated through the introduction of compliance between the two clamp jaw assemblies 200 and between the two clamp jaw assemblies 200 and any actuator 801 used to adjust the nominal clamping radius of curvature. An un-commanded motion of the clamp housing 201 will apply a force on one end of the housing 811 of the jaw compliance mechanism 810 through link pin 286 . Springs 814 within the jaw compliance mechanism 810 (see FIG. 45 ) permit the exterior components of the jaw compliance mechanism 810 to move relative to the compliance shaft 813 which is connected to the rest of the jaw adjustment system 800 . The strength and configuration of the springs 814 within the jaw compliance mechanism 810 determine the compliance performance of the jaw compliance mechanism 810 .
FIG. 46 is a section through the jaw compliance mechanism 810 . In this example, the jaw compliance mechanism consists of housing 811 connected by a link pin 286 to the clamp housing 201 part of the clamp jaw assembly 200 . The parts internal to the jaw compliance mechanism 810 are secured by a cap 812 . The housing 811 contains a piston 813 with a central stop 815 and springs 814 that act upon the central stop and upon the housing 811 at one end and upon the cap 812 on the other end. The opposing springs 814 act to centralise the piston 813 , returning the mechanism to a preset neutral position if perturbed. The details of each spring 814 may be varied to provide specified piston performance to suit the desired overall requirements of the tool. In addition, a damping element, not shown in this embodiment, may be added to the mechanism to further customise its performance. Piston 813 is then connected to the rest of the jaw adjustment system 800 through pin 806 connected to moment arm 803 .
An alternate embodiment, not shown, may omit the actuator 801 and any linkage between the bell crank 807 and the idler gear 805 and add actuators to drive the bell crank 807 and idler gear 805 independently of one another. This would further increase the capability of the tool 980 to grasp capture features of varying shapes.
It will be understood that the alternate embodiments described above may be incorporated in the tool 100 of FIG. 1 singly or in any combination depending upon the demands of the purpose for which the tool 100 is being used. The exact alternate embodiments described above are also exemplary, there being other arrangements of mechanical triggers, shock absorbers and actuators that will perform the same functions as those listed above.
The operation of clamping mechanism 100 of FIG. 1 will now be described but it will be understood that this description applies also to the embodiments shown in FIGS. 37 to 46 , noting that the operation of the additional features shown in these Figures have been largely described above.
In operation, referring to FIGS. 1 and 4 , when the launch adapter ring 502 breaks the forward light beam 300 formed between the forward light 154 and the forward receiver 156 a signal is sent to and interpreted by the computer system 600 . Any differences in the signals sent by the forward receivers 156 on each clamp jaw assembly 200 (shown in more detail in FIG. 29 ) are interpreted as errors by the computer system 600 and may be used, as part of a broader control system, to correct the position of the capture mechanism 100 in real time.
The capture mechanism 100 continues to be advanced over the launch adapter ring 502 until the aft light beams 301 formed by the aft lights 155 and the aft receivers 157 are broken by the launch adapter ring 502 . If the two forward light beams 302 remain broken and at least one of the aft light beams 301 is broken, the capture mechanism is configured to be in an acceptable position to grasp the launch adapter ring 502 . This prompts the optical initator's activation of the trigger 140 whereby the computer system 600 generates a signal that causes the solenoid 161 ( FIG. 17 ) to activate, causing the solenoid lever 162 ( FIGS. 17 and 25 ) to rotate and forcing the trigger striker 165 to contact the trigger 140 causing it to rotate. FIG. 25 shows an exploded view of the solenoid assembly which includes solenoid 161 , solenoid lever 162 , trigger striker 165 , a lever pin 164 , solenoid pin 163 and solenoid mounting plate 160 .
An alternate embodiment to initiating the motion of the trigger 140 would be to introduce a mechanical initiator that is activated by physical contact of the capture mechanism with the launch adapter ring 502 or other bracket to be grasped. This mechanical initiator would include a contact rod secured to the main housing 110 in such a way that the contact force as the rod strikes the client bracket is transmitted directly to the trigger 140 . The use of sliding bearings, bell cranks and other methods of mechanical force transmission well known in the art, permit the location of the contact rod to be optimised to the client bracket and the design of the rest of the capture mechanism 100 . This mechanical contact means of initiating the trigger 140 could be the primary trigger initiation method or act as a secondary or back-up to the electromechanical trigger initiation method.
A second alternative embodiment for initiating the rotation of the trigger 140 would involve replacing the optical light curtain with inductive sensing means which detected when the launch adapter ring 502 is sufficiently aligned over the inductive sensors.
Once the trigger 140 rotates, the trigger roller 145 ( FIGS. 13, 14, 15 and 17 ) rolls up the face of the sear 141 , the trigger roller 145 acting to reduce friction and ensuring a smooth and repeatable release. FIG. 26 is a partial exploded view showing installation of the shuttle plungers 170 . Referring to FIGS. 11 and 26 , the plunger springs 171 and plungers 170 push against the draw bars 116 attached to the shuttle 114 and apply a force that attempts to move the shuttle 114 forward.
The sear 141 is in contact with the trigger bar 130 ( FIG. 15 ) attached to the shuttle 114 preventing the shuttle 114 from moving forward. See FIGS. 13, 14, 15 and 16 that illustrate how the trigger 140 and sear 141 resist the motion of the trigger bar 130 . When the trigger roller 145 has moved far enough that it no longer restricts the rotation of the sear 141 , the sear 141 is rotated by the forces generated by the plunger springs 171 and the shuttle 114 and draw bars 116 are free to move forward very quickly. Referring to FIG. 10 , as the shuttle 114 moves forward it is guided by sliding on the guide shaft 111 , friction being reduced by the use of the guide shaft bearings 112 , appropriately spaced by the guide shaft bearing spacer 113 .
Should the capture mechanism 100 be triggered in error or fail to capture the client spacecraft 503 the shuttle 114 may continue too far forward striking the ball screw nut 124 ( FIG. 9 ). To prevent damage in such a condition, the ball screw nut 124 is fitted with two shock absorbers 125 that will absorb the impact of the shuttle 114 from a failed capture.
Referring to FIGS. 19A and 33 , the forward motion of the draw bars 116 also forces the cam follower assembly 240 forward. The cam follower 240 assembly is connected to the main housing 110 by journal bearings 206 and 262 ( FIGS. 29 and 31 ) that restrict lateral movement but permit rotational and axial movement and by a compliance spring 260 that prevents damage at the extremes of motion which is contained by the clamp retainer 261 which is bolted to the main housing 110 .
FIG. 19A shows the configuration of the clamp jaw assembly 200 at the instant the shuttle 114 begins to move. The launch adapter ring 502 is in the correct position to be grasped. As the cam follower assembly 240 moves forward the cam rollers 248 move along a predetermined jaw cam surface 302 ( FIG. 5 ) and force the variable jaw assembly 210 and the locking jaw assembly 230 closer towards each other overcoming the biasing effect of the jaw hinge springs 207 . FIG. 19B shows the clamp jaw assembly 200 at the end of the plunger spring 171 stroke with the variable jaw assembly 210 and the locking jaw assembly 230 closed sufficiently such that the launch adapter ring 502 cannot escape, yet there is no actual contact with the launch adapter ring 502 . The launch adapter ring 502 is now considered “soft captured” and the first, automatic step of the two-step capture is complete.
Referring to FIGS. 11, 11, 26, 27 and 28 , microswitches 117 ( FIG. 11 ) within the capture mechanism 100 are closed as the shuttle 114 passes by them providing a signal to the computer system 600 that soft capture has been achieved. The computer system 100 then commands the actuator 180 to rotate such that the torque is transmitted from the motor output gear 184 through the idler 185 and to the ball screw input gear 186 causing the ball screw 120 to rotate. The ball screw 120 rotates within and is connected to the main housing 110 by the ball screw thrust bearing 121 and the ball screw tail bearing 122 ( FIG. 21 ). As shown in FIG. 21 , Ball screw 120 also rotates within the ball nut 124 which is fixed within the shuttle 114 by the shock absorber mount plate 126 and the nut plate 127 . Because the ball nut 124 is constrained from rotating within the shuttle 114 , the actuator 180 torque results in an axial force on the shuttle 114 forcing the shuttle to continue to move forward also driving the two cam follower assemblies 240 further forward. During the rotation of actuator 180 during the capture sequence, the rotation location of the actuator shaft may be continuously monitored and stored in the computer 600 . Alternatively, calibration during assembly will reveal the number of rotations of the actuator shaft of actuator 180 required to perform the capture sequence and hence the reset sequence.
As the cam follower assembly 240 moves further forward, the shape of the jaw cam surfaces 302 forces the variable jaw assembly 210 and the lock jaw assembly 230 closer together, as shown in FIG. 19C . Part of the cam follower assembly 240 is the contact 246 . in the position defined as “seated”, shown in FIG. 19C , the jaws 210 and 230 are closed to the point that they just about touch the outer and inner diameters of the launch adapter ring 502 and the contact 246 almost touches the face of the launch adapter ring 502 . As the actuator 180 continues to apply torque the cam follower continues to move forward and the variable jaw assembly 210 and the lock jaw assembly 230 continue to get closer together. The launch adapter ring eventually contacts the contact rods 232 on the locking jaw assembly 230 , the contact plungers 217 on the variable jaw assembly 210 and the contact 246 on the cam follower assembly 240 .
The actuator 180 continues to force the cam follower assembly 240 further forward and, as shown in FIG. 19C , the shape of the jaw cam surface 302 forces the variable jaw assembly 210 and the lock jaw assembly 230 even closer together. In doing so, the contact rods 232 ( FIG. 34 ) force the launch adapter ring 502 down onto the contact plungers 217 compressing the contact springs 218 ( FIG. 30 ). At the same time the contact 246 in FIG. 33 is pushed into the face of the launch adapter ring 502 compressing the contact spring 245 in FIG. 33 . When the desired level of force is generated in the contact springs 218 and 245 the launch adapter ring 502 is considered fully preloaded to the point where the attachment between the capture mechanism 100 and the launch adapter ring 502 has achieved the desired level of stiffness (i.e. has been “rigidised”) to permit the attachment to resist loads generated during spacecraft stabilisation and other servicing tasks. This condition is shown in FIG. 19D .
In order to provide a further lock between the two spacecraft, the locking jaw assembly 230 in FIG. 34 is equipped with a lock that physically prevents the launch adapter ring 502 from being removed from the capture mechanism 100 . As shown in FIG. 19E , when the cam follower assembly 240 has reached the position where the full preload has been developed, it is advanced still further. The combination of the cam rollers 248 and the jaw cam surface 302 do not act to compress the jaws 210 and 230 further, but the lock roller 252 now engages with the lock cam surface 303 on the back of the lock 235 and overcomes the biasing effect of the lock spring 236 (shown in FIG. 34 ) to force the lock 235 into a position where it prevents the movement of the launch adapter ring 502 . The capture mechanism 100 and the launch adapter ring 502 are now preloaded and locked together completing the second stage of the two-stage capture sequence.
Referring again to FIGS. 19E to 19A , to permit the servicing of several spacecraft or to permit additional attempts to capture a client spacecraft that might not have been captured on the first attempt, the capture mechanism 100 can be unlatched and reset to its initial condition. To do so generally amounts to running the actuator 180 in the opposite direction and causing the cam follow assembly 240 to move aft, moving the cam rollers 248 in the reverse direction down the lock cam surface 302 and the jaw cam surface 301 which, in sequence allows the lock 235 to be biased away from the launch adapter ring 502 and then unloads the contact 246 and the contact plungers 217 . The jaw hinge springs then can bias the jaws 210 and 230 away from the launch adapter ring 502 . At any point between FIGS. 19B and 19A it is possible for the capture mechanism to be maneuvered away from the launch adapter ring 502 by the robotic arm 501 .
To fully reset the capture mechanism 100 , the trigger 140 must be reset in its initial position. To do so, the actuator 180 continues to force the shuttle 114 aftwards within the capture mechanism 100 until the trigger reset pawl 135 , see FIG. 15 , located on the trigger reset lever 136 , contacts the trigger pawl surface 304 on the trigger bar support 131 . The trigger reset lever 136 is biased in the untriggered position by the trigger lever reset spring 146 and prevented from rotating too far by the trigger lever reset stop 147 as shown in FIG. 15 . As the shuttle 114 is pushed aft, the contact between the trigger reset pawl 135 and the trigger pawl surface 304 rotates the trigger reset lever 136 . The sear reset rod 143 contacting the back of the lever slot 305 then forces the sear 141 to rotate along with the trigger reset lever 135 . The trigger 140 and trigger roller 145 are flexibly secured within the trigger housing 132 and biased to the untriggered position by the trigger spring 142 . As the trigger roller 145 is moved out of the way by the motion of the sear 141 , the trigger 140 rotates until the trigger roller 145 passes over the top of the sear 141 and then starts to contact the trigger surface 306 , see FIG. 16 . Prior knowledge of how many actuator 180 turns are required to reset the trigger 140 allows the computer system 600 or a human operator to know when the trigger 140 has been reset. Alternately, a position sensor (not shown in the embodiment) may be used to determine when the sear 141 had returned to the untriggered state. The trigger spring 142 biases the trigger 140 into the correct position against the trigger surface 306 on the sear 141 .
The rotation of the actuator 180 is once again reversed to drive the shuttle 114 forward. As the shuttle 114 moves forward the trigger bar 130 contacts the trigger bar surface 307 on the sear 141 . The trigger mechanism is now reset, however the ball screw nut 124 continues to be driven forward in the ball screw nut slot 308 , ( FIGS. 22 and 24 ) leaving the shuttle 114 to be retained by the trigger mechanism. The ball screw nut 124 has been moved forward sufficiently that when the capture mechanism 100 is triggered the shuttle 114 can move forward far enough to attain the soft capture state without being restricted by the shuttle 114 prematurely striking the ball nut screw 124 . The capture mechanism 100 is now completely reset and ready for another capture.
Referring to FIG. 1 , in order to service a wider range of clients and to accommodate variations in bracket size and position, the capture mechanism 100 may include additional features. To accommodate differences in launch adapter ring 502 diameter, the two clamp jaw assemblies 200 are mounted on clamp housing bearings 203 as shown in FIG. 29 . These bearings 203 permit the clamp housing 201 to rotate about the axis of the cam follower assembly 240 with respect to the main housing 110 . In this embodiment the two clamp jaw assemblies 200 are free to rotate independently. To keep the clamp jaw assemblies 200 in their nominal positions, each assembly 200 is connected to a torque rod 284 ( FIG. 32 ) by a link 282 and then connected to the main housing 110 by a bracket 281 . To keep the torque rod 284 centred on the bracket 281 a spring 283 is located on either side of the bracket 281 . Rotations of the clamp jaw assembly 200 are accommodated by the sliding of the torque rod 284 within a slot in the bracket 281 which compresses one or the other spring 283 which generates a righting moment that returns the clamp jaw assembly 200 to the nominal position.
As shown in FIG. 30 , to accommodate launch adapter rings 502 of differing profile shape the variable jaw assembly 210 incorporates a two-part jaw with a fixed clamp hinge plate 212 connected flexibly to a variable jaw 214 by a clamp hinge pin 215 . Rotation of the variable jaw 214 is limited to a desired range by features machined into the variable jaw 214 and the clamp hinge plate 212 and the variable jaw 214 is biased to any desired position relative to the clamp hinge plate 212 by the spring 216 . When the variable jaw assembly 210 is closed over varying profiles within a known range of shapes, the shape and flexible position of the variable jaw 214 permits the entire clamp jaw assembly 200 to correctly grasp varying shapes within a predetermined range.
An alternate embodiment can incorporate a linking mechanism that coordinates the rotation of the two clamp jaw assemblies 200 so that a wider range of launch adapter ring 502 diameters can be accommodated. To further increase the range of launch adapter ring 502 diameters, each bracket 281 can be connected to an actuator that changes the nominal position of the bracket, and therefore the changes nominal diameter of launch adapter ring 502 being grasped.
An alternate embodiment has the entire capture mechanism 100 as a separate tool that the robotic arm 501 may releasably grip to permit the robotic arm to perform additional functions. The separate tool embodiment would include a releaseable interface between the robotic arm 501 and the capture mechanism 100 such that mechanical forces, electrical power and sensor signals can be transmitted across the interface. Several such interfaces exist in prior art and they are not part of this invention.
An alternate embodiment would delete the vision system 602 , and the line producing lasers 151 and rely exclusively upon human control to maneuver the capture mechanism 100 and upon mechanical contact to actuate the trigger mechanism per the alternate embodiment above.
The capture mechanism disclosed herein is very advantageous over the spacecraft capture mechanism disclosed in US Patent Publication 2013-0249229-A1 published Sep. 26, 2013, (hereinafter '229), for the following reasons. The capture mechanism disclosed in '229 has a very limited range of objects that it can optimally grasp, while the mechanism disclosed herein is designed for a much greater range of objects that it can optimally grasp and that adjustment can be varied during the use of the tool to greatly increase the utility of the tool. As one example of this, the pairs of grasping jaws include structural features configured to accommodate local variations in size and shape of the capture feature at the two locations on the capture feature being grasped by the two pairs grasping jaws.
Further, mechanism disclosed in '229 has a single set of grasping members, or jaws, which results in larger forces within the entire capture mechanism during the rigidising operation thereby requiring members of greater size and mass to withstand those forces. Larger and more massive members not only reduce response time, but also lead to a higher overall mechanism size and mass which is highly undesirable for spacecraft systems.
The single set of grasping members in '229 is manufactured to optimally grasp features of a limited range of sizes. This range cannot be changed once the grasping members are manufactured and installed in the mechanism. To increase its adjustability and utility, the mechanism in the current disclosure has multiple grasping mechanisms which may be adjusted in service to optimally grasp a much wider range of features and that may be changed for each grasping operation to greatly increase the utility of the tool.
In addition, the individual grasping members or pairs of grasping jaws of the capture mechanism disclosed herein also have adjustability designed into them to allow each of the grasping members to optimally contact and grasp objects with their anticipated relative motion with respect to the capture mechanism. This greatly enhances the tool's ability to accommodate varying objects to be grasped and increases the utility of the tool.
As an example of this, at least one grasping jaw of each pair of grasping jaws has a distal end locking portion which is flexibly mounted to a remainder of the grasping jaw and includes a cam surface which when in contact with an associated cam follower is forced into a locking position to lock the feature within the grasping jaws. In addition the present capture mechanism includes positioning mechanisms connected to each of the pairs of grasping jaws configured to vary a pose of each pair of grasping jaws with respect to the capture feature being grasped prior to being grasped. The quick grasp mechanism is configured such that each pair of grasping jaws is positioned independently of all other pairs of grasping jaws.
It will be understood that while the above discussion relates to an embodiment with at least two pairs of grasping jaws spaced from each other, it will be understood that more than two pairs of grasping jaws may be used, as the present disclosure is not meant to be limited to two pairs. In addition, the present disclosure may encompass an embodiment where only one pair of grasping jaws are needed. As the grasping jaws disclosed herein have various structure features that allow them to be adjusted for various sizes and shapes of capture features. This would be beneficial when the satellite being captured is very small and the capture feature is such that it is more amenable to grasping by one pair of grasping jaws.
In addition, a satellite may be produced with the capture system as part of the satellite.
Referring again to FIG. 35 , a block diagram showing those items pertaining to the capture of a client spacecraft 503 in addition to the capture mechanism 100 . These include the servicer spacecraft 500 , the client spacecraft 503 with launch adapter ring 502 to be captured, a robotic arm 501 to which the capture mechanism 100 is interfaced and a communication system 506 to provide a two-way radio link 504 to Earth 505 (or space station or mother ship, whichever is the location of the teleoperation control).
In addition, the servicer spacecraft 500 includes an onboard computer control system 600 (see FIG. 36 ) which may be interfaced with the capture mechanism 100 , so that it can coordinate all the components that are involved in the capture process, including the vision system 602 , robotic arm(s) 501 (if more than one capture mechanism 100 is used). This control system 600 is also interfaced with any sensors used to determine the position and loading state of the soft capture or rigidise mechanisms. These sensors may include contact or non-contact sensors used to trigger the quick grasp mechanism (in lieu of the plunger) and position sensors to determine the degree of closure of the mechanisms using continuous means (encoders or resolvers) or discretely (using limit switches). With the presence of the computer system 600 interfaced with the capture mechanism 100 , the capture process may be autonomously controlled by a local mission manager or may include some levels of supervised autonomy so that in addition to being under pure teleoperation there may be mixed teleoperation/supervised autonomy.
Referring again to FIG. 36 , an example computing system 600 forming part of the servicing system is illustrated. The system includes a computer control system 601 configured, and programmed to control movement of the robotic arm 501 during the entire procedure of capturing launch adapter ring 502 on the client satellite 503 .
The command and control system is also configured to control movement of the robotic arm 501 and for controlling the action of the capture mechanism 100 . This may be the same command and control system that is interfaced with the capture mechanism 100 , for example a computer mounted on the servicer spacecraft which is programmed with instructions to carry out all operations needed to be performed by the servicer satellite during approach, capture/docking with the client satellite and refueling operations. It may also be a separate computer system.
Communication system 506 is interfaced with the robotic arm 501 and configured to allow remote operation (from the Earth 505 or from any other suitable location) of the vision system 602 (which may include one or more cameras), the robotic arm 501 and hence the capture mechanism 100 . The vision system 602 may include distinct markers mounted on the capture mechanism 100 . The communication system allows local automatic or autonomous control, and may send
a) vision system information robot control computer on spacecraft, where it processes visual information to determine relative pose and allow the arm/positioning device to position the capture mechanism relative to the capture 500 ; and/or b) capture tool information/telemetry including the light beam state and trigger information.
Alternatively, it may be under teleoperated control from a remote location (earth) where the vision system information and other telemetry is provided to the operator to make decisions and control the action of the positioning device (arm) and the capture tool.
In one form, the vision system 602 may include one or more video cameras. To improve depth perception, it may be augmented with a range finding device, such as a laser range finder or radar. The cameras of vision system 602 may be used within a telerobotic control mode where an operator controlling the servicing actions on earth or from some other remote location views distinct views of the worksite on display screens at the command and control console. In an alternative mode, the position of elements of the capture mechanism 100 or launch adapter ring 502 may be determined by either a stereo camera and vision system which extracts 3 d points and determines position and orientation of the capture mechanism 100 or other relevant features on the ring 502 , client spacecraft 503 or capture mechanism 100 from which the robotic arm 501 can be driven to desired locations according the sensed 6 degree-of-freedom coordinates. It should be noted that the term position in the context of the positioning of the servicing spacecraft with respect to the spacecraft to be captured includes the orientation of the object as well as the translation vector between the two objects, i.e. the overall relative pose of the capture feature on the client spacecraft with respect to servicer spacecraft.
The stereo camera could also be replaced with a scanning or flash lidar system from which desired 6 degree-of-freedom coordinates could be obtained by taking measured 3-D point clouds and estimating the pose of desired objects based on stored CAD models of the desired features or shapes on the refueling worksite. For those applications where the spacecraft was designed with the intention to be serviced, a simple target such as described in Ogilvie et al. (Ogilvie, A., Justin Allport, Michael. Hannah, John Lymer, “Autonomous Satellite Servicing Using the Orbital Express Demonstration Manipulator System,” Proc. of the 9th International Symposium on Artificial Intelligence, Robotics and Automation in Space (i-SAIRAS '08), Los Angeles, Calif., Feb. 25-29, 2008) could be used in combination with a monocular camera on the servicing robotics to locations items of interest. Finally, the robotic arm or device used to position the capture mechanism 100 may include a sensor or sensors capable of measuring reaction forces between the capture tool and the bracket being captured. These can be displayed to the operator to aid the operator in teleoperation control or can be used in an automatic force-moment accommodation control mode, which either aids a tele-operator or can be used in a supervised autonomous control mode.
As mentioned above, computer control system 603 is interfaced with vision system 602 and robotic arm 501 . Previously mentioned communication system 506 is provided which is interfaced with the robotic arm 501 and configured to allow remote operation (from the Earth 506 or from any other suitable location) of the vision system 602 (the robotic arm 501 and capture mechanism 100 . A system of this type is very advantageous particularly for space based systems needing remote control.
The robotic arm 501 possesses its own embedded processor and receives commands from the servicing spacecraft computer. The robotic arm 501 also passes power and data from the central computer through to the capture mechanism 100 in the event there are sensors of any type, gauges or other power requiring devices
Some aspects of the present disclosure can be embodied, at least in part, in software. That is, the techniques can be carried out in a computer system or other data processing system in response to its processor, such as a microprocessor, executing sequences of instructions contained in a memory, such as ROM, volatile RAM, non-volatile memory, cache, magnetic and optical disks, or a remote storage device. Further, the instructions can be downloaded into a computing device over a data network in a form of compiled and linked version. Alternatively, the logic to perform the processes as discussed above could be implemented in additional computer and/or machine readable media, such as discrete hardware components as large scale integrated circuits (LSI's), application-specific integrated circuits (ASIC's), or firmware such as electrically erasable programmable read-only memory (EEPROM's).
FIG. 37 provides an exemplary, non-limiting implementation of computer control system 601 , forming part of the command and control system, which includes one or more processors 603 (for example, a CPU/microprocessor), bus 609 , memory 607 , which may include random access memory (RAM) and/or read only memory (ROM), one or more internal storage devices 604 (e.g. a hard disk drive, compact disk drive or internal flash memory), a power supply 606 , one more communications interfaces 605 , and various input/output devices and/or interfaces 608 .
Although only one of each component is illustrated in FIG. 37 , any number of each component can be included in computer system 600 . For example, a computer typically contains a number of different data storage media. Furthermore, although bus 609 is depicted as a single connection between all of the components, it will be appreciated that the bus 609 may represent one or more circuits, devices or communication channels which link two or more of the components. For example, in personal computers, bus 609 often includes or is a motherboard.
In one embodiment, computer control system 601 may be, or include, a general purpose computer or any other hardware equivalents configured for operation in space. Computer control system 601 may also be implemented as one or more physical devices that are coupled to processor 603 through one of more communications channels or interfaces. For example, the computer control system 601 can be implemented using application specific integrated circuits (ASIC). Alternatively, computer control system 601 can be implemented as a combination of hardware and software, where the software is loaded into the processor from the memory or over a network connection.
The computer control system 601 may be programmed with a set of instructions which when executed in the processor causes the system to perform one or more methods described in the present disclosure. Computer control system 601 may include many more or less components than those shown.
While some embodiments have been described in the context of fully functioning computers and computer systems, those skilled in the art will appreciate that various embodiments are capable of being distributed as a program product in a variety of forms and are capable of being applied regardless of the particular type of machine or computer readable media used to actually effect the distribution.
A computer readable medium can be used to store software and data which when executed by a data processing system causes the system to perform various methods. The executable software and data can be stored in various places including for example ROM, volatile RAM, non-volatile memory and/or cache. Portions of this software and/or data can be stored in any one of these storage devices. In general, a machine readable medium includes any mechanism that provides (i.e., stores and/or transmits) information in a form accessible by a machine (e.g., a computer, network device, personal digital assistant, manufacturing tool, any device with a set of one or more processors, etc.). Examples of computer-readable media include but are not limited to recordable and non-recordable type media such as volatile and non-volatile memory devices, read only memory (ROM), random access memory (RAM), flash memory devices, floppy and other removable disks, magnetic disk storage media, optical storage media (e.g., compact discs (CDs), digital versatile disks (DVDs), etc.), among others. The instructions can be embodied in digital and analog communication links for electrical, optical, acoustical or other forms of propagated signals, such as carrier waves, infrared signals, digital signals, and the like.
The present system is also configured for full autonomous operation. A fully autonomous system is a system that measures and responds to its external environment; full autonomy is often pursued under conditions that require very responsive changes in system state to external conditions or for conditions that require rapid decision making for controlling hazardous situations. The implementation of full autonomy is often costly and is often unable to handle unforeseen or highly uncertain environments. Supervised autonomy, with human operators able to initiate autonomous states in a system, provides the benefits of a responsive autonomous local controller, with the flexibility provided by human teleoperators. | The present invention provides a capture mechanism for capturing and locking onto the Marman flange located on the exterior surfaces of spacecraft/satellites. The capture mechanism achieves its goal of quickly capturing a client spacecraft by splitting the two basic actions involved into two separate mechanisms. One mechanism performs the quick grasp of the target while the other mechanism rigidises that grasp to ensure that the target is held as firmly as desired. | 1 |
[0001] This application is a divisional of U.S. application Ser. No. 09/800,645 filed on Mar. 7, 2001.
BACKGROUND OF THE INVENTION
[0002] In the manufacture of paper products, it is often desirable to enhance physical and/or optical properties by the addition of chemical additives. Typically, chemical additives such as softeners, colorants, brighteners, strength agents, etc. are added to the fiber slurry upstream of the headbox in a paper making machine during the manufacturing or converting stages of production to impart certain attributes to the finished product. These chemical additives are usually mixed in a stock chest or stock line where the fiber slurry has a fiber consistency of from between about 0.15 to about 5 percent or spraying the wet or dry paper or tissue during production.
[0003] One disadvantage of adding a chemical additive at each paper machine is that the manufacturer has to install equipment on each paper machine to accomplish the chemical additive addition. This, in many cases, is a costly proposition. In addition, the uniformity of the finished product coming off of each paper machine may vary depending upon how the chemical additive was added, variations in chemical additive uniformity and concentrations, the exact point of chemical additive introduction, water chemistry differences among the paper machines as well as personnel and operational differences of each paper machine.
[0004] Another difficulty associated with wet end chemical additive addition is that the water soluble or water dispersible chemical additives are suspended in water and are not completely adsorbed or retained onto the fibers prior to formation of the wet mat. To improve adsorption of wet end chemical additives, the chemical additives are often modified with functional groups to impart an electrical charge when in water. The electrokinetic attraction between charged chemical additives and the anionically charged fiber surfaces aids in the deposition and retention of chemical additives onto the fibers. Nevertheless, the amount of the chemical additive that can be adsorbed or retained in the paper machine wet end generally follows an adsorption curve exhibiting diminishing incremental adsorption with increasing concentration, similar to that described by Langmuir. As a result, the adsorption of water soluble or water dispersible chemical additives may be significantly less than 100 percent, particularly when trying to achieve high chemical additive loading levels.
[0005] Consequently, at any chemical addition level, and particularly at high addition levels, a fraction of the chemical additive is retained on the fiber surface. The remaining fraction of the chemical additive remains dissolved or dispersed in the suspending water phase. These unadsorbed or unretained chemical additives can cause a number of problems in the papermaking process. The exact nature of the chemical additive will determine the specific problems that may arise, but a partial list of problems that may result from unadsorbed or unretained chemical additives includes: foam, deposits, contamination of other fiber streams, poor fiber retention on the machine, compromised chemical layer purity in multi-layer products, dissolved solids build-up in the water system, interactions with other process chemicals, felt or fabric plugging, excessive adhesion or release on dryer surfaces, physical property variability in the finished product.
[0006] Therefore, what is lacking and needed in the art is a method for applying chemical additives onto pulp fiber surfaces in the initial or primary pulp processing, providing more consistent chemical additive additions to the pulp fiber and a reduction or elimination of unretained chemical additives in the process water on a paper machine. The method minimizes the associated manufacturing and finished product quality problems that would otherwise occur with conventional wet end chemical addition at the paper machine.
SUMMARY OF THE INVENTION
[0007] It has now been discovered that chemical additives can be applied to pulp fibers at high and/or consistent levels with at most a minimal amount of unretained chemical additives present in the papermaking process water after the treated pulp fiber has been redispersed in water. This is accomplished by treating a fibrous web prior to the finishing operation at a pulp mill with a chemical additive, completing the finishing operation, redispersing the finished pulp at the paper mill and using the finished pulp in the production of a paper product.
[0008] Hence in one aspect, the invention resides in a method for applying chemical additives to the pulp fibers. The method comprises creating a fiber slurry comprising water and pulp fibers. The fiber slurry is formed into a wet fibrous web using a web forming apparatus. The wet fibrous web is dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. A chemical additive is applied to the dewatered fibrous web, thereby forming a chemically treated dewatered fibrous web. In other embodiments of the present invention, the process may include further dewatering of the dewatered fibrous web, thereby forming a crumb-form before or after the application of the chemical additive. The chemically treated dewatered fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated pulp fiber is then used in a separate process to produce paper product.
[0009] In another aspect, the invention resides in a method for applying chemical additives to the pulp fibers. The method comprises creating a fiber slurry comprising water and pulp fibers. The fiber slurry is formed into a wet fibrous web using a web forming apparatus. The wet fibrous web is dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. In other embodiments of the present invention, the process may include further dewatering of the dewatered fibrous web, thereby forming a crumb-form. The dewatered fibrous web is dried to a predetermined consistency, thereby forming a dried fibrous web. A chemical additive is applied to the dried fibrous web, thereby forming a chemically treated dried fibrous web. The chemically treated dried fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated pulp fiber is then used in a separate process to produce paper product.
[0010] According to another embodiment of the present invention is a method for applying a chemical additive to the pulp fiber during the pulp processing stage. During the pulp processing stage, upstream of a paper machine, one can obtain chemically treated pulp fiber. Furthermore, the chemically treated pulp fiber can be transported to several different paper machines that may be located at various sites, and the quality of the finished product from each paper machine will be more consistent. Also, by chemically treating the pulp fiber before the pulp fiber is made available for use on multiple paper machines or multiple runs on a paper machine, the need to install equipment at each paper machine for the chemical additive addition can be eliminated.
[0011] The term “unretained” refers to any portion of the chemical additive that is not retained by the pulp fiber and thus remains suspended in the process water. The term “web-forming apparatus” includes fourdrinier former, twin wire former, cylinder machine, press former, crescent former, and the like used in the pulp stage known to those skilled in the art. The term “water” refers to water or a solution containing water and other treatment additives desired in the papermaking process. The term “chemical additive” refers to a single treatment compound or to a mixture of treatment compounds. It is also understood that a chemical additive used in the present invention may be an adsorbable chemical additive.
[0012] The consistency of the dried fibrous web is from about 65 to about 100 percent. In other embodiments, the consistency of the dried fibrous web is from about 80 to about 100 percent or from about 85 to about 95 percent. The consistency of the dewatered fibrous web is from about 20 to about 65 percent. In other embodiments, the consistency of the dewatered fibrous web is from about 40 to about 65 percent or from about 50 to about 65 percent. The consistency of the crumb form is from about 30 to about 85 percent. In other embodiments, the consistency of the crumb form is from about 30 to about 60 percent or from about 30 to about 45 percent.
[0013] The present method allows for the production of pulp fibers that are useful for making paper products. One aspect of the present invention is a uniform supply of chemically treated pulp fiber, replacing the need for costly and variable chemical treatments at one or more paper machines.
[0014] In another embodiment, the chemically treated pulp fiber slurry of the present invention comprises process water and having an applied chemical additive retained by the pulp fibers. The amount of chemical additive retained by the chemically treated pulp fibers is about 0.1 kilogram per metric ton or greater. In particularly desirable embodiments, the amount of retained chemical additive is about 0.5 kg/metric ton or greater, particularly about 1 kg/metric ton or greater, and more particularly about 2 kg/metric ton or greater. Once the chemically treated pulp fibers are redispersed at the paper machine, the amount of unretained chemical additive in the process water phase is between 0 and about 50 percent, particularly between 0 and about 30 percent, and more particularly between 0 and about 10 percent, of the amount of chemical additive retained by the pulp fibers.
[0015] According to one embodiment of the present invention, the method for adding a chemical additive to pulp fiber comprises creating a fiber slurry. The fiber slurry comprises water and pulp fibers. The fiber slurry is passed to a web-forming apparatus of a pulp sheet machine where a wet fibrous web is formed from the fiber slurry. The wet fibrous web is dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. The dewatered fibrous web is dried to a predetermined consistency, thereby forming a dried fibrous web. A chemical additive is then applied to the dried fibrous web. The resulting chemically treated dried fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated dried fibrous web may be transported to a paper machine. The chemically treated dried fibrous web is mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry contains the fibers having the chemical additive secured thereto or retained thereby. A finished product having enhanced quality due to the retention of the chemical additive by the chemically treated pulp fibers may be produced from the chemically treated pulp fiber slurry.
[0016] Another aspect of the present invention resides in a method for making chemically treated paper products. The method comprising mixing pulp fibers with water to form a fiber slurry. The fiber slurry is formed into a wet fibrous web. This may be accomplished in a web-forming apparatus of a pulp sheet machine. The wet fibrous web may be dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. A chemical additive is then applied to the dewatered fibrous web. The resulting chemically treated dewatered fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated pulp fibers, as a chemically treated dewatered fibrous web, may be transported or otherwise delivered to one or more paper machines. The chemically treated pulp fiber, as a chemically treated dewatered fibrous web, is mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry contains the chemically treated pulp fibers having the chemical additive secured thereto or retained thereby. A finished product having enhanced qualities due to the retention of the chemical additive by the chemically treated pulp fibers may be produced.
[0017] Another aspect of the present invention resides in a method for making chemically treated paper products. The method comprising mixing pulp fibers with water to form a fiber slurry. The fiber slurry is formed into a wet fibrous web. This may be accomplished in a web-forming apparatus of a pulp sheet machine. The wet fibrous web may be dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. A chemical additive is then applied to the dewatered fibrous web, thereby forming a chemically treated dewatered fibrous web. The resulting chemically treated dewatered fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated dewatered fibrous web is dried to a predetermined consistency, thereby forming a chemically treated dried fibrous web. The resulting chemically treated dried fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated pulp fibers, as a chemically treated dried fibrous web, may be transported or otherwise delivered to one or more paper machines. The chemically treated pulp fiber, as a chemically treated dried fibrous web, is mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry contains the chemically treated pulp fibers having the chemical additive secured thereto or retained thereby. A finished product having enhanced qualities due to the retention of the chemical additive by the chemically treated pulp fibers may be produced.
[0018] Another aspect of the present invention resides in a method for making chemically treated paper products. The method comprising mixing pulp fibers with water to form a fiber slurry. The fiber slurry is formed into a wet fibrous web. This may be accomplished in a web-forming apparatus of a pulp sheet machine. The wet fibrous web may be dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. The dewatered fibrous web is dried to a predetermined consistency, thereby forming a dried fibrous web. A chemical additive is then applied to the dried fibrous web. The resulting chemically treated dried fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated pulp fibers, as a chemically treated dried fibrous web, may be transported or otherwise delivered to one or more paper machines. The chemically treated pulp fiber, as a chemically treated dried fibrous web, is mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry containing the chemically treated pulp fibers having the chemical additive secured thereto or retained thereby. A finished product having enhanced qualities due to the retention of the chemical additive by the chemically treated pulp fibers may be produced.
[0019] Another aspect of the present invention resides in a method for making chemically treated finished paper or tissue products. The method comprising mixing pulp fibers with water to form a fiber slurry. The fiber slurry is formed into a wet fibrous web. This may be accomplished in a web-forming apparatus of a pulp sheet machine. The wet fibrous web may be dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. A chemical additive is applied to the dewatered fibrous web, thereby forming a chemically treated dewatered fibrous web. In other embodiments, the dewatered fibrous web may be processed to a wet lap or processed to a crumb form before or after the application of the chemical additive. The resulting chemically treated pulp fiber contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated dewatered fibrous web, once treated with the chemical additive, may be transported or otherwise delivered to one or more paper machines in the chemically treated form of a dewatered fibrous web, a dried fibrous web, a wet lap, or a crumb form. The chemically treated pulp fiber, as a wet fibrous web, a wet lap, or a crumb form, is mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry contains the chemically treated pulp fibers having the chemical additive secured thereto. A finished product having enhanced qualities due to the retention of the chemical additive by the chemically treated pulp fibers is produced.
[0020] Another aspect of the present invention resides in a method for making chemically treated finished paper or tissue products. The method comprising mixing pulp fibers with water to form a fiber slurry. The fiber slurry is formed into a wet fibrous web. This may be accomplished in a web-forming apparatus of a pulp sheet machine. The wet fibrous web may be dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. A chemical additive is applied to the dewatered fibrous web, thereby forming a chemically treated dewatered fibrous web. In other embodiments, the dewatered fibrous web may be processed to a wet lap or processed to a crumb form before or after the application of the chemical additive. The resulting chemically treated pulp fiber contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated dewatered fibrous web is dried to a predetermined consistency, thereby forming a chemically treated dried fibrous web. The resulting chemically treated dried fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The dried fibrous web, once treated with the chemical additive, may be transported or otherwise delivered to one or more paper machines in the chemically treated form of a dried fibrous web. The chemically treated pulp fiber, as a chemically treated dried fibrous web, is mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry contains the chemically treated pulp fibers having the chemical additive secured thereto. A finished product having enhanced qualities due to the retention of the chemical additive by the chemically treated pulp fibers is produced.
[0021] Another aspect of the present invention resides in a method for making chemically treated finished paper or tissue products. The method comprising mixing pulp fibers with water to form a fiber slurry. The fiber slurry is formed into a wet fibrous web. This may be accomplished in a web-forming apparatus of a pulp sheet machine. The wet fibrous web is dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. The dewatered fibrous web is dried to a predetermined consistency, thereby forming a dried fibrous web. A chemical additive is applied to the dried fibrous web, thereby forming a chemically treated dried fibrous web. In other embodiments, the dewatered fibrous web may be processed to a wet lap or processed to a crumb form before or after the application of the chemical additive. The resulting chemically treated pulp fiber contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. The chemically treated dried fibrous web, once treated with the chemical additive, may be transported or otherwise delivered to one or more paper machines in the chemically treated form of a dried fibrous web, a dried fibrous web, a wet lap, or a crumb form. The chemically treated pulp fiber, as a wet fibrous web, a wet lap, or a crumb form, is mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry contains the chemically treated pulp fibers having the chemical additive secured thereto. A finished product having enhanced qualities due to the retention of the chemical additive by the chemically treated pulp fibers is produced.
[0022] Another aspect of the present invention resides in a method for making chemically treated paper products. The method comprises creating a fiber slurry comprising water and pulp fibers. The fiber slurry is formed into a wet fibrous web. This may be accomplished in a web-forming apparatus of a pulp sheet machine. The wet fibrous web may be dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. In other embodiments, the pulp fiber may be processed to a wet lap or processed to a crumb form. A first chemical additive is applied to the dewatered fibrous web. At least a second chemical additive may be applied to the dewatered fibrous web, thereby forming a multi-chemically treated dewatered fibrous web. The second chemical additive may be added simultaneously with the first chemical additive or at different times or points of the pulp processing stage. The multi-chemically treated dewatered fibrous web, containing the first and second chemical additives, may be further dried to a predetermined consistency, thereby forming a chemically treated dried fibrous web. The resulting chemically treated dried fibrous web may have from about 10 to about 100 percent retention of the applied first and second chemical additives. The resulting chemically treated pulp fibers contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of at least each of the first and second chemical additives when the chemically treated pulp fibers are redispersed in water. The chemically treated pulp fibers, as a multi-chemically treated dried fibrous web or as a multi-chemically treated dewatered fibrous web, are transported or otherwise delivered to one or more paper machines. The chemically treated pulp fibers, as a chemically treated dried fibrous web or a chemically treated dewatered fibrous web, are mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry contains the chemically treated pulp fibers having the chemical additives secured thereto. A finished product having enhanced qualities due to the retention of the chemical additives by the chemically treated pulp fibers may be produced.
[0023] Another aspect of the present invention resides in a method for making chemically treated paper products. The method comprises creating a fiber slurry comprising water and pulp fibers. The fiber slurry is formed into a wet fibrous web. This may be accomplished in a web-forming apparatus of a pulp sheet machine. The wet fibrous web may be dewatered to a predetermined consistency, thereby forming a dewatered fibrous web. The dewatered fibrous web may be dried to a predetermined consistency, thereby forming a dried fibrous web. In other embodiments, the pulp fiber may be processed to a wet lap or processed to a crumb form. A first chemical additive is applied to the dried fibrous web. At least a second chemical additive may be applied to the dried fibrous web, thereby forming a multi-chemically treated dried fibrous web. The second chemical additives may be added simultaneously with the first chemical additives or at different times or points of the pulp processing. The resulting chemically treated dried fibrous web contains chemically treated pulp fibers that have retained from between about 10 to about 100 percent of the applied amount of at least each of the first and second chemical additives when the chemically treated pulp fibers are redispersed in water. The chemically treated pulp fibers, as a multi-chemically treated dried fibrous web, are transported or otherwise delivered to one or more paper machines. The chemically treated pulp fibers, as a chemically treated dried fibrous web, are mixed with process water to form a chemically treated pulp fiber slurry. The chemically treated pulp fiber slurry contains the chemically treated pulp fibers having the chemical additives secured thereto. A finished product having enhanced qualities due to the retention of the chemical additives by the chemically treated pulp fibers may be produced.
[0024] The present invention is particularly useful for adding chemical additives such as softening agents to the pulp fibers, allowing for the less problematic and lower cost production of finished products having enhanced qualities provided by the retained chemical additives by the pulp fibers.
[0025] Hence, another aspect of the present invention resides in paper products formed from pulp fibers that have been chemically treated to minimize the amount of residual, unretained chemical additives in the process water on a paper machine. The term “paper” is used herein to broadly include writing, printing, wrapping, sanitary, and industrial papers, newsprint, linerboard, tissue, bath tissue, facial tissue, napkins, wipers, wet wipes, towels, absorbent pads, intake webs in absorbent articles such as diapers, bed pads, meat and poultry pads, feminine care pads, and the like made in accordance with any conventional process for the production of such products. With regard to the use of the term “paper” as used herein includes any fibrous web containing cellulosic fibers alone or in combination with other fibers, natural or synthetic. It can be layered or unlayered, creped or uncreped, and can consist of a single ply or multiple plies. In addition, the paper or tissue web can contain reinforcing fibers for integrity and strength.
[0026] The term “softening agent” refers to any chemical additive that can be incorporated into paper products such as tissue to provide improved tactile feel and reduce paper stiffness. A softening agent may be selected from the group consisting of quaternary ammonium compounds, quaternized protein compounds, phospholipids, polysiloxane compounds, quaternized, hydrolyzed wheat protein/dimethicone phosphocopolyol copolymer, organoreactive polysilxanes, polyhydroxy compounds, and silicone glycols. These chemical additives can also act to reduce paper stiffness or can act solely to improve the surface characteristics of tissue, such as by reducing the coefficient of friction between the tissue surface and the hand.
[0027] The term “dye” refers to any chemical that can be incorporated into paper products, such as bathroom tissue, facial tissue, paper towels, and napkins, to impart a color. Depending on the nature of the chemical, dyes may be classified as acid dyes, basic dyes, direct dyes, cellulose reactive dyes, or pigments. All classifications are suitable for use in conjunction with the present invention.
[0028] The term “polyhydroxy compounds” refers to compounds selected from the group consisting of glycerol, sorbitols, polyglycerols having a weight average molecular weight of from about 150 to about 800, polyoxyethylene glycols and polyoxypropylene glycols having a weight average molecular weight from typically about 200 to about 10,000, more typically about 200 to about 4,000.
[0029] The term “water soluble” refers to solids or liquids that will form a solution in water, and the term “water dispersible” refers to solids or liquids of colloidal size or larger that can be dispersed into an aqueous medium.
[0030] The term “bonding agent” refers to any chemical that can be incorporated into tissue to increase or enhance the level of interfiber or intrafiber bonding in the sheet. The increased bonding can be either ionic, Hydrogen or covalent in nature. It is understood that a bonding agent refers to both dry and wet strength enhancing chemical additives.
[0031] The method for applying chemical additives to the pulp fibers may be used in a wide variety of pulp finishing processing, including dry lap pulp, wet lap pulp, crumb pulp, and flash dried pulp operations. By way of illustration, various pulp finishing processes (also referred to as pulp processing) are disclosed in Pulp and Paper Manufacture The Pulping of Wood, 2 nd Ed., Volume 1, Chapter 12. Ronald G. MacDonald, editor, which is incorporated by reference. Various methods may be used to apply the chemical additives in the present invention, including, but not limited to: spraying, coating, foaming, printing, size pressing, or any other method known in the art.
[0032] In addition, in situations where more than one chemical additive is to be employed, the chemical additives may be added to the fibrous web in sequence to reduce interactions between the chemical additives.
[0033] Many pulp fiber types may be used for the present invention including hardwood or softwoods, straw, flax, milkweed seed floss fibers, abaca, hemp, kenaf, bagasse, cotton, reed, and the like. All known papermaking fibers may be used, including bleached and unbleached fibers, fibers of natural origin (including wood fiber and other cellulose fibers, cellulose derivatives, and chemically stiffened or crosslinked fibers), some component portion of synthetic fiber (synthetic papermaking fibers include certain forms of fibers made from polypropylene, acrylic, aramids, acetates, and the like), virgin and recovered or recycled fibers, hardwood and softwood, and fibers that have been mechanically pulped (e.g., groundwood), chemically pulped (including but not limited to the kraft and sulfite pulp processings), thermomechanically pulped, chemithermomechanically pulped, and the like. Mixtures of any subset of the above mentioned or related fiber classes may be used. The pulp fibers can be prepared in a multiplicity of ways known to be advantageous in the art. Useful methods of preparing fibers include dispersion to impart curl and improved drying properties, such as disclosed in U.S. Pat. Nos. 5,348,620 issued Sep. 20, 1994 and 5,501,768 issued Mar. 26, 1996, both to M. A. Hermans et al. and U.S. Pat. No. 5,656,132 issued Aug. 12, 1997 to Farrington, Jr. et al.
[0034] According to the present invention, the chemical treatment of the pulp fibers may occur prior to, during, or after the drying phase of the pulp processing. The two generally accepted methods of drying include flash drying, can drying, flack drying, through air drying, I.R. drying, fluidized bed, or any method of drying known in the art. The present invention may also be applied to wet lap pulp processes without the use of dryers.
[0035] Numerous features and advantages of the present invention will appear from the following description. In the description, reference is made to the accompanying drawings which illustrate preferred embodiments of the invention. Such embodiments do not represent the full scope of the invention. Reference should therefore be made to the claims herein for interpreting the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 depicts a schematic process flow diagram of a method according to the present invention for treating pulp fibers with chemical additives.
[0037] FIG. 2 depicts a schematic process flow diagram of a method according to the present invention for treating pulp fibers with chemical additives.
[0038] FIG. 3 depicts a schematic process flow diagram of a method of making a creped tissue sheet.
[0039] FIG. 4 depicts a schematic process flow diagram of a method according to the present invention for treating pulp fibers with multiple chemical additives.
[0040] FIG. 5 depicts a schematic process flow diagram of a method according to the present invention for treating pulp fibers with multiple chemical additives.
DETAILED DESCRIPTION
[0041] The invention will now be described in greater detail with reference to the Figures. A variety of conventional pulping apparatuses and operations can be used with respect to the pulping phase, pulp processing, and drying of pulp fiber. It is understood that the pulp fibers could be virgin pulp fiber or recycled pulp fiber. Nevertheless, particular conventional components are illustrated for purposes of providing the context in which the various embodiments of the present invention can be used. Improved retention of chemical additives by the pulp fibers may be obtained by treating the pulp fibers according to the present invention rather than treating the pulp fibers in wet end additions at papermaking machines. In addition, the present invention allows for quick pulp fiber grade changes at the paper mills.
[0042] FIG. 1 depicts pulp processing preparation equipment used to apply chemical additives to pulp fibers according to one embodiment of the present invention. A fiber slurry 10 is prepared and thereafter transferred through suitable conduits (not shown) to the headbox 28 where the fiber slurry 10 is injected or deposited into a fourdrinier section 30 thereby forming a wet fibrous web 32 . The wet fibrous web 32 may be subjected to mechanical pressure to remove process water. It is understood that the process water may contain process chemicals used in treating the fiber slurry 10 prior to a web formation step. In the illustrated embodiment, the fourdrinier section 30 precedes a press section 44 , although alternative dewatering devices such as a nip thickening device, or the like may be used in a pulp sheet machine. The fiber slurry 10 is deposited onto a foraminous fabric 46 such that the fourdrinier section filtrate 48 is removed from the wet fibrous web 32 . The fourdrinier section filtrate 48 comprises a portion of the process water. The press section 44 or other dewatering device known in the art suitably increases the fiber consistency of the wet fibrous web 32 to about 30 percent or greater, and particularly about 40 percent or greater thereby creating a dewatered web 33 . The process water removed as fourdrinier section filtrate 48 during the web forming step may be used as dilution water for dilution stages in the pulp processing or discarded.
[0043] The dewatered fibrous web 33 may be further dewatered in additional press sections 44 or other dewatering devices known in the art. The suitably dewatered fibrous web 33 may be transferred to a dryer section 34 where evaporative drying is carried out on the dewatered fibrous web 33 to an airdry consistency, thereby forming a dried fibrous web 36 . The dried fibrous web 36 is thereafter wound on a reel 37 or slit, cut into sheets, and baled via a baler 40 (see FIG. 2 ) for delivery to paper machines 38 (see FIG. 3 ).
[0044] Chemical additive 24 may be added or applied to the dewatered fibrous web 33 or the dried fibrous web 36 at a variety of addition points 35 a , 35 b , and 35 c as shown in FIG. 1 . It is understood that while only three addition points 35 a , 35 b , and 35 c are shown in FIG. 1 , the application of the chemical additive 24 may occur at any point between the point of initial dewatering of the wet fibrous web 32 to the point the dried fibrous web 36 is wound on the reel 37 or baled for transport to the paper machines 38 . The addition point 35 a shows the addition of the chemical additive 24 within press section 44 . The addition point 35 b shows the addition of the chemical additive 24 between the press section 44 and the dryer section 34 . The addition point 35 c shows the addition of the chemical additive 24 between the dryer section 34 and the reel 37 or baler 40 .
[0045] A list of chemical additives that can be used in conjunction with the present invention include: dry strength agents, wet strength agents, softening agents, debonding agents, adsorbency agents, sizing agents, dyes, optical brighteners, chemical tracers, opacifiers, dryer adhesive chemicals, and the like. Additional chemical additives may include: pigments, emollients, humectants, viricides, bactericides, buffers, waxes, fluoropolymers, odor control materials and deodorants, zeolites, perfumes, vegetable and mineral oils, polysiloxane compounds, surfactants, moisturizers, UV blockers, antibiotic agents, lotions, fungicides, preservatives, aloe-vera extract, vitamin E, or the like. Suitable chemical additives are retained by the papermaking fibers and may or may not be water soluble or water dispersible.
[0046] At the paper machines 38 , (see FIG. 3 ) the dried fibrous web 36 is mixed with water to form a chemically treated pulp fiber slurry 49 . The chemically treated pulp fiber slurry 49 contains the chemically treated pulp fiber having the chemical additive 24 retained by the individual fibers. The chemically treated pulp fiber slurry 49 is passed through the paper machine 38 and processed to form a finished product 64 . By way of illustration, various paper or tissue making processes are disclosed in U.S. Pat. No. 5,667,636 issued Sep. 16, 1997 to Engel et al.; U.S. Pat. No. 5,607,551 issued Mar. 4, 1997 to Farrington, Jr. et al.; U.S. Pat. No. 5,672,248 issued Sep. 30, 1997 to Wendt et al.; and, U.S. Pat. No. 5,494,554 issued Feb. 27, 1996 to Edwards et al., which are incorporated herein by reference. The finished product 64 has enhanced qualities due to the retention of the chemical additive 24 by the chemically treated pulp fibers during the pulp processing. In other embodiments of the present invention, additional chemical additive 24 may be added to the chemically treated pulp fiber slurry 49 during stock preparation at the paper machine 38 .
[0047] FIG. 2 depicts an alternative embodiment of the present invention using a different dry lap machine to prepare and treat the pulp. A fiber slurry 10 is prepared and thereafter transferred through suitable conduits (not shown) to the headbox 28 where the fiber slurry 10 is injected or deposited into a fourdrinier section 30 thereby forming a wet fibrous web 32 . The wet fibrous web 32 may be subjected to mechanical pressure to remove process water. In the illustrated embodiment, the fourdrinier section 30 precedes a press section 44 , although alternative dewatering devices such as a nip thickening device, or the like known in the art may be used in a pulp sheet machine. The fiber slurry 10 is deposited onto a foraminous fabric 46 such that the fourdrinier section filtrate 48 is removed from the wet fibrous web 32 . The fourdrinier section filtrate 48 comprises a portion of the process water. The press section 44 or other dewatering device suitably increases the fiber consistency of the wet fibrous web 32 to about 30 percent or greater, and particularly about 40 percent or greater, thereby forming a dewatered fibrous web 33 . The process water removed as fourdrinier section filtrate 48 during the web forming step may be used as dilution water for dilution stages in the pulp processing or discarded.
[0048] The dewatered fibrous web 33 may be further dewatered in additional press sections 44 or other dewatering devices known in the art. The suitably dewatered fibrous web 33 may be transferred to a dryer section 34 where evaporative drying is carried out on the dewatered fibrous web 33 to an airdry consistency, thereby forming a dried fibrous web 36 . The dried fibrous web 36 is thereafter slit, cut into sheets, and baled via a baler 40 or wound on a reel 37 or wound onto a reel 37 (see FIG. 1 ) for delivery to paper machines 38 (see FIG. 3 ).
[0049] The chemical additive 24 may be added or applied to the dewatered fibrous web 33 or the dried fibrous web 36 at a variety of addition points 35 a , 35 b , and 35 c as shown in FIG. 2 . It is understood that while only three addition points 35 a , 35 b , and 35 c are shown in FIG. 2 , the application of the chemical additive 24 may occur at any point between the point of initial dewatering of the wet fibrous web 32 to the point the dried fibrous web 36 is wound on the reel 37 or baled for transport to the paper machines 38 . The addition point 35 a shows the addition of the chemical additive 24 within press section 44 . The addition point 35 b shows the addition of the chemical additive 24 between the press section 44 and the dryer section 34 . The addition point 35 c shows the addition of the chemical additive 24 between the dryer section 34 and the reel 37 or baler 40 .
[0050] At the paper machines 38 , (see FIG. 3 ) the dried fibrous web 36 is mixed with water to form a chemically treated pulp fiber slurry 49 . The chemically treated pulp fiber slurry 49 contains the chemically treated pulp fiber having the chemical additive 24 retained by the individual fibers. The chemically treated pulp fiber slurry 49 is passed through the paper machine 38 and processed to form a finished product 64 . By way of illustration, various paper or tissue making processes are disclosed in U.S. Pat. No. 5,667,636 issued Sep. 16, 1997 to Engel et al.; U.S. Pat. No. 5,607,551 issued Mar. 4, 1997 to Farrington, Jr. et al.; U.S. Pat. No. 5,672,248 issued Sep. 30, 1997 to Wendt et al.; and, U.S. Pat. No. 5,494,554 issued Feb. 27, 1996 to Edwards et al., which are incorporated herein by reference. The finished product 64 has enhanced qualities due to the retention of the chemical additive 24 by chemically treated the chemically treated pulp fibers during the pulp processing. In other embodiments of the present invention, additional chemical additive 24 may be added to the chemically treated pulp fiber slurry 49 during stock preparation at the paper machine 38 .
[0051] FIG. 4 depicts an alternative embodiment of the present invention in which sequential addition of the first and second chemical additives 24 and 25 , respectively, are added to the dewatered fibrous web slurry 33 and/or the dried fibrous web 36 . It is understood that the addition of the first chemical additive 24 may occur anywhere that the second chemical additive 25 may be applied. It is also understood that the addition of the second chemical additive 25 may occur anywhere that the first chemical additive 24 may be applied. A fiber slurry 10 is prepared and thereafter transferred through suitable conduits (not shown) to the headbox 28 where the fiber slurry 10 is injected or deposited into a fourdrinier section 30 thereby forming a wet fibrous web 32 . The wet fibrous web 32 may be subjected to mechanical pressure to remove process water. In the illustrated embodiment, the fourdrinier section 30 precedes a press section 44 , although alternative dewatering devices such as a nip thickening device, or the like known in the art may be used. The fiber slurry 10 is deposited onto a foraminous fabric 46 such that the fourdrinier section filtrate 48 is removed from the wet fibrous web 32 . The fourdrinier section filtrate 48 comprises a portion of the process water. The press section 44 or other dewatering device suitably increases the fiber consistency of the wet fibrous web 32 to about 30 percent or greater, and particularly about 40 percent or greater thereby forming a dewatered fibrous web 33 . The process water removed as fourdrinier section filtrate 48 during the web forming step may be used as dilution water for dilution stages in the pulp processing or discarded.
[0052] The dewatered fibrous web 33 may be further dewatered in additional press sections 44 or other dewatering devices known in the art. The suitably dewatered fibrous web 33 may be transferred to a dryer section 34 where evaporative drying is carried out on the dewatered fibrous web 33 to an airdry consistency, thereby forming a dried fibrous web 36 . The dried fibrous web 36 is thereafter wound on a reel 37 or slit, cut into sheets, and baled via a baler 40 (see FIG. 5 ) for delivery to paper machines 38 (see FIG. 3 ).
[0053] The first chemical additive 24 may be added or applied to the dewatered fibrous web 33 or the dried fibrous web 36 at a variety of addition points 35 a , 35 b , and 35 c as shown in FIG. 4 . It is understood that while only three addition points 35 a , 35 b , and 35 c are shown in FIG. 4 , the application of the first chemical additive 24 may occur at any point between the point of initial dewatering of the wet fibrous web 32 to the point the dried fibrous web 36 is wound on the reel 37 or baled for transport to the paper machines 38 . The addition point 35 a shows the addition of the first chemical additive 24 within press section 44 . The addition point 35 b shows the addition of the first chemical additive 24 between the press section 44 and the dryer section 34 . The addition point 35 c shows the addition of the first chemical additive 24 between the dryer section 34 and the reel 37 or baler 40 .
[0054] The second chemical additive 25 may be added or applied to the dewatered fibrous web 33 or the dried fibrous web 36 at a variety of addition points 35 a , 35 b , and 35 c as shown in FIG. 4 . It is understood that while only three addition points 35 a , 35 b , and 35 c are shown in FIG. 4 , the application of the second chemical additive 25 may occur at any point between the point of initial dewatering of the wet fibrous web 32 to the point the dried fibrous web 36 is wound on the reel 37 or baled for transport to the paper machines 38 downstream of at least the initial point of application of the first chemical additive 24 . The addition point 35 a shows the addition of the second chemical additive 25 within press section 44 . The addition point 35 b shows the addition of the second chemical additive 25 between the press section 44 and the dryer section 34 . The addition point 35 c shows the addition of the second chemical additive 25 between the dryer section 34 and the reel 37 or baler 40 .
[0055] At the paper machines 38 , (see FIG. 3 ) the dried fibrous web 36 is mixed with water to form a chemically treated pulp fiber slurry 49 . The chemically treated pulp fiber slurry 49 contains the chemically treated pulp fiber having the first and second chemical additives 24 and 25 retained by the individual fibers. The chemically treated pulp fiber slurry 49 is passed through the paper machine 38 and processed to form a finished product 64 . By way of illustration, various paper or tissue making processes are disclosed in U.S. Pat. No. 5,667,636 issued Sep. 16, 1997 to Engel et al.; U.S. Pat. No. 5,607,551 issued Mar. 4, 1997 to Farrington, Jr. et al.; U.S. Pat. No. 5,672,248 issued Sep. 30, 1997 to Wendt et al.; and, U.S. Pat. No. 5,494,554 issued Feb. 27, 1996 to Edwards et al., which are incorporated herein by reference. The finished product 64 has enhanced qualities due to the retention of the first and second chemical additives 24 and 25 by the chemically treated pulp fibers during the pulp processing. In other embodiments of the present invention, additional chemical additives may be added to the chemically treated pulp fiber slurry 49 during stock preparation at the paper machine 38 .
[0056] In other embodiments, it is understood that a third, fourth, fifth, so forth, chemical additives may be used to treat the dewatered fibrous web 33 and/or dried fibrous web 36 .
[0057] FIG. 5 depicts an alternative embodiment of the present invention in which sequential addition of the first and second chemical additives 24 and 25 , respectively, are added to the dewatered fibrous web slurry 33 and/or the dried fibrous web 36 . It is understood that the addition of the first chemical additive 24 may occur anywhere that the second chemical additive 25 may be applied. It is also understood that the addition of the second chemical additive 25 may occur anywhere that the first chemical additive 24 may be applied. A fiber slurry 10 is prepared and thereafter transferred through suitable conduits (not shown) to the headbox 28 where the fiber slurry 10 is injected or deposited into a fourdrinier section 30 thereby forming a wet fibrous web 32 . The wet fibrous web 32 may be subjected to mechanical pressure to remove process water. In the illustrated embodiment, the fourdrinier section 30 precedes a press section 44 , although alternative dewatering devices such as a nip thickening device, or the like known in the art may be used. The fiber slurry 10 is deposited onto a foraminous fabric 46 such that the fourdrinier section filtrate 48 is removed from the wet fibrous web 32 . The fourdrinier section filtrate 48 comprises a portion of the process water. The press section 44 or other dewatering device suitably increases the fiber consistency of the wet fibrous web 32 to about 30 percent or greater, and particularly about 40 percent or greater thereby forming a dewatered fibrous web 33 . The process water removed as fourdrinier section filtrate 48 during the web forming step may be used as dilution water for dilution stages in the pulp processing or discarded.
[0058] The dewatered fibrous web 33 may be further dewatered in additional press sections 44 or other dewatering devices known in the art. The suitably dewatered fibrous web 33 may be transferred to a dryer section 34 where evaporative drying is carried out on the dewatered fibrous web 33 to an air dry consistency, thereby forming a dried fibrous web 36 . The dried fibrous web 36 is thereafter slit, cut into sheets, and baled via a baler 40 or wound onto a reel 37 (see FIG. 4 ) for delivery to paper machines 38 (see FIG. 3 ).
[0059] The first chemical additive 24 may be added or applied to the dewatered fibrous web 33 or the dried fibrous web 36 at a variety of addition points 35 a , 35 b , and 35 c as shown in FIG. 4 . It is understood that while only three addition points 35 a , 35 b , and 35 c are shown in FIG. 4 , the application of the first chemical additive 24 may occur at any point between the point of initial dewatering of the wet fibrous web 32 to the point the dried fibrous web 36 is wound on the reel 37 or baled for transport to the paper machines 38 . The addition point 35 a shows the addition of the first chemical additive 24 within press section 44 . The addition point 35 b shows the addition of the first chemical additive 24 between the press section 44 and the dryer section 34 . The addition point 35 c shows the addition of the first chemical additive 24 between the dryer section 34 and the reel 37 or baler 40 .
[0060] The second chemical additive 25 may be added or applied to the dewatered fibrous web 33 or the dried fibrous web 36 at a variety of addition points 35 a , 35 b , and 35 c as shown in FIG. 5 . It is understood that while only three addition points 35 a , 35 b , and 35 c are shown in FIG. 5 , the application of the second chemical additive 25 may occur at any point between the point of initial dewatering of the wet fibrous web 32 to the point the dried fibrous web 36 is wound on the reel 37 or baled for transport to the paper machines 38 downstream of at least the initial point of application of the first chemical additive 24 . The addition point 35 a shows the addition of the second chemical additive 25 within press section 44 . The addition point 35 b shows the addition of the second chemical additive 25 between the press section 44 and the dryer section 34 . The addition point 35 c shows the addition of the second chemical additive 25 between the dryer section 34 and the reel 37 or baler 40 .
[0061] At the paper machines 38 , (see FIG. 3 ) the dried fibrous web 36 is mixed with water to form a chemically treated pulp fiber slurry 49 . The chemically treated pulp fiber slurry 49 contains the chemically treated pulp fiber having the first and second chemical additives 24 and 25 retained by the individual fibers. The chemically treated pulp fiber slurry 49 is passed through the paper machine 38 and processed to form a finished product 64 . By way of illustration, various paper or tissue making processes are disclosed in U.S. Pat. No. 5,667,636 issued Sep. 16, 1997 to Engel et al.; U.S. Pat. No. 5,607,551 issued Mar. 4, 1997 to Farrington, Jr. et al.; U.S. Pat. No. 5,672,248 issued Sep. 30, 1997 to Wendt et al.; and, U.S. Pat. No. 5,494,554 issued Feb. 27, 1996 to Edwards et al., which are incorporated herein by reference. The finished product 64 has enhanced qualities due to the retention of the first and second chemical additives 24 and 25 by the chemically treated pulp fibers during the pulp processing. In other embodiments of the present invention, additional chemical additives may be added to the chemically treated pulp fiber slurry 49 during stock preparation at the paper machine 38 .
[0062] In other embodiments, it is understood that a third, fourth, fifth, so forth, chemical additives may be used to treat the dewatered fibrous web 33 and/or dried fibrous web 36 .
[0063] The amount of first chemical additive 24 is suitably about 0.1 kg./metric ton of pulp fiber or greater. In particular embodiments, wherein the first chemical additive 24 is a softening agent and is added in an amount from about 0.1 kg./metric ton of pulp fiber or greater.
[0064] The amount of the second chemical additive 25 is suitably about 0.1 kg./metric ton of pulp fiber or greater. In particular embodiments, wherein the second chemical additive 25 is a softening agent and is added in an amount from about 0.1 kg./metric ton of pulp fiber or greater.
[0065] In other embodiments of the present invention, each of the first and second chemical additives 24 and 25 may be added to the fiber slurry 10 at a variety of positions in the pulp processing apparatus.
[0066] In other embodiments of the present invention, one batch of pulp fibers may be treated with a first chemical additive 24 according to the method of the present invention as discussed above while a second batch of pulp fibers may be treated with a second chemical additive 25 according to the present invention. During the papermaking process, different pulp fibers or pulp fibers having different treatments may be processed into a layered paper or tissue product as disclosed in the U.S. Pat. No. 5,730,839 issued Mar. 24, 1998 to Wendt et al., which is incorporated herein by reference.
[0067] Referring to the FIG. 3 , a tissue web 64 is formed using a 2-layer headbox 50 between a forming fabric 52 and a conventional wet press papermaking (or carrier) felt 56 which wraps at least partially about a forming roll 54 and a press roll 58 . The tissue web 64 is then transferred from the papermaking felt 56 to the Yankee dryer 60 applying the vacuum press roll 58 . An adhesive mixture is typically sprayed using a spray boom 59 onto the surface of the Yankee dryer 60 just before the application of the tissue web to the Yankee dryer 60 by the press roll 58 . A natural gas heated hood (not shown) may partially surround the Yankee dryer 60 , assisting in drying the tissue web 64 . The tissue web 64 is removed from the Yankee dryer by the creping doctor blade 62 . Two tissue webs 64 may be plied together and calendered. The resulting 2-ply tissue product can be wound onto a hard roll.
[0068] In other embodiments of the present invention, a gradient of the first and/or the second chemical additives 24 and 25 along the z-direction of the dewatered fibrous web 33 and/or the dried fibrous web 36 may be established by a directed application of the first and/or the second chemical additives 24 and 25 . In one embodiment, the first and/or the second chemical additives 24 and 25 are applied to one side of the dewatered fibrous web 33 and/or the dried fibrous web 36 . In another embodiment, one side of the dewatered fibrous web 33 and/or the dried fibrous web 36 is saturated with the first and/or the second chemical additives 24 and 25 . In another embodiment, a dual gradient may be established in the z-direction of the dewatered fibrous web 33 and/or the dried fibrous web 36 by applying the first chemical additive 24 to one side of the dewatered fibrous web 33 and/or the dried fibrous web 36 and applying the second chemical additive 25 to the other (opposing) side of the dewatered fibrous web 33 and/or the dried fibrous web 36 . The term “z-direction” refers to the direction through the thickness of the web material.
[0069] The first and/or the second chemical additives 24 and 25 may be applied so as to establish a gradient wherein about 100 percent of each of the first and/or the second chemical additives 24 and 25 is located from the side of the dewatered fibrous web 33 and/or the dried fibrous web 36 treated with the first and/or the second chemical additives 24 and 25 to the middle of the dewatered fibrous web 33 and/or the dried fibrous web 36 along the z-direction of the dewatered fibrous web 33 and/or the dried fibrous web 36 and substantially none of each of the first and/or the second chemical additives 24 and 25 is located from the middle of the dewatered fibrous web 33 and/or the dried fibrous web 36 to the opposing side of the dewatered fibrous web 33 and/or the dried fibrous web 36 along the z-direction of the dewatered fibrous web 33 and/or the dried fibrous web 36 .
[0070] The first and/or the second chemical additives 24 and 25 may be applied so as to establish a gradient wherein about 66 percent of each of the first and/or the second chemical additives 24 and 25 is located from the side of the dewatered fibrous web 33 and/or the dried fibrous web 36 treated with the first and/or the second chemical additives 24 and 25 to the middle of the dewatered fibrous web 33 and/or the dried fibrous web 36 along the z-direction of the dewatered fibrous web 33 and/or the dried fibrous web 36 and about 33 percent of each of the first and/or the second chemical additives 24 and 25 is located from the middle of the dewatered fibrous web 33 and/or the dried fibrous web 36 to the opposing side of the dewatered fibrous web 33 and/or the dried fibrous web 36 along the z-direction of the dewatered fibrous web 33 and/or the dried fibrous web 36 .
[0071] It is understood that in any of these embodiments, the first and second chemical additives 24 and 25 may be each applied an opposing side of the dewatered fibrous web 33 and/or the dried fibrous web 36 . Alternatively, the first and second chemical additives 24 and 25 could be applied to both opposing sides of the dewatered fibrous web 33 and/or the dried fibrous web 36 . In still another variation, the first and second chemical additives 24 and 25 could be applied to only one side of the dewatered fibrous web 33 and/or the dried fibrous web 36 . Where only a first chemical additive 24 is applied to the dewatered fibrous web 33 and/or the dried fibrous web 36 , the first chemical additive 24 may be applied to one side or both opposing sides of the dewatered fibrous web 33 and/or the dried fibrous web 36 .
[0072] The first and/or the second chemical additives 24 and 25 may be applied so as to establish a gradient wherein about 60 percent of each of the first and/or the second chemical additives 24 and 25 is located from the side of the dewatered fibrous web 33 and/or the dried fibrous web 36 treated with the first and/or the second chemical additives 24 and 25 to the middle of the dewatered fibrous web 33 and/or the dried fibrous web 36 along the z-direction of the dewatered fibrous web 33 and/or the dried fibrous web 36 and about 40 percent of each of the first and/or the second chemical additives 24 and 25 is located from the middle of the dewatered fibrous web 33 and/or the dried fibrous web 36 to the opposing side of the dewatered fibrous web 33 and/or the dried fibrous web 36 along the z-direction of the dewatered fibrous web 33 and/or the dried fibrous web 36 .
[0073] In another embodiment of the present invention, the amounts of the first and/or second chemical additives 24 and 25 may be reduced to impart unique product characteristics due to the distribution of the first and/or second chemical additives 24 and 25 of the dewatered fibrous web 33 and/or the dried fibrous web 36 as opposed to an embodiment of the present invention wherein an equilibrated distribution of the first and/or second chemical additives 24 and 25 of the dewatered fibrous web 33 and/or the dried fibrous web 36 . The establishment of a gradient of the application of the first and/or the second chemical additives 24 and 25 of the dewatered fibrous web 33 and/or the dried fibrous web 36 is one way in which this may be accomplished. A directed application of a debonding chemical additive according to the present invention results in a reduced amount of the debonding chemical additive which produces a product having improved tensile strength as some of the pulp fiber is not treated by the debonding chemical additive.
EXAMPLES
[0074] The following example will describe how to produce chemically treated pulp as described according to the present invention. In these examples the definition of applied refers to the amount of chemical measured to be on the dry fiber mat after treatment. This amount is determined through measurement of chemical described in the Measurement Methods section.
[0075] Chemical retention in these examples is defined as the percentage of applied chemical treatment that remains with the fiber after the treated mat is redispersed to a low percent solids content in hot water. The percent retention was calculated according to Equation 1.
[0000]
%
R
=
C
f
-
C
w
/
S
ρ
C
f
(
100
%
)
Equation
1
[0000] where % R is the chemical retention
C f is the measured chemical level applied to pulp in units of kg/MT C W is the measured chemical level in the redispersed treated pulp water phase in units of mg/L S is the solids content of redispersed treated pulp in units of g fiber/g slurry ρ is the density of the pulp water slurry in units of g/L (typically 1000 g/L for dilute solutions)
Measurement Methods
[0080] Imidazoline concentrations were measured in water by using a DR/2010 Portable Datalogging Spectrophotometer commercially available from Hach Company, located in Loveland, Colo. The spectrophotometer method #401 for Quaternary Ammonium Compounds was employed using suitable blanks and dilution. Imidazoline concentrations were measured on fiber using a liquid extraction procedure consisting of oven-drying the pulp for 4 hours at 105° C.; weighing out 5 g of pulp and placing it in 100 mL of anhydrous methanol in a 125 mL container. The pulp-methanol was then placed in a Lab-line model 3590 orbital shaker bath, commercially available from Lab-line Instruments Melrose Park, Ill., which was operated at 300 rpm for 2 hours. An aliquot of the liquid sample absorbance was then measured at 238 nm on a Hewlett Packard model 8453 UV/VIS spectrophotometer, commercially available from Hewlett Packard Company, located in Palo Alto, Calif. This value was used with a prepared calibration curve using the identical procedure with imidazoline spiked samples.
Example 1
[0081] The untreated pulp in this example is a fully bleached eucalyptus pulp fiber slurry with a pH value of 4.5. Referencing FIG. 1 , this fiber was formed into a mat a basis weight of approximately 600 grams per square meter, pressed and dried to 95 percent solids. Next, a 4 percent (active content basis) water dispersion of imidazoline softening agent (methyl-1-oleyl amidoethyl-2-oleyl imidazolinium methylsulfate identified as Mackernium DC-183, commercially available from McIntyre Ltd., located in University Park, Ill.), was sprayed on the surface of the fiber mat. The dispersion was created by mixing the imidazoline compound with water at approximately 120° F. for 10 minutes with a Lightnin Duramix mixer with an A100 axial flow impeller commercially available from Lightnin Mixers, located in Rochester, N.Y. The spray was applied using 7 mini-misting hollow cone nozzles with an 80 degree spray angle available from McMaster-Carr. The nozzles were place 5 inches center-to-center, 2.5 inches away from the sheet. The nozzles were aligned to spray perpendicular to the sheet applying single coverage. The nozzles were positioned approximately 5 feet after the dryer section. Each nozzle's output was adjusted approximately 40 milliliters per minute of the imidazoline-water dispersion by adjusting the dispersion feed pressure to 40 psig.
[0082] The amount of the chemical softener applied to the mat was approximately 3 kilograms per metric ton of eucalyptus fiber. The chemical softener was allowed to remain on the pulp mat for 2 weeks after which it was dispersed to approximately 1.6 percent solids with hot water at 120° F. Samples from this treatment were taken and used to determine the amount of chemical softener that remained in the water phase, which was drained as filtrate from the pulp fiber. The concentrations of the aqueous chemical softener levels were converted into a percent retention basis. The chemical softener retention level is shown in Table 1.
Example 2
[0083] Identical to Example 1 with the exception that the eucalyptus slurry pH was adjusted to a pH value of 7. The chemical softener retention level is shown in Table 1.
Example 3
[0084] The untreated pulp in this example is a fully bleached eucalyptus pulp fiber slurry with a pH value of 4.5. Referencing FIG. 1 , this fiber was formed into a mat a basis weight of 900 grams oven-dry pulp per square meter, pressed and dried to 95 percent solids. Next, a 5 percent (active content basis) water dispersion of imidazoline softening agent (methyl-1-oleyl amidoethyl-2-oleyl imidazolinium methylsulfate identified as Mackernium DC-183, commercially available from McIntyre Ltd., located in University Park, Illinois), was sprayed onto the surface of the fiber mat. The dispersion was created by mixing the imidazoline compound with water at approximately 120° F. for 10 minutes with a Lightnin Duramix mixer with an A100 axial flow impeller commercially available from Lightnin Mixers, located in Rochester, N.Y. The spray was applied using 15 mini-misting hollow cone nozzles with an 80 degree spray angle available from McMaster-Carr. The nozzles were place 2.5 inches center-to-center, 1.5 inches away from the sheet. The nozzles were aligned to spray perpendicular to the sheet applying single coverage. The nozzles were positioned approximately 5 feet after the dryer section. Each nozzle's output was adjusted to approximately 55 milliliters per minute of the imidazoline-water dispersion by adjusting the dispersion feed pressure to 60 psig.
[0085] The amount of the chemical softener applied to the mat was approximately 7.5 kilograms per metric ton of eucalyptus fiber. The chemical softener was allowed to remain on the pulp mat for 2 weeks after which it was dispersed to approximately 1.6 percent solids with hot water at 120° F. Samples from this treatment were taken and used to determine the amount of chemical softener that remained in the water phase, which was drained as filtrate from the pulp fiber. The concentrations of the aqueous chemical softener levels were converted into a percent retention basis. The aqueous chemical softener retention level is shown in Table 1.
Example 4
[0086] The untreated pulp in this example is a fully bleached eucalyptus pulp fiber slurry with a pH value of 4.5. Referencing FIG. 1 , this fiber was formed into a mat at a basis weight of 600 grams per square meter, and pressed to 45% solids after which a 4 percent dispersion of an imidazoline softening agent (methyl-1-oleyl amidoethyl-2-oleyl imidazolinium methylsulfate identified as Mackernium DC-183), was sprayed onto the surface of the fiber mat. The nozzles were positioned approximately 1 foot prior to the second press. Chemical softener was applied at approximately 1.5 kg/MT in this manner after which the pulp sheet was dried to approximately 95 percent solids.
[0087] The chemical softener was allowed to remain on the pulp mat for 2 weeks after which it was dispersed to approximately 1.6 percent solids with hot water at 120° F. Samples from this treatment were taken and used to determine the amount of chemical softener that remained in the water phase, which was drained as filtrate from the pulp fiber. The concentrations of the aqueous chemical softener levels were then converted into a percent retention basis. The chemical softener retention level is shown in Table 1.
Example 5
[0088] Identical to Example 4 with the exception that the eucalyptus slurry was adjusted to a pH value of 7.0. The aqueous chemical softener retention level is shown in Table 1.
Example 6
[0089] The untreated pulp in this example is a fully bleached eucalyptus pulp fiber slurry with a pH value of 4.5. Referencing FIG. 1 , this fiber was formed into a mat at a basis weight of 900 grams per square meter, and pressed to 60% solids after which a 4 percent dispersion of an imidazoline softening agent (methyl-1-oleyl amidoethyl-2-oleyl imidazolinium methylsulfate identified as Mackernium DC-183), was sprayed onto the surface of the fiber mat. The nozzles were positioned approximately 3 feet before the dryer section. Chemical softener was applied at approximately 7.5 kg/MT in this manner after which the pulp sheet was dried to 95 percent solids.
[0090] The chemical softener was allowed to remain on the pulp mat for 2 weeks after which it was dispersed to approximately 1.6 percent solids with hot water at 120° F. Samples from this treatment were taken and used to determine the amount of chemical softener that remained in the water phase, which was drained as filtrate from the pulp fiber. The concentrations of the aqueous chemical softener levels were then converted into a percent retention basis. The aqueous chemical softener retention level is shown in Table 1.
Example 7
[0091] The untreated pulp in this example is a fully bleached eucalyptus pulp fiber slurry with a pH value of 4.5. Referencing FIG. 2 , this fiber was formed into a mat a basis weight of approximately 1000 grams per square meter, pressed and dried to 90 percent solids, after which a 4 percent dispersion of an imidazoline softening agent (methyl-1-oleyl amidoethyl-2-oleyl imidazolinium methylsulfate identified as Mackernium DC-183), was sprayed on the surface of the fiber mat. The spray was applied using 21 Veejet HVV 11004 nozzles with a 110 degree spray angle available from Spraying Systems, located in Wheaton, Ill. The nozzles were place 8.1 inches center-to-center, 1.5 inches away from the sheet. The nozzles were aligned to spray perpendicular to the sheet applying single coverage. The nozzles were positioned approximately 10 feet after the dryer section. Each nozzle's output was adjusted to approximately 500 milliliters per minute of the imidazoline-water dispersion by adjusting the dispersion feed pressure to 35 psig. The fiber mat's velocity was approximately 500 meters per minute during the application.
[0092] The amount of the chemical softener applied to the mat was approximately 2 kilograms per metric ton of eucalyptus fiber. The chemical softener was allowed to remain on the pulp mat for 3 weeks after which it was dispersed to approximately 8.5 percent solids with hot water at 120° F. Samples from this treatment were taken and used to determine the amount of chemical softener that remained in the water phase, which was drained as filtrate from the pulp fiber. The concentrations of the aqueous chemical softener levels were converted into a percent retention basis. The chemical softener retention level is shown in Table 1.
Example 8
[0093] Identical to Example 7 with the exceptions that the eucalyptus slurry pH was adjusted to a pH value of 7, the chemical softening agent was applied at a 1.5 kg/MT level, and the pulp was redispersed at 2.5 percent solids. The chemical softener retention level is shown in Table 1.
[0000]
TABLE 1
Aqueous Chemical Softener Levels
Chemical Softener
Chemical
Chemical
Application
Pre-treated
Application Level
Softener
Sample
Softener
location
pulp pH
(kg/MT fiber)
Retention (%)
Example 1
Imidazoline
Post-dryer
4.5
3.2
87.9%
Emulsion
Example 2
Imidazoline
Post-dryer
7.0
3.2
87.8%
Emulsion
Example 3
Imidazoline
Post-dryer
4.5
7.4
78.8%
Emulsion
Example 4
Imidazoline
Press-
4.5
1.5
91.2%
Emulsion
section
Example 5
Imidazoline
Press-
7.0
1.5
91.6%
Emulsion
section
Example 6
Imidazoline
Pre-dryer
4.5
7.4
86.0%
Emulsion
Example 7
Imidazoline
Post-dryer
4.5
1.9
99.5%
Emulsion
Example 8
Imidazoline
Post-dryer
7.0
1.6
87.3%
Emulsion
Example 9
[0094] The chemically treated eucalyptus pulp in Example 1 was used to produce a layered soft tissue product. The tissue product was made using the overall process shown in FIG. 3 . The first stock layer contained the chemically treated Eucalyptus hardwood pulp fiber, which made up about 65 percent of the tissue web by weight. This first stock layer was the first layer to come into contact with the forming fabric and was also the layer that came into contact with the drying surface of the Yankee dryer. The second stock layer contained northern softwood kraft pulp fiber. The second stock layer made up about 35 percent of the tissue web by weight. The two layers were pressed together at an approximately 15% solids vacuumed, pressed, and dried with a Yankee Dryer.
[0095] A modified polyacrylamide dry strength agent, Parez 631 NC commercially available from Cytec Industries Inc. located in West Paterson, N.J., was added to the pulp fiber of the softwood layer. The Parez 631 NC was added to the thick stock at an addition level of about 0.2% of the pulp fiber in the entire tissue web. A polyamide epichlorohydrin wet strength agent, Kymene 557LX commercially available from the Hercules, Inc., located in Wilmington, Del., was added to both the Eucalyptus and northern softwood kraft furnishes at an addition level of about 0.2% based on the pulp fiber in the entire tissue web. The basis weight of the tissue web was about 7.0 pounds per 2880 square feet of oven dried tissue web.
[0096] Referring to the FIG. 3 , the tissue web was formed using 2 separate headboxes with a 94M forming fabric commercially available from Albany International, located in Albany, N.Y., and a conventional wet press papermaking (or carrier) felt (Duramesh commercially available from Albany International, located in Albany, N.Y.) which wraps at least partially about a forming roll and a press roll. The basis weight of the tissue web was about 7.0 pounds per 2880 square feet of oven dried tissue web.
[0097] The tissue web was then transferred from the papermaking felt to the Yankee dryer by the press roll. The water content of the tissue web on the papermaking felt just prior to transfer of the tissue web to the Yankee dryer was about 80 percent. The moisture content of the tissue web after the application of the press roll was about 55 percent. An adhesive mixture was sprayed using a spray boom onto the surface of the Yankee dryer just before the application of the tissue web by the press roll. The adhesive mixture consisted of about 40% polyvinyl alcohol, about 40% polyamide resin and about 20% quaternized polyamido amine as disclosed in U.S. Pat. No. 5,730,839 issued to Wendt et al. which is herein incorporated by reference. The application rate of the adhesive mixture was about 6 pounds of dry adhesive per metric ton of dry pulp fiber in the tissue web. A natural gas heated hood partially surrounding the Yankee dryer had a supply air temperature of about 680° F. to assist in drying the tissue web. The temperature of the tissue web after the application of the creping doctor was about 225° F. as measured with a handheld infrared temperature gun. The machine speed of the X inch wide tissue web was about 50 feet per minute. The crepe blade had a 10 degree bevel and was loaded with a ¾ inch extension. The crepe ratio was about 1.30 or about 30%.
Example 10
[0098] Identical to Example 9 with the exception that chemically treated eucalyptus pulp in Example 2 was used to produce a layered soft tissue product.
Example 11
[0099] Identical to Example 10 with the exception that chemically treated eucalyptus pulp in Example 3 was used to produce a layered soft tissue product.
Example 12
[0100] Identical to Example 11 with the exception that chemically treated eucalyptus pulp in Example 4 was used to produce a layered soft tissue product.
Example 13
[0101] Identical to Example 12 with the exception that chemically treated eucalyptus pulp in Example 5 was used to produce a layered soft tissue product.
Example 14
[0102] Identical to Example 13 with the exception that chemically treated eucalyptus pulp in Example 6 was used to produce a layered soft tissue product.
Example 15
[0103] The chemically treated eucalyptus pulp in Example 7 was used to produce a layered soft tissue product. The tissue product was made using the overall process shown in FIG. 3 . The first stock layer contained the chemically treated Eucalyptus hardwood pulp fiber, which made up about 65 percent of the tissue web by weight. This first stock layer was the first layer to come into contact with the forming fabric and was also the layer that came into contact with the drying surface of the Yankee dryer. The second stock layer contained northern softwood kraft pulp fiber. The second stock layer made up about 35 percent of the tissue web by weight. A polyamide epichlorohydrin wet strength agent, Kymene 557LX commercially available from the Hercules, Inc., was added to both the Eucalyptus and northern softwood kraft furnishes at an addition level of about 0.2% based on the pulp fiber in the entire tissue web. The basis weight of the tissue web was approximately 7.0 pounds per 2880 square feet of oven dried tissue web.
[0104] Referring to the FIG. 3 the tissue web was formed using a 2-layer headbox between an Albany P-621 forming fabric commercially available from Albany International Corp., located in Menasha, Wis., and a conventional wet press papermaking (or carrier) felt (Weavex M1C commercially available from Weavex located in Wake Forest, N.C.) which wraps at least partially about a forming roll and a press roll. The basis weight of the tissue web was about 7.0 pounds per 2880 square feet of oven dried tissue web.
[0105] The tissue web was then transferred from the papermaking felt to the Yankee dryer by the vacuum press roll. The water content of the tissue web on the papermaking felt just prior to transfer of the tissue web to the Yankee dryer was about 87 percent. The moisture content of the tissue web after the application of the press roll was about 55 percent. An adhesive mixture was sprayed using a spray boom onto the surface of the Yankee dryer just before the application of the tissue web by the press roll. The adhesive mixture consisted of about 40% polyvinyl alcohol, about 40% polyamide resin and about 20% quaternized polyamido amine as disclosed in U.S. Pat. No. 5,730,839 issued to Wendt et al. which is herein incorporated by reference. The application rate of the adhesive mixture was about 5.5 pounds of dry adhesive per tonne of dry pulp fiber in the tissue web. A natural gas heated hood (not shown) partially surrounding the Yankee dryer had a supply air temperature of about 680° F. to assist in drying the tissue web. The temperature of the tissue web after the application of the creping doctor was about 240° F. as measured with a handheld infrared temperature gun. The machine speed of the 24 inch wide tissue web was about 3000 feet per minute. The crepe ratio was about 1.30 or about 30%.
[0106] Two tissue webs were unwound from two soft rolls (or parent rolls) and plied together and calendered with two steel rolls at 80 pounds per lineal inch. The 2-ply tissue product was constructed such that the first stock layer containing the chemically treated Eucalyptus pulp fiber was plied to the outside of the 2-ply tissue product, which was wound onto a hard roll. The hard roll is converted into finished product, such as facial tissue and the like. The finished basis weight of the 2-ply tissue product at standard TAPPI standard temperature and humidity was about 17 pounds per 2880 square feet. The MD tensile was about 1100 grams per 3 inches and the CD tensile was about 500 grams per 3 inches. The thickness of one 2-ply tissue product was about 0.2 millimeters. The MD stretch in the finished tissue product was about 18 percent. All 2-ply tissue tests were conducted in an environmentally controlled room with 50% relative humidity and a temperature of 73° F.
Example 16
[0107] Identical to Example 15 with the exception that chemically treated eucalyptus pulp in Example 8 was used to produce a layered soft tissue product.
[0108] While the invention has been described in conjunction with specific embodiments, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the appended claims. | Pulp fibers can be treated with chemical additives with a minimal amount of unretained chemical additives present later in the process water. The present invention is a method for preparing chemically treated pulp fiber. A fiber slurry is created comprising process water and pulp fibers. The fiber slurry is transported to a web-forming apparatus of a pulp sheet machine thereby forming a wet fibrous web. The wet fibrous web is dried to a predetermined consistency thereby forming a dried fibrous web. The dried fibrous web is treated with a chemical additive thereby forming a chemically treated dried fibrous web. The dried fibrous web contains chemically treated pulp fibers. The chemically treated pulp fibers retain from between about 10 to about 100 percent of the applied amount of the chemical additive when the chemically treated pulp fibers are redispersed in water. | 3 |
This invention was supported in part by Federal Aviation Administration grant FAA/DOT 93-G-004, and by NASA grant NA S8-36125. The Government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates to methods for improving pseudorange measurements in a global positioning system (GPS). More specifically, it relates to methods for reducing and eliminating multipath errors in GPS pseudorange measurements.
BACKGROUND
Multipath is a major GPS ranging error source. Multipath error is traditionally considered to be noise correlated over time in GPS pseudorange and continuous carrier phase measurement. FIG. 1 shows how multipath, which depends on the geometry around a GPS antenna, is generated by reflected signals from nearby structures. Although the multipath error in present continuous carrier phase measurements is on the order of a few centimeters or less, the multipath error in pseudorange can be as much as 50 meters. Because receiver noise and multipath errors in continuous carrier phase measurement are very small compared to those in pseudorange measurement, it is always preferable to use differential measurement techniques which are based on continuous carrier phase. But the success of differential techniques using continuous carrier phase depends on how quickly the right cycle ambiguity can be found. Since the reliability and success rate of solving for cycle ambiguities are highly related to the degree to which multipath error can be eliminated, there is a need for eliminating multipath errors in pseudorange measurements.
The continuous carrier signal comprises an integer and a fraction of wavelength. The precision of the fraction currently can be reduced to 0.2 to 2 centimeters, but this phase information is of little use unless the correct integer can be determined (one unit corresponds to about 20 cm). Solving for cycle ambiguity is the determination of this integer.
Because the noise in continuous carrier phase measurement is very small compared to the accuracy of pseudorange measurement, it is natural to use continuous carrier phase measurement and attempt to solve cycle ambiguity. In principle, cycle ambiguity can be solved using the fact that pseudorange and continuous carrier phase measurements are supposed to be the same except for ionospheric time delay which is opposite in the above two different measurements and can be measured using a dual-frequency receiver. But cycle ambiguity can not be solved completely with present techniques without waiting a very long time because multipath noise in the pseudorange is too large.
Differential techniques can eliminate most GPS errors common both to a user and a nearby reference station, such as ephemeris errors, satellite clock error, Selective Availability (SA), ionospheric time delay, and tropospheric errors. But multipath errors are not common to a user and a reference station and therefore cannot be eliminated in this way.
In the article Cohen, C. E. and Parkinson, B. W., "Mitigating Multipath in GPS-Based Attitude Determination," Advances in the Astronautical Sciences, AAS Guidance and Control Conference, Keystone, Colo., 1991, a technique is described that successfully calibrated the relative multipath error in continuous carrier phases between two antennas for attitude determination. This technique, however, cannot be used for calibrating or eliminating multipath errors in position measurements since it only applies to flight vehicles and other relatively isolated vehicles where the only significant multipath source is the vehicle body itself.
A method for obtaining a significant reduction in multipath error is described in the article Van Nee, R. D. J., Siereveld, J., Fenton, P. C., and Townsend, B. R., "The Multipath Estimating Delay Lock Loop: Approaching Theoretical Accuracy Limits," IEEE 1994 Position Location and Navigation Symposium, Las Vegas, Nev., April, 1994, pp. 246-251. Van Nee used a new receiver hardware architecture using multiple correlators to identify multipath in the GPS signal. Although this approach greatly reduced multipath error in the laboratory prototypes, because it needs multiple correlators for each channel to estimate multipath, it requires a CPU in the GPS receiver that is more powerful than the CPU present in current receivers. Consequently, the existing receivers cannot benefit from this technique and its implementation would require replacing old receivers with expensive new
Another technique to reduce multipath is described in the article Bishop, G. J., Coco, D. S., Kappler, P. H., and Holland, E. A., "Studies and Performance of a New Technique for Mitigation of Pseudorange Multipath Effects in GPS Ground Stations," Proceedings of the 1994 National Technical Meeting, The Institute of Navigation, San Diego, Calif., January, 1994, pp. 231-242. Bishop used a template technique to reduce multipath error in pseudorange. His technique takes advantage of the daily repetition of the GPS satellite trajectory from a fixed ground station to create a template of the averaged multipath error signature specific to each satellite pass. This time-averaging technique, however, eliminates only the noise component of the multipath and not the bias component. Consequently, it results in a multipath with absolute level accurate only to the degree that the multipath is zero-mean for each satellite pass. In short, rather than solving multipath mean bias, it simply assumes zero-mean when this is not actually the case. Solving for the multipath mean bias, however, is crucial to solving for cycle ambiguities. Without determining the actual values of these biases, which are different for different satellites, an attempt to solve cycle ambiguity and to determine user position will give erroneous results. This technique, therefore, does not reduce multipath errors to the degree necessary to solve cycle ambiguity and obtain positioning information to within centimeter accuracy.
In summary, although multipath errors in GPS pseudorange measurements have been studied by many people, no prior art has succeeded in the actual calibration and elimination of multipath errors, including multipath mean bias, on GPS pseudorange measurements without introducing expensive new receiver hardware architectures.
OBJECTS OF THE INVENTION
It is a primary object of the present invention to reduce multipath error in pseudorange and greatly improve the speed and reliability of solving cycle ambiguity. It is an additional object of the present invention to calibrate multipath error surrounding GPS antenna, eliminate it in real time, find the right cycle ambiguity very quickly and reliably, and finally achieve centimeter level of positioning accuracy. It is a further object of the invention to obtain these results using a software approach which can be easily applied to existing GPS receivers.
SUMMARY OF THE INVENTION
These objects and advantages are achieved by a method for multipath calibration in a global positioning system comprising a GPS receiver, a first satellite having a first trajectory, and a second satellite having a second trajectory that intersects the first trajectory in an azimuth vs. elevation plot at a cross-over point. The method comprises the steps of (1) receiving first and second signals at the receiver from first and second satellites, where a portion of each signal is received when the respective satellite is at the cross-over point; and (2) determining first and second calibrated multipath signals by correlating the cross-over portions of the signals with each other, whereby the relative mean multipath bias between the signals is eliminated. This calibration technique is used to eliminate multipath pseudorange errors in subsequent signals received at the receiver from the two satellites by using the two calibrated multipath signals. By fitting a linear combination of spherical harmonic functions to the two calibrated multipath signals and eliminating multipath pseudorange errors in subsequent signals received at the receiver from the satellites by using the linear combination of spherical harmonic functions, multipath errors can be compensated for. This technique is normally applied to more than two satellites whose respective signals are simultaneously correlated. Another aspect of the invention includes the steps of mounting around an antenna of the receiver a cylinder that reflects GPS signals and is tapered outward toward the top, then measuring the attitude of the receiver and the antenna and correlating the attitude with the subsequent signals.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is an illustration of how a multipath signal is generated by reflection from a nearby structure.
FIG. 2 is an azimuth and elevation angle graph of the trajectories of two satellites, indicating their cross-over point.
FIG. 3 is a graph of calibrated multipath error versus azimuth angle for the two satellites shown in FIG. 2.
FIG. 4 is a graph of divergence versus local time (noisy curve) superimposed upon a graph of two times ionospheric time delay using carrier phases of L1 and L2 versus local time (smooth curve).
FIG. 5 is a graph of pseudo-multipath versus local time for the data shown in FIG. 4.
FIG. 6 is a graph of averaged pseudo-multipath over 15 epochs vs. local time.
FIG. 7 is a graph of uncalibrated pseudo-multipath versus azimuth angle for two satellites, indicating the pseudo-multipath mean bias and the differing pseudo-multipath values at the cross-over point.
FIG. 8 is a flow diagram of the multipath calibration procedure using spherical harmonics, and the process for estimating multipath in real time.
FIG. 9 is an azimuth vs. elevation plot of the trajectories of three satellites during a test period.
FIG. 10 is an elevation angle vs. local time graph of the trajectories of four satellites.
FIG. 11 is a rectangular azimuth vs. elevation graph for two satellites whose trajectories are very close to each other.
FIG. 12 is a graph of the averaged pseudo-multipaths over 15 epochs versus elevation angle for the two satellites whose trajectories are shown in FIG. 11.
FIG. 13 is a graph of averaged pseudo-multipath for PRN 18 over 15 epochs versus azimuth angle.
FIG. 14 is a graph of averaged pseudo-multipath residual for PRN 18 over 15 epochs.
FIG. 15 is a graph of averaged pseudo-multipath for PRN 19 over 15 epochs versus azimuth angle.
FIG. 16 is a graph of averaged pseudo-multipath residual for PRN 19 over 15 epochs.
FIG. 17 is a graph of averaged pseudo-multipath for PRN 27 over 15 epochs versus azimuth angle.
FIG. 18 is a graph of averaged pseudo-multipath residual for PRN 27 over 15 epochs.
FIG. 19 is a graph of averaged pseudo-multipath for PRN 29 over 15 epochs versus azimuth angle.
FIG. 20 is a graph of averaged pseudo-multipath residual for PRN 29 over 15 epochs.
FIG. 21 shows a three-dimensional plot of pseudo-multipath versus azimuth and elevation angle for several satellites.
FIG. 22 is a close up view of the cross-over region indicated by the circle drawn in FIG. 21.
FIG. 23 is a graph for PRN 18 of calibrated multipath (noisy curve) and reconstructed multipath (smooth curve) versus local time.
FIG. 24 is a graph for PRN 19 of calibrated multipath (noisy curve) and reconstructed multipath (smooth curve) versus local time.
FIG. 25 is a graph for PRN 27 of calibrated multipath (noisy curve) and reconstructed multipath (smooth curve) versus local time.
FIG. 26 is a graph for PRN 29 of calibrated multipath (noisy curve) and reconstructed multipath (smooth curve) versus local time.
FIG. 27 illustrates an antenna shield which may be used in conjunction with the method of the present invention to calibrate pseudorange multipath in the case of a mobile receiver.
DETAILED DESCRIPTION
The present invention includes a method for calibrating multipath errors on pseudorange measurements without changing the receiver hardware. The technique begins by recognizing that multipath is dependent on the environment geometry around a GPS antenna (buildings, metal structures, etc.). Because of the geometric dependency of multipath, multipath error is uniquely determinedly a given azimuth and elevation angle. Consequently, the multipath error of each satellite must be the same at a cross over point, i.e., a point where the trajectories of two different satellites meet in an azimuth vs. elevation plot (see FIGS. 2 and 3). As a result, as the present inventor apparently has recognized and exploited for the first time, it is possible to develop a method that uses these facts to calibrate the multipath errors of GPS satellites relative to the constant multipath mean bias of a reference GPS satellite and thereby eliminate multipath errors--including mean bias errors--to obtain unprecedented accuracies in GPS measurements.
These calibrated multipath errors can be fitted to spherical harmonics functions to generate a hemisphere multipath surface model that is then used to subtract out the multipath later. Fitting the multipath error to spherical harmonics has the advantages that the multipath can then be interpolated between satellites and the storage space required for the multipath calibration data can be dramatically reduced. This technique does not need any hardware modification to existing GPS receivers, and it can be applied to any GPS receiver by calibrating the multipath around the GPS antenna and upgrading software.
The following discussion presents a detailed description of one embodiment of the invention and introduces a new multipath observable called pseudo-multipath.
Let us assume that receiver noise and multipath in continuous carrier phase are negligibly small compared to those in pseudorange. The following are general GPS observation equations for pseudoranges (ρ1, ρ2) and continuous carrier phases (φ1, φ2) for L1 and L2 frequencies from the GPS antenna to the j-th satellite (superscripts indicate satellites).
ρ1.sup.j =d.sup.j +i.sup.j +t.sup.j +m1.sup.j -B.sup.j +b+η1.sup.j (1)
φ1.sup.j =d.sup.j -i.sup.j +t.sup.j -B.sup.j +b+N1.sup.j ·λ1 (2)
ρ2.sup.j =d.sup.j +γ·i.sup.j +t.sup.j +m2.sup.j -B.sup.j +b+η2.sup.j (3)
φ2.sup.j =d.sup.j -γ·i.sup.j +t.sup.j -B.sup.j +b+N2.sup.j ·λ2 (4)
where
ρ1, ρ2: measured pseudorange for L1 and L2 frequencies
φ1, φ2: measured continuous carrier phase for L1 and L2 frequencies
d: physical distance from receiver to satellite
i: ionospheric time delay for L1 frequency
t: tropospheric delay
m1, m2: multipath in pseudorange for L1 and L2 frequencies
B: satellite clock offset
b: receiver clock offset
η1, η2: receiver noise of pseudorange for L1 and L2 frequencies
N1, N2: number of cycles in continuous carrier phase
λ1, λ2: wavelength of L1 and L2 frequencies ##EQU1## Define the divergence (λ1) for L1 frequency and the carrier ionospheric time delay (i.sub.φ) for L1 frequency as follows: ##EQU2##
Notice that divergence has only ionospheric terms, multipath error, and cycle ambiguities which are constant. Carrier ionospheric time delay is a very precise ionospheric time delay measurement which has unknown bias due to the cycle ambiguity. A plot of divergence and carrier ionospheric time delay using real data is given in FIG. 4.
Now we introduce a new quantity (μ), `pseudo-multipath`, which comes after eliminating the precise ionospheric time delay from the divergence.
μ1.tbd.Δ1.sup.j +2·i.sub.φ.sup.j (7)
where μ1 is the pseudo-multipath for the L1 frequency. Pseudo-multipath for the data used to plot FIG. 4 is given in FIG. 5. An averaged pseudo-multipath over 15 epochs for the same data is shown in FIG. 6. The multipath signature is visible in this figure.
After some algebraic manipulation, we find the following relationship:
m1.sup.j -m1.sup.j +η1.sup.j =μ1.sup.j -μ1.sup.j (8)
∴m1.sup.j =μ1.sup.j -(μ1.sup.j -m1.sup.j )-μ1.sup.1 (9)
where (·) is the mean value of (·).
The above equation means that pseudo-multipath is equivalent to multipath error in pseudorange except for bias and receiver noise. The receiver noise in the above equation is relatively small compared to multipath error and can be reduced using a Hatch filter. However, the bias can be very big because of unknown cycle ambiguities and is different for each satellite. But this bias can be calibrated using the fact that multipath is dependent on geometry around the GPS antenna. Consequently, the multipath at the cross over point for two different satellites must be the same.
If we rewrite equation (9) with a new variable, we get:
∴m1.sup.j =μ1.sup.j -dμ.sub.c.sup.j -η1.sup.j (10)
dμ c j =μ1 j -m1 j is the pseudo-multipath mean bias of j-th satellite compared to that of a reference satellite at the cross over point.
Now the remaining problem is to find the pseudo-multipath mean biases for all satellites. Multiple days of data will help reduce errors in estimating relative multipath biases. If we use multiple days of data and there is no change in the multipath environment, the mean of multipath of each satellite for the first day should be the same as that for the rest of days in the same interval of azimuth and elevation angle. So the mean value of pseudo-multipath has to be adjusted for all of the days as follows. The subscript, i, in the following equations indicates the i-th day.
μ1.sub.i.sup.j =μ1.sub.i.sup.j -Δμ1.sub.i/l.sup.j (11)
Δμ1.sub.i/l.sup.j =μ1.sub.i.sup.j -μ1.sub.l.sup.j (12)
where
μ1 i j : pseudo-multipath of j-th satellite for i-th day
μ1 i j : mean value adjusted pseudo-multipath of j-th satellite for i-th day
Δμ1 i/l j : relative pseudo-multipath mean value bias of j-th satellite for i-th day relative to first day.
Unless we know the absolute multipath bias of a reference satellite, we estimate the relative multipath bias for each satellite relative to the reference satellite. Pseudo-multipath and pseudo-multipath mean bias at the cross over point are shown in FIG. 7.
An equation to calibrate pseudo-multipath mean value bias (dμ c j/k ) using m days (i=1, 2, . . . , m) of data and n satellites (j, k=1, 2, . . . , n) is:
z=Hx (13)
where ##EQU3##
d.sub.i.sup.j/k =μ1.sub.ci.sup.j -μ1.sup.ci.sup.k
dμ.sub.c.sup.j/k =μ1.sub.c.sup.j -μ1.sub.c.sup.k.
Because the above equation is obviously overdetermined, we use a simple batch least squares technique to solve the equation.
x=(H.sup.T H).sup.- H.sup.T z (14)
After we solve the above equation, we put it back into equation (10) to get a calibrated multipath (m1) of each satellite (j=1, 2, . . . , n) for all days.
m1.sup.j =μ1.sup.j -dμ.sub.c.sup.j/l (15)
The calibrated multipath (m1) ) equals the true multipath (m1) plus a constant bias of the reference satellite multipath (dμ c 1 ). But the constant bias is the same for all satellites and will be absorbed as a receiver clock bias when we do positioning fixes with the pseudoranges, in which multipaths are eliminated using the calibrated multipaths. Therefore, this bias will not reduce positioning accuracy at all.
Once we get the calibrated multipath, we use it to eliminate multipath pseudorange errors. There are many methods for storing the calibrated multipath and using the data. We discuss two methods in this disclosure. One method is to make a table of azimuth and elevation angle vs. calibrated multipath for each satellite and find the multipath in the table using the available azimuth and elevation angle at each epoch. This will require a fairly large storage space and is very sensitive to GPS orbital fluctuations, but provides very good accuracy. The other method is to fit all the available data to n-th order spherical harmonics and call the resulting spherical harmonics function when we need it. This technique compensates for the low-frequency multipath pseudorange errors and is more robust to GPS orbital fluctuations. This method will also require a lot less storage space than the first method because we need to store only the spherical harmonics calibration coefficients. The spherical harmonics functions and the calibration coefficients are defined as follows: ##EQU4## where θ: elevation angle
ψ: azimuth angle
J l , C lm , S lm : spherical harmonics calibration coefficients
P lm (·): Legendre polynomial
To summarize, the following is a general procedure for calibrating multipath using a spherical harmonics surface fit.
1. Find where cycle slips occur and divide the measured data into cycle-slip-free intervals.
2. Smooth the measured pseudorange with continuous carrier phase for the cycle-slip-free intervals using averaging techniques that reduce receiver noise in the pseudorange.
3. Compute the pseudo-multipath (μ1) of each satellite using the smoothed pseudorange for L1 frequency (ρ1) and the continuous carrier phase for the L1 and L2 frequencies (φ1, φ2).
4. Form the adjusted pseudo-multipath (μ1) of each satellite so that the mean value of pseudo-multipath for the first day is the same as that for the rest of days in the same elevation and azimuth interval.
5. Compute the pseudo-multipath mean bias (dμ c ) using data given at all cross over points for all days.
6. Compute the calibrated multipath (m1) of each satellite.
7.Feed the calibrated multipath (m1), azimuth (ψ), and elevation angle (θ) of all satellites to the spherical harmonics surface fit algorithm, which computes the spherical harmonics calibration coefficients (J l , C lm , S lm ).
Once we compute the spherical harmonics calibration coefficients, we can use them until the multipath environment around the GPS antenna changes. Whenever we need to eliminate multipath from a measured pseudorange, we input the azimuth and elevation angles to the spherical harmonics function along with the already-computed coefficients (J l , C lm , S lm ) to find the corresponding multipath error.
FIG. 8 shows a block diagram of the multipath calibration procedure using spherical harmonics and the process for estimating multipath in real time. This algorithm can be implemented on conventional GPS receivers by anyone skilled in the art. It is obvious that spherical harmonics need not be used to model the multipath. Any type of function or algorithm that maps points of the hemisphere to multipath values can be used.
In order to verify this multipath calibration technique, we collected data on Aug. 26 and 29, 1994 at Stanford, Calif. A GPS antenna was installed on the top of a building, and a data collection schedule (six hours from 9:30 PM until 3:30 AM next day) was carefully chosen so that at least four satellites were seen for most of test period and more than four cross over points could be found for the same set of satellites. The sampling time was 15 seconds, and all the data was smoothed with continuous carrier phase over 15 epochs to see the multipath signature clearly.
FIG. 9 shows the azimuth vs. elevation plot during the test period. Six cross over points can be found in the plot. Notice that near the cross over point for PRN18, PRN27, and PRN29, all three satellite trajectories are close together and thus have the potential to confirm multipath's geometry dependency. FIG. 10 shows the elevation angle vs. local time plot. Generally, satellites do not arrive at the cross over point at the same time, and this can be confirmed by FIG. 10.
FIG. 11 shows the trajectories of PRN27 and PRN29 in rectangular azimuth vs. elevation coordinates. For about two hours, the two satellite trajectories are very close to each other. FIG. 12 shows the averaged pseudo-multipaths of PRN27 and PRN29 over 15 epochs. There are very strong correlations between the averaged pseudo-multipath of PRN27 and PRN29, and this clearly indicates multipath's geometric dependency. Because the trajectories of the satellites are not exactly the same, the pseudo-multipaths are also not exactly the same.
FIGS. 13-20 show averaged pseudo-multipaths and residuals of each PRN for two different days after the relative pseudo-multipath mean value bias is eliminated using equations (11) and (12). All the plots demonstrate the daily repetition of multipath. Table 1 is a summary of FIGS. 13-20.
TABLE 1______________________________________Summary of RMS error template technique(FIGS. 13-20) RMS error (cm)______________________________________Averaged pseudo-multipath 18.2Residual for two days 10.4______________________________________
FIG. 21 shows a three-dimensional plot of pseudo-multipath vs. azimuth and elevation angle for all satellites, and FIG. 22 is a close up view of the circle drawn in FIG. 21. As mentioned before, the trajectories of PRN 18, 26, and 29 are close together in the circle drawn in FIG. 21; therefore this example has potential to confirm the geometry dependency of multipath. FIG. 22 shows that the multipath of all the satellites inside the circle have very strong correlations in both tendency and magnitude, and those of PRN27 and PRN29 match together. This verifies the existence of a geometric dependency.
In FIG. 22 the trajectories of all satellites are very close together; thus multipath signals of all the satellites on the region are expected to be similar. Note that the multipath signals of PRN27 and PRN29 are very close.
We assigned PRN18 to be the reference satellite and computed the pseudo-multipath mean biases for PRN19, PRN27, and PRN29 using the data available at the cross over points. Table 2 shows the results of solving equation (14).
TABLE 2______________________________________Computed pseudo-multipath mean bias computed pseudo-multipath mean bias (cm)______________________________________dμ.sub.c.sup.18 0.0dμ.sub.c.sup.19 -0.9dμ.sub.c.sup.27 -10.0dμ.sub.c.sup.29 2.3______________________________________
Note that the pseudo-multipath mean bias for PRN27 is fairly large. Consequently, if we were to use an unadjusted pseudo-multipath to reduce multipath in pseudorange (as is done in Bishop's technique), this would result in large unexpected errors in positioning accuracy.
After we adjust the pseudo-multipath mean bias and get the calibrated multipath for each satellite, we feed the calibrated multipath, azimuth, and elevation angle to the spherical harmonics surface fit and compute calibration coefficients. FIGS. 23-26 show the reconstructed multipath for each satellite using the spherical harmonics function with the computed calibration coefficients on top of the calibrated multipath. The reconstructed multipath matches the calibrated multipath at low frequency, and the residual has only a high-frequency component. Averaging pseudorange with continuous carrier phase for longer periods of time can reduce most of these high-frequency residuals. The RMS error residual for the surface fit shown in FIGS. 23-26 is 13.7 cm.
TABLE 3______________________________________Summary of residual RMS errors for spherical harmonicssurface fit (FIGS. 23-26) RMS error (cm)______________________________________Residual 13.7______________________________________
APPLICATIONS, VARIATIONS AND ALTERNATIVE EMBODIMENTS
This multipath calibration technique will help not only static users but it can also help kinematic survey and real-time differential GPS (DGPS) users solve for cycle ambiguities faster and more reliably. It will also help reduce errors in ionospheric time delay measurements for dual-frequency users.
The present technique is not limited to receivers in a constant multipath environment, i.e., to fixed reference stations such as reference stations for precise orbit determination, stations for monitoring ionosphere, Differential GPS (DGPS) reference stations, and Wide Area Differential GPS (WADGPS) monitor stations. For example, in the case of relatively isolated vehicles like aircraft and spacecraft, for which the multipath environment changes with vehicle attitude but does not change in the body coordinate frame, the technique can be applied by interfacing the multipath calibration with an attitude sensor.
In the case of a mobile user whose multipath environment may change frequently, the multipath must be actively calibrated. The following technique can be used to calibrate multipath in such cases. A hollow aluminum cylinder, tapered so that it is narrower on the bottom and wider and open on the top, is placed around the antenna as shown in FIG. 27. Since multipath signals generally approach the antenna from nearby objects at low elevation angles (10-15 deg), this multipath shield blocks the multipath signals while permitting the high elevation satellite signal to reach the antenna. Because the aluminum transmits some of the multipath signal, several such shields can be nested to reject more of the multipath.
Although this multipath shield reduces the multipath error due to the low-elevation object in the environment, it generates multipath of its own. It is still necessary, therefore, to calibrate the multipath generated by the tapered cylinder. Because the multipath will be constant with respect to the attitude of the shield and nearly cylindrically symmetric, the multipath calibration technique is relatively simple. By receiving signals either from satellites or pseudollites in a lab and interfacing them with a knowledge of shield attitude, the multipath can be determined as a function of elevation and azimuth in the shield frame of reference. Because the cylinder is symmetric around the antenna, however, the multipath caused by this cylinder will be almost symmetric. Thus for a given elevation angle multipath will be constant for all azimuth angles and so multipath only needs to be calibrated as a function of elevation angle. Once the multipath is calibrated in this way, multipath can be compensated for exactly as in the case previously described. Installing a tapered cylinder to the user antenna, therefore, will give users a huge benefit to solve cycle ambiguity more quickly and more reliably without changing the receiver hardware itself.
Because of the particular tapered shape of this multipath shield, absolute multipath can be determined using the following technique. By adjusting the attitude of the antenna and tapered cylinder while measuring multipath from a satellite, the attitude corresponding to the minimum multipath can be found. Since only the direct satellite signal arrives at the antenna at this critical angle, the mean bias can be absolutely determined.
The primary beneficiary of the technique of this invention will be dual-frequency receivers from which we can measure ionospheric time delay; but it can be also applied to single-frequency receivers if we use a dual-frequency receiver to eliminate the ionospheric time delay component from measured pseudorange when we calibrate the multipath of a single frequency user. If we use a pseudollite we can calibrate the satellite multipath on the ground. We can calibrate multipath not only for L1 frequency but also for L2 frequency so that people who use wide-lane to solve cycle ambiguity can get benefit from it.
This multipath calibration technique will help both kinematic survey and real-time DGPS users to solve cycle ambiguities faster and more reliably. Wide Area Differential GPS (WADGPS) will get very precise pseudorange observables from Wide Area Reference Stations (WRSs) which do not have multipath-caused biases and as a result can provide very precise WADGPS correction to the users. This technique also gives benefit to estimate ionospheric time delays. For survey applications we can use this calibration technique to calibrate static reference station in passive way (which is the same technique described in the above) To calibrate mobile users, we have to use the technique in an active way because the multipath environment will change from one place to another place. Also this technique will improve time synchronization accuracy for time transfer application much faster, for example, computer network or cellular phone network.
Because the multipath calibration can be done for L1 only, L2 only, or wide-lane (L1/L2) single-frequency C/A code receivers can be a beneficiary. Once the calibration of the tapered cylinder is done using a dual-frequency receiver and a single-frequency receiver we no longer need the dual-frequency receiver to compensate the multipath. After the single-frequency user compensates the multipath using the multipath parameters then cycle ambiguity can be solved to get a centimeter level of positioning accuracy.
A very similar method can be applied to airborne or space-borne single-frequency users. While an aircraft is in the air it will generate the same multipath given the aircraft attitude, i.e., the multipath generated by the aircraft metal surface is fixed to the aircraft body coordinate frame. By interfacing its attitude and the GPS satellite direction the multipath can be compensated and cycle ambiguity can be solved faster and more reliably.
A real-time adaptive scheme can be applied to this technique so that the multipath calibration can be done on line without being done off-line.
Although the above description of the invention contains many specific details, these should not be construed to limit the scope of the invention in any way. Rather, the scope of the invention should be determined by the following claims and their legal equivalents. | Novel techniques are disclosed for eliminating multipath errors, including mean bias errors, in pseudorange measurements made by conventional global positioning system receivers. By correlating the multipath signals of different satellites at their cross-over points in the sky, multipath mean bias errors are effectively eliminated. By then taking advantage of the geometrical dependence of multipath, a linear combination of spherical harmonics are fit to the satellite multipath data to create a hemispherical model of the multipath. This calibration model can then be used to compensate for multipath in subsequent measurements and thereby obtain GPS positioning to centimeter accuracy. | 6 |
DESCRIPTION
The present invention relates to a process for the batchwise dyeing in jet-dyeing machines of textile material circulating therein in endless rope form and composed of linear polyester fibers in a blend with wool with dyes suitable for each of these fiber types by the exhaust dyeing technique, the forward feed for the transport of the textile material within the rinsed loop machine being effected via the actuation of the jet system by means of the kinetic energy of a circulating gas stream which is not inert with respect to the dyeing behavior of dyes and textile material, and at the same time the dyeing liquor being added in atomized form to this gas stream in the jet section for driving the textile material and thus, having been brought into contact with the textile material under the preselected temperature and pressure conditions, directly coming to impingement therein under fixing conditions.
The conjoint dyeing of the two constituents of polyester fiber/wool blends in an exhaust dyeing process is in itself common knowledge. To this end the wool portion of the textile material is customarily colored with acid, metal complex or reactive dyes, depending on the fastness requirements in the trade, the disperse dyes required for dyeing of the polyester fiber component usually being present in the same bath and frequently also being fixed simultenesouly. This fixing of the disperse dyes takes place either at the boil or at a temperature around 106° C. in the presence of carriers, or, alternatively, under high-temperature (HT) conditions (120°-125° C.) without the use of a carrier. However, the latter HTprocess for dye fixation requires in the case of the particular composition of the fiber blend to be dyed the addition of wool-protection agents. This is because in their absence the wool would be severely damaged owing to the high dyeing temperatures employed. The least costly effective wool-protecting agent in the present field has proved to be formaldehyde.
European Patent Specification No. EP-B-0,078,022, then, describes a wet treatment process, in particular for dyeing, wherein a gas stream in a jet-dyeing machine performs the function of advancing the rope form textile material to be finished, isothermal conditions being provided for carrying out the successive operations. The dyeing liquor is then metered into the driving gas stream and contacted under isothermal conditions with the material to be dyed. This system ensures rapid distribution of liquor in the material to be dyed, and also, at the same time, dyes start to become fixed on the respective fiber materials.
If blends of polyester fibers and wool are dyed, the liquor used for that purpose contains, in the aqueous medium used, dispersed or dissolved dyes for both fiber types and acid or buffer substances for setting a pH within the range of 4.6-6.5.
Polyester fibers are preferably hereinafter to be understood as meaning standard-dyeable types of this fiber category, i.e. those kinds of fibers which, as consequences of a modification of their homogeneous polymeric fiber structure, cannot anyhow be dyed at the boil without carrier.
If the above-described process of No.l EP-B-0,078,022 considered here for the one-bath dyeing of polyester fiber/wool blends is now to be carried out under high-temperature conditions, it has been found in this context that the use of formaldehyde as a wool-protecting agent, this use being necessary because of the given conditions, can lead to the operating personnel being exposed to a severe nuisance and possibly harm since the jet-dyeing machines used can be sealed off sufficiently tightly thereagainst only at an uneconomically high outlay. As a consequence, the difficulties which exist in this respect make it impossible to employ the HT dyeing process for the purpose in question.
Yet if the alternative process variant is contemplated for carrying out the said dyeing of the fiber blend, carrying out the exhaust dyeing operation at the boil or at a temperature around 106° C.requires carriers for the previously defined, unmodified polyester fiber type in order to be able to obtain a sufficient depth of shade on the textile material. However, the use of carriers directly in the dyeing liquor again presents in this case levelness problems and fastness reductions for the wool dyeing.
The invention described hereinafter thus had for its object to be able to dye polyester fiber/woodl blends at the boil or at a temperature around 106° C.in a jet-dyeing machine under isothermal conditions by an exhaust dyeing method while avoiding the abovementioned unacceptable shortcomings due to the presence of formaldehyde on the environment yet level and without the occurrence of fastness losses.
The object is achieved according to the invention by following the isothermal addition of a dyeing liquor containing the dyes for the two fiber types and pH-regulants by initially treating the textile material therewith at the boil or at a temperature around 106° C.for 10-20 minutes, only then metering the dispersion/emulsion of a carrier into the driving gas stream, and finally completing the dyeing in the course of a further 10-30 minutes under isothermal conditions.
The principle underlying the invention, namely the subsequent metering of the carrier emulsion into the driving gas stream, results not only in the achievement of the full carrier action but also in the elimination of fastness problems and levelness difficulties. This novel process produces perfectly level dyeings and, compared with the customary methods employed for the same purpose, results in savings in energy and chemicals and in a reduction in the output of waste waters.
The color yield on the two fiber types in the process is likewise improved, owing to the short liquor ratio employed, and the reduced fastness levels as a consequence of adding the carrier directly to the dyeing liquor in the initial stages of the treatment process are avoided.
In the claimed process, the wool portion can be dyed with any acid dye suitable for wool; to dye the polyester fiber portion, dyes which can be applied by carrier dyeing methods have to be selected from the class of the C.I. Disperse Dyes.
Suitable carries are commercially available dispersions or emulsion of substituted aromatics, for example chloroaromatics, phenols, salicylates and mixtures thereof which can also contain hydrocarbons and the like. Before use in the process according to the invention they are diluted with water and metered into the gas stream of the jet in such a way that they can become deposited on the textile material in the form of a fine mist.
The procedure for the claimed process accordingly takes approximately the following form:
After the jet-drying machine has been charged with the textile material made of polyester fibers and wool, the blower of the piece dyeing machine is set in operation and in this way the circulation of the material in rope form is brought about aerodynamically. In some instances even the loading process itself can advantageously be effected using the gas stream produced by the blower. By mixing steam into the transport gas stream not only is the textile material then heated up to a temperature of 100-106° C.together with the dyeing kier loaded therewith but at the same time a moistening of the circulating rope is brought about.
The separately prepared dye liquor is then metered into the hot gas stream via the injection pump serving the addition of treatment agent and a jet system present within the gas circulation system. This dye liquor contains dyes for the two fiber types and pH-regulants for setting a pH between 4.5 and 6.5 and any other auxiliaries; its temperature if 80°-100° C., so that the isothermal conditions on the textile material are only disturbed to a small extent, if at all, by the addition of the liquor, in particular since the amount of liquid is also kept as short as possible, to approximately 2-4 times the weight of pure fiber. The process of bleeding is effected in the course of a plurality of circulations of the textile material. This liquor is then left to act at 100°-106° C.for about 10-20 minutes on the circulating material to be dyed.
After expiry of this period, the metering in starts of the carrier preparation diluted with a little water (2-3 times the amount) at 60° C. The metering-in is effected in the same way as the addition of the liquor via a metering pump and the atomizer jet, distributed over at least one circulation of the textile material. After a further 10-30 minutes of treatment at 100°-106° C.the measures for the dyeing operation are concluded, and the after-treatment of the fiber blend thus dyed can take place in a conventional manner.
The examples which follow are not intended to restrict the claimed process in any way, especially not in respect of the dye combinations used, but merely serve to illustrate the procedure of the present invention. The percentages contained in these working examples are based on the weight of the articles thus designated and are calculated in relation to the dry state of the material to be dyed. The dyes mentioned are used in commercially available form and constitution.
EXAMPLE 1
A gaberdine comprising a wool/polyester fiber blend (in a ratio 45:55) is introduced in rope form into a jetdyeing machine, and, by means of a steam/air mixture is set in circulation and at the same time moistened and preheated to 95° C. Thereafter the fabric has a moisture content of 50% resulting from condensed steam.
150% of additional moisture is then injected via the jet system in the form of a hot aqueous liquor at treatment temperature containing 2% of a buffer mixture of ammonium acetate and acetic acid for setting to pH 5 and also 3 g/l of a leveling agent based on the reaction product of 1 mol of stearylamine with 12 mol of ethylene oxide, followed in succession, dispersed or dissolved in a further 100% of added water at 95° C., the following colorants:
0.7% of the dye Disperse Yellow 64 having the C.I. No. 47023
0.655 of the dye Disperse Red 60 having the C.I. No. 60756,
0.6% of the dye Disperse Red 65 having the C.I. No. 11228, and
0.14% of the dye Disperse Blue 56 having the C.I. No. 63285, and
0.16% of the 1:2 chromium complex compound of the acid wool dye of the formula ##STR1## 0.07% of the 1:2 chromium complex compound of the acid wool dye of the formula ##STR2## 0.08% of a 1:2 metal complex compound prepared by mix-chroming from the two (in the ratio of 1:1) acid woodl dyes of the formlae ##STR3## After charging of the dye-bath is complete the temperature of the circulating liquor is raised to 100° C. by blowing in steam, the textile material being dyed under these conditions for 20 minutes.
In the meantime, 0.9% of commercially available carrier based on methyl salicylate, in a mixture with aliphatic hydrocarbons, has been emulsified into 2-3 times the amount of water at 60° C. separately from the circulating liquor. After expiry of the previously mentioned 20 minute treatment period, this emulsion is metered into the jet-dyeing machine via the jet system and--while the material to be dyed circulates several times--is thus applied to the rope at 100° C.
After a further 20 minutes of dyeing at 100° C., the circulating treatment bath is dropped; the dyed material is then cooled down and at the same time rinsed by running less hot water into the dyeing jet and is subsequently aftertreated at 75° C. and a liquor ratio of 1:10 for 20 minutes with a freshly prepared aqueous bath containing
0.5% of acetic acid and
2 g/l of an auxiliary containing
40% of castor oil ethoxylated with 36 mol,
42% of Ca-phenylcoagasinulfonate and
16% of isopropanol.
Finally, the dyeing produced in the stated manner is again rinsed with hot and cold water and dried.
The result obtained is a gaberdine dyed a satisfactory tone-on-tone brown.
EXAMPLE 2
A fabric comprising a polyester fiber/wool blend (in a ratio of 55:45) is introduced in rope form into a jet-dyeing machine which permits isothermal dyeing in a gas stream and is then, by means of a steam/air mixture, set in circulation, heated up to 106° C. and at the same time impinged with 200% moisture formed by steam condensation.
Thereafter a further 20% of moisture is bled in through the injection jet system in the form of water at 95° C. containing
2% ammonium acetate
2% acetic acid (60% strength) and
1.5% of a leveling auxiliary based on the reaction product of 1 mol stearylamine with 12 mole of ethylene oxide
and distributed over the textile material. All the time the temperature of the treatment bath is maintained at 106° C. After about 5 minutes, an additional 180% of moisture is applied to the material to be dyed in the same manner in the form of an aqueous liquor at 95° C. containing
0.06% of the dye Disperse Yellow 64 having the C.I. No. 47023,
0.875 of the dye Disperse Blue 56 having the C.I. No. 63285 and
1.4% of a blue disperse dye based on a mixture of differently containing less than 1 mol of bromine per mol of dye, and
10.04% of the reactive dye of the formula ##STR4## 0.22% of the reactive dye of the formula ##STR5## and 1.9% of the reactive dye of the formula ##STR6## and the material to be dyed is then dyed at 106° C. for 20 minutes.
In the meantime, 0.9% of a commercially available carrier based on p-hydroxydiphenyl has been emulsified in 3 times the amount of water at 60° C. separately from the circulating liquor. After expiry of the 20-minute treatment period this emulsion is metered via the jet system into the jet-dyeing machine and--while the material to be dyed circulates several times--is applied to the same eat 106° C.
After a further 30 minutes of dyeing time at 106° C. and subsequent dropping of the dyeing liquor, less hot water is then run into the dyeing jet to cool down and at the same time rinse the dyed material, which is then aftertreated as in Example 1.
The result obtained is a satisfactory tone-on-tone and very fast navy dyeing of the fabric. | Because the high dyeing temperatures employed necessitate the use of formaldehyde as customary wool-protecting agent and because of the resulting sealing problems on jet-dyeing machines, an HT dyeing of polyester fibre/wool blends cannot be carried out without polluting the environment. If, however, to achieve this purpose, lower temperatures are employed and the consequently required carriers are added directly to the dyeing liquor, this in turn gives rise to levelness problems and fastness reductions on the wool portion of the textile material.
It has now been found according to the invention that by metering the carrier under isothermal conditions into the dyeing after 10-20 minutes via the gas stream driving the textile material it is possible to obtain a homogeneous distribution thereof and its full effectiveness without fastness losses. The dyeing can be completed 10-30 minutes later. All the advantages of jet dyeing are fully retained in this process. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a lambda-shaped carbazole and a main-chain NLO polyurethane containing the same.
2. Description of the Prior Art
Nonlinear Optical (NLO) materials can be categorized into two groups, i.e. organic and inorganic. Conventional inorganic NLO materials are LiNbO 3 or GaAs crystals. Organic NLO materials, as described in Chemical Review vol. 94, No.1, 31-76(1994) published by American Chemical Society, have higher electro-optical coefficients than inorganic NLO materials. It is also reported that organic NLO materials possess characteristics of high optical coefficiency, short response time, and ease of processing (G. R. Meredith, et al, Macromolecules 1982, 15, 1385). Although organic NLO materials possess the superior characteristics described above, they have the disadvantages of inferior thermal stability, low temporal stability of polarized dipole and relatively high optical loss.
In fabrication of organic NLO materials, organic NLO chromophore is incorporated into polymeric materials by blending. One example of these organic NLO materials is guest-host type NLO material. Organic NLO materials can also be fabricated by incorporating organic NLO chromophore into polymeric materials through chemical bonding reaction. Example of these organic NLO materials are main-chain, side-chain or cross-linking NLO polymers.
In a main-chain NLO polymer, the dipole of a chromophore can be parallel to the main chain of a polymer to form head-to-tail main-chain NLO polymers (G. A. Lindsay et al. Macromolecules 1992, 25, 6075, and C. Wu et al. Macromolecules 1992, 25, 6716), or the dipole of a chromophore can be perpendicular to the main chain of a polymer to form shoulder-to-shoulder main-chain NLO polymer( N. Tsutsumi et al., Macromolecules 1996, 29, 592) and I. Teraoka et al. J. Appl. Phys. 1991, 69, 2568).
In head-to-tail main-chain NLO materials, the high driving voltage can cause significantly low effective order parameters, especially when the molecular weight is high enough to cause chain-entanglement; and the molecular structure thereof is more difficult to be ordered by electric field. This limits head-to-tail main-chain NLO polymers' practical applications. In the shoulder-to-shoulder main-chain NLO materials, however, the aligning efficiency in electric field is raised because the dipole alignment of chromophores is perpendicular to the main chain of the polymer ( Theory of Polymer Dynamics Oxford University Press: Oxford 1987”, M. Doi and S. F. Edward). The solid stick-like structure increases the stability of the NLO coefficients of the materials at low temperatures. However, the solid stick-like structure also increases the local free volume between main chains of the material. The expanded local free volume may cause rapid relaxation when the temperature approaches the glass transition temperature of the material.
Accordingly, an ideal main-chain NLO material should possess both high poling efficiency in electric field and good thermal stability of NLO coefficients at high temperatures. However, in choosing polymeric materials for the main-chain NLO materials, some limitations should be considered, for example, polyacrylate and polymethacrylate have a glass transition temperature (T g ) of −105° C., and thus are unstable under the actual application temperature. Polyimide, despite a high glass temperature when used in main-chain NLO materials, shows poor poling efficiency in electric field and low solubility. Accordingly, polyimide also has limited application in main-chain NLO materials. Polyurethane, however, thanks to ease of synthesis, good film-forming ability, and a glass transition temperature that can be modified by incorporating aromatic structure with different degrees of rigidity, has become an important base polymer of main-chain NLO materials ( S. S. H. Ma et al. ( Chem. Mater. 1998, 10, 146).
In choosing NLO chromophores, two aspects should be considered. The first is whether the behavior of the chromophores per se, with respect to the NLO materials is stable after being incorporated into the polymers. For example, the size of the chromophores and the resonance length thereof will affect the alignment stability of dipole, the thermal stability of chromophores can be improved by increasing the resonance length, and the bulky structure can improve the volatility of the chromophores. Another aspect is the phase-matched phenomena of the NLO material. Generally, the phase-matched phenomena of the material can be improved by changing the structure of chromophores. However, conventionally, the phase match of second-order NLO coefficients is improved by adjusting the dielectric constant of materials. Recently, it has been found that the phase-matched phenomena can be improved by elevated off-diagonal components(i.e. d 31 , d 32 . . . ). It has also been reported that carbazoles can be the base structures of the NLO chromophores because carbazoles possess a variety of electro-optical properties, such as photoconductivity ( B. Kippelen et al., J. Phys. Rev. B 1993, 48, 10710) and Y. Zhang et al., Appl. Phys. Lett. 1994, 66, 2561). It has also been disclosed that NLO chromophores with two-dimensional structure can be easily fabricated from carbazoles, because they possesses isoelectronic structure at 3rd and 6th positions (H. Yamamoto et al., Appl. Phys. Lett. 1992, 60, 935, X. T. Tao et al., Chem. Mater. 1995, 6, 1961, and X. T. Tao et al., J. Polym. Sci. B. Polym. Phys. 1995, 33, 2205). By using a two-dimensional carbazole, phase-matched second-harmonic coefficients can be significantly improved.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a two-dimensional chromophore containing a lambda-shaped carbazole. The two-dimensional chromophore can increase the phase-matched second-harmonic coefficient.
Another object of the present invention is to provide a main-chain NLO polyurethane containing lambda-shaped chromophores.
The lambda-shaped carbazole has the following structure:
wherein,
R 1 and R 2 are the same or different, independently selected from the group consisting of (—CH 2 —) n wherein n=2-11, (—CH 2 CH 2 O—) m wherein m=1-4, phenylene and naphthalene;
R 3 represents H(—CH 2 —) n wherein n=2-11 or H(—CH 2 CH 2 O—) m wherein m=1-4.
Preferably, the n of (—CH 2 —) n is selected from n=2-6 and the m of (—CH 2 CH 2 O—) m is selected from m=1-3.
Preferred lambda-shaped carbazoles include but are not limited to 9-hexyl-3,6-di(2-(6-hydroxyhexyl)sulfonylphenyl)-ethenyl)-9H-carbazole, 9-hexyl-3,6-di(2-(3-hydroxypropyl)sulfonylphenyl)-ethenyl)-9H-carbazole, 9-hexyl-3,6-di(2-(4-hydroxyphenyl)sulfonylphenyl)-ethenyl)-9H-carbazole, or 9-hexyl-3,6-di(2-(5-hydroxynaphthyl)sulfonylphenyl)-ethenyl)-9H-carbazole.
The above lambda-shaped carbazole chromophore can reduce the plasticization caused by chromophore to the main chain of a polymer material, and thus the temporal stability of the nonlinear optical coefficients is increased.
The following structure further illustrates the main-chain NLO polyurethanes containing the lambda-shaped carbazole of the invention.
wherein,
R 1 and R 2 are the same or different, independently selected from the group consisting of (—CH 2 —) n wherein n=2-11, (—CH 2 CH 2 O—) m wherein m=1-4, phenylene and naphthalene;
R 3 represents H(—CH 2 —) n , wherein n=2-11 or H(—CH 2 CH 2 O—) m wherein m=1-4.
Aromatic (Ar) diisocyanate moiety is derived from monomers selected from diisocyanate or the derivatives thereof.
Preferably, the n of (—CH 2 —) n is selected from n=2-6 and the m of (—CH 2 CH 2 O—) m is selected from m=1-3. The diisocyanate derivatives include but are not limited to p-phenylene diisocyanate, 2,6-toluene diisocyanate, naphthalene-1,5-diisocyanate, methylene di(p-phenylene isocyanate), 2,2′-di(p-isocyanato phenylene)propane, 2,2′-di(p-isocyanato phenylene)hexafluoropropane, 3,3′-tolidene-4,4′diisocyanate, 3,3′-dimethoxy-4,4′-diisocyanato biphenyl, 2,2′-di(4-isocyanato phenoxy)biphenyl or isophorone diisocyanate.
Preferred main-chain NLO polyurethanes are the polymerization products of 9-hexyl-3,6-di(2-(3-hydroxypropyl)sulfonylphenyl)-ethenyl)-9H-carbazole and 2,2-di(p-isocyantophenylene)hexaflouropropane; 9-hexyl-3,6-di(2-(3-hydroxypropyl)sulfonylphenyl)-ethenyl)-9H-carbazole and 3,3′-dimethoxy-4,4′-diisocyanto biphenyl; or 9-hexyl-3,6-di(2-(3-hydroxypropyl)sulfonylphenyl)-ethenyl)-9H-carbazole and 2,2′-di(4-isocyanato phenoxy)biphenyl.
The main-chain NLO polyurethanes have a higher alignment stability in electric field because the dipole thereof is perpendicular to the main chain of the polymer, and thus the NLO coefficient is stabilized. The off-diagonal component d 33 of the NLO materials is between 28-36, the d 31 is between 8-12, and the d 33 /d 31 ratio is about 3.
Hereinafter, the present invention will be described in more detail with reference to the Examples and drawings, however, it should be noted that the present invention is not limited to those Examples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the FT-IR spectra of the PU-HSU synthesized in Example 9 according to the present invention.
FIG. 2 is a graph showing the thermal analysis of the PU-HSU synthesized in Example 9 according to the present invention.
FIG. 3 is a graph showing the dynamic thermal stability of the PU-HSU synthesized in Example 9 according to the present invention.
FIG. 4 is a graph showing the temporal stability under 100° C. of the PU-HSU synthesized in Example 9 according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
Synthesis of 9-Hexyl-9H-carbazole
20 g of carbazole was dissolved in 100 mL dry N,N-dimethyl acetamide (DMAc) in a 500 mL round bottomed flask. NaH (60% in mineral oil) was added into the flask slowly in nitrogen to form a mixture. The mixture was stirred for 20 minutes in ice/water bath. 30 g of 1-bromohexane was then added slowly to the flask and stirred for 6 hours in ice/water bath. The resulting solution was poured into 2L deionized water and extracted with ethyl acetate several times. The extract was re-extracted by deionized water. The final extract was concentrated by a rotary evaporator and further purified by column chromatography. A product of the following structure was obtained.
EXAMPLE 2
Synthesis of 9-Hexyl-9H-3,6-diformyl Carbazole
30 g dry N,N-dimethyl formamide(DMF) was dissolved in POCl 3 solution in a 500 mL round bottomed flask in ice/water bath. After the solution reached room temperature, 9-Hexyl-9H-carbazole dissolved in 50 mL 1,2-dichloroethane was charged into the solution slowly. The mixture was heated to 90° C. and reacted at the temperature for 24 hours. Then the hot mixture was poured into 500 mL 5% sodium hydroxide aqueous ice solution and extracted with dichloromethane several times. The organic fraction was extracted repeatedly with deionized water. The extract was dried over anhydrous magnesium sulfate and then concentrated by a rotary evaporator and further purified by column chromatography. A product of the following structure was obtained.
EXAMPLE 3
Synthesis of 4-Methylphenyl-6′-hydroxyhexyl Sulfide
5 g of p-methylthiolphenol, 6.7 g of potassium carbonate and 30 mL of dry DMF were added to a 250 mL 2-neck round bottomed flask and stirred for 30 minutes in nitrogen. Then 6.6 g of 6-chloro-1-hexanol was added into the mixture. The solution was heated to 70° C. and reacted for 12 hours. After reaction was complete, the solution was poured into 500 mL of deionized water and extracted by ethyl acetate several times. Then the organic fraction was extracted with deionized water three times. The extract was dried over anhydrous magnesium sulfate and concentrated by a rotary evaporator. The concentrate was further purified by column chromatography to produce a clear liquid. The yield was 98% and a product of the following structure was obtained.
EXAMPLE 4
Synthesis of 4-Methylphenyl-6′-acetoxyhexyl Sulfide
8.85 g of 4-Methylphenyl-6′-hydroxyhexyl sulfide, 8.06 g of acetic anhydride and 40 mL of acetic acid were added to a 250 mL round bottomed flask. The solution was heated to 70° C. and reacted for 6 hours. After reaction was complete, excess acetic anhydride and acetic acid was removed by distillation under reduced pressure. After that, the resulting crude product was dissolved in 300 mL of ethyl acetate and then washed by potassium carbonate solution and deionized water three times. The organic fraction was dried over anhydrous magnesium sulfate and then concentrated by a rotary evaporator. The concentrate was further purified by column chromatography to produce a clear liquid. The yield was 97% and a product of the following structure wasobtained.
EXAMPLE 5
Synthesis of 4-[(6-acetoxyhexyl)sulfonyl]toluene
10.2 g of 4-Methylphenyl-6′-acetoxyhexyl sulfide, and 20 mL of acetic acid were added to a 250 mL round bottomed flask. 10.8 g of 30% hydrogen peroxide was charged into the flask slowly. The solution was heated to 70° C. and reacted for 5 hours. After reaction was complete, excessive acetic acid was removed by distillation under reduced pressure. After that, the resulting crude product was dissolved in 300 mL of ethyl acetate and then washed by potassium carbonate solution and deionized water three times. The organic fraction was dried over anhydrous magnesium sulfate and then concentrated by a rotary evaporator. The concentrate was further purified by column chromatography to produce a clear sticky liquid having the following structure.
EXAMPLE 6
Synthesis of 4-[(6-acetoxyhexyl)sulfonyl]benzyl Bromide
2.0 g of 4-[(6-acetoxyhexyl)sulfonyl]toluene, 1.3 g of N-bromo-succinimide (NBS), 0.015 g of benzoyl peroxide (BPO) , and 20 mL of carbon tetrafluoride were added to a 250 mL round bottomed flask and heated with reflux for 12 hours in nitrogen. The mixture was allowed to cool down and then filtered. The filtrate was washed by deionized water repeatedly. The organic fraction was dried over anhydrous magnesium sulfate and then concentrated by a rotary evaporator. The concentrate was further purified by re-crystallization to produce a white solid. The yield was 71% with the following structure.
EXAMPLE 7
Synthesis of 4-[(6-acetoxyhexyl)sulfonyl]benzyl Diethyl Phosphate
2.9 g of 4-[(6-acetoxyhexyl)sulfonyl]benzyl bromide, and 15 mL of dried triethyl phosphorous ester(P(OEt) 3 ) were poured into a 250 mL round bottomed flask and heated with reflux for 6 hours in nitrogen. Excessive triethyl phosphorous ester was removed by distillation under reduced pressure. After that, the resulting crude product was dissolved in 100 mL of ethyl acetate and then washed by 100 mL of deionized water three times. The organic fraction was dried over anhydrous magnesium sulfate and then concentrated by a rotary evaporator. The concentrate was further purified by column chromatography to produce a clear sticky liquid. The yield was 83% with the following structure.
EXAMPLE 8
Synthesis of 9-Hexyl-3,6-di(2′-(6-hydroxyhexyl)sulfonylphenyl)-1′-ethenyl)-9H-carbazole(HSC)20 Monomer
0.32 g of sodium hydride(60% in mineral oil)and 5 mL of dried tetrahydrofuran(THF) were added to a 150 mL 2-neck round bottomed flask in ice bath and nitrogen to obtain a suspension solution. 0.5 g of 9-hyxyl-9H-3, 6-diformyl carbazole and 2.34 g of 4-[(6-acetoxyhexyl)sulfonyl]benzyl diethyl phosphate were dissolved in 5 mL of dried THF to obtain a mixed solution. The mixed solution was then added to the suspension solution in the 2-neck round flask dropwise, and reacted. 20 mL of deionized water was added to the reaction mixture to terminate the reaction after 4 hours. THF was removed by a rotary evaporator and then 50 mL methanol and 50 mL 25% Sulfuric acid solution were added thereto, and heated with reflux for 12 hours to undergo the hydrolysis reaction. The reaction solution was thereafter cooled down and neutralized with sodium carbonate, and methanol was removed by a rotary evaporator. Aqueous solution was removed by decantation, and the resulting crude product was dissolved in ethyl acetate and dried over anhydrous magnesium sulfate and then concentrated by a rotary evaporator. The resulting concentrate was further purified by column chromatography to produce a yellow sticky clear liquid having the following structure.
EXAMPLE 9
Synthesis of Main-chain Type NLO Polyurethanes Containing Lambda-shaped Carbazols PU-HSC(Polyurethanes)
1.02 g of 9-Hexyl-3,6-di(2′-(6-hydroxyhexyl)sulfonylphenyl)-1′-ethenyl)-9H-carbazole was dissolved in 5 mL of dried N-methylpyrrolidone (NMP) in nitrogen to obtain a solution. 0.3257 g of 4,4′-methylene bis(phenyl isocyanate (MDI monomers, Lancast, Britain) was added to the solution to obtain a mixture. The mixture was heated to 100° C. and reacted for 6 hours. The reaction mixture was then dropped into 100 mL of methanol to precipitate. The precipitate was filtrated and then dissolved in NMP. A crude product was obtained after re-precipitating with methanol three times. A yellow solid was finally obtained after filtration and drying. The final product has the following structure.
The structures and characteristics of the carbazole based chromophore obtained in example 8 and the main-chain type NLO Polyurethanes containing lambda-shaped carbazoles obtained in Example 9 were tested and identified by various instruments.
Fourier-transform infrared spectrometer (Bio-Rad, scanning wave number: 400 cm −1 to 4000 cm −1 ; KBr) and Nuclear magnetic resonance spectrometer, 1 H-NMR (Bruker AM-400, operation frequency: 300 MHz; solvent: CDCl 3 or d 6 -DMSO) were used to identify the structure of the main-chain NLO polyurethanes (PU-HSC). FIG. 1 shows the FT-IR spectra of the PU-HSU synthesized in Example 9. As can be seen, an absorption at 1723 cm −1 appears, while no absorption of isocyanate from diisocyanate monomers is shown at nearby 2300 cm −1 . 1 H-NMR of the NLO polyurethanes indicates that chemical shift of urethanes proton is on 9.45 ppm, chemical shift of aliphatic proton near sulfonyl group is on 3.28 ppm, and chemical shift of methylene proton near isocyanate is on 2.68 ppm.
Moreover, the NMR data and element analysis data of compounds synthesized in Example 1 to Example 9 are respectively summarized in table 1 and table 2 below.
TABLE 1
compound
1 H-NMR (CDC13) δ: ppm
example
9-Hexyl-9H-carbazole
0.83-0.87 (t, 3H, —C H 3 ), 1.25-1.40 (m, 6H, —C H 2 —), 1.82-1.88 (p, 2H, —N—CH 2 —C H 2 —), 4.26-4.30
1
(t, 2H, —N—C H 2 —), 7.20-7.24 (t, 2H, Ar— H , para to NH), 7.38-7.41 (d, 2H, Ar— H , ortho to
NH), 7.43-7.47 (t, 2H, Ar— H , meta to NH), 8.08—8.10 (d, 2H, AR—H, ortho to NH)
example
9-Hexyl-9H-3,6-
0.76—0.80 (t, 3H, —C H 3 ), 1.17-1.32 (m, 6H, —C H 3 —), 1.80-(p, 2H, —N—CH 2 —C H 2 —), 4.27-4.30
2
diformyl carbazole
(t, 2H, C H 2 —), 7.44-7.46 (d, 2H, Ar— H , ortho to NH), 7.98-8.00 (d, 2H, Ar— H , ortho to CHO),
8.55 (s, 2H, Ar— H , ortho to CHO), 10.04 (s, 2H, C H O)
example
4-Methylphenyl-6′-
1.31-1.63 (m, 8H, —C H 2 —), 2.29 (s, 3H, Ph—C H 3 ), 2.85 (t, 2H, S—C H 2 ), 3.60 (t, 3H, O—
3
hydroxyhexyl sulfide
C H 2 —), 7.06 (d, 2H, Ar—H, ortho to SC H 2 —), 7.23 (d, 2H, Ar—H, ortho to CH 3 )
example
4-Methylphenyl-6′-
1.28-1.61 (m, 8H, —C H 2 —), 1.99 (s, 3H, —O—C(O)—C H 3 ), 2.27 (s, 3H, Ph—C H 3 ), 2.82 (t, 2H,
4
acetoxyhexyl sulfide
S—C H 2 ), 4.00 (t, 3H, —COO—C H 2 —), 7.03 (d, 2H, Ar—H, ortho to S—C H 2 —), 7.20 (d, 2H, Ar—H,
ortho to CH 3 )
example
4-[(6-
1.23-1.64 (m, 8H, —C H 2 —), 1.94 (s, 3H, —O—C(O)—C H 3 ), 2.37 (s, 3H, Ph—C H 3 ), 2.98 (t, 2H,
5
acetoxyhexyl)sulfonyl]
SO 2 —C H 2 —), 3.93 (t, 3H, —COO—C H 2 —), 7.28 (d, 2H, Ar—H, ortho to SO 2 —), 7.69 (d, 2H, Ar—H,
toluene
ortho to CH 3 )
example
4-[(6-
1.31-1.71 (m, 8H, —C H 2 —), 2.00 (s, 3H, —O—C(O)—C H 3 ), 3.05 (t, 2H, SO 2 —C H 2 —), 3.98 (t, 3H,
6
acetoxyhexyl)sulfonyl]
—COO—CH 2 —), 4.48 (s, 3H, Ph—C H 2 Br),7.55 (d, 2H, Ar—H, ortho to SO 2 —), 7.85 (d, 2H, Ar—H,
benzyl bromide
ortho to CH 3 )
example
4-[(6-
1.20 (t, 6H, P—OCH 2 —C H 3 ), 1.23-1.70 (m, 8H, —CH 2 —), 1.98 (s, 3H, —O—C(O)—C H 3 ), 3.01 (t,
7
acetoxyhexyl)sulfonyl]
2H,SO 2 —C H 2 —), 3.15 (d, 2H,Ph—C H 2 —P(O) (OEt) 2 , J = 22.16 Hz), 3.98 (t, 3H, —COO—C H 2 —). 7.55 (d,
benzyl diethyl
2H, Ar—H, ortho to CH 2 P(O) (OEt) 2 ), 7.85 (d, 2H, Ar—H, ortho to SO 2 —)
phosphate
example
9-Hexyl-3,6-di(2-
1.20-1.81 (m, 22H, —CH 2 —), 2.36 (s, 2H, —O H ), 3.04 (t, 4H, SO 2 —C H 2 —), 3.52 (t, 4H, —CH 2 —OH),
8
(6-
4.18 (t, 2H, —N—C H 2 —), 7.07 (d, 2H, CH═C H —PhSO 2 —, J = 16.24 Hz), 7.24 (d, 6H, Ar—H, meta to
hydroxyhexyl)sulfonyl
SO 2 — and ortho to vinyl group), 7.30 (d, 2H, C H ═CH—PhSO 2 —, J = 25.72 Hz), 7.68 (d, 6H, Ar—H,
phenyl)-
meta to SO 2 — and ortho to vinyl group), 7.80 (d, 4H, Ar—H, ortho to SO 2 —), 8.21 (s, 2H,
ethenyl)-9H-
Ar—H, ortho to vinyl group)
carbazole
example
Polyurethanes
0.77 (3H, (—CH 2 ) 5 C H 3 ), 1.03-1.24 (16H, —C H 2 ), 1.30, 1.52, 2.68 (2H, —Ph—C H 2 —Ph—), 3.27 (4H,
9
SO 2 —C H 2 —), 3.74 (4H, —C H 2 —O—), 3.97 (2H, —N—C H 2 —C 5 H 11 ), 7.05 (—C═CH—P H SO 2 —), 7.29 (2H,
C H ═CH—PhSO 2 — and Ar—H, meta to urethane linkage), 7.33-7.50, 7.74-7.85 (4H, Ar—H, ortho
to SO 2 — and Ar—H, ortho to urethane linkage), 8.48 (2H, Ar—H, ortho to vinyl group), 9.44
(2H, —OCON H —)
TABLE 2
compound
formula
Experiment Data
Analysis Data
example
9-Hexyl-9H-carbazole
C 18 H 21 N
C: 86.12%
C: 86.01%
1
H: 8.31%
H: 8.42%
N: 5.54%
N: 5.57%
example
9-Hexyl-9H-3,6-
C 20 H 21 NO 2
C: 78.08%
C: 78.15%
2
diformyl carbazole
H: 6.83%
H: 6.89%
N: 4.51%
N: 4.56%
example
4-Methylphenyl-6′-
C 13 H 20 OS
C: 69.62%
C: 69.59%
3
hydroxyhexyl sulfide
H: 8.87%
H: 8.98%
example
4-Methylphenyl-6′-
C 15 H 22 O 2 S
C: 67.59%
C: 67.63%
4
acetoxyhexyl sulfide
H: 8.34%
H: 8.32%
example
4-[(6-
C 15 H 22 O 4 S
C: 60.42%
C: 60.38%
5
acetoxyhexyl) sulfonyl]
H: 7.41%
H: 7.43%
toluene
example
4-[(6-
CD 15 H 21 O 4 SBr
C: 47.69%
C: 47.75%
6
acetoxyhexyl) sulfonyl]
H: 5.57%
H: 5.61%
benzyl bromide
example
4-[(6-
C 19 H 31 O 7 PS
C: 52.47%
C: 52.52%
7
acetoxyhexyl) sulfonyl]
H: 7.26%
H: 7.19%
benzyl diethyl
phosphate
example
9-Hexyl-3,6-di (2′-
C 24 H 57 NO 6 S 2
C: 69.43%
C: 70.46%
8
(6-
H: 7.53%
H: 7.33%
hydroxyhexyl) sulfonyl
N: 1.84%
N: 1.79%
phenyl)-1′-
ethenyl)-9H-
carbazole
example
Polyurethanes
C 61 H 67 N 3 O 8 S 2
C: 69.41%
C: 70.83%
9
(repeat unit)
H: 6.93%
H: 6.53%
N: 4.31%
N: 4.06%
The glass transition temperature(T g ) and the degradation temperature(T d ) of the PU-HSU synthesized in Example 9 were measured using Differential scanning calorimeter(DSC, Seiko SSC/5200) and thermogravimetric analyzer (TGA, Seiko 2200). The DSC and TGA were operated at a heating rate of 10° C./min in 50 mL/min nitrogen atmosphere. The results are shown in FIG. 2, which indicates the glass transition temperature(T g ) is about 145° C., and the degradation temperature(T d ) of 5% weight loss is about 310° C.
The optoelectronic characteristics of the PU_HSC synthesized from Example 9 were also tested. The NLO polyurethane was first dissolved in an aprotic solvent, such as N,N-dimethyl formamide (DMF) N,N-dimethyl acetamide (DMAc) dimethylsulfoxide (DMSO) and N-methylpyrrolidone (NMP) at room temperature to form a solution. The solution was then coated on ITO glasses by spin coating technique to obtain transparent film specimens. The thickness of these transparent film specimens was controlled at a range of 1 to 2 micrometers.
The transparent film specimens were then subject to a corona poling process by using in-situ poling. The corona discharge was generated by using a tungsten filament probe disposed 1 cm above the transparent film specimens. The electric current flowing through these film specimens were between 0.2 to 1.0 A, and 1.064 m Nd:YaG laser was used to determine the d 33 and d 31 of the film specimens. The values of d 33 and d 31 are 34 pm/V and 11 pm/V, respectively.
The stability of the NLO coefficient of the film specimens with respect to temperature and time was also measured. The NLO coefficients (including d 33 and d 31 ) of the film specimens were measured by using a Q-switched Nd:YAG laser (wave length 1.064 m), and a Y-cut quartz crystal (d 11 =0.5 pm/V)was used as reference. The stability of the film specimens after poling with respect to the change of time in different temperature was respectively shown in FIG. 3 and FIG. 4 .
As shown in FIG. 3, the NLO coefficient (d eff (t)/d eff (0)) is stable at 122° C., however, when the temperature is higher than 122° C., the value of the NLO coefficient decreases rapidly because the movement of the main-chain polymers induce rapid relaxation of the dipole alignment.
As can be seen from FIG. 4, the value of the NLO coefficient decreases 20% rapidly at the beginning, however maintains at 62% of the value of the NLO coefficient even after 200 hours. This indicates that even operation temperature closes to the glass transition temperature of the material, the NLO coefficients thereof still show superior temporal stability, and thus incorporating chromophores into main-chain polymers can suppress the movement of the dipole effectively even when the temperature closes to the glass transition temperature of the material.
From the above results, it is known that the NLO polyurethanes obtained according the present invention possess excellent temporal stability at 100° C. Based on the structure design of the present invention, superior temporal stability is obtainable and the decline of NLO coefficients can be improved. The structure design also raises the actual application temperature to be close to the glass transition temperature of the material.
While the invention has been shown and described of the preferred embodiment thereof, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | The present invention provides a lambda-shaped carbazole based chromophore, and a main-chain NLO polyurethane containing the same. The lambda-shaped structure reduces the plasticization to the main-chain polymers caused by the chromophore and increases temporal stability of the NLO coefficients of the main-chain NLO polyurethane. The NLO coefficients of the main-chain NLO polyurethane are stable because the efficiency of dipole alignment in electric field is increased due to the dipole thereof being perpendicular to the main chain of the polyurethane. | 2 |
TECHNICAL FIELD
[0001] This invention relates generally to refrigerators, including refrigerators with separate temperature zones controlled by separate heat exchangers.
BACKGROUND
[0002] Many modern refrigerators operate by sharing air flow from a single heat exchanger between a freezer compartment and a fresh food compartment to maintain each compartment at desired temperatures. In such refrigerators, colder air typically is borrowed or forced from the freezer compartment to mix with warmer air in the fresh food compartment. This colder air can be forced into the entire fresh food compartment for expedited cooling thereof, or, can be directed to certain areas of the fresh food compartment to chill certain areas more quickly. Generally, the refrigerator and freezer compartments are separated by an insulated wall, with the two compartments not being in thermal communication with each other.
[0003] Some conventional refrigerators create dual temperature zones by utilizing adjustable dampers between the two compartments and a thermostat that controls the temperature required to switch off the compressor and evaporator fan. Other refrigerators employ a separate thermostat to electronically control dampers within the freezer compartment. In these refrigerators, temperature settings typically are adjusted in one compartment relative to the other compartment.
SUMMARY
[0004] The refrigerator, as detailed herein, provides one or more temperature zones, a system for maintaining the different zones at different temperatures, a first evaporator or heat exchanger for cooling the first zone, a second evaporator or heat exchanger for cooling a separate second zone, and a system for controlling drawer temperatures within the first zone.
[0005] In accordance with one embodiment, a refrigerator is provided having a cabinet with a refrigerated compartment. The refrigerated compartment comprises one or more zones in thermal communication with each other and with each zone operated at a particular temperature. In another aspect, a method for controlling the temperatures of one or more zones in a refrigerator is provided.
[0006] A refrigerator as detailed herein, comprises one or more temperature zones and a system for controlling the zones at different temperatures. For a more complete understanding of the present invention, reference should be made to the following detailed description and accompanying drawings, wherein like reference numerals designate corresponding parts throughout the figures. Although the figures illustrate a refrigerator having two separate zones, the refrigerator may comprise several zones, which can be maintained at various temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a diagram of a refrigerator with dual evaporators and a dual air circulation system.
[0008] FIG. 2 provides a partial view of a refrigerator with first and second zones, with the first zone being in a drawer.
[0009] FIG. 3 provides a partial view of a refrigerator illustrating the air ducts in the first zone.
[0010] FIG. 4 provides a partial view of a refrigerator illustrating first zone air inlets and outlets.
[0011] FIG. 5 provides a partial view of a refrigerator illustrating the first zone evaporator.
[0012] FIG. 6 provides a partial view of a refrigerator illustrating air flow within the first zone.
DETAILED DESCRIPTION
[0013] Referring to FIG. 1 , a refrigerator 5 includes a refrigeration system for cooling a first zone 10 , and a separate, second zone 100 . The second zone 100 can be, for example, a fresh food compartment, and the first zone 10 can be, for example, a chilled compartment or drawers (e.g., useful for storing meat). The refrigeration system comprises a compressor 280 , a condenser 290 , an expansion valve 300 , a first evaporator or heat exchanger 20 situated in air flow communication with the first zone 10 , and a second evaporator or heat exchanger 110 situated in air flow communication with the second zone 100 . The refrigeration system optionally can include a thermostat (not shown). The condenser typically includes a warm air exhaust fan to remove heat from the condenser. The first evaporator 20 substantially cools the first zone 10 , while the second evaporator 110 substantially cools the second zone 100 . Typically, though not necessarily, the first zone 10 is maintained about 2 to about 10° F. cooler than the second zone 100 .
[0014] The first zone 10 is cooled by the circulation of air that has been passed over the first evaporator or heat exchanger 20 . A first evaporator fan 30 draws air across the first evaporator 20 , with the cooled air passing through a first duct 40 . The first evaporator fan 30 generates a first air flow 80 within the first zone 10 . Although the first duct 40 and first evaporator 20 are located behind the first zone rear wall 50 in FIG. 1 , any number of duct configurations are possible for cooling the first zone 10 . For example, the first air flow 80 can pass through one or more ducts with one or more inlets and outlets located in various positions throughout the first zone 10 . As illustrated in FIG. 1 , the first duct 40 is in communication with the first zone 10 by a first zone inlet 60 and a first zone outlet 70 . The first zone inlet 60 can be positioned below the first zone outlet 70 , above the first zone outlet 70 , or horizontal to the first zone outlet 70 .
[0015] As provided in FIG. 1 , the second zone 100 is cooled in manner analogous to first zone 10 by circulation of refrigerated air, which has been passed over the second evaporator or heat exchanger 110 . A second evaporator fan 120 draws air across the second evaporator 110 , typically with the cooled air passing through a second duct 130 behind the rear wall 170 of the fresh food compartment or second zone 100 . The second evaporator fan 120 generates a second air flow 200 within the second zone 100 . As illustrated in FIG. 1 , second duct 130 is in communication with the second zone 100 by one or more second zone inlets 180 and one or more second zone outlets 190 , which can be located in any position with respect to each other. For example, the second zone inlet 180 can be positioned below the second zone outlet 190 or positioned horizontally relative to the second zone outlet 190 . Typically, the second zone inlet 180 , which admits cooled air into the second zone 100 after contact with the second evaporator 110 , is located above the second zone air outlets 190 to assist in the circulation of more dense, colder air.
[0016] Although the first zone 10 is situated generally below the second zone 100 , near the bottom of the refrigerator in FIGS. 1-5 , other arrangements are encompassed by this invention. For example, the first zone 10 can be located above the second zone 100 , between the top and bottom of the second zone 100 , beside the second zone 100 , or otherwise situated anywhere within the second zone 100 . Typically, though not necessarily, the first zone 10 is smaller than the second zone 100 and operates at a lower temperature than the second zone 100 .
[0017] The elements of the refrigeration system are connected in series in a closed loop in a refrigerant flow relationship. In one aspect, the refrigerant flows in a continuous cycle through the expansion valve 300 , through the first evaporator 20 , through the second evaporator 110 , through the compressor 280 , through the condenser 290 , and returns to the expansion valve 300 . In this configuration, air in the first zone 10 passes over the first evaporator 20 and reduces the refrigerant cooling capacity before the refrigerant passes through the second evaporator 110 . Accordingly, the first zone 10 is maintained at a lower temperature than the second zone 100 , as the refrigerant continuously flows through the refrigeration system.
[0018] Although one type of evaporator is shown in the Figures provided herewith, this invention is not limited to a particular type of evaporator or heat exchanger. Rather, the present invention encompasses any type of evaporator or heat exchanger known in the art. For example, an evaporator with tubes or coils in any configuration, and an evaporator with fins, plates, or similar devices attached thereto for improved heat exchange performance, and similar devices, are all encompassed by this invention. In addition, this invention also encompasses any type of compressor, condenser, and expansion device known in the art.
[0019] The volume of the first evaporator 20 can be smaller than the volume of the second evaporator 110 . The internal volume of the first evaporator 20 can be decreased in several ways, for example, by decreasing the internal diameter of the evaporator coils, shortening the evaporator coils, decreasing the number of evaporator coils, or any combination thereof. Similarly, the internal volume of the second evaporator 110 can be increased in several ways, for example, by increasing the internal diameter of the evaporator coils, lengthening the evaporator coils, increasing the number of evaporator coils, or any combination thereof. For example, the first evaporator 20 can comprise coils with a smaller internal diameter than the internal diameter of the coils of the second evaporator 110 . Further, the coils of the first evaporator 20 can have an internal diameter that is about 10% to about 100% of the internal diameter of the coils of the second evaporator 110 . For example, the second evaporator 110 can comprise coils with an internal diameter of about ⅜ inch, while the first evaporator 20 can comprise coils with an internal diameter of about 3/16 inch. Here, the refrigerant would expand as it proceeded from the first evaporator 20 to the second evaporator 110 . Alternatively, the first and second evaporators can be separated by a second expansion valve through which the refrigerant further expands as it enters the first evaporator 20 .
[0020] In FIG. 1 , the first zone 10 is located below the second zone 100 and a thermally conductive wall 90 separates the two zones. The wall 90 can be formed from any material that allows the first zone 10 to be in thermal communication with the second zone 100 . The wall 90 maintains the first air flow 80 substantially independent from the second air flow 200 . In one aspect, the wall 90 is formed from metal, plastic, or glass. Typically, the wall 90 is not insulated, but could be insulated to reduce the thermal communication between the first and second zones. In other arrangements, the second zone 100 could share more than one thermally conductive common wall 90 with the first zone 10 .
[0021] If desired, small gaps can be included between the rear or side walls of the refrigerator 5 and the thermally conductive wall 90 to allow air from the first and second zones to mix to a limited extent. Further, when the first zone 10 comprises one or more compartments or drawers, the first air flow 80 and the second air flow 200 generally mix during the time that the user opens the compartments or drawers. Generally, the first air flow 80 remains substantially independent from the second air flow 200 . Alternatively, the thermally conductive wall 90 can be sealed to maintain the first air flow 80 independent from the second air flow 200 when the compartments or drawers in the first zone 10 are closed.
[0022] Referring now to FIG. 2 , a front sectional view of a refrigerator 5 is shown with both the first and second evaporators or heat exchangers concealed. The evaporators or heat exchangers can be located in any position in the respective zone, as long as the first evaporator is in air flow communication with the first zone 10 and the second evaporator in air flow communication with the second zone 100 . The first evaporator can be located, for example, behind the second zone rear wall 170 , or optionally, behind the first zone rear wall (not shown). The first evaporator is in air flow communication with the first zone 10 by one or more first zone outlets (not shown) and one or more first zone inlets (not shown). The first zone inlets and outlets can be located in any position relative to each other for effective cooling of the first zone 10 . The second evaporator can also be located behind the second zone rear wall 170 . The second evaporator is in air flow communication with the second zone 100 by one or more second zone outlets 190 and one or more second zone inlets (not shown). The second zone inlets and outlets can be located in any position relative to each other for effective cooling of the second zone 100 . In FIG. 2 , the first zone 10 is located below the second zone 100 and the two zones are separated by a thermally conductive wall 90 .
[0023] As shown in FIG. 2 , the first zone 10 can comprise a drawer 210 that abuts or is otherwise proximate the thermally conductive wall 90 . Although only one drawer is shown in FIG. 2 , the first zone 10 can comprise multiple drawers or compartments. The first zone 10 further comprises one or more ducts for channeling air flow within the first zone 10 . For example, the first zone 10 can comprise a left duct 140 , a center duct 150 , and a right duct 160 , any combination of which can be used to circulate air through the first zone 10 . The air handling functions are separated into one or more ducts, which can function as air receiving ducts and air distributing ducts. Any of the ducts can encompass or otherwise house or conceal the first evaporator (not shown). The one or more ducts can comprise one or more inlets and outlets (not shown) for air flow communication with the first zone 10 . Further, the one or more ducts can include ribs (not shown) for channeling the air in a particular desired direction, depending on the duct and evaporator arrangement.
[0024] The drawer 210 optionally has one or more openings (not shown) that correspond to inlets or outlets (not shown) in the receiving ducts or distributing ducts, for allowing air to circulate through the drawer 210 . The first zone 10 further can comprise a dial 220 or other operating means to enable a user to open or close the openings in the drawer 210 . The dial 220 can also be used in conjunction with blocking features to reduce the size of the openings in the drawer 210 . When the openings are closed, air circulates around the drawer 210 , but generally not over the thermally conductive wall 90 . When the dial is operated to open the openings in the drawer 210 , the second zone air circulates through the drawer, directly using the air flow to cool the contents of the drawer. Thus, the user can choose between two modes of operation for cooling the first zone 10 . In either mode of operation, the second air flow is maintained substantially independent from the first air flow by the thermally conductive wall 90 .
[0025] FIG. 3 is a front sectional view of the refrigerator 5 illustrated in FIG. 2 with the thermally conductive wall 90 and drawer 210 removed. Removal of the drawer 210 and wall 90 reveals the left duct 140 , right duct 160 , first zone rear wall 50 , and drawer supports 240 . As shown in FIG. 3 , the left duct 140 , center duct 150 , and right duct 160 are not concealed behind the refrigerator walls. However, the ducts optionally can be located behind any refrigerator wall, such as the first zone rear wall 50 or the second zone rear wall 170 , in front of the refrigerator walls, or any combination thereof. Additionally, any number of ducts can be included in the first zone 10 and can be arranged in any fashion.
[0026] In one aspect, the thermally conductive wall 90 rests on ledge 230 , the left duct 140 , and the right duct 160 . However, the wall 90 can be positioned in the refrigerator in any conventional manner. As illustrated in FIG. 3 , the ledge 230 is part of the center duct 150 with the thermally conductive wall 90 abutting the center duct 150 instead of the second zone rear wall 170 . The center duct 150 and ledge 230 allow air flow from the first zone 10 into the center duct 150 through the one or more duct apertures 250 in the center duct 150 and ledge 230 . In FIG. 3 , portions of the center duct 150 are removed to reveal the first evaporator fan 30 . The first evaporator fan 30 draws air from the first zone 10 through duct aperture 250 and over the first evaporator 20 (see FIG. 4 ). Although the first evaporator fan is shown in the center duct in FIG. 3 , the first evaporator fan can be located in any of the ducts for generation of air flow in the first zone.
[0027] Referring now to FIG. 4 , the refrigerator 5 from FIG. 3 is illustrated with the left duct 140 , center duct 150 , right duct 160 , drawer supports 240 , and ledge 230 removed. Removal of the center duct 150 exposes the first zone outlet 70 and the first evaporator outlet 260 . Portions of the first evaporator 20 are visible through the first zone outlet 70 and the first evaporator outlet 260 . The first evaporator 20 is encompassed by a first evaporator duct 270 , all of which are located behind the second zone rear wall 170 . The first evaporator 20 can be located in any position in the refrigerator with corresponding ducts as long as air flow communication with the first evaporator 20 is maintained.
[0028] The first evaporator fan draws air through duct aperture 250 and into the first evaporator duct 270 through the first zone outlet 70 . The air reenters the center duct 150 via the first evaporator outlet 260 , then enters the first zone 10 through any number of distributing ducts in air flow communication with the center duct 150 and the first zone 10 .
[0029] In FIG. 5 , portions of the second zone rear wall 170 are removed to reveal the first evaporator 20 as encompassed by the first evaporator duct 270 . The first evaporator duct 270 optionally can include means for channeling the air in a desired direction over the first evaporator 20 . For example, a blocking means (not shown) can be installed and can extend upwardly from the bottom of the first evaporator duct 270 to create a substantially U-shaped air flow channel in the first evaporator duct 270 . Thus, air enters the first evaporator duct 270 via the first zone outlet 70 , flows through the U-shaped channel over the first evaporator or heat exchanger 20 , and exits the first evaporator duct 270 via the first evaporator outlet 260 .
[0030] In the configuration of FIG. 6 , first air flow 80 passes through the center duct 150 and right duct 160 . The right duct 160 is in air flow communication with the first zone 10 via the first zone inlet 60 . In one aspect, the first zone inlet 60 is located near the front of the right duct 160 away from the first zone rear wall 50 . Such a configuration directs air from the front right corner of the first zone 10 to the rear left corner of the first zone 10 .
[0031] The first zone typically operates at a temperature from about 4° F. to about 7° F. below the average second zone temperature. To achieve this temperature difference, the second evaporator or heat exchanger typically operates at a temperature from about 15° F. to about 20° F., which can create a second zone temperature from about 38° F. to about 43° F. The first evaporator or heat exchanger typically operates at a temperature from about −5° F. to about −10° F., which can create a first zone temperature from about 31° F. to about 34° F.
[0032] Both the first and the second evaporator coils are cooled by liquid refrigerant ejected from the high pressure side of a compressor, into the corresponding low pressure evaporator coils. The condenser and condenser fans can be located in a variety of places, for example, under the compartment or on the back of the compartment, for removal of the transferred heat by exhaust or condenser fans.
[0033] With respect to the above description, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art. All equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. Further, the various components of the embodiments of the present invention can be interchanged to produce further embodiments and these further embodiments are intended to be encompassed by the present invention. Various modifications can be made to the invention without departing from the scope thereof. Therefore, the foregoing is considered as illustrative only. | A refrigerator is provided with a refrigerated compartment comprising one or more zones in thermal communication with each other and with each zone independently controlled and operated at a particular temperature. Each zone temperature is controlled by a separate evaporator or heat exchanger. A method for maintaining different temperatures in one or more zones in thermal communication with one another in a refrigerator is also provided. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a fluid-operable rotary drive clutch.
2. Description of the Prior Art
A rotary drive clutch of this kind is used in machine construction to transmit the rotary movement of an input shaft to an output shaft as needed, the rotary drive clutch naturally being engaged or open, or being slippingly operated in the transitional range.
When the clutch is engaged, in order to transmit the required torque the drive plates concerned must be pressed together under high pressure via a piston/cylinder unit and an associated annular piston.
This function is performed by piston/cylinder units, from which operating fluid is delivered to the front face of the annular piston via a co-rotating pressure chamber. A basic problem with rotary drive clutches of this kind is the presence of sealing surfaces that rotate relative to one other, and that do so at the rotation speed of the input assembly at least when the clutch is engaged.
Hence, the only way to supply the pressure chamber in order to exert pressure on the drive plates is via a rotary leadthrough connected to a conduit system, one subconduit of which rotates at the shaft speed of the clutch and the other subconduit does not, and in which both subconduits are pressure-sealed against the pressure applied by the piston/cylinder unit.
A pressure-tight rotary leadthrough must therefore be provided between the output of the piston/cylinder unit and the conduit system communicating with the additional pressure chamber.
Particularly in the case of large machine installations, for example hydraulic presses used in the automotive industry, high pressures of up to about 100 bars must be sealed off via a leadthrough of this kind to prevent contamination of the environment.
Such a system is very onerous to design and build, however.
SUMMARY OF THE INVENTION
There is, therefore, a need for a fluid-operable rotary drive clutch in which the parts between the rotary drive clutch and the piston/cylinder unit that move in opposite directions as a result of their relative rotation do not require any elaborate hydraulic or pneumatic sealing measures.
It is consequently an object of the present invention to eliminate this disadvantage of the prior art and to specify measures that eliminate the need for elaborate rotary leadthroughs between the piston/cylinder unit and the rotary drive clutch.
The invention provides the advantage that the piston/cylinder unit, in combination with the clutch component that also carries the line connection communicating with the additional pressure chamber, forms a module whose components do not rotate relative to one another.
The piston/cylinder unit is therefore connected co-rotatingly for example to the clutch shaft, and can optionally be journaled in such a way that a rigid system can be assumed with respect to the need for pressure-tightness between the piston/cylinder unit and the clutch.
The piston/cylinder unit, together with the clutch shaft and generally the clutch component at which the delivery opening of the connecting line into the additional pressure chamber is disposed, can therefore be considered a static system in which the required pressure-tightness can be achieved by static measures alone.
These static measures can consist, for example, of pressure-tight flange connections between the clutch shaft and the piston/cylinder unit.
Thus, there is no further need for a leadthrough for the operating fluid.
The piston/cylinder unit is advantageously acted upon by an external force generator. The external force generator comprises a rotor that can be moved in the axial direction of the piston/cylinder unit and an assigned stator. The rotor is provided to be traversable in the axial direction of the piston/cylinder unit, and for purposes of pressure generation the pistons and cylinders are able to displace relative to one another, reducing the size of the fluid space.
Various embodiment examples can be conceived of for this purpose. In a first embodiment example, the rotor is journaled in a rotationally movable manner with respect to the stator. The rotor could then be connected to the piston/cylinder unit in a rotationally fixed manner.
A further embodiment example provides that the rotor and the stator are unable to rotate relative to each other.
For this case, it is proposed that the rotor be coupled to the rotary piston/cylinder unit via an axially acting pivot bearing.
This pivot bearing acting in the axial direction can be, for example, a sliding bearing or a roller bearing.
In a further embodiment example, the external force generator is a linear motor whose rotor is journaled not only axially traversably, but also rotatingly via the piston/cylinder unit.
Since, in linear motors of this kind, a contactless annular gap is provided between the rotor and the stator, this improvement of the invention also makes use of the free rotational movement of the rotor. Such linear motors are, for example, electrically or magnetoelectrically driven and belong to the prior art. Their particular advantage is their ability to be driven via a servo controller, for example in dependence on certain operating parameters.
It is not known, however, to use such magnetoelectric linear motors as co-rotating components in piston/cylinder units for actuating rotary drive.
The considerable pressures, ranging up to approximately 100 bars or more, that can occur in such rotary drive can be reduced in an especially simple manner if the piston/cylinder unit is mounted in a pair of oppositely disposed angular ball bearings.
The mutual positioning of the angular ball bearings, preferably at the outer circumference of the piston/cylinder unit, permits compact construction and, in particular, makes it easier to use standardized components.
The possibility of easily integrating the invention into a so-called clutch/brake combination is of particular advantage.
In such a clutch/brake combination, the annular piston serves both as the clutch actuating ring and as the brake actuating element. Which function is performed depends on the direction of displacement at any given time, although the piston/cylinder unit must be able to rotate only in combination with the rotary drive clutch.
In terms of the braking function, as along as there is no problem of rotary movement, there is no problem of a fluid-tight rotary leadthrough.
Of course, if the brakes are also acted on via a rotary-mounted ring, then all of the above statements apply accordingly.
However, an embodiment is preferred in which the force is applied to the displacing element of the brake by elastically biased springs, which are tensioned against increasing elastic force as pressure is exerted to actuate the clutch.
A clutch/brake combination of this kind operates in two precisely defined end positions: a braking position, in which the clutch is disengaged and the brake is engaged, and a clutch engagement position, in which only the clutch is engaged and the brake is idle.
To reduce wear and tear on the clutch linings, it can additionally be provided to feed cooling oil to the clutch chamber through an also co-rotating conduit system.
Embodiment examples are specified for this purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described more thoroughly hereinbelow with reference to embodiment examples. In the drawing:
FIG. 1 shows a first embodiment example of the invention;
FIG. 2 shows an additional embodiment example of the invention;
FIG. 3 shows an embodiment example of the invention in a clutch/brake combination.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Unless otherwise stated below, the following description applies throughout to all the figures.
The figures depict a rotary drive clutch 1 .
Said rotary drive clutch 1 comprises drive plates 2 . The drive plates 2 are connected in a rotationally fixed manner to the input assembly 3 and in a rotationally fixed manner to the output assembly 4 .
The drive plates 2 are seated, in a minimally axially translatable manner, respectively either on the central clutch shaft 12 or on the component of the clutch facing away from the clutch shaft.
For the present considerations, it makes no difference in principle whether clutch shaft 12 is considered to be the input assembly or the output assembly.
Depending on the foregoing choice, the indicated pulley at whose periphery the force vectors are applied then serves as the output or input assembly 4 or 3 , respectively.
For all individual components of the rotary drive clutch that are individually named but not depicted, see the prior art.
It is essential that the frictional forces that are to be transmitted to the clutch be applied by an annular piston 5 . Here, annular piston 5 is seated on clutch shaft 12 and is axially translatable.
At its end facing away from the drive plate 2 , annular piston 5 has a front face that is impinged on by an operating fluid.
Said operating fluid 11 can be a hydraulic or pneumatic medium.
Said impingement on the front face of annular piston 5 takes place from the pressure chamber 30 of piston/cylinder unit 7 , which is connected via a connecting line 8 to an additional pressure chamber 6 , said connecting line 8 opening into additional pressure chamber 6 via a corresponding opening.
This additional pressure chamber 6 is sealed by the front face of annular piston 5 . Whereas annular piston 5 is seated translatably on clutch shaft 12 and is also sealed via the seals not denoted in greater detail, it is surrounded at its outer periphery by a piston housing that forms the additional enclosing walls of pressure chamber 6 .
When pressure is applied to additional pressure chamber 6 by operating fluid 11 , clutch actuating ring 9 is acted upon such that it is translated axially in the direction of rotary drive clutch 1 . This causes drive plates 2 to come into positive and frictionally locking contact so that the required torques are transmitted.
The embodiment examples show a rotary drive clutch in which the clutch actuating ring, when subjected to pressure, engages the clutch.
However, it is also possible to conceive of a rotary drive clutch that is engaged for example by spring biasing, while the operating fluid, via a suitably arranged additional pressure chamber, causes said rotary drive clutch to disengage.
In this case, the front face of the piston, facing the pressure chamber, would have to point in the direction of the rotary drive clutch 1 , while at the opposite end, annular piston 5 , subjected to elastic force, is displaced into the engaged position of the rotary drive clutch.
It is essential in this case that the operating fluid be conducted via piston/cylinder unit 7 through an axial bore, here provided in clutch shaft 12 , into co-rotating additional pressure chamber 6 .
To this end, the discharge opening of connecting line 8 is constantly connected to additional pressure chamber 6 , while the other end of connecting line 8 is disposed at the outlet of piston/cylinder unit 7 .
So that a pressure-tight connection with no rotary leadthroughs exists between the clutch component from which connecting line 8 opens into additional pressure chamber 6 —i.e., in the present case clutch shaft 12 —and piston/cylinder unit 7 , piston/cylinder unit 7 is connected to clutch shaft 12 in a rotationally fixed, pressure-resistant and co-rotatable manner.
This means, however, that piston/cylinder unit 7 rotates with clutch shaft 12 as soon as the clutch is in the slipping state or the disengaged state.
The tight connection between piston/cylinder unit 7 and clutch shaft 12 can therefore consist of an easily made flange connection, sealed with O-ring seals if appropriate.
The figures further illustrate different ways of acting on the piston/cylinder unit.
An external force generator 13 is, however, provided in all cases. The external force generator 13 comprises a rotor 14 able to move in the axial direction of piston/cylinder unit 7 and an assigned stator 15 . Between the stator and the rotor, according to the principle of action and reaction a force is transmitted to the piston/cylinder unit 7 that ultimately causes a relative displacement of the piston and the cylinder, so that the pressure chamber of piston/cylinder unit 7 , when a force is applied, is correspondingly reduced in size to actuate rotary drive clutch 1 .
FIGS. 1 , 3 and 2 additionally disclose different principles.
In the case of FIGS. 1 and 3 , external force generator 13 comprises a rotor 14 that is rotationally movably mounted opposite the stator 15 .
Rotor 14 is additionally traversable in the axial direction of piston/cylinder unit 7 . FIG. 2 , by contrast, shows an improvement in which piston/cylinder unit 7 is acted on by the rotor 14 of an external force generator 13 , which rotor 14 , although traversable in the axial direction of piston/cylinder unit 7 , is not seated in a rotary bearing.
To this end, provided between rotor 14 and piston/cylinder unit 7 is an axial-force pivot bearing 16 that eliminates the relative movement between the rotary piston/cylinder unit 7 and external force generator 13 .
This can be a sliding bearing or, preferably, a roller bearing.
The figures additionally show an external force generator 13 in the form of a linear motor 17 .
This arrangement is a direct drive, in which the linear motion is generated in a wear-free manner without the interposition of mechanical gearing. The unique feature is that the linear motor is composed of only two parts: the rotor 14 and the stator 15 .
Furthermore, in addition to the motor windings, any necessary bearings for the rotor, for the position detector and for any microprocessor circuit that may be present can be accommodated in the housing of the linear motor, which is stationarily disposed.
The advantage of a linear motor with an electrically or magnetoelectrically driven rotor is absolute freedom from wear.
Between the rotor 14 and the stator 15 is an annular air gap 28 that must, of course, be provided in order to prevent short circuits.
The embodiment of FIGS. 1 and 3 makes use of this annular air gap, which ensures that the rotor 14 is able to rotate freely in the stator 15 in any axial position.
As a complement hereto, FIG. 3 shows an improvement in which the linear motor 17 is driven via a servo controller 27 .
Servo controller 27 can, moreover, be a component of a closed control circuit in which predefined operating parameters or predefined time functions for pressure buildup, etc., are controlled.
In the present case, servo controller 27 is driven via a pressure sensor disposed in additional pressure chamber 6 , in order to displace clutch actuating ring 9 according to a preset time function.
It is understood that any other useful operating parameters can be used as input variables for the servo controller, for example the temperature of the friction linings, the play of the clutch, the wear of the clutch, etc.
In addition, FIG. 3 shows that piston/cylinder unit 7 is mounted axially immovably on a pair of oppositely disposed angular ball bearings 18 .
The advantage of this improvement is that even in the event of high pressures of up to 100 bars or more, all of the axial forces acting on piston/cylinder unit 7 are removed by the stationary housing.
Furthermore, FIG. 3 shows an embodiment example in which clutch actuating ring 9 is also acted on translatably in its axial direction of movement opposite the action of the pressure by a counteracting force generator 20 . In this case, the counteracting force generator 20 is formed by spring coils that act on the clutch side of clutch actuating ring 19 and endeavor to displace it in the direction of additional pressure chamber 6 .
These elastically biased springs are therefore tensioned against increasing resilient force as the pressure applied by annular piston 5 increases during the operation of the clutch.
Obviously, as the volume of the piston/cylinder unit is increased by the displacement of the piston in the direction of external force generator 13 , the operating fluid 11 exits additional pressure chamber 6 to the extent dictated by the displacement of piston/cylinder unit 7 .
Clutch actuating ring 9 is thereby displaced on the clutch shaft in the direction of a brake 19 disposed opposite rotary drive clutch 1 , so that after rotary drive clutch 1 is disengaged, the still-rotating clutch shaft 12 subsequently comes to a stop.
The present invention therefore is not limited to the use of rotary drive clutch 1 alone, but also lends itself to use in connection with brakes.
One can also contemplate actuating the brake, not with spring coils, but by means of a fluid-operated—i.e., pneumatically or hydraulically operated—counteracting force generator, which according to the present invention is also connected co-rotatingly to the clutch shaft 12 .
Thus far, the foregoing description applies.
If, as illustrated in particular by FIG. 3 , the piston/cylinder unit 7 is journaled rotatably in a stationary and self-contained housing 21 , additional communicating conduits can be provided that are connected communicatingly in the form of a co-rotating conduit system 22 to the clutch chamber and/or to the brake chamber 24 , if present.
It is essential in this case that the sealed chamber between closed housing 21 and piston/cylinder unit 7 be connected to co-rotating conduit system 22 .
This can be effected, for example, by means of an annular feed line 25 , which is connected to the sealed chamber between stationary housing 21 and piston/cylinder unit 7 , regardless of the rotational position of piston/cylinder unit 7 .
One option in particular in this case is to connect this co-rotating conduit system 22 via annular feed line 25 to a non-co-rotating cooling oil tank 26 in order to better dissipate the heat generated during the braking or clutching process and to reduce or minimize lining wear.
LIST OF REFERENCE NUMERALS
1 Rotary drive clutch
2 Drive plate
3 Input assembly
4 Output assembly
5 Annular piston
6 Additional pressure chamber
7 Piston/cylinder unit
8 Connecting line
9 Clutch actuating ring
10 Front face of piston, facing the additional pressure chamber
11 Operating fluid
12 Clutch shaft
13 External force generator
14 Rotor
15 Stator
16 Axial-force rotating bearing
17 Linear motor
18 Angular ball bearing
19 Brake
20 Counteracting force generator
21 Stationary housing
22 Co-rotating conduit system
23 Clutch chamber
24 Brake chamber
25 Annular feed line
26 Cooling oil tank
27 Servo controller
28 Air gap
30 Pressure chamber of piston/cylinder unit | The present invention concerns a rotary drive clutch that is fluid-operable by a piston/cylinder unit rigidly coupled to a clutch shaft and bearing-mounted so as to rotate therewith. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a nut disengagement prevention structure, and more particularly to a nut disengagement prevention structure of the type in which a nut, once threaded onto a bolt, is held against withdrawal unless an artificial external force is exerted on the nut.
For example, for connecting a battery cord 3 to an electrode 2 of a battery 1 mounted on an automobile, an annular connection portion 4 a of a battery terminal 4 , press-fastened to a distal end of the battery cord 3 , is fitted on the electrode 2 , and then a bolt 5 is passed through passage holes 4 c , formed respectively through a pair of clamping piece portions 4 b and 4 b , and is tightened to be fastened, together with a washer 6 , to a nut 7 . As a result, the annular connection portion 4 a is deformed to be reduced in diameter through the pair of clamping piece portions 4 b and 4 b , so that the battery terminal 4 is fixedly secured to the electrode 2 .
For effecting the above operation in the vehicle-assembling process, the bolt 5 , passed through the passage holes 4 c , is beforehand loosely tightened relative to the nut 7 . Namely, the battery terminal 4 , having the bolt 5 and the nut 7 beforehand connected thereto in an integrated manner, is fed to a production line where the nut and the bolt are finally completely fastened together.
In such form of use, however, the nut 7 is often disengaged from the bolt 5 by vibrations, an impact and the like during the transport of the battery terminal 4 , and the nut 7 need to be again attached to the bolt, and in some cases the nut is lost.
Therefore, there has been proposed a nut disengagement prevention structure (disclosed, for example, in JP-A-10-61647) for preventing the disengagement of a nut from a bolt, in which an E-ring or a retaining cap is fitted on a distal end of the bolt, or an internal thread portion is formed in the distal end of the bolt, and a small screw, having a head larger in diameter than a thread ridge, is threaded into this internal thread portion, or an enlarged-diameter portion is formed at the distal end of the bolt by an expanding slot or a stamped section.
Another nut disengagement prevention structure is provided by coating, for example, a coating material, an adhesive or the like onto the distal end of the bolt.
In the above nut disengagement prevention structures, however, the pre-processing step for the bolt or the post-processing step, such as the operation for attaching the retaining member to the bolt after the bolt is threaded into the nut, the diameter-enlarging operation, or the coating operation, is added, and therefore there were encountered problems that the mounting operation is troublesome, and required much time and labor, and that the production cost increased because of the increased number of the component parts.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a nut disengagement prevention structure and a battery terminal incorporating the same, in which the disengagement of a nut can be easily prevented with the simple structure.
In order to achieve the above object, according to the present invention, there is provided a nut disengagement prevention structure comprising:
a bolt, having an external thread; and
a nut, thread on the bolt, having an internal thread;
wherein the thread portion which is the closest to a leading end of the bolt has a first minor diameter;
wherein any other portion of the thread of the bolt has a second minor diameter which is smaller than the first minor diameter; and
wherein the second minor diameter is substantially identical with a minor diameter of the internal thread of the nut.
In this construction, when the bolt is tightened relative to the nut with a turning torque of above a predetermined value, the nut is threaded toward a proximal end of the bolt, while an internal thread of the nut and the thread portion which is the closest to a leading end of the bolt, engaged with each other, are resiliently deformed.
The second minor diameter of the any other portion of the thread of the bolt is substantially identical with the minor diameter of the internal thread of the nut, and therefore an ordinary tightening operation can be effected.
Therefore, the nut, once threaded onto the proximal end of the bolt, is held against withdrawal from the bolt unless a turning torque of above a predetermined value is artificially exerted on the nut.
According to the present invention, there is also provided a nut disengagement prevention structure comprising:
a bolt, having an external thread; and
a nut, thread on the bolt, having an internal thread;
wherein the thread portion which is the closest to a leading end of the bolt has a first major diameter;
wherein any other portion of the thread of the bolt has a second major diameter which is smaller than the first major diameter; and
wherein the second major diameter is substantially identical with a major diameter of the internal thread of the nut.
In this construction, when the bolt is tightened relative to the nut with a turning torque of above a predetermined value, the nut is threaded toward a proximal end of the bolt, while an internal thread of the nut and the thread portion which is the closest to a leading end of the bolt, engaged with each other, are resiliently deformed.
The second major diameter of the any other portion of the thread of the bolt is substantially identical with the major diameter of the internal thread of the nut, and therefore an ordinary tightening operation can be effected.
Therefore, the nut, once threaded onto the proximal end of the thread portion of the bolt, is held against withdrawal from the bolt unless a turning torque of above a predetermined value is artificially exerted on the nut.
According to the present invention, there is also provided a nut disengagement prevention structure comprising:
a bolt, having an external thread; and
a nut, thread on the bolt, having an internal thread;
wherein adjacent thread portions which are closest to a leading end of the bolt are provided with a first pitch;
wherein each of any other adjacent thread portions of the bolt are provided with a second pitch which is different from the first pitch; and
wherein the second pitch is substantially identical with a pitch of each adjacent thread portions of the nut.
In this construction, when the bolt is tightened relative to the nut with a turning torque of above a predetermined value, the nut is threaded toward a proximal end of the bolt while an internal thread of the nut and the thread portion which is the closest to the leading end of the bolt, engaged with each other, are resiliently deformed.
The second pitch each of the any other adjacent thread portions of the bolt is substantially identical with the pitch of each adjacent thread portions of the nut, and therefore an ordinary tightening operation can be effected.
Therefore, the nut, once threaded onto the proximal end of the thread portion of the bolt, is held against withdrawal from the bolt unless a turning torque of above a predetermined value is artificially exerted on the nut.
Namely, in the bolt having the above nut disengagement prevention structures, only the thread portion which is the closest to the leading end of the bolt need to be formed into a thread configuration slightly different from the specification dimension during an ordinary bolt-producing process, and any special pre-processing step, such as the formation of an expanding slot or a stamped portion at the distal end of the bolt, and any post-processing step, such as the mounting of a retaining member, as used in the related technique, are not necessary, and the number of the component parts will not increase.
Therefore, there can be provided the inexpensive nut disengagement prevention structure in which the disengagement of the nut can be easily prevented with the simple structure.
According to the present invention, there is also provided a battery terminal comprising:
a connection member, fitted with a battery post of a battery;
a pair of clamping portions, extended respectively from both ends of the connecting portion;
a bolt, having an external thread; and
a nut, thread on the bolt, having an internal thread;
wherein the thread portion which is the closest to a leading end of the bolt has a first minor diameter;
wherein any other portion of the thread of the bolt has a second minor diameter which is smaller than the first minor diameter; and
wherein the second minor diameter is substantially identical with a minor diameter of the internal thread of the nut.
According to the present invention, there is also provided a battery terminal comprising:
a connection member, fitted with a battery post of a battery;
a pair of clamping portions, extended respectively from both ends of the connecting portion;
a bolt, having an external thread; and
a nut, thread on the bolt, having an internal thread;
wherein the thread portion which is the closest to a leading end of the bolt has a first major diameter;
wherein any other portion of the thread of the bolt has a second major diameter which is smaller than the first major diameter; and
wherein the second major diameter is substantially identical with a major diameter of the internal thread of the nut.
According to the present invention, there is also provided a battery terminal comprising:
a connection member, fitted with a battery post of a battery;
a pair of clamping portions, extended respectively from both ends of the connecting portion;
a bolt, having an external thread; and
a nut, thread on the bolt, having an internal thread;
wherein adjacent thread portions which are closest to a leading end of the bolt are provided with a first pitch;
wherein each of any other adjacent thread portions of the bolt are provided with a second pitch which is different from the first pitch; and
wherein the second pitch is substantially identical with a pitch of each adjacent thread portions of the nut.
In the constructions, the bolt and the nut, beforehand connected to the battery terminal in an integrated manner, will not be disengaged from each other by vibrations, an impact or the like during the transport before this battery terminal is fed to a production line where the nut and the bolt are finally completely fastened together.
Therefore, the battery terminal, incorporated with the bolt and the nut connected thereto in an integrated manner, can be positively stored as one part, and the cost for the parts management can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein:
FIG. 1 is an enlarged, cross-sectional view showing an important portion of one preferred embodiment of a nut disengagement prevention structure of the present invention; and
FIG. 2 is a perspective view showing the structure of mounting a battery terminal on an electrode of a battery.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One preferred embodiment of a nut disengagement prevention structure according to the present invention will now be described bellow in detail with reference to the accompanying drawings.
Dimensions of a bolt 10 of this embodiment are so determined that a root diameter (minor diameter) d 1 of an external thread 10 a at a distal end of a thread portion of the bolt 10 is larger than a root diameter d 2 of an external thread 10 b at a proximal-side portion (left side portion in FIG. 1) of the thread portion of the bolt, as shown in FIG. 1 .
A nut 12 for being threaded on the bolt 10 has an internal thread 12 a having an inner diameter D 2 corresponding to the root diameter d 2 of the external thread 10 b at the proximal-side portion of the thread portion of the bolt 10 .
The root diameter d 1 of the external thread 10 a at the distal end of the thread portion of the bolt 10 is larger than the inner diameter D 2 of the internal thread 12 a of the nut 12 for being threaded on the bolt 10 , and the external thread 10 a is formed into such a slightly-different thread configuration as to provide a tighter threaded engagement as compared with the root diameter d 2 (which is the proper specification dimension) of the external thread 10 b (at the proximal-side portion of the thread portion) corresponding to the internal thread 12 a of the nut 12 .
Namely, when the bolt 10 is tightened relative to the nut 12 with a turning torque of above a predetermined value, the nut 12 is threaded toward the proximal-side portion of the thread portion of the bolt 10 while the crest of the internal thread 12 a is resiliently deformed at a root R of the external thread 10 a at the distal end of the thread portion of the bolt. Then, when the internal thread 12 a of the nut 12 reaches the external thread 10 b at the proximal-side portion of the thread portion of the bolt 10 , the threaded condition of the nut 12 and bolt 10 becomes normal.
Therefore, the nut 12 , once threaded onto the proximal-side portion of the thread portion of the bolt 10 , is held against withdrawal from the bolt 10 unless a turning torque of above the predetermined value is artificially exerted on the nut 12 .
Therefore, for example, in the case of the battery terminal 4 (shown in FIG. 2) in which the nut is beforehand loosely tightened relative to the bolt, if a battery terminal, having the bolt 10 and the nut 12 connected thereto in an integrated manner, is used instead of using the related bolt 5 and nut 7 , the nut 12 will not be disengaged from the bolt 10 by vibrations, an impact or the like during the transport, and the nut 12 does not need to be again attached to the bolt, or will not be lost.
Therefore, the battery terminal, having the bolt 10 and the nut 12 connected thereto in an integrated manner, can be positively stored as one part, and the cost for the parts management can be reduced.
The root diameter d 2 of the external thread 10 b at the proximal-side portion of the thread portion of the bolt 10 is the specification dimension corresponding to the inner diameter D 2 of the internal thread 12 a of the nut 12 . For example, in the case where the battery terminal, having the bolt 10 and the nut 12 beforehand connected thereto in an integrated manner as described above, is fed to the production line, and is finally completely fastened to the electrode, this fastening operation can be carried out totally in the same manner as the ordinary fastening operation.
In the bolt 10 having the structure for preventing the disengagement of the nut 12 , it is merely necessary to produce this bolt 10 during an ordinary production process in such a manner that only the root diameter d 1 of the external thread 10 a at the distal end of the thread portion is slightly longer than the root diameter d 2 (which is the specification dimension) of the external thread 10 b at the proximal-side portion of the thread portion, and any special pre-processing step, such as the formation of an expanding slot or a stamped portion at the distal end of the bolt, and any post-processing step, such as the mounting of a retaining member, as used in the conventional technique, are not necessary, and the number of the component parts will not increase.
Therefore, the production cost will not increase, and the disengagement of the nut can be easily prevented with the simple structure.
In the above embodiment, the root diameter d 1 of the external thread 10 a at the distal end of the thread portion of the bolt 10 is larger than the root diameter d 2 (which is the proper specification dimension) of the external thread 10 b at the proximal-side portion of the thread portion, and with this construction, the external thread 10 a is formed into such a slightly-different thread configuration as to provide a tighter threaded engagement relative to the inner diameter D 2 of the internal thread 12 a of the nut 12 . However, the nut disengagement prevention structure of this invention is not limited to this embodiment, and within the scope of the invention, the distal end of the thread portion of the bolt can be formed into any other suitable, slightly-different thread configuration which can provide a tighter threaded engagement relative to the internal thread of the nut.
In FIG. 1, for example, the outer diameter d 4 of the external thread 10 a at the distal end of the thread portion of the bolt 10 may be made larger than the outer diameter d 3 (the proper specification dimension) of the external thread 10 b at the proximal-side portion of the thread portion, or the pitch P 1 of the external thread 10 a at the distal end of the thread portion of the bolt 10 may be made larger or smaller than the pitch P 2 (the proper specification dimension) of the external thread 10 b at the proximal-side portion of the thread portion, and by doing so, the distal end of the thread portion of the bolt 10 can be formed into such various slightly-different thread configurations as to provide the tighter threaded engagement relative to the internal thread 12 a of the nut 12 .
The nut disengagement prevention structure of the present invention is not limited to the bolt-nut assembly for the above battery terminal, but can be applied to any other suitable bolt-nut assembly in so far as the nut can be beforehand provisionally mounted on the bolt. | In a nut disengagement prevention structure, a bolt has an external thread. A nut which is thread on the bolt has an internal thread. A thread portion which is the closest to a leading end of the bolt has a first minor diameter. Any other portion of the thread of the bolt has a second minor diameter which is smaller than the first minor diameter. The second minor diameter is substantially identical with a minor diameter of the internal thread of the nut. | 8 |
TECHNICAL FIELD
The present invention relates generally to sealing systems for hydrocarbon-producing wells and specifically to a spillproof sealing system for an oil well.
BACKGROUND ART
The extraction of liquid and gas hydrocarbons from subterranean deposits is performed by well drilling and pumping apparatus that has not changed substantially over the years. This apparatus usually includes a well casing and a well tubing that extends down inside the casing to a point below the normal level of oil in the casing. A reciprocating motor driven pump is usually provided inside the tubing. The pump has a plunger which is connected to a string of sucker rods that extends up through the tubing to connect with a polished rod which extends out of the ground and is attached to conventional oil well pumping structure such as a horse head walking beam and counterweights. The action of the reciprocating pump and the horse head walking beam cause the sucker rods and polished rod to lift a column of oil from a subterranean pool or deposit at the bottom of the well casing to the surface. A stuffing box or similar structure is typically located around the polished rod and contains packing or sealing material to prevent oil from being pumped out of the well casing and into the surrounding environment as the polished rod and sucker rods reciprocate to pump oil out of the well. Hydrocarbon-producing wells also include some type of delivery pipe or production line through which crude oil and well gas can be pumped to storage tanks.
The stuffing box or like structure that surrounds the polished rod usually contains one or more packing glands or sealing elements. The packing glands perform a sealing function and prevent oil from leaking out of the well around the polished rod. The packing glands and sealing materials available for this purpose are not indestructible and eventually are worn by chemical or physical contaminants, such as sand, and by the constant reciprocating motion of the polished rod. As a result, these structures will ultimately fail unless they are replaced first.
If a packing gland or sealing element fails, crude oil from the well may simply leak or spill around the polished rod or it may be forcibly blown out of the well. If an oil leak around the polished rod is not stopped promptly, the amount of leaking oil will quickly increase with the reciprocating action of the polished rod, especially if the polished rod is worn. As the leakage increases, the likelihood of damage to the polished rod and its associated structures also increases. Additionally, pumping action may also be affected, with the result that the effectiveness of the well in bringing oil to the surface is greatly decreased. If the leaking oil forcibly blows out of the well, damage to the surrounding environment could result.
In many oil fields the wells are spaced far apart over a large area and are not inspected frequently. Consequently, a failure of the polished rod sealing structures on one of these wells may not be discovered and corrected for some time after the leak actually occurred. If the sealing structures have failed to the point where oil is blown out of well, moreover, serious environmental damage could occur before it is discovered. Many jurisdictions impose heavy fines on oil well operators when the atmosphere, ground and/or water supply are polluted by hydrocarbon-producing well contaminants. Consequently, manual oil well inspections must be conducted at relatively short intervals to detect leaks as soon as possible after they begin.
Oil from the well may be used to lubricate the polished rod as it reciprocates axially upward and downward through the stuffing box and packing or sealing materials during well operation. If the flow of oil to the polished rod stops while the pump mechanism driving the polished rod is still operating, the polished rod will not be sufficiently lubricated. Unless the pump is stopped immediately, the polished rod and surrounding packing materials will be seriously damaged and require replacement. When oil wells are located far apart over a large area, the manual inspections typically performed by a single operator may not detect an oil flow stoppage early enough to prevent the substantial damage to the polished rod or associated structures which occurs when the well operates with too little or no lubrication of the polished rod.
The prior art has proposed various solutions to the aforementioned problems. U.S. Pat. No. 3,967,678 to Blackwell, for example, discloses a stuffing box control system for sensing the leakage of oil past the polished rod seals. In the event a leak is detected, it is corrected by adjusting the seals with a pressurized piston system. A pressure switching box including switches actuated by the hydrostatic head of the well fluid in a chamber separate from the polished rod and sealing structure is provided to control oil flow conditions in the stuffing box. However, the system described in this patent still requires an operator to monitor the piston system and correct any problems manually.
In U.S. Pat. No. 3,580,586 Burns discloses an inflatable packing glad to prevent the leakage of crude oil around the well polished rod which automatically maintains a predetermined optimum pressure of a packing member against the polished rod. This pressure, which may be amplified by well pressure, is exerted on the outer periphery of the packing member so that wear on the inner peripheral portion of the packing member in contact with the polished rod will not result in oil leaking around the polished rod. While this system does minimize the leakage of crude oil around the polished rod by maintaining a seal when the packing member is worn, it also has its limitations. In particular, adequate lubrication of the polished rod may not always be maintained.
U.S. Pat. No. 4,917,190 to Coppedge and U.S. Pat. No. 2,674,474 to Lister disclose, respectively, a system for containing an oil well blowout in the event of a failure of the packing gland and a system for maintaining a supply of lubrication fluid for the polished rod if the flow of oil from the well stops while the pump is still operating. The Coppedge system, however, still relies on manual inspection to ensure that it is functioning properly. The Lister system is limited to supplying lubricant to the polished rod and does not address the problem of oil leakage around the polished rod.
The prior art, therefore, has failed to disclose a sealing system for a hydrocarbon-producing well which simultaneously prevents the leakage of crude oil around the polished rod while providing sufficient oil to lubricate the polished rod during well operation. The prior art has further failed to provide a sealing system for a hydrocarbon-producing well which employs gas from the well casing to perform the primary sealing function.
SUMMARY OF THE INVENTION
It is a primary object of the present invention, therefore, to provide a hydrocarbon-producing well sealing system which overcomes the disadvantages of the prior art and effectively seals the well against crude oil leakage while providing adequate lubrication to the polished rod.
It is another object of the present invention to provide an oil well sealing system that prevents the spillage of crude oil and contamination of the environment surrounding the well.
It is yet another object of the present invention to provide a sealing system for an oil well that provides a controlled leakage of oil to lubricate and cool the well polished rod.
It is still another object of the present invention to provide a sealing system for a hydrocarbon-producing well which employs well gas to perform the primary well sealing function.
It is a further object of the present invention to provide a sealing system for an oil well which uses well gas to seal the well against oil spills and then recovers this well gas for subsequent reuse.
It is yet a further object of the present invention to provide a sealing system for an oil well which substantially increases the production of the well.
The aforesaid objects are accomplished by providing a sealing system for a hydrocarbon-producing well that prevents the leakage of crude oil and contamination of the environment surrounding the well. The oil well sealing system of the present invention includes a liquid sealing element and a cooperating gas sealing component positioned around the polished rod. The liquid sealing element is attached to the well tubing and includes a plurality of liquid seals configured to allow a desired quantity of crude oil to leak past the seals to the polished rod to lubricate and cool the polished rod. The liquid sealing element also centers the polished rod within the well tubing. The gas sealing component is preferably removably secured to the liquid sealing element by a sealing adapter. A plurality of gas seals is provided at the uppermost end of the gas sealing component and is covered by a protective seal. The gas sealing component includes a liquid/gas separation chamber which receives the well gas required to perform the gas sealing function and which discharges excess well gas and crude oil into the well production line. A compressor is provided to pump gas from the well casing to the gas sealing component liquid/gas separation chamber. A liquid level sensor and automatically actuated switch cooperate to shut down the pump motor in the event the liquid level rises above safe limits.
Additional objects and advantages of the present invention will be apparent from the following description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a portion of a hydrocarbon-producing well pumping apparatus including the sealing system of the present invention;
FIG. 2 is a cross-sectional view of the hydrocarbon-producing well sealing system of the present invention;
FIG. 3 is a side cross-sectional view of the gas sealing component of the hydrocarbon-producing well sealing system of the present invention; and
FIG. 4 is a side cross-sectional view of the gas sealing component of the hydrocarbon well sealing system of FIG. 3, viewed from a different side.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The leakage and spillage of liquids, particularly crude oil, from hydrocarbon-producing wells can pose both environmental and equipment operation problems. The leakage of a sufficient amount of crude oil can easily contaminate the environment surrounding the well and have adverse effects on plant and animal life. If the well is near a populated area, leaked crude oil, especially crude oil under pressure, could be sprayed over a wide area, causing atmospheric and ground pollution and property damage which must be cleaned up and repaired. The leakage of even small quantities of oil into the ground could contaminate ground water and possibly drinking water supplies. If a leak is found right after it has started, the repair of the well sealing structures can usually be accomplished relatively quickly and any environmental contamination by crude oil minimized. However, because many oil wells are widely scattered in remote locations and are operated and monitored by a single operator, the operator does not always get to a well soon enough to avert major problems.
The present invention provides a sealing system for a hydrocarbon well which prevents the leakage and spillage of hydrocarbon liquid, in particular crude oil. Moreover, this system functions substantially automatically to return otherwise contaminating hydrocarbon liquid or crude oil to the well production line. Consequently, the present sealing system is especially well suited for use in oil fields where constant operator attention is not available.
The term "hydrocarbon-producing well" as used herein is used to refer to a well that produces both hydrocarbon liquids, namely crude oil, and the hydrocarbon gases that are typically found in such wells. The term "oil well" is used interchangeably with "hydrocarbon-producing well" to mean the same thing.
Referring to the drawings, FIG. 1 illustrates a portion of a hydrocarbon-producing well pumping apparatus that includes the sealing system of the present invention. The upper end 10 of the well polished rod 12 is shown extending from the sealing system 14, which will be described in detail hereinbelow. The sealing system 14 is positioned above the well tubing 16, which extends downwardly into the ground in a well casing (not shown) to a hydrocarbon deposit which contains crude oil. Various conduits, 18, 20 and 22 for example, and valves, 24, 26 and 28 for example, are provided to permit the flow of well fluids from the well to storage tanks or other storage facilities.
FIG. 2 illustrates the sealing system 14 of the present invention in cross-section. The present sealing system has two primary components. The first component is a liquid sealing element 30 of the kind conventionally used to seal a polished rod against the leakage of crude oil from the well. Liquid sealing element 30 preferably includes several sealing rings 32 around the polished rod 12. The sealing rings 32 are held in place around the polished rod by a sleeve 34. A seal 36 is used only when the well is stopped for maintenance. The sealing rings 32 are configured to permit a controlled amount of oil to leak past the polished rod 12 to lubricate the polished rod as it reciprocates axially within the well. Many available polished rod sealing systems are sealed only by a sealing arrangement similar to liquid sealing element 30. However, such an arrangement by itself will develop oil leaks and spills in the absence of constant operator attendance.
To prevent such leaks and spills, the present sealing system also includes a gas sealing component 38. The gas sealing component 38 is attached to the liquid sealing element 30 in a manner that preferably creates a substantially liquid and air tight seal between the two polished rod sealing components. One structure found to be effective is the sealing adapter 40 shown in FIG. 2. The sealing adapter 40 is preferably threaded onto the upper end 31 of the liquid sealing element 30. The gas sealing component is secured to the adapter 40 by several circumferentially spaced bolts 42, two of which can be clearly seen in FIG. 2. Threaded recesses 41 are provided in adapter 40 to receive the threaded ends 43 of the bolts 42. The sealing adapter 40 is preferably removably attached between the liquid sealing element 30 and the gas sealing component 38 to provide access to the interior of the sealing system so that the sealing elements can be changed when necessary. The sealing adapter 40 further includes a spring biased pressure element 44 that is held in contact with the seals 32 by a spring 45 to press the seals against the bottom of the sleeve 34.
The gas sealing component 38 includes a liquid/gas separation chamber 46. The liquid/gas separation chamber 46 includes an inlet 48 and an outlet 50. The inlet 48 and outlet 50 are fluidically connected with conduits 52 and 54, respectively (FIG. 1).
The liquid/gas separation chamber 46 is sealed above the inlet 48 by a gas sealing assembly 57 which includes several gas seal elements 58. The gas sealing elements 58 are preferably formed from pressure packing rings of the kind used to seal gas in reciprocating compressors and have the composite construction shown. However, other kinds of sealing elements able to maintain a reliable seal under pressure in the presence of the continuous reciprocating movement of a structure like an oil well polished rod could also be used. A dust seal 60 is provided on top of the outermost gas seal 58 to protect the gas sealing assembly 57 from dust, dirt and the like.
The arrangement of the liquid seals 32 in the liquid sealing element 30 allows a controlled amount of oil to reach the polished rod to lubricate it and cool it. An oil wiper ring assembly 62 is provided around the polished rod 12 at the bottom of the gas sealing assembly 57 to keep the crude oil from reaching the gas seals 58. Two oil wiper rings 64 are shown secured to the lowermost gas seal 58 by bolts 66. This method of attachment insures the easy removal of the oil wiper rings when their replacement is required.
The entire gas sealing component 38 is removably attached to the sealing adapter 40 by the threaded bolts 42. This method of attachment facilitates the removal of the sealing assembly 57 and the replacement of the gas seals 58 or the oil wiper rings 64 when necessary.
FIGS. 3 and 4 illustrate the upper portion of the sealing adapter 40 and the gas sealing component 38 of the present sealing system in two different cross-sectional views. The FIG. 3 view is substantially the same as that shown in FIG. 2. FIG. 4 shows, in addition, a chamber 68 to hold a liquid level sensor 70 which activates a microswitch 72 to stop the well motor (not shown) in the event a large hydrocarbon liquid leak occurs which causes crude oil to rise above the liquid drain or above the normal liquid level 56.
The sealing system of the present invention additionally includes a compressor 74. Compressor 74 is fluidically connected to the inlet 48 of the gas sealing component 38 through conduit 52 and pressurizes the well gas delivered to the chamber 46 to just above the pressure of the well discharge line. This pressure is contained by the gas seal assembly 57. The specific pressure of the gas supplied to chamber 46 will depend on the operating conditions and physical characteristics of each well.
The hydrocarbon well sealing system of the present invention employs gas sealing principles to prevent and contain crude oil leakage from operating hydrocarbon-producing wells. The conventional liquid sealing elements employed in the past form a part of the present sealing system. However, the liquid sealing element 30 employed herein is used for an additional purpose as well. The liquid sealing element 30 is not intended to prevent completely the leakage of hydrocarbon liquid past the well polished rod. Rather, the liquid seals 32 are designed to allow a controlled amount of leakage of oil from the well around the polished rod 12 to lubricate and cool the polished rod 12 during well operation. The liquid sealing element 30 additionally functions to center the polished rod 12 and to insure its axial alignment during operation of the well.
The gas sealing component 38 of the present sealing system functions in concert with the components described above to effectively prevent the leakage of crude oil from a hydrocarbon-producing well. The liquid/gas separation chamber 46 shown and described in connection with FIGS. 2, 3 and 4 is instrumental in achieving this result. Gas from the well casing is pumped into conduits 18 and 19 by the compressor 74 and from compressor 74 through conduit 52 and into chamber 46 through inlet 48. A check valve 53 is provided in conduit 52 between the compressor 74 and the liquid/gas separation chamber inlet 48 to prevent the gas flow from reversing direction. Sufficient gas is supplied to chamber 46 by the compressor 74 at a pressure which maintains the required sealing pressure on the gas seals 58 and to keep the liquid level at or below the level of line 56 (FIG. 2).
Any excess gas is returned to the well production line from chamber 46 through the outlet 50 and into conduit 54. Conduit 54 includes at least one check valve 55 so that fluid flow from the chamber cannot reverse direction. Conduit 54 is fluidically connected to the well production line so that the well gas used to seal the gas seals 58 can be returned to the well production line, where it is available for recovery or reuse. The use of well gas from the well casing to perform the sealing function as described lowers the casing pressure of the well and, as a result, can substantially increase the hydrocarbon liquid production of the well. An additional advantage of using a gas seal as described herein will be evident when the gas seals 58 wear, which will eventually happen. Instead of leaking potentially noxious and environmentally contaminating crude oil as the currently available seals do, small quantities of relatively harmless natural gas will be leaked around the sealing assembly of the present invention.
In the event of the failure of the liquid seal element 30 or other circumstances which cause hydrocarbon liquid or crude oil to enter the chamber 46 and rise above the level of line 56, the liquid level sensor 70 activates a liquid level microswitch 72 (FIG. 1) to stop the well motor. Consequently, crude oil is effectively precluded from spilling or leaking beyond the well sealing structures. In addition, an oil well using the sealing system of the present invention does not require the constant monitoring by operating personnel currently required by available sealing structures because the present sealing system automatically detects excess crude oil in chamber 46 and shuts down.
The present invention has been described with respect to preferred embodiments. However, alternatives, modifications and variations of the foregoing preferred embodiment of the present invention that fall within the scope and spirit of the appended claims may be apparent to those skilled in the art and are intended to be covered by the appended claims.
INDUSTRIAL APPLICABILITY
The sealing system of the present invention will find its primary applicability in the sealing of hydrocarbon-producing wells to prevent contaminating leaks and spills of crude oil. However, the present sealing system may also be adapted to provide an effective seal for other types of pumping apparatus and operations which involve the production of a gas component and a liquid component. | A spillproof sealing system for hydrocarbon-producing wells which produce gas and crude oil is provided. The sealing system includes a liquid sealing element which cooperates with a gas sealing component positioned about the well polished rod to seal the well against crude oil leaks while simultaneously providing sufficient oil to lubricate and cool the polished rod during well operation. A liquid/gas separation chamber is provided to receive gas from the well that has been pressurized by a compressor to seal the gas sealing component. Excess gas and crude oil are returned to the well production line. Liquid level sensing and switch means are further provided to automatically shut down the well motor if the crude oil level in the liquid/gas separation chamber exceeds an established minimum level. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a defibrator for recycled materials such as waste paper.
In the known apparatus of the prior art, the material, such as waste paper, is defibrated by repeatedly falling against a hard surface, and this falling develops shearing forces which convert the paper into fibres without disintegrating the unwanted substances.
The operation is carried out in a rotating drum into which paper, moistened by the addition of water, is fed axially at one end. On its inner peripheral surface, the drum comprises longitudinal deflectors which lift the material when the drum rotates and lets it fall back just before it reaches the top of the drum, thus causing defibration. As the drum is slightly inclined relative to the horizontal, the material travels from the upstream to the downstream end of the drum, and during its retention time (18 to 20 minutes) in the drum, it is made to fall from the top of the drum on to the inner surface at the bottom 200 to 250 times.
The material then passes into a separator drum, also rotating, known as a sorting drum, having a perforated surface. Water is projected over the outer surface of the drum, thus forcing inwards any material lodged in the perforations. The fibres suspended in the water escape through the perforations in the bottom part of the rotating drum, whilst foreign matter (wires, plastics, etc.) are evacuated from the drum at the end of said drum.
These known machines have a variety of disadvantages:
the defibrating drum has to be considerable in size: in diameter, because the material has to fall from a sufficient height to produce the shearing forces needed for defibration; and in length, to ensure that any one portion of material is subjected to a sufficient number of falls in the course of its passage from the upstream to the downstream end of the defibrating drum;
the drive torque to be applied to the drum is considerable, as the material is all contained in one side of the drum. This also results in an imbalance which fatigues the bearings and causes premature wear thereof;
as the drum operates in only half its section, the space taken up by the drum is not used to full advantage.
SUMMARY OF THE INVENTION
The apparatus according to the invention is based on the idea that the material is defibrated by its contact with a moving hard substance, and it is therefore advantageous to multiply these contacts. For this purpose, the invention provides a defibrator comprising at least one rotary cylindrical drum provided on its inner surface with longitudinal deflectors, and driven in rotation and axially supplied with material to be defibrated, characterised in that it comprises, on the inside, a rotor consisting of a shaft coaxial with the cylindrical drum and longitudinal blades branching radially off the shaft, and having ends which are curved in the direction of rotation, capable of receiving the material which is to be defibrated and projecting it on to the inner wall of the drum.
Thus, the material is subjected to contact with a moving hard substance twice each time the drum rotates: once when it meets the surface of the blades of the rotor and again when it is projected against the inner surface of the drum.
In a preferred embodiment of the invention, the rotor rotates in the same direction as the drum. The angular velocity of the drum is of the order of 15 to 30 r.p.m. and the angular velocity of the rotor is of the order of 100 to 200 r.p.m.
According to another advantageous feature, the blades of the rotor are slightly helicoidal so as to promote the advance of the material from the upstream to the downstream end of the rotor.
In a preferred arrangement, the defibrating drum mentioned hereinbefore is preceded by a shredder drum into which the material is fed radially by means of an upper hopper and falls through openings formed in the cylindrical surface of the drum, on to a rotor similar to that of the defibrating drum. This apparatus comprising the shredder and the defibrator is followed by a sorting section, which is known per se, which advantageously contains small blades mounted on a rotor the axis of which is concentric with the axis of the drum.
Advantageously, the drums of the shredding, defibrating and sorting sections are integral and driven in rotation from outside, and the shaft carrying the blades of the shredder, the blades of the defibrator and the small blades of the rotor in the sorting section is in one piece, driven by a separate motor.
The advantages of the invention are as follows:
1. The material is distributed over almost all the defibrating drum and not just one side of it. The drum can therefore receive, per unit of length, almost double the amount of material treated in known apparatus.
The power needed for driving the drum is significantly less than in a conventional machine, thanks to this uniformity of distribution.
2. As has already been pointed out, the material coming into contact with the blades of the rotor and then with the inner wall of the drum is ground twice each time the drum rotates.
3. Because of this, the shearing forces no longer depend on the diameter of the rotor.
4. Consequently, for the same capacity, the drum may have a diameter slightly larger than half the diameter of a conventional drum. The length and the retention time can be reduced by about half.
The energy consumed does not exceed that consumed by a conventional apparatus.
The invention is hereinafter described with reference to a preferred embodiment by way of example, shown in the drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial longitudinal section through a complete defibrator having, in particular, a defibrating section according to the invention;
FIG. 2 is a cross section through the apparatus on the line II--II in FIG. 1;
FIG. 3 is a cross section through the apparatus on the line III--III in FIG. 1;
FIG. 4 is a cross section through the apparatus on the line IV--IV in FIG. 1.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
In this preferred embodiment, the apparatus consists of a drum 1 having three sections: a feed section A, a defibrating section B and a sorting section C. The drum is supported at its periphery by rollers 2,2' at least some of which are drive rollers and drive the drum by friction. A single central shaft 3 connected to a motor 4 passes through all three sections. The machine is also provided with two external housings 5 and 6. The housing 5 contains the shredder section A of th drum 1. The housing 6 contains the sorting section C. The three sections of the machine will now be described in the order in which the material to be treated passes through them.
Section A of the drum 1 comprises a solid cheek 7 which closes the drum at the upstream end, and a perforated cheek 8 which forms a reinforcing partition between section A and section B. These cheeks are connected by profiles 9 having a concavity in front (in the direction of rotation of the drum, indicated by the arrow F). The housing 5 is open at its upper end and is connected to a hopper 10 supplied by a conveyor belt 11. It comprises perforated ducts 12 which project water into the drum, passing through the openings left between the profiles 9. In the centre of the drum and keyed on the shaft 3 there is a rotor consisting of longitudinal blades branching off radially (at 13) from the shaft 3 and curved at their ends (at 14) in the direction of rotation F.
The section B of the drum 1, which is actually the defibrating section, consists of a solid outer casing provided with longitudinal deflectors of triangular section 15 the base of which is contained in the peripheral surface of the drum and the two sides of which are inclined relative to a radial median plane. The inclination of the sides facilitates the detachment of the material enclosed between two successive deflectors, thus preventing the formation of a bridge. The surface which does not come into direct contact with the material acts as a reinforcement for the deflector and the drum as a whole. The sharp ridges formed at the apices of the triangles are oriented towards the shaft 3, at the centre of the drum. The shaft 3 comprises blades 13', 14' similar to the blades 13, 14 of section A. These blades rotate in the same direction (F) as the drum, but a speed equal to or more than ten times the angular speed of the drum.
The section C of the drum 1 is separated from section B by a perforated reinforcing partition 8', analogous to the partition 8. Section C comprises the external housing 6 and the downstream portion of the drum 1, terminating in an almost entirely open partition consisting of reinforcing bars 16 connected by a annular plate 17. In this section, the drum comprises a cylinder 18 perforated over its entire surface with holes 6 to 7 mm in diameter (as shown at 22), and, inside, keyed on the shaft 3, a conventional blade system 19. The housing 6 which encloses the drum, its mounting and the rotor comprises below it a chimney 20 opening in the direction of discharge of the fibres, and an outlet spout 21 for the foreign matter which is to be eliminated.
The operation of the apparatus can be analysed as follows:
The material to be treated, carried by the conveyor belt 11, falls between the profiled bars 9 of the movable drum 1 on to the rotor with blades 13, 14, which projects the material on to the profiles 9, from where it falls back into the bottom of the drum, where the presence of the external housing 5 prevents it from escaping. To ensure that it does not pass upwards through the spaces existing between the bars 9, the dimensions of these spaces and of the blades 13, 14, and the shape of the latter, must be judiciously chosen. Under the effect of the helical shape of the blades 14 and possibly the inclination of the entire machine relative to the horizontal, if such inclination is provided, the material shredded by the mechanical operation, aided by the sprinkling of water supplied through nozzles fed by the ducts 12, passes into section B, the actual defibrating section.
In this section, the material enters partly through the centre, between the blades 13' and 14' of the central rotor which is an extension of the shredder. This portion of the material which has already been subjected to impact on making contact with the rotor is again subjected to a crushing action between the blades 13' and is soon projected, by the curved parts 14' of the blades, towards the deflectors 15 in the half of the machine which is on the left in FIG. 3. The sharp ridges of the deflectors 15 contribute to the defibrating action. Another fraction of the material, arriving along the deflectors 15 in the lower part of the drum 1, is lifted by the deflectors, from which it slides downwards shortly before reaching the top of the drum. It thus falls on to the blades 13', 14' which also project it, as mentioned hereinbefore. All the material, which has finally fallen back several times (in the left-hand part of the machine) into the bottom of the rotor, finally leaves this rotor axially, through the partition 8', to arrive in the section C, known as the sorting section, the general construction and method of operation of which are known per se. There, it is diluted by the addition of water (provided through nozzles (not shown) located in the upper part of the housing 6) and, urged by the radial blades 19 of the central rotor, it passes through the perforations 22 and escapes into the chimney 20. Foreign matter (wires, metal, plastics) is evacuated through the spout 21.
To give an idea of the superiority of the machine according to the invention over known machines, the actual defibrator (section B) of the invention will now be compared with two known defibrators. All the comparisons are based on the flow rate per 24 hours.
The calculations are made with the aid of the following formulae:
Weight of dry matter in the drum= ##EQU1##
Production of dry pulp in 24 hours= ##EQU2## where D 1 =diameter measured at the inner edges of the deflectors;
D 2 =diameter of drum;
F=degree of filling between the deflectors;
L=length of the defibrating zone;
C=consistency of the dry matter in %
R=retention time in the drum.
A1. Known machine with a drum 2.25 m in diameter, with a length
L=5.8 m, F=4/8
P=799 kg
Q=63.9 tonnes/24 hours
A2. Machine according to the invention with a drum
2.25 m in diameter, length L=4 m,
F=7/8
P=964 kg
Q=155 tonnes/24 hours.
B1. Known machine with a drum 3.00 m in diameter,
Length L=11 m,
F=4/8
P=3,238 kg
Q=259 tonnes/24 hours.
B2. Machine according to the invention with a drum
3.00 min diameter, length L=6 m, F=7/8
P=3,090 kg
Q=495 tonnes/24 hours.
The following are the characteristics of a machine according to the invention having small dimensions:
(diameter 1.5 m, L=4 m, degree of filling F=7/8)
P=428 kg
Q=68.5 tonnes/24 hours.
This last machine should be compared with the first (A1). | The invention relates to a defibrator comprising at least one rotary cylindrical drum provided on its inner surface with longitudinal deflectors, driven in rotation and axially supplied with material which is to be defibrated. On the inside, the defibrator comprises a rotor consisting of a shaft coaxial with the cylindrical drum, and longitudinal blades branching off radially from the shaft and having ends which are curved in the direction of rotation, capable of receiving the material which is to be defibrated and of projecting it on to the inner wall of the drum. | 3 |
[0001] This application claims priority to provisional application No. 62/177,346.
TECHNICAL FIELD
[0002] The present disclosure relates in general to beverage dispensing, and more particularly to the dispensing of a carbonated beverage from any container into a glass, providing a portion of the beverage as foam atop of the dispensed beverage.
BACKGROUND
[0003] Although any carbonated beverage may produce a foam layer on top of its poured contents, the foam layer on a poured serving of beer is of particular interest to many consumers. The foam layer, referred to as a head, atop a vessel of beer is produced by bubbles of gas, commonly carbon dioxide, that rise to the surface. The compounds that produce the head comprise proteins, yeast and starches in the form of grain residue in the beer. The interaction between the carbon dioxide the proteins and starches in the liquid determine the physical properties of the foam. Carbon dioxide may be produced during fermentation or if the beer is pasteurized it may be carbonated by injecting pressurized gas after pasteurization. Of particular interest to consumers is the density and longevity of the head. As with many reactions, agitation can increase the rate of reaction. Although it is common to produce a head on top of a glass of beer, similarly, foam may also be produced from carbonated soft drinks, carbonated juices or non-alcoholic malt beverages.
[0004] It is commonly considered that a greater-than-desired volume of head on the beverage detracts from the mass of the drink, while some head is considered essential to the beverage. The head gives off an aroma of the beer/beverage, and adds to the experience of enjoying the beverage. The production of the head reduces the amount of carbon dioxide in the remainder of the beverage.
[0005] While many methods exist for providing a stable, dense head on beer dispensed from casks or pressurized bulk containers, it has long been understood that there are problems associated with attempting to achieve the same effect on beer dispensed from bottles, cans or common single-serve containers. There is a need for a means and apparatus to produce a fine, dense head on a dispensed beer from a variety of disparate containers.
SUMMARY
[0006] In accordance with embodiments of the present disclosure, an apparatus and method, in general, for dispensing a liquid, including a carbonated beverage such as beer; and in particular, for dispensing a portion of the beverage without altering the concentration of pressurized gas in the beverage; and further, for dispensing a portion of the beverage in the form of a fine, dense head of foam. One skilled in the art will understand that a variety of liquids may be dispensed in a foamed state, and that while it may be desirable to dispense a portion of the liquid in a non-foamed state and a portion of the liquid in a foamed state, in other applications it may be desirable to dispense the entirety of the contents in a foamed state or the entirety of the contents in a non-foamed state.
[0007] In one embodiment the apparatus comprises a base for supporting a container such as a glass or mug or the like. Engaged with the base is a body providing a chamber, closed on all but one side, suitable for housing a beverage container such as a can, bottle, jug or the like. An upper housing is engaged with the body, in a manner wherein a fluid-tight seal may be obtained between the body and the upper housing at the open end of the body.
[0008] A fluid path, or conduit, extends from the interior of the body into the upper housing and terminates at a spout that is proximal to the top of the glass to be filled with the dispensed liquid. The liquid in the beverage container is moved through the conduit by increasing the air pressure in the body, thus moving the liquid by the property of displacement. In the region proximal to the spout an oscillation means produces a sonic wave through the conduit and hence through the liquid being dispensed. The oscillation's agitation of the liquid increases the reaction that produces foam or head. Small rapid oscillations tend to produce a fine, dense foam.
[0009] One skilled in the art will understand that the end result achieved by a control circuit employed to send an electrical current to a solenoid valve may also be achieved by a manually operated valve and subsequent substitutions of mechanical operators to an electronic system. In other words, although the same means may be achieved by a mechanical apparatus, the following embodiment is described as having an electronic controller.
[0010] Other objects and features will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration and not as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] To assist those of skill in the art in making and using the disclosed beverage dispenser and associated methods, reference is made to the accompanying figures, wherein:
[0012] FIG. 1 is a diagram depicting the arrangement of components of an example embodiment
[0013] FIG. 2 is a diagram depicting the arrangement of components of an example embodiment.
[0014] FIG. 3 is a perspective drawing of an iteration of the embodiment.
[0015] FIG. 4 is a partial section, perspective drawing of an iteration of the embodiment.
[0016] FIG. 5 is a perspective drawing of an iteration of the embodiment.
[0017] FIG. 6 is a partial section, side view of the iteration of FIG. 5 .
[0018] FIG. 7 is a diagram depicting the arrangement of components of an example embodiment.
DESCRIPTION
[0019] As discussed in greater detail below, an apparatus and method providing dispensed liquid and dispensed, foamed liquid is described. In general, a beverage container is placed in the body with the conduit inserted into the liquid that is in the container. With the upper housing closed and creating a fluid-tight, or in this case, an air-tight seal, over the open side of the body, the control lever may be moved in the first direction wherein the pump increases the air pressure inside the body. The increased air pressure in the body moves the beverage by the property of displacement, through the conduit and into the container. When the lever is moved to a second position the high frequency oscillation means produces a sonic wave through the conduit and hence through the liquid being dispensed. The high frequency produces a fine, dense foam that floats on top of the dispensed beverage. The lever may subsequently be moved to a third position wherein the control circuit opens a valve so as to dispel the relatively higher pressure air in the interior of the body, thus returning the pressure to that of the ambient pressure.
[0020] Referring to FIG. 1 , an example embodiment 100 comprises a base 110 engaged with a body 112 that is further engaged by way of a gasket 114 with an upper housing 116 . One skilled in the art will understand that there are a number of methods for securing the upper housing with the body such as methods including threaded or clamping closure methods.
[0021] The body 112 is a hollow chamber closed on all but one side. The open side is engaged with a gasket 114 which is further engaged with the upper housing. A conduit 118 extends from the proximal end in the interior of the body 112 where it is intended to be inserted into the liquid 124 to be dispensed, through the upper housing where the distal end forms a spout 119 . The upper housing 116 contains a control lever 125 , a power source 121 , a pump 120 , a valve 115 , a high frequency oscillation means, otherwise referred to as an oscillator 122 , and a control circuit 123 . The control circuit 123 directs power to the aforementioned components to achieve the following described method.
[0022] A beverage container 130 is inserted into the body 112 and the conduit 118 is inserted into the beverage 124 . The upper housing 116 is closed over the body 112 and sealed against the gasket 114 . The operation means or lever 125 , is moved to the position relative to the dispensing of the liquid. The control circuit 122 turns the valve 115 to allow air from the pump 120 into the interior of the body 112 . The control circuit 122 then turns on the pump 120 that transfers air into the interior of the body 112 . As the air pressure increases inside the body 112 , the liquid in the beverage container 124 is moved through the conduit 118 by the property of displacement, and out the spout 119 , into the glass 126 . When the user chooses to create a foamed liquid, the lever 125 is moved to the position relative to the foaming of the liquid. The control circuit 123 turns on the oscillator 122 that produces an oscillatory wave through the conduit 118 and hence through the carbonated liquid, thus causing it to foam. The oscillatory wave agitates the liquid, increasing the reaction between the carbon dioxide and the proteins and starches in the liquid producing foam 132 that floats on top of the dispensed liquid 128 . When the beverage and foam have been dispensed, the lever 125 is moved to a neutral position wherein the control circuit 123 switches the valve 115 to open the purge conduit 117 so that the pressure in the body 112 exits through the purge conduit 117 , thus returning the pressure inside the body 112 to that of the ambient environment. The upper housing is opened and the empty beverage container 130 removed.
[0023] In an iteration of the embodiment, a beverage container is placed in the body with the conduit inserted into the liquid that is in the container. With the upper housing closed and creating a fluid-tight, or in this case, an air-tight seal, over the open side of the body, air is pumped into the interior of the body wherein the increased the air pressure moves the beverage by the property of displacement, through the conduit and into the container. A switch sends power to a high-frequency oscillation means produces a sonic wave through the conduit and hence through the liquid being dispensed. The high frequency waves produce a fine, dense foam that floats on top of the dispensed beverage. A manually operated valve is opened to dispel the relatively higher pressure inside the body so that the air in the interior of the body may return to ambient pressure.
[0024] Referring to FIG. 2 , an example embodiment 200 comprises a base 210 engaged with a body 212 that is further engaged by way of a gasket 214 with an upper housing 216 . One skilled in the art will understand that there are a number of methods for securing the upper housing with the body such as methods including threaded or clamping closure methods.
[0025] The body 212 is a hollow chamber closed on all but one side. The open side is engaged with a gasket 214 which is further engaged with the upper housing. A conduit 218 extends from the proximal end in the interior of the body 212 where it is intended to be inserted into the liquid 224 to be dispensed, through the upper housing where the distal end forms a spout 219 . The upper housing 216 contains a pumping lever 221 , a power source 221 , a pump 220 , a valve 215 , and a high frequency oscillation means, otherwise referred to as an oscillator 222 .
[0026] A beverage 224 is poured into the body 212 and the proximal end of the conduit 218 is inserted into the beverage 224 . The upper housing 216 is closed over the body 212 and sealed against the gasket 214 . The valve 215 is moved to a position that closes the purge conduit 217 and opens the pump conduit 219 , to allow air from the pump 220 into the interior of the body 212 . The pump lever 225 , is moved so as to pump air into the body 212 . As the air pressure increases inside the body 212 , the liquid in the beverage container 224 is moved through the conduit 218 by the property of displacement, and out the distal end, otherwise referred to as a spout 219 , into the glass 226 . When the user chooses to create a foamed liquid, a switch 223 is turned on, providing power from the power source 221 to the oscillator 222 , thus powering the oscillator 222 that produces an oscillatory wave through the conduit 218 and hence through the carbonated liquid, thus causing it to foam. The oscillatory wave agitates the liquid, increasing the reaction between the carbon dioxide and the proteins and starches in the liquid producing foam 232 that floats on top of the dispensed liquid 228 . The user may then move the valve 215 to the position wherein the purge conduit 217 is opened and conduit 219 is closed, so that the pressure in the body 212 exits through the purge conduit 217 , thus returning the pressure inside the body 212 to that of the ambient environment.
[0027] Referring to FIG. 3 an iteration of the embodiment is illustrated. A base 310 supports a vessel 326 and the body 312 of the embodiment. Clamps 315 engage the upper housing 316 with the body 312 . An operation means, or lever 325 actuates the control circuit that in turn operates the internal components, illustrated in FIG. 4 .
[0028] Referring to FIG. 4 , an example embodiment 300 comprises a base 310 engaged with a body 312 that is further engaged by way of a gasket 314 with an upper housing 316 . At least one clamping means 315 engages with a portion of the upper housing 316 and the body 312 . One skilled in the art will understand that there are a number of methods for securing the upper housing with the body such as methods including threaded or clamping closure methods.
[0029] The body 312 is a hollow chamber closed on all but one side. The open side is engaged with a gasket 314 which is further engaged with the upper housing 316 . A conduit 318 extends from the proximal end in the interior of the body 312 where it is intended to be inserted into a container 330 that holds a carbonated beverage to be dispensed, through the upper housing 316 where the distal end forms a spout 319 . The upper housing 316 comprises a lever 325 , a power source 321 , a control circuit 323 , a pump 320 , a valve 315 , and a high frequency oscillation means, otherwise referred to as an oscillator 322 . One skilled in the art will understand that a control circuit and subsequently engaged switches, actuators, solenoid valves and the like are powered by a cord intended for engagement with a wall outlet or a battery operated power source.
[0030] A beverage in a container 330 is placed inside the body 312 and the proximal end of the conduit 318 is inserted into the beverage container 330 . The upper housing 316 is closed over the body 312 and sealed against the gasket 314 by engaging clamps 334 . Movement of the lever 325 actuates a switch 323 that engages the control circuit 323 that in turn moves the valve 315 to a position that closes a purge conduit and opens a pump conduit, to allow air from the pump 320 into the interior of the body 312 . As the air pressure increases inside the body 312 , the liquid in the beverage container 330 is moved through the conduit 318 by the property of displacement, and out the distal end, otherwise referred to as a spout 319 , into the glass 326 . When the user chooses to create a foamed liquid, the lever 325 is moved to a third position wherein a signal to the control circuit, provides power from the power source 321 to the oscillator 322 , thus powering the oscillator 322 that produces an oscillatory wave through the conduit 318 and hence through the carbonated liquid, causing it to foam. The oscillatory wave agitates the liquid, increasing the reaction between the carbon dioxide and the proteins and starches in the liquid producing foam 332 that floats atop the dispensed liquid 328 in the glass 326 . The user may then move the lever 325 to the final position, signaling the control circuit to open the valve 315 to purge the pressure from inside the body 312 , thus returning the pressure inside the body 312 to that of the ambient environment.
[0031] Referring to FIG. 5 and FIG. 6 , an iteration of the embodiment is illustrated in a perspective view in FIG. 5 and a side, section view in FIG. 6 . The example embodiment is intended as an integral design to be engaged with a tap 401 . The tap 401 comprises a valve that allows carbonated liquid to flow from a pressurized vessel such as a keg, along a conduit 418 to the spout 419 . The embodiment includes a housing 405 that contains a power supply 421 that supplies power to an oscillator 422 , through momentary switch 425 . The oscillator produces an oscillatory wave through the conduit 418 and hence through the carbonated liquid, causing it to foam. The oscillatory wave agitates the liquid, increasing the reaction between the carbon dioxide and the proteins and starches in the liquid producing foam 432 that floats atop the dispensed liquid 428 in the glass 426 .
[0032] Referring to FIG. 7 , an example embodiment 500 comprises a base 510 engaged with a body 512 that is further engaged by way of a gasket 514 with an upper housing 516 . One skilled in the art will understand that there are a number of methods for securing the upper housing with the body such as methods including threaded or clamping closure methods.
[0033] The body 512 is a hollow chamber closed on all but one side. The open side is engaged with a gasket 514 which is further engaged with the upper housing. A conduit 518 extends from the proximal end in the interior of the body 512 where it is intended to be inserted into the liquid 524 to be dispensed, through the upper housing where the conduit 518 passes through a vessel 550 that may contain a filter or flavored infusion pod 552 wherein it continues to the distal end that forms a spout 519 . The upper housing 516 contains a control lever 525 , a power source 521 , a pump 520 , a valve 515 , a high frequency oscillation means, otherwise referred to as an oscillator 522 , and a control circuit 523 . The control circuit 523 directs power to the aforementioned components to achieve the following described method.
[0034] A beverage container 530 is inserted into the body 512 and the conduit 518 is inserted into the beverage 524 . The upper housing 516 is closed over the body 512 and sealed against the gasket 514 . The operation means or lever 525 , is moved to the position relative to the dispensing of the liquid. The control circuit 522 turns the valve 515 to allow air from the pump 520 into the interior of the body 512 . The control circuit 522 then turns on the pump 520 that transfers air into the interior of the body 512 . As the air pressure increases inside the body 512 , the liquid in the beverage container 524 is moved through the conduit 518 by the property of displacement, and through the vessel 550 where it interacts with the filter and/or infusion pod 552 and continues out the spout 519 , into the glass 526 . When the user chooses to create a foamed liquid, the lever 525 is moved to the position relative to the foaming of the liquid. The control circuit 523 turns on the oscillator 522 that produces an oscillatory wave through the conduit 518 and hence through the carbonated liquid, thus causing it to foam. The oscillatory wave agitates the liquid, increasing the reaction between the carbon dioxide and the proteins and starches in the liquid producing foam 532 that floats on top of the dispensed liquid 528 . When the beverage and foam have been dispensed, the lever 525 is moved to a neutral position wherein the control circuit 523 switches the valve 515 to open the purge conduit 517 so that the pressure in the body 512 exits through the purge conduit 517 , thus returning the pressure inside the body 512 to that of the ambient environment. The upper housing is opened and the empty beverage container 530 removed. One skilled in the art understands that an infusion pod 552 may contain flavors or additives for enhancing the liquid and foam or for enhancing only the liquid or only the foam dispensed. One skilled in the art understands that an infusion pod may be replaced with a filter for the purpose of removing contaminants from the dispensed liquid.
[0035] Although embodiments describe liquid under pressure, one skilled in the art can understand that the invention may also work with liquid flowing through a conduit at ambient pressure.
[0036] A more complete understanding of the components, processes, and apparatuses disclosed herein can be obtained by reference to the accompanying figures. These figures are intended to demonstrate the present disclosure and are not intended to show relative sizes and dimensions or to limit the scope of the disclosed embodiment(s). In particular, the figures provided herein are not necessarily to scale and, in certain views, parts may be exaggerated for clarity.
[0037] Although specific terms are used in the following description, these terms are intended to refer only to particular structures in the drawings and are not intended to limit the scope of the present disclosure. It is to be understood that like numeric designations refer to components of like function.
[0038] The term “about” or “approximately” when used with a quantity includes the stated value and also has the meaning dictated by the context. For example, it includes at least the degree of error associated with the measurement of the particular quantity. When used in the context of a range, the term “about” or “approximately” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the range “from about 2 to about 4” or “from approximately 2 to approximately 4” also discloses the range “from 2 to 4.”
[0039] While example embodiments have been described herein, it is expressly noted that these embodiments should not be construed as limiting, but rather that additions and modifications to what is expressly described herein also are included within the scope of the invention. Moreover, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations, even if such combinations or permutations are not made express herein, without departing from the spirit and scope of the invention. | The embodiment relates to beverage dispensing, and more particularly to the dispensing of a carbonated beverage, from any container into a vessel, providing a portion of the beverage as foam atop the dispensed beverage. To avoid the reduction of absorbed carbon dioxide in a carbonated beverage, increased atmospheric pressure is employed to move the beverage from the container through the apparatus and into the vessel. An oscillating means provides a sonic wave through the conduit and the liquid therein; the sonic wave initiates the reaction between the carbon dioxide and the ingredients in the beverage to cause the liquid to foam prior to dispensing into the vessel. Iterations include an adaptable apparatus for a beer tap and a means for passing the liquid to be dispensed through a permeable container filled with soluble material or a permeable container filled with a filtration means. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to micromachining and microfabrication, and more particularly, to a mold structure and associated fabrication method to form high-precision multi-dimensional components at the micro and millimeter scale, including components formed from metallic glass alloys.
BACKGROUND
[0002] Micro-electromechanical systems (MEMS) enable miniaturization of engineering systems and tools for a variety of applications due to their ability to create micro-scale systems having high sensitivity and low power consumption. Micro- and nano-scale components for a MEMS device may be fabricated concurrently as an integrated system, or components can be fabricated individually and then incorporated into a MEMS device. Advanced materials and fabrication techniques are required to produce highly precise multidimensional components for use in the MEMS devices.
[0003] Bulk metallic glasses are a class of material which can be used to fabricate components for MEMS devices. Bulk metallic glasses (BMGs) are amorphous metals that are rapidly quenched from a molten state to prevent crystal structure formation. A significant factor that determines the glass forming ability of a metal is the critical cooling rate. A sufficiently high critical cooling rate is required to bypass crystallization when cooling from a stable liquid phase in order to form a glass. Once in a glassy amorphous state, it is possible to complete a thermoplastic forming of BMGs at comparatively low temperatures using simplistic forming processes compared to traditional metals that result in near-net shaping. Thermoplastic forming is achieved by elevating the temperature of the BMG above the glass transition temperature followed by the application of pressure, which causes the BMG to conform to the shape of a mold patterned with the desired final features. Methods of thermoplastic forming of BMGs include but are not limited to hot embossing, blowmolding, and imprinting.
[0004] The complexity and precision of BMG components for use in MEMS devices is dependent of a mold structure used as part of the BMG processing. The methods of forming mold structures for metallic glass components with micro and nano-scale features offer the ability to produce a variety of highly-precise two-dimensional (2D) variation, but the resulting features are limited to a constant feature size, or minor variation of the 2D feature such as a taper angle, in the third dimension since the molds generally consist of a single substrate.
[0005] Referring now to FIG. 1 a - 1 b, a cross-sectional view of a typical mold used to produce bulk metallic glass microscale components as known in the prior art is illustrated. A typical mold consists of a substrate 101 , generally made of silicon. The top surface of substrate 101 contains a cavity 102 that is formed into the surface of substrate 101 using patterning processes known to those skilled in the art, including but not limited to photolithography and reactive ion etching, e.g., a RIE etching of the silicon substrate material. FIG. 1B shows a top view along line A-A (of FIG. 1A ) illustrating cavity 102 formed in substrate 101 . Due to the limitations of forming mold patterns on a single surface of a substrate, the molds existing in the prior art are limited to have a single two-dimensional feature as depicted in FIGS. 1A and 1B , having only features with a larger diameter than the nominal dimensions of cavity 102 on the top exposed surface of the mold. Mold cavity 102 is then filled with the desired high-temperature filling material, such as a bulk metallic glass alloy, by thermoplastic forming of the BMG into substrate 101 . After removal of the mold substrate, the resulting BMG component features variation in two dimensions but only an extrusion of the 2D feature with no additional variation in the third dimension.
[0006] Mold structures with increased complexity can be formed by bonding stacked substrates to form a bonded mold. However, several limitations with bonded mold structures prohibit the use of metallic glass or other filling materials requiring elevated processing temperatures. For example, polymer-based adhesive materials that have been previously demonstrated as a way of bonding stacked silicon substrates induce thermal budget limitations on the filling materials that may be used. Since the processing temperature of zirconium-based and other metallic glass systems exceeds 400° C., a polymer-based adhesive would not be conducive for use in a bonded mold for many metallic glass forming applications. Additionally, the accuracy of features able to be produced using polymer-based adhesives to create a bonded mold is not precise due to the flow ability of polymer bonding agents during the substrate bonding process, which is typically completed using thermocompression bonding. The application of pressure at elevated temperatures required for successful thermocompression bonding of adhesives causes shifting of the substrates with respect to each other that can result in misalignment in excess of several microns. The flowability of the adhesive also causes local distortion of any patterned feature, which prohibits net-shape forming of feature with sharp angles or precise dimensions.
[0007] In the case of both 2D and 3D molds used for thermoplastic forming of BMGs, removing any residual BMG overburden from the top surface of the mold for highly precise micro and nano-scale parts remains a challenge. Removal methods known in the art such as grinding, polishing, and hot scraping may be applied as post-processing methods for larger-scale BMG components. However, for micro and nano-scale BMG components with highly precise features, the comparably large cross sectional area of the BMG overburden with respect to the final component exposed features can result in localized high forces that may cause delamination or distortion of the final BMG component during the overburden removal process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will be understood and appreciated more fully from the following detailed description of the invention, taken in conjunction with the accompanying drawings of which:
[0009] FIGS. 1A-1B show a conventional mold used to produce bulk metallic glass micro-scale components, as is known in the prior art;
[0010] FIGS. 2A-4B illustrate an exemplary embodiment of the structure and method of forming a three-dimensional mold having multiple patterned layers, according to an embodiment of the invention;
[0011] FIGS. 5A-5B illustrate an exemplary embodiment of the method of filling of three-dimensional mold having multiple patterned layers according to an embodiment of the invention;
[0012] FIGS. 6A-6B illustrate a method of removing excess filling material from the three-dimensional mold having multiple patterned layers, according to an embodiment of the invention;
[0013] FIGS. 7A-7B is a final molded component resulting from the structure and method of forming and filling the three-dimensional mold having multiple patterned layers according to an exemplary embodiment of the invention; and
[0014] FIGS. 8A-8B illustrates an alternate exemplary method of removing excess filling material from the three-dimensional mold having multiple patterned layers according to an embodiment of the invention.
SUMMARY
[0015] In one aspect, an embodiment of the invention provides a silicon mold structure consisting of multiple silicon substrates patterned with a portion of an integrated design and bonded together using dielectric bonding in a sequential order to create a mold material with varying features in the x, y, and z-directions. The mold is then filled with bulk metallic glass using thermo-compression molding. The overburden of bulk metallic glass is removed from the fill side, and is followed by removing the silicon mold which leaves individual components with high-accuracy 3D features.
[0016] In another aspect, in one embodiment, multiple substrates with deposited oxide layer are patterned, including patterning one or more of the deposited oxide layers. The substrates are then positioned so that the deposited oxide layers in contact with each other, and an oxide-oxide fusion bonding process is completed such that a three-dimensional (3D) mold structure containing multiple patterned layers is formed. An opening in the top surface of the mold structure is formed exposing the internal mold cavity consisting of multiple patterned layers.
[0017] In still another aspect, in one embodiment, the cavity of three-dimensional mold structure is filled with material such as a metallic glass at elevated temperatures using thermoplastic formation. Any overburden of the filling material existing on the top surface of the mold structure is then removed, followed by the removal of the mold itself. The resulting molded component is a highly-precise replication of the initial three-dimensional mold structure with multiple patterned layers.
[0018] In yet another aspect, an embodiment of the present invention enables the formation of structures with features that vary in the third dimension. By utilizing a deposited oxide layer as one of the patterned layers of the mold, very fine micron- and sub-micron scale variation in all three dimensions of the mold can be incorporated that would not be practical to achieve simply by adding an additional substrate.
[0019] In a further embodiment, the use of oxide as the bonding material and fusion bonding as the bonding method for the mold enables achievement of improved alignment accuracy of bonded substrates that is rendered possible since there is no bulk deformation or modification of the bond interface layers or the material that occurs during the bonding process, as is the case with adhesive or metal-metal bonding, resulting in a higher feature integrity in the final molded components. The use of oxide dielectrics as a bonding material further enables the use of bulk metallic glasses as a filling material for the complex mold since oxide dielectrics are thermally stable at the higher temperatures required to thermo-plastically form BMGs, where adhesive materials typically used for bonding of substrates are generally not thermally stable at the temperatures required thermo-plastically form BMGs. Additionally, oxide-oxide fusion bonding provides a significantly improved bonding quality and high percentage of bonded area across a substrate during at wafer-level processing, which enables large-scale, cost-effective fabrication of three-dimensional mold structures with multiple patterned layers.
[0020] In yet a further aspect, an embodiment provides the entire top substrate in the bonded stack that is in direct contact with the resulting overburden of filling material after the filling operation is removed, with the interface between the deposited oxide layer and the substrate material serving as an endpoint indicator.
[0021] Enablement of selective endpoint capability during the process of removing any excessive fill material remaining on the surface of the mold is made possible by using the interface of the oxide layer and substrate, which allows for high precision tolerances of micro scale components. Additionally, higher process yields are able to be achieved due to reduced deformation of BMG molded final work piece after molding, which results from minimizing the cross section of overburden to be removed, compared to non-selective direct removal of any overburden from the top surface of the mold by scraping or non-selective grinding processes.
[0022] The invention provides a method of forming a mold structure having high-precision multi-dimensional components that includes: forming a plurality of substrates patterned with at least one integrated design; bonding in sequential order the plurality of substrates using a patterned dielectric bonding layer to form a three dimension (3D) mold; and filling the 3D mold followed by an overburden removal of the mold using oxide layer endpoint.
[0023] The invention further provides a mold structure having high-precision multi-dimensional components comprising: a plurality of semiconductor substrates; an oxide layer superimposed on top of each substrate of the plurality of semiconductor substrates; integrated designs patterned in one or more of the oxide layers; and the plurality of semiconductor substrates bonded in sequential order, using dielectric bonding into a three dimensional (3D) mold, the 3D mold selectively filled with the filling material, and the molded component providing a precise replica of the 3D mold structure having multiple patterned layers.
DETAILED DESCRIPTION
[0024] Embodiments of the present invention will now be described in greater detail by referring to the following discussion and drawings that accompany the present application. It is noted that the drawings of the present application are provided for illustrative purposes only and, as such, they are not drawn to scale. In the following description, numerous specific details are set forth, such as the particular structures, components and materials, dimensions, processing steps and techniques, in order to provide a thorough understanding of the present invention. However, it will be appreciated by one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known structures or processing steps have not been described in detail in order to avoid obscuring the invention.
[0025] Referring to FIG. 2A , a cross-section view of an exemplary embodiment of a portion of a three-dimensional mold structure is illustrated with multiple patterned layers consisting of a first substrate 201 onto which an oxide layer 202 is formed.
[0026] In a preferred embodiment, substrate 201 is made of silicon. Substrate 201 may include silicon germanium, 3-5 group semiconductors, quartz, polymers or other organic compounds, and the like. Layer 202 may be formed using any dielectric material that can be fusion bonded. In an embodiment of the present invention, layer 202 is an oxide layer, which may include but is not limited to silicon dioxide material. Oxide layer 202 may be formed using methods commonly known in the art, including but not limited to chemical vapor deposition (CVD), plasma-enhanced chemical vapor deposition (PECVD), thermal oxidation, or spin-coating. The precursor for oxide layer 202 may consist of a silane-based precursor, tetraethyl orthosilicate (TEOS)-based precursor, or other precursor for dielectric materials. The thickness of oxide layer 202 may range from 100 nm to several millimeters, depending on the desired feature size.
[0027] A cavity 203 is formed through oxide layer 202 and extending into substrate 201 . In a preferred embodiment, the cavity 203 may be extended through the substrate to the bottom surface of substrate 201 . In an alternate embodiment, oxide layer 202 may also be patterned using a different pattern than that is used to pattern substrate 201 . The cavity 203 may be formed by patterning processes which include but are not limited to photolithography and deep reactive ion etching, or RIE, of the substrate material. The formation of cavity 203 may be accomplished in one or more process steps, depending on the patterning processes required for the materials associated with substrate 201 and oxide layer 202 , respectively.
[0028] FIG. 2B illustrates a top view along line A-A (of FIG. 2A ) showing cavity 203 formed through the exposed top surface of oxide layer 202 disposed on substrate 201 .
[0029] In parallel with the processing of first substrate 201 depicted in FIGS. 2A and 2B , a second substrate 301 is processed as depicted in FIGS. 3A and 3B . The second substrate 301 also has an oxide layer 302 deposited on the top surface. Similar to substrate 201 , in a preferred embodiment, a second substrate 301 is shown using silicon. In other embodiments, substrate 301 may also be made of silicon germanium, III-V semiconductors, quartz, polymers or other organic compounds, or other materials known in the art. However, substrate 301 may be formed using a different material than substrate 201 . Layer 302 may include any dielectric material that can be fusion bonded. In a preferred embodiment, layer 302 is an oxide layer, which may include but is not limited to silicon dioxide material. Oxide layer 302 may be formed using methods commonly known in the art, including but not limited to chemical vapor deposition (CVD), plasma-enhanced chemical vapor deposition (PECVD), thermal oxidation, or spin-coating. The precursor for oxide layer 202 may consist of a silane-based precursor, tetraethyl orthosilicate (TEOS)-based precursor, or other precursor for dielectric materials. The thickness of oxide layer 302 may range from 100 nm to several millimeters, depending on the desired feature size.
[0030] Unlike the pattern formed in the first substrate previously described, two cavities corresponding to cavities 303 and 304 are formed wherein different patterns are used for the respective cavities 303 and 304 . Cavity 303 is formed with a first pattern in both substrate 301 and oxide layer 302 , respectively, and a second pattern is used to form cavity 304 in oxide layer 302 only. Cavities 303 and 304 may be formed by patterning processes including but not limited to photo-lithography and deep reactive ion etching (RIE), of the substrate material. The formation of cavity 303 may be accomplished in one or more process steps, depending on patterning processes required for the materials associated with substrate 301 and oxide layer 302 , respectively. Cavity 303 may have a depth ranging from less than 1 μm to the full thickness of the substrate 301 . It is to be understood that separate photolithography and etch steps may be required to pattern features 303 and 304 , depending on the materials used for substrate 301 and dielectric layer 302 .
[0031] FIG. 3B illustrates a top view along line A-A (of FIG. 3A ) illustrating cavities 303 and 304 formed through the exposed top surface of oxide layer 302 disposed on substrate 301 .
[0032] After completing the patterning substrates 201 and 301 , both substrates are joined using fusion bonding of the oxide layers. By utilizing fusion-bonded oxide as a substrate joining method, a substrate alignment accuracy of less than 1 μm may be achieved, which is a significant improvement over polymer-based adhesives.
[0033] Referring to FIG. 4A , illustrating a cross section, in one embodiment, substrate 201 is inverted and joined face-to-face with substrate 301 , In an alternate embodiment, substrates 201 and 301 may be aligned and joined face-to-back, using additional processing methods known in the art. Prior to fusion bonding, an activation process may be completed on the top exposed surfaces of dielectric layers 202 and 302 . The activation process may include a wet chemical operation, plasma clean operation, or etch operation. After fusion bonding of the oxide layers 202 and 302 , a thermal annealing operation may be performed. Additionally, after fusion bonding, if cavity 203 does not extend completely through substrate 201 , the surface of substrate 201 that was the bottom exposed surface prior to bonding, which then becomes the top exposed surface of the bonded structure consisting of substrates 201 and 301 after fusion bonding, may be thinned to expose the bottom portion of cavity 203 that was formed in substrate 201 . The thinning operation may be achieved by mechanical removal by grinding, chemical removal by wet etching or reactive ion etching (RIE), chemical mechanical planarization (CMP), or other substrate thinning methods. In a preferred embodiment, the thinning is accomplished with grinding.
[0034] The ability to fabricate molds having complex designs, such as significant undercuts formed by overhanging areas of the constituent mold layers, with high dimensional accuracy is a significant advantage of embodiments of the invention, which is achieved by the use of oxide as the bonding material and fusion bonding as the bonding methodology. Because of the thermal stability of oxide films, it is possible to create highly precise features in each of the oxide layers 202 and 302 that retain the design integrity once joined into a bonded mold structure at significantly higher temperatures than the same features formed in a bonded mold that uses an adhesive as bonding material. The ability to retain integrity of the features during bonding allows for designs that incorporate areas of overhang in which portions of the surfaces of the layers do not overlap, as illustrated in FIG. 4A . The result is a bonded mold that may contain comparably large precise undercuts in the design which would not be possible to produce in mold formed in a single substrate. It is to be understood that while FIG. 4A is not to scale, as long as a sufficient portion of the exposed surface area of oxide layers 202 and 302 are in physical contact and bonded, it is possible to create a mold design in which features exist that one oxide layer may overhang another without compromising the structural integrity of the mold.
[0035] Still referring to FIG. 4A , the resulting three-dimensional mold structure having multiple patterned layers is shown. Composite cavity 405 is formed following bonding accompanied by any required thinning operations. The top surface 404 of the bonded mold structure contains an exposed opening to composite cavity 405 in the exposed surface of substrate 201 , which previously may have been the bottom surface of substrate 201 .
[0036] Referring back to FIG. 4B , a top view along line A-A (of FIG. 4A ) is depicted, with only one design layer of the composite mold cavity 405 visible from the top surface 404 of substrate 201 , concealing the more complex structure of the mold existing in oxide layer 302 and substrate 301 in the bonded stack. After completing the three-dimensional mold structure with multiple patterned layers, filling and finishing operations may be completed to form a component with the shape of composite cavity 405 .
[0037] Referring now to FIG. 5A , the composite cavity 405 from FIG. 4 a - 4 b is illustrated after completion of the filling operation. In one embodiment, the resulting filled cavity 502 may exceed the initial volume of cavity 405 due to the presence of additional overburden of the filling material to ensure adequate fill of the initial composite cavity 405 . The presence of the overburden of the filling material on the top exposed surface of the mold is also depicted in FIG. 5B , which illustrates a top view along line A-A (of FIG. 5A ). In an alternate embodiment, the filled cavity 502 will not cover the top exposed surface of substrate 201 .
[0038] Filling cavity 405 and filled cavity 502 may be achieved by way of any material that may be formed thermoplastically. Additionally, due to the thermal stability of the oxide-oxide bond interface, the filling materials may be selected from those that require high processing temperatures which may be feasible using adhesive-based bonding agents. In a preferred embodiment, the filled cavity 502 may consist of a bulk metallic glass (BMG) composition, including but not limited to BMGs with e.g., platinum-based, zirconium-based, palladium-based, iron-based, silver-based, magnesium-based, or other BMG systems of compositions known in the art. In an alternate embodiment, the filling material may consist of metal in liquid form. In another embodiment, the filling material may consist of polymer. In yet another alternate embodiment, the filling material may be a ceramic material.
[0039] Referring now to FIGS. 6A and 6B , after filling the mold cavity with selected filling material, any additional overburden of the filling material that are present are preferably removed as illustrated in FIGS. 6A and 6B , the latter being a top view along line A-A the cross section as depicted in FIG. 6A . The filled mold cavity 602 with the overburden removed, as indicated by the exposure of substrate 201 as part of the top surface of the mold structure 601 . In a preferred embodiment, the top exposed surface of filled mold cavity 602 is planar with the exposed surface of substrate 201 . In another embodiment, the top exposed surface of the filled mold cavity 602 may be recessed below the exposed surface of substrate 201 . Overburden removal methods may include but are not limited to mechanical removal by grinding, chemical removal by wet etching or reactive ion etching (RIE), chemical mechanical planarization (CMP), mechanical scraping at an elevated temperature, or other overburden removal method. The optimal overburden removal process may depend on the filling material selected for the molded component. In a preferred embodiment, mechanical grinding and CMP are employed as methods of overburden removal. In another embodiment, the interface between the fill material overburden and substrate 201 may be used as an indicator for endpoint detection methods associated with the overburden removal process.
[0040] Referring to FIGS. 7A and 7B , the final molded component resulting from the structure and method of forming and filling the three-dimensional mold having multiple patterned layers is illustrated, according to an exemplary embodiment of the invention after removal from the mold. As illustrated in FIG. 7A , depicting a cross-sectional view of the molded component, and FIG. 7B showing a top view along line A-A (of FIG. 7A ). Mold removal methods preferably include but are not limited to chemical etching of the mold and mechanical fracturing of the mold, with the selected removal method resulting in the complete separation of the final molded component from the mold structure. In one embodiment, the chemical etching of the mold may be achieved using potassium hydroxide (KOH), using concentrations known to those skilled in the art. In an alternate embodiment other wet chemical agents may be used to etch the mold, including but not limited to TMAH, NH 4 OH, HNA, SPIN-ETCH“B”™, or other chemical etchants, dependent on the substrate material selected for substrates 201 and 301 .
[0041] Referring to FIGS. 8A and 8B illustrate an embodiment showing an alternate exemplary method of removing the excess overburden of filling material from the three-dimensional mold having multiple patterned layers in which the interface between substrate 201 and oxide layer 202 is used as an endpoint indicator for the overburden removal process. As a result, substrate 201 is entirely removed from the mold, exposing the top surface of the mold consisting of the non-fusion bonded surface of oxide layer 202 , as shown in the resulting structure depicted in FIGS. 8A and 8B , which illustrate the cross-sectional view and top view along line A-A (of FIG. 8A ), respectively. In an alternate embodiment, the pattern formed in oxide layer 202 and the pattern formed in oxide layer 302 or substrate 301 may consist of the same pattern. When thin oxide layers are used, the use of the same pattern may allow for high precision and micron-scale final thickness of the final molded component resulting after the filled mold cavity 802 is released from the mold.
[0042] While the present disclosure has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the scope and spirit of the present disclosure. It is therefore intended that the present disclosure not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims. | A mold structure having high-precision multi-dimensional components includes: depositing an oxide layer on a top surface of a plurality of semiconductor substrates, patterning a design integrated in one or more of the oxide layers; repositioning the substrates to enable the oxide layers make contact with one another; bonding in sequential order the repositioned substrates using a dielectric bonding, forming a three dimension (3D) mold; filling the 3D mold with filling material and removing the overburden filling material present on a top surface of the component. | 1 |
This is a continuation application of application Ser. No. 08/116,858, filed on Sep. 7, 1993, abandoned, which is a continuation of Ser. No. 07/906,364, filed Jul. 6, 1992, abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a table tennis game, and in particular, to a table tennis game that can be played by one player, requiring the player to return a served ball and score by striking one or more targets strategically placed on the table surface.
Table tennis is a popular recreational activity commonly known as "ping-pong". The traditional game is played by two players, each positioned at an opposite end of the table so as to volley the table tennis ball across the net affixed at the mid-point of the table. Four players can play a doubles game in similar fashion.
The object of the traditional game is to make a shot across the net that the opposing player cannot return. A point is scored when one player cannot return a shot. Therefore, a successful or skillful player is one who can strategically place the ball at a point on the table that will cause the ball to carom out of the opponent's reach or to carom in a such a manner as to be difficult for the other player to return.
One draw back of traditional table tennis or "ping-pong", is that it takes at least two players to play. It is desirable, therefore, to have a game that can be played by only one player. To that end, ball-throwing or ball-serving devices serve a useful purpose. Ball-serving devices or robots are well known to the art. Generally speaking, a ball serving device serves a ball to the player and the player returns the shot to a net or other ball catching device affixed to the ball serving machine. Although such table tennis ball serving devices or "robots" allow a player to play alone, they do not have the capacity to require the player to return a shot with particular accuracy or refinement. As stated above, the player simply returns the shot into a net or catching device surrounding the robot. The robot allows the player to develop overall ability in the game, such as returning a serve in the general field of play. Robots play does not reward a player for stroke accuracy or placement.
The present invention is designed to be used with an automatic table tennis ball serving device or robot such as those described in U.S. Pat. Nos. 4,844,458; 4,854,588; and 4,917,380, all to Gatchel et al. and all assigned to the inventor of the present invention, the disclosures of which are hereby incorporated by reference. The present invention consists, basically, of a plurality of low profile sensors that can be placed strategically on the table tennis table surface. The sensors can accurately record a "hit" made by a table tennis ball striking the sensor. The sensors are electronically connected to a score-keeping device that keeps track of the player's score as well as the robot's score and the elapsed time of the game. Therefore, the game rewards the player who can direct his shot with accuracy and speed. This provides a more challenging game and also provides a method for the player to hone shot-making skills.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a table tennis game that can be played by one player which requires the player to score by making strategically placed shots.
Another object of the invention is to provide a table tennis game that can be used with an automatic ball serving device.
Another object of the invention is to provide a table tennis game that employs sensors that can accurately record a "hit" made by a table tennis ball striking the sensor.
Still another object of the invention is to provide a table tennis game that provides a score-keeping mechanism that keeps track of the player's score, the automatic server's score, and the amount of time in which to play a game.
Still another object of the invention is to provide a game that allows the player to select the difficulty of the game by manipulating the number of sensors, size of the sensors, the point level assigned to each sensor, time of the game, or the difficulty of the serve or shot made by the automatic ball server.
Another object of the invention is to provide a table tennis game that can be used with a conventional table tennis table.
Yet another object of the invention is to provide a game that is simple and economical to manufacture, low cost, easy to set-up and to use, and well suited for its intended purpose.
Briefly stated, an automatic table tennis game to be used on a table with a table tennis ball serving device, the game having a plurality of sensors capable of arrangement on the surface of the table so as to provide one or more targets for the player returning a table tennis ball served by the ball serving device, the sensors having means for detecting impact of a table tennis ball, a micro computer means for converting the impact into a score, and means for displaying the score of the player, the score of the serving device, and the time of the game or variations thereof. The level of the difficulty of the game can be varied by the selection of the sensor size, the shot value, time of the game, and speed or trajectory of the served ball.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one arrangement of the table tennis game of the present invention placed on a table, shown in phantom, employing a robot table tennis ball sensor;
FIG. 2 is a perspective view of a sensor element of the present invention shown with a table tennis ball in phantom, illustrating the low profile of the sensor;
FIG. 3 is an exploded view of a sensor element of the present invention;
FIG. 4 is a top plan view of an illustrative embodiment of a strain relief component of the present invention;
FIG. 5 is a side elevational view of the strain relief component of FIG. 4;
FIG. 6 is a front elevational view of the electronic control component of the table tennis game of the present invention;
FIG. 7 is a schematic illustrating the impact signal circuitry of the present invention; and
FIG. 8 is a schematic illustrating the microcomputer support circuitry of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, a table tennis game of the present invention is shown generally in FIG. 1 at 1. Game 1 is shown in one of an infinite number of arrangements on a table tennis table T, shown in phantom to illustrate environment. In this particular embodiment, game 1 is shown in use with a robot table tennis serving device 3 and the surrounding net 5 so as to provide a source of balls to be used in the game as will be explained hereinafter.
Game 1, as shown in FIG. 1, includes a plurality of sensors pads 7, 7a, 7b, 7c, 7d, 7e. The sensor pads serve as targets at which the human player aims a shot when returning a table tennis ball served by the robot server 3.
The game utilizes a control box, shown generally at 9. Control box 9 houses a microprocessor unit programmed to coordinate and integrate the elements of the game. Control box 9, which is removably mounted to table T, is connected to sensors 7, 7a, 7b, etc. by wires 8, 8a, 8b, etc. Control box 9 also serves as a score board and control center with appropriate displays and input keys (see FIG. 7) as will be explained in detail.
In use, game 1 can be played with an automatic robot server 3 in the following manner:
Sensors 7, 7a, 7b etc. are placed on the top of table T on the opposite side of table T from the player (on the same side as robot 3). A game begins with a player selecting the number and size of sensors 7, 7a, 7b, etc. that the player wishes to use. The player can arrange the sensors on table T in any desired arrangement. The player then mounts the control box 9 on table T and connects wires 8, 8a, 8b, etc. to the control box. Wires 8, 8a, 8b, etc. are long enough to allow placement of the sensors anywhere on table T.
The player can select the type of shot the robot delivers and the frequency of the shots as described in U.S. Pat. No. 4,854,588 the disclosure of which is hereby incorporated by reference. The game begins when the player presses an input key pad on the control box to start counting down the game time. The object of the game is beat the robot by scoring, for example 21 points, before the robot scores 21 points. The player scores by returning a ball served by the robot and making his shot strike a sensor, for example, by striking sensor 7. Control box 9 can be programmed to assign any one of a range of points, for example, 1-3 points per sensor, thereby varying the point value of the sensors and altering the difficulty of the game as will be explained hereinafter.
In the preferred embodiment, the robot scores points from the amount of time it takes to play the game. For example, if the amount of time selected for a game is 21 minutes (programmable into control box 9 as will be explained), the robot will score one point for every minute that elapses from the time the game starts until it ends. In this embodiment the robot wins if 21 minutes elapses before the human player scores 21 points; the player wins if he scores 21 points before 20 minutes have elapsed. Should either of these two conditions not occur, the game will continue until either the robot or the human player is two points ahead of the other.
The game allows many options for the player to match the difficulty of the game to his or her skill level. For example, the length of the game can be changed; the more time in the game, the easier it is for the player to win. The second option that can be varied is the number of sensors used. The more sensors placed on table T, the easier it is for the player to score. Sensors 7, 7a, 7b, etc. may be varied in size. The larger the sensor, the easier it is for the player to strike the sensor and therefore the easier it is for the human player to win. Finally, control box 9, as stated, can be programmed to set the point level for the sensors. For example, point levels could be set at 1, 2, or 3 points per strike. Obviously, the higher the score per strike, the easier it is for the human player to win.
Finally the difficulty of the serve or shot of the table tennis ball delivered by the robot be adjusted. The various perimeters that can be adjusted can include the spin placed on the ball, ball speed, frequency of the shot deliver, height of the ball trajectory, and whether the ball is served to one spot on table T or served to different spots. As stated above, the adjustment of the robot is as disclosed in U.S. Pat. No. 4,854,588 and is incorporated by reference.
Turning now to a more detailed description of the elements of the game, FIG. 2 illustrates a sensor 7 used in conjunction with the present invention. In FIG. 2, sensor 7 is shown next to a table tennis ball B in phantom so as to demonstrate the low profile aspect and construction of sensor 7. It is to be understood that sensor 7 can be of any diameter. Generally, the game employs sensors of three different diameters as shown in FIG. 1.
Sensor 7, shown in greater detail in FIG. 3, includes an impact pad 11, an impact disc 13 and an impact sensor element, shown at 17, interposed between pad 11 and disc 13. As previously stated, pad 11 and disc 13 are of variable diameter depending upon the contact area size desired for the sensor.
Impact disc 13 is made of an appropriate material, for example, 0.76 mm thick polystyrene plastic. Impact disc 13 serves as the base of sensor 7.
Piezo film sensor element 17 is bonded to disc 13, near the periphery. Piezo film sensor 17 includes a piezo film material that generates voltage when a compressive or expansive stress is applied. Element 17 has a wire connector 18 on the top side and has a suitable adhesive on the bottom side. Sensor element 17 is bonded to disc 13 so that any flexing of disc 13, for example, due to the contact of a table tennis ball on sensor 7, will apply stress to sensor element 17. Sensor element 17 generates voltage when stressed and is electrically connected to control box 9 (FIG. 1, 6), by wires, for example, a wire pair 8. The electrical voltage generated by element 17 when sensor 7 is struck by a table tennis ball travels along wire pair 8 to control box 9 and is processed by the microcomputer contained therein as will be explained below.
Wire pair 8 is secured in place by strain relief support 19, a small, slightly rigid, transparent plastic component that provides support to wire 8 for a short distance beyond the periphery of disc 13. Flexible film 21, with a suitable adhesive on the bottom surface, serves to bond wire 8 to strain relief 19 and bond strain relief 19 to disc 13. Therefore, film 21 must be oversized as to strain relief 19. The area covered by film 21 includes connector 18 on sensor element 17 providing strength and protection to the connection.
FIGS. 4 and 5 give a more detailed view of strain relief 19. Strain relief 19 has wire access hole 20 formed in one end of elongate section 27. Wire pair 8 is introduced up through hole 20 and along elongate portion 27. Wire pair 8 is split and each segment laced through indention 23 and 23a resting against shoulders 24 and 24a respectively and then laced under rectangular segment 25. The ends of wire pair 8 are exposed and secured to connector 18 on sensor element 17 and bent back across rectangular segment 25 so as to be secured by film 21. If a force or strain is exerted on either wire of the pair 8, the two segments of wire pair 8 are braced against shoulders 24 and 24a of slots 23 and 23a respectively so as to prevent wire pair 8 and the connected element 17 from being pulled away from disc 13.
Impact pad 11 is of an appropriate diameter so as to cover the sensor element 17 and strain relief element 19 and center over pad 13. Pad 11 can be formed from appropriate material, such as a high-density polyurethene foam with a very fine cell structure. Pad 11 is extremely flexible and may stretch more than 150% of its original length without failure.
Turning now to a detailed description of control box 9, shown in detail at FIG. 6. Control box 9 has a housing 10 that can be constructed in any convenient or functional configuration and constructed of appropriate material such as high impact plastic or light gauge metal. Mounting bracket 14 affixed to the bottom of housing 10 serves to mount control box 9 on the edge of table T so as to be visible to and in convenient reach of the player, yet remaining outside of the field of play. Face plate 12 serves as a score board, having displays, for example, a display 16 to display the robot server's score, a display 18 to display the human player's score, a display 22 to display the elapsed time of the game. Box 19 has input keys to initiate functions of the game. Input key 24 for example, can be pushed to increase the length of time of the game; input key 26 can be pushed to decrease the playing game of the game; input key 28 serves to reset the time controls; and input key 30 functions as a start switch which is pushed to begin the game. Lights 31, 33 can be color coded, for example red and green respectively, to indicate game on or game over. It should be noted that the configuration of face plate 12 as well as the design and placement of the displays, and design and placement of the input keys as well as the various functions of the input keys can be varied without departing from the scope of the invention.
A programmable microcomputer (shown in FIG. 8) is housed in control box 9 and functions to control the input from the sensors, for example, sensors 7, 7a, 7b, etc. (FIG. 1), and to provide timing and score keeping functions. User interface is provided by the input keys, for example, input keys 24, 26, 28 and 30 as well as by displays 14-18 as described above.
The input signal conditioning circuitry (FIG. 7) consists of three channels, 32, 34, and 36 with two inputs per channel. This provides for six inputs per game. Each channel's output is split and applied through switches 38, 40 and 42 to summing/latch circuits 44, 46. One of the latches represents, for example, a score of 1 point and the other a score of 2 points. Scoring for each channel is determined by closing the switch to either the "1" scoring latch or the "2" scoring latch. If both latches are selected, channel scores 3 points. Each channel can be independently set for 1, 2 or 3 points or points as desired.
FIG. 8 illustrates the remainder of the electronic control circuitry shown generally at 48. Circuitry 48 is composed of displays 50, 52 and 54, the input switches 56, 58, 60 and 62, the microcomputer 64, and support circuitry 66. The microcomputer drives displays 50, 52 and 54 and also reads input keys 56, 58, 60 and 62; the microcomputer monitors the latch conditions and determines game status. The microcomputer is driven by a program which may be varied or enhanced without departing from the scope or spirit of the invention.
In view of the above, it will be seen that various objects and features of the present invention are achieved and other advantageous results are obtained. As various changes could be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A table tennis game is provided that can be used with an automatic table tennis ball serving device, the game including a plurality of sensors which can be arranged on the surface of the table to serve as targets, the sensors having means for detecting the impact of a table tennis ball. The game contains a programmable microcomputer connected to the sensors which converts the impact into a score, calculates the automatic server's score, times the game, and displays the respective scores and elapsed time of play. | 0 |
BACKGROUND OF THE INVENTION
Diisopropenylbenzene is a monomer that can be used in the preparation of useful polymers and is also a chemical intermediate that can be used in a number of chemical processes. Diisopropenylbenzene can be synthesized by the dehydrogenation of diisopropylbenzene. For example, meta-diisopropylbenzene (m-DIPB) can be dehydrogenated into meta-diisopropenylbenzene (m-DIB) and para-diisopropylbenzene (p-DIPB) can be dehydrogenated into para-diisopropenylbenzene (p-DIB). Unfortunately, in this dehydrogenation process some olefinic impurities are produced as by-products. These olefinic impurities include isopropylstyrene, divinylbenzene, isopropenyl styrene, and other similar organic impurities. Obviously, it would be very desirable to remove these impurities from the meta- or para-diisopropenylbenzene produced by the dehydrogenation of diisopropylbenzene.
It was believed that meta- or para-diisopropenylbenzene could be removed from these organic impurities by fractional distillation. However, when fractional distillations were attempted the contents of the distillation pot (p-DIB or m-DIB and the organic impurities) polymerized into a gel at the elevated temperature needed for the distillation making it impossible. This polymerization even takes place with as much as 1,000 ppm (parts per million) of polymerization inhibitor present in the distillation pot with gel formation long before all of the diisopropenylbenzene can be recovered.
Sometimes unwanted by-products can be removed by hydrogenation. For example, U.S. Pat. Nos. 3,887,632, 3,912,789, and 3,922,318 show that acetylenes can be removed from a stream containing butadiene and/or isoprene by selective hydrogenation.
SUMMARY OF THE INVENTION
It was found that if a dehydrogenation mixture (mixture of diisopropenylbenzene and organic impurities formed in the dehydrogenation of diisopropylbenzene) containing about 3.7% or less by weight isopropenylstyrene (IPS) is heated to the temperature required for fractional distillation (about 150° C. to about 165° C.) that it will not polymerize to a gel in the distillation pot. On the other hand, it was found that if a dehydrogenation mixture containing 7.4% or more by weight isopropenylstyrene is distilled, the contents of the distillation pot polymerizes to a gel in 2 to 5 hours. This is long before all of the diisopropenylbenzene can be recovered. Thus, it was discovered that polymerization and gel formation in the dehydrogenation mixture during distillation can be eliminated by reducing isopropenylstyrene concentrations to below about 3.7 weight percent.
It was unexpectedly found that the isopropenylstyrene in the dehydrogenation mixture could be selectively hydrogenated wihout a significant amount of diisopropenylbenzene being hydrogenated by utilizing a rhodium catalyst. After a dehydrogenation mixture is selectively hydrogenated using a rhodium catalyst to reduce isopropenylstyrene concentrations below 3.7% by weight, it can be fractionally distilled to separate the m-DIB or p-DIB from the organic impurities without gel formation.
This invention discloses a process for the separation of diisopropylbenzene from organic impurities in a dehydrogenation mixture comprising: (1) hydrogenating said dehydrogenation mixture to a maximum isopropenylstyrene concentration of no more than about 5 percent by weight in the presence of a rhodium catalyst and hydrogen to form a hydrogenated dehydrogenation mixture, followed by, (2) fractionally distilling said hydrogenated dehydrogenation mixture under conditions sufficient to separate said diisopropenylbenzene from said organic impurities in said hydrogenated dehydrogenation mixture. This invention utilizes a process for removing isopropenylstyrene from a dehydrogenation mixture with only minimal hydrogenation of diisopropenylbenzene which comprises: hydrogenating said dehydrogenation mixture in the presence of a rhodium catalyst and hydrogen.
DETAILED DESCRIPTION
Meta-diisopropenylbenzene and para-diisopropenylbenzene can be produced by the dehydrogenation of meta-diisopropylbenzene and para-diisopropylbenzene, respectively. In this diisopropylbenzene dehydrogenation process a dehydrogenation mixture is produced that contains diisopropenylbenzene and a number of organic impurities. These organic impurities include isopropylstyrene, divinylbenzene, isopropenylstyrene, and a number of other olefinic impurities. A small amount of diisopropylbenzene that was not dehydrogenated is usually also present in the dehydrogenation mixture. During the dehydrogenation of meta-diisopropylbenzene as much as 12 percent of the dehydrogenation mixture produced can be isopropenylstyrene which was produced as an unwanted by-product.
In order to fractionally distill the dehydrogenation mixture, to separate the diisopropenylbenzene from organic impurities, the amount of isopropenylstyrene present in the dehydrogenation mixture must be kept below about 5 percent by weight. It is preferable to reduce the amount of isopropenylstyrene (IPS) in a dehydrogenation mixture that will be distilled to about 3.4 weight percent or less.
IPS can be removed from a dehydrogenation mixture by hydrogenation utilizing a rhodium catalyst. The rhodium catalyst that is used in this dehydrogenation reaction can be either supported or unsupported. It is generally preferable for the rhodium to be supported. Some representative examples of supports that can be used for the rhodium include: carbon, aluminum oxide (alumina), barium sulfate, calcium carbonate, and strontium carbonate. A rhodium-on-charcoal catalyst is an excellent choice as the catalyst in this hydrogenation reaction. The catalyst can be in a fixed bed for hydrogenation on a continuous basis or distributed throughout the dehydrogenation mixture in the case of a batch process. This hydrogenation of the dehydrogenation mixture obviously must be conducted in the presence of hydrogen gas.
This hydrogenation reaction can be done in a batch process by distributing the hydrogen gas and rhodium catalyst throughout the dehydrogenation mixture. For example, hydrogen gas can be sparged through the dehydrogenation mixture containing the catalyst while agitating the dehydrogenation mixture to keep the catalyst well dispersed throughout the mixture. This hydrogenation reaction can be run on a continuous bases by introducing hydrogen gas into the zone of the fixed bed catalyst while passing the dehydrogenation mixture through the fixed bed catalyst.
This hydrogenation reaction can be carried out at atmospheric pressure (1.0×10 5 Pa) up to about 1000 gauge pounds per square inch (7.0×10 6 Pa). It is preferred for the hydrogenation reaction to be run at about 50 gauge pounds per square inch (4.5×10 5 Pa) up to about 70 gauge pounds per square inch (5.8×10 5 Pa). The hydrogenation reaction for the dehydrogenation mixture containing meta-diisopropenylbenzene can be run at a temperature from about 0° C. up to about 120° C. It is preferable to run this hydrogenation reaction at room temperature (about 20° C. to 24° C.). The hydrogenation reaction for the dehydrogenation mixture containing para-diisopropenylbenzene can be carried out at a temperature from about 50° C. up to about 100° C. It is preferable to run this hydrogenation reaction at about 55° C. to 60° C. This hydrogenation reaction should preferably be continued until about 2 moles of hydrogen are absored for every mole of isopropenylstyrene originally present in the dehydrogenation mixture. More preferably the hydrogenation should be continued until 3 moles of hydrogen are absorbed for every mole of isopropenylstyrene originally present in the dehydrogenation mixture. The hydrogenation of the dehydrogenation mixture results in the formation of a hydrogenated dehydrogenation mixture.
The rhodium catalyst can be removed from a hydrogenated dehydrogenation mixture that was hydrogenated in a batch process by filtration, centrifugation, sedimentation, and the like. If a fixed bed catalyst is used in a continuous hydrogenation process then obviously there is no catalyst that needs to be removed from the hydrogenated dehydrogenation mixture. The m-DIB or p-DIB can be fractionally distilled from a hydrogenated dehydrogenation mixture containing less than about 5 weight percent (preferably 3.4 weight percent or less) isopropenylstyrene using distillation techniques known to those skilled in the art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples demonstrate the effectiveness of rhodium catalysts in selectively hydrogenating isopropenylstyrene without significantly hydrogenating diisopropenylbenzene in a dehydrogenation mixture. These examples are merely for the purpose of illustration and are not to be regarded as limiting the scope of the invention or the manner in which it can be practiced. Unless specifically indicated otherwise parts and percentages are given by weight.
EXAMPLE 1
Meta-diisopropylbenzene was dehydrogenated to a crude dehydrogenation mixture that contained the composition shown in Table I. 194 g (grams) of this dehydrogenation mixture was placed into a Parr bottle with 0.6 g of a 5% rhodium-on-charcoal catalyst (50% water weight). The catalyst added contained only 0.015 g of rhodium (50% of the 0.6 g was water weight and 95% of the remaining 0.3 g was carbon). This dehydrogenation mixture was hydrogenated with 50 gauge pounds per square inch (4.5×10 5 Pa) of hydrogen gas at room temperature. The composition of the hydrogenated dehydrogenation mixture being produced was determined after 1, 2, and 3 moles of hydrogen per mole of isopropenylstyrene originally present in the dehydrogenation mixture was absorbed. The amounts of the various components given in Table I are given as area percentages as determined by gas chromatography.
TABLE I______________________________________Gas Chromatograph Area Percentages forVarious Mixture ComponentsIPS Moles of H.sub.2 absorbed/moleComponent 0 1 2 3______________________________________m-isopropenylethylbenzene 2.0 4.1 6.3 8.5m-diisopropylbenzene 8.7 9.1 9.2 9.8m-isopropenylstyrene 7.5 5.4 2.8 0.3m-isopropenylisopropyl- 16.5 16.1 15.8 16.1benzenem-diisopropenylbenzene 39.8 38.6 39.0 37.8______________________________________
As can be determined from Table I, after 2 moles of hydrogen per mole of IPS had been absorbed 63 percent of the m-IPS was removed (hydrogenated) while only 2 percent of the m-DIB was removed. After 3 moles of hydrogen per mole of IPS had been absorbed 96% of the m-IPS was removed while only 5% of the m-DIB was removed. This example illustrates the fact that rhodium is an excellent catalyst for the selective hydrogenation of IPS that hydrogenates only a minimal amount of DIB.
EXAMPLE 2
The same procedure that was employed in Example 1 was used in Example 2 except that palladium was substituted for the rhodium. After 2 moles of hydrogen per mole of IPS was absorbed 46% of the m-IPS had been removed and 13% of the DIB had been removed. After 3 moles of hydrogen per mole of IPS was absorbed 73% of the IPS had been removed and 19% of the DIB had been removed. This Example illustrates the fact that palladium is not as good as rhodium for the selective hydrogenation of IPS in a dehydrogenation mixture (compare Examples 1 and 2).
EXAMPLE 3
100 g of a dehydrogenation mixture containing 87.1% p-DIB, 6.9% p-IPS, and 6% unknown impurities; 220 cubic centimeters of isopropanol; and 0.7 g of a 5% rhodium-on-charcoal catalyst (50% water weight) was placed in a Parr bottle. This mixture was heated to 55° C. at which point all of the solids dissolved. Hydrogen gas was introduced to the bottle at a pressure of 4.5×10 5 Pa(Pascal) and the mixture was allowed to hydrogenate at 55° C. to 60° C. until 3 moles of hydrogen had been absorbed per mole of IPS originally present in the dehydrogenation mixture. The catalyst was filtered from the hydrogenated dehydrogenation mixture and the mixture was allowed to cool and crystallize. 51.13 g of material was recovered which had a composition of 98.9% p-DIB, 0.5% p-ethylisopropenylbenzene, 0.2% p-isopropenylisopropylbenzene, and 0.4% unknown impurities.
While certain representative embodiments and details have been shown for the purpose of illustrating the invention, it will be apparent to those skilled in this art that various changes and modifications may be made therein without departing from the scope of the invention. | This invention discloses a process for the separation of diisopropenylbenzene from organic impurities in a dehydrogenation mixture comprising: (1) hydrogenating said dehydrogenation mixture to a maximum isopropenylstyrene concentration of no more than about 5% by weight in the presence of a rhodium catalyst and hydrogen to form a hydrogenated dehydrogenation mixture, followed by, (2) fractionally distilling said hydrogenated dehydrogenation mixture under conditions sufficient to separate said diisopropenylbenzene from said organic impurities in said hydrogenated dehydrogenation mixture. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to strains of bacteria and pharmaceutical compositions containing one or more of such strains and the use of same for preventing and treating diseases associated with or caused by an altered metabolism of bile acids.
[0003] 2. Discussion of the Background
[0004] Hepatic bile is a pigmented isotonic fluid with an electrolyte composition resembling blood plasma. Major components of bile include water (82 percent), bile acids (12 percent), lecithin and other phospholipids (4 percent), and unesterified cholesterol (0.7 percent). Other constituents include conjugated bilirubin, proteins, electrolytes, mucus and the final products of hepatic transformation of drugs, hormones, etc. The liver production of bile, in basal conditions, is approximately 500-1000 ml/day.
[0005] The primary bile acids, cholic acid (CA) and chenodeoxycholic acid (CDCA), are synthesized from cholesterol in the liver, conjugated with glycine or taurine, and excreted into the bile. Secondary bile acids, including deoxycholic acid (DCA) and lithocholic acid (LA), are formed in the colon as bacterial metabolites of the primary bile acids. Other bile acids, called tertiary bile acids (e.g.: ursodeoxycholic acid—UDCA), are formed in the gut following the enzymatic epimerization of —OH groups on sterol rings by the intestinal flora.
[0006] In normal bile, the ratio of glycine to taurine conjugates is about 2:1, while in patients with cholestasis, increased concentrations of sulfate and glucuronide conjugate of bile acids are often found. The intestinal microflora transforms the bile acids into different metabolites. These biotransformations include the hydrolysis of the bond between the bile acid and taurine or glycine, with formation of unconjugated or free bile acids and taurine or glycine. The unconjugated bile acids are therefore made available for the oxidation of the hydroxylic groups in positions C3, C7, and C12 and for the dehydroxylation in positions 7α and 7β. This latter transformation leads to the formation of the secondary bile acids DCA and LA. The primary bile acids, deconjugated bile not transformed, and the secondary biliary acids are reabsorbed from the gut lumen and enter the portal bloodstream, then are taken up by hepatocytes, conjugated with glycine or taurine and resecreted into the bile (enterohepatic circulation).
[0007] Normally, the bile acid pool circulates approximately 5 to 10 times daily. Intestinal absorption of the pool is about 95% efficient, so fecal loss of bile acids is in the range of 0.3 to 0.6 g/day. The fecal loss is compensated by an equal daily synthesis.
[0008] For this reason the composition of the pool of biliary acids present in the bile is the result of complex interactions occurring between the liver and the microflora enzymes.
[0009] Deconjugation activity is a characteristic shared by many bacteria, aerobes and anaerobes, but is particularly common among the obligate anaerobic bacteria, i.e. Bacteroides, Eubacteria, Clostridia, Bifidobacteria , etc. The majority of the bacteria is active against both glycine and taurine conjugates; however, some of them have a certain degree of specificity, depending on the bound amino acid and the number of hydroxides bound to the steroid nucleus. The free biliary acids obtained following the action of the bacterial hydrolases can undergo the oxidation of the hydroxide groups present at the C3, C7, and C12 positions by the hydroxysteroidodehydrogenase.
[0010] The interest in the metabolic disorders of biliary acids comes from the hypothesis that biliary acids and/or metabolites thereof are involved in the pathogenesis of some hepato-biliary and gastroenterologic diseases: biliary dyspepsia, cholelithiasis, acute and chronic hepatopathies, inflammatory diseases of the colon, etc.
[0011] Very often in literature the hydrophobicity of the bile acid is correlated with detergency; the secondary bile acids are more hydrophobic than the primary bile acids, the deoxycholic acid (DCA) being actually more detergent than the cholic acid (CA). Therefore an increased concentration of DCA in the bile may involve: a) an augmentation of the secretion of cholesterol, with increased saturation index; b) a cytotoxic effect on the liver cells.
[0012] For this reason a qualitative modification of the bile acids pattern could be a decisive factor, especially in treating the above-mentioned pathologies.
[0013] Thus, there remains a need for effective bacterial strains or compositions that, by reducing the 7α-dehydroxylase activity and at the same time deconjugation, can be used for treating and/or preventing diseases associated with metabolic disorders of the biliary acids.
[0014] No bacteria strains have been found that are capable of qualitatively modifying the bile acid pattern in such a way.
SUMMARY OF THE INVENTION
[0015] Accordingly, it is one object of the present invention to provide novel strains of bacteria, in particular gram-positive bacteria, which are useful for treating and/or preventing diseases associated with or caused by a metabolic disorder of biliary acids.
[0016] It is another object of the present invention to provide pharmaceutical compositions which contain one or more strains of such bacteria and are useful for treating and/or preventing diseases associated with or caused by a metabolic disorder of biliary acids.
[0017] It is another object of the present invention to provide a novel method for treating and/or preventing diseases associated with or caused by a metabolic disorder of biliary acids.
[0018] The foregoing and other objects, which will become more apparent during the following detailed description, have been achieved by the inventors, who have found bacteria strains having a reduced or zero 7α-dehydroxylase activity and a reduced or zero ability to deconjugate bile acids. This is in contrast with the previous known art. Accordingly, the present invention provides the use of such strains to modify the bile acid metabolism in a useful manner to prevent or treat diseases caused by or associated with metabolic disorders of biliary acids.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Thus, in a first embodiment, the present invention provides novel strains of bacteria which have a 7α-dehydroxylase activity of less than 50%, preferably less than 25%, and a conjugated bile acid deconjugation activity of less than 50%, preferably less than 25%.
[0020] The essential features of the strains according to the present invention are defined in claim 1 ; specific strains having said features are defined in the dependent claims 2 to 11 .
[0021] The present invention also provides a pharmaceutical composition for treating and/or preventing diseases associated with or caused by an altered metabolism of biliary acids, said composition comprising at least one bacteria strain according to the present invention. The essential features of the composition according to the present invention are defined in claim 12 ; specific embodiments of said composition are defined in the dependent claims 13 to 25 .
[0022] In another embodiment, the present invention provides a method for treating and/or preventing diseases caused by or associated with an altered metabolism of biliary acids by administering to a patient in need thereof one or more strains of bacteria which have a 7α-dehydroxylase activity of less than 50%, preferably less than 25%, and a conjugated bile acid deconjugation activity of less than 50%, preferably less than 25%, or a pharmaceutical composition containing one or more such strains of bacteria.
[0023] The essential features of said method are defined in claim 26 ; specific embodiments are defined in the dependent claims 27 to 36 .
[0024] In the context of the present invention, the diseases associated with or caused by a metabolic disorder of the biliary acids include liver diseases and diseases of the digestive apparatus, such as blind loop syndrome, biliary gallstones, cirrhosis, chronic hepatopathies, acute hepatopathies, cystic fibrosis, intrahepatic cholestasis, intestinal inflammatory diseases, colonpathies, malabsorption. The present pharmaceutical compositions may also be used to prevent the onset of biliary gallstones in women during pregnancy or subsequent periods and in subjects undergoing weight-loss programs or diets.
[0025] The 7α-dehydroxylase activity of the bacteria strain should be less then 50%, preferably less than 25%. The 7α-dehydroxylase activity values are those measured by the method described in Example 1 below. Specifically, the 10 7 cells of the strain in question are incubated at 37° C. for 48 hours, in 15 ml of the specific culture medium with the addition of 2 mg/ml of glycocholic acid (GCA) or 2 mg/ml of taurocholic acid (TCA), and then the amount of 7α-dehydroxylated product is measured. The percentage value for the 7α-dehydroxylase activity is calculated by the following formula:
7 α - dehydroxylase activity = mass of 7 α - dehydroxylated product after 48 hours of incubation mass of GCA or TCA at the start of incubation × 100
[0026] The 7α-dehydroxylase activity for any given strain is the higher of the numbers measured for GCA and TCA.
[0027] Based on the above, the bacteria strain to be administered should in addition have a conjugated bile acid deconjugation activity of less than 50%, preferably less than 25%. The ability to deconjugate bile acid is determined by using the same incubation procedure described for measuring the 7α-dehydroxylase activity followed by measuring the amount of deconjugated product formed. The deconjugation activity is calculated using the following formula:
Deconjugation activity = mass of deconjugated GCA or TCA after 48 hours of incubation mass of GCA or TCA at the start of incubation × 100
[0028] The deconjugation activity for any given strain is the higher of the numbers measured for GCA and TCA.
[0029] The bacteria strains of the present invention may be administered enterically. Preferably, the bacteria strains of the present invention are administered orally.
[0030] Although a single bacteria strain may be administered, it is also possible to administer a mixture of two or more bacteria according to the present invention.
[0031] Although the exact dosage of bacteria to be administered will vary with the condition and size of the patient, the exact disease being treated, and the identity of the strains being administered, good results have been achieved by administering 10 3 to 10 13 cells of the bacteria/g, preferably 10 8 to 10 12 of the bacteria strain/g. To achieve the good effects of the present invention, it is preferred that the strain be administered in an amount and a concentration sufficient to result in the intestines of the patient being populated with an important amount thereof. Thus, it is preferred that the strain be administered in a composition which contains 10 3 to 10 13 cells of the strain/g, preferably 10 8 to 10 12 cells of the strain/g and that the composition be administered in such a regimen so that the patient receives 100 mg to 100 g of the strain/day, preferably 1 g to 20 g of the strain/day, for a period of 1 to 365 days, preferably 3 to 60 days in case of therapy, or according to periodical cycles in case of prophylaxis. The bacteria strain may be administered in any form suitable for enteral administration, such as capsules, tablets, or liquids for oral administration or liquids for enteral administration.
[0032] Typically, the administration of the bacteria strain according to the present invention can be prescribed after the diagnosis of metabolic disorders of the biliary acids. However, in the case of the prophylaxis of biliary gallstones, the strain may be administered when the subject is determined to belong to an at-risk population, such as becoming pregnant or beginning a weight-loss program or diet. In addition, the present strain of bacteria may be administered after a patient has had their gallbladder removed.
[0033] In a preferred embodiment, the coadministration of lactulose is provided when the disease being treated is cirrhosis. Suitably, the lactulose is administered in an amount of 100 mg to 100 g/day, preferably 1 g to 20 g/day.
[0034] In another preferred embodiment, the coadministration of bile acid-based preparations, such as ursodeoxycholic acid or tauroursodeoxycholic acid, is provided. Suitably, the ursodeoxycholic or tauroursodeoxycholic acid is administered in an amount of 10 to 3,000 mg/day, preferably 50 to 800 mg/day.
[0035] The present invention finally provides novel pharmaceutical compositions for treating and/or preventing the metabolic disorders of the biliary acids which comprise (a) one or more strains of bacteria having a 7α-dehydroxylase activity of less than 50%, preferably less than 25%, and a bile acid deconjugation activity of less than 50%, preferably less than 25%, and (b) a pharmaceutically acceptable carrier. Preferably, the present pharmaceutical compositions contain the strain(s) of bacteria in a concentration of 10 3 to 10 13 cells/g, preferably 10 8 to 10 12 cells/g. The pharmaceutically acceptable carrier may be any which is suitable for enteral administration and is compatible with the strain of bacteria, such as dextrose, calcium carbonate together with different additional substances such as starch, gelatin, vitamins, antioxidants, stains or taste-improving substances.
[0036] As an optional component, the compositions of the invention may possibly contain a drug compatible with the bacteria employed and capable of potentiating the activity of the active ingredients present. Anticholinergic drugs, antihistamines, adrenergic, antiulcer, antiacid, antidiarroic, and anti-inflammatory drugs, sedatives, antipyretis, choleretics antirheumatic agents, analgesic drugs, diuretics, antiseptic agents, antilipemic hepatoprotective drugs and drugs active on the gastrointestinal motility (e.g., trimebutine) may be herein mentioned.
[0037] When treating cirrhosis, it is preferred that the pharmaceutical composition further comprise lactulose. Suitably, the composition will contain sufficient lactulose to result in the administration of 100 mg to 100 g/day, preferably 1 g to 20 g/day of lactulose. When treating biliary cirrhosis and chronic hepatitis, it is preferred that the pharmaceutical composition comprise bile acid-based preparations, such as ursodeoxycholic acid or tauroursodeoxycholic acid. Suitably, the composition will contain sufficient bile acid preparation to result in the administration of 10 to 3,000 mg/day of such bile acid preparations, preferably 50 to 800 mg/day of ursodeoxycholic acid or tauroursodeoxycholic acid.
[0038] Other features of the invention will become apparent in the course of the following descriptions of exemplary embodiments which are given for illustration of the invention and are not intended to be limiting thereof.
EXAMPLES
Example 1
[0039] Strains of the following species have been tested: Streptococcus thermophilus, Streptococcus faecium, Lactobacillus acidophilus, Lactobacillus bulgaricus, Lactobacillus plantarum, Bifidobacterium infantis . Each strain (10 7 CFU) was cultivated in duplicate in specific nutrient broths (15 ml); “CFU” means “colony forming units”.
[0040] List of the Employed Culture Media Depending on the Different Species
Bifidobacterium infantis : MRS + 0.5% glucose (added after sterilization by diluting a 20% sterile solution) Streptococcus thermophilus : M17 All the remaining strains MRS
[0041] Composition of the MRS Broth:
g/liter universal peptone 10.0 g meat extract 5.0 g yeast extract 5.0 g D(+)-glucose 20.0 g potassium hydrogen phosphate 2.0 g Tween 80 1.0 g dibasic ammonium citrate 2.0 g sodium acetate 5.0 g magnesium sulfate 0.1 g manganous sulfate 0.05 g
[0042] Preparation: dissolve 50 g/l in distilled water, sterilized at 121° C. for 15 minutes—pH 6.5±0.1 at 25° C.
[0043] Composition M17 broth (Merck):
g/liter soybean flour peptone 5.0 g meat peptone 2.5 g casein peptone 2.5 g yeast extract 2.5 g meat extract 5.0 g D(+)-lactose 5.0 g ascorbic acid 0.5 g sodium-β-glycerophosphate 19.0 g magnesium phosphate 0.25 g
[0044] Preparation: dissolve 42.5 g/l in distilled water, sterilized at 121° C. for 15 minutes—pH 7.2±0.1 at 25°
[0045] [0045] Bifidobacterium infantis was cultivated under anaerobic conditions since it is known that it is an anaerobic bacterium. After 24 hours of incubation at 37° C. to each tube was added an amount of bile salt equivalent to 30 mg in order to obtain a final concentration of 2 mg/ml. The bile acids employed are: glycocholic acid (GCA) and taurocholic acid (TCA), obtained from Sigma Chemicals. Each bile acid was added separately to each series of bacterial cultures.
[0046] After 48 hours of incubation, isopropanol, 3 ml, was added for 2 minutes. Then it was centrifuged at 400 rpm for 15 minutes and the supernatant was collected (5 ml). The supernatant was kept refrigerated at −30° C. until it was analyzed. The percentage of conjugated bile salt present was determined by HPLC (high performance liquid chromatography) utilizing a Gilson apparatus equipped with a detector Diode array mod 1000 and a Spherisorb 5 μm ODS 2 C18 reverse phase column, a mobile phase composed by methanol/buffered phosphate (20 mMol), pH 2.5 in water/acetonitrile/water (150:60:20:20 by volume), a fluid speed of 0.85 ml/min, at a wavelength of 205 nm; 100 μl of the sample to be tested, dried under nitrogen, were extracted with 100 μl of the mobile phase containing as an internal standard 7α-OH-12α-OH-dihydroxy-58-cholanic acid (Calbiochem U.S.A.) at a concentration of 2 mg/ml.
[0047] The recovery percentage of the bile acid incubated with the bacterial cultures was calculated by the ratio of the area of the bile acid to be detected (GCA or TCA) to the area of the internal standard. When the quantity of the conjugated bile acid found in the bacterial cultures after 48 hours of incubation was less than 50%, thin layer chromatography (TLC) was performed on silica 60 gel plates to detect the presence of CA and DCA, using a mobile phase of cyclohexane/isopropanol/acetic acid (30:10:1 by volume). On every plate, 20 μl of the alcoholic extract of the sample, 20 μl of a solution of CA and DCA, and 20 μl of CA, 20 μl of DCA, were spotted. The plates after development at room temperature, were treated with sulfuric acid and warmed at 145° C. until the appearance of the colored spots.
[0048] The results of the deconjugation experiments (Table I) show that 5 out of the 16 strains tested with GCA were able to completely deconjugate the bile acid added to the culture, as previously reported in the literature and widely known to all researchers. Surprisingly, ten strains were able to deconjugate GCA but not completely, ranging from 9 to 90 percent (Table I). There was no difference among aerobic and anaerobic bacteria. Two strains, Streptococcus thermophilus YS 52 and Bifidobacterium infantis Bi 6 do not have any deconjugating activity for GCA. The strain YS 52 in addition does not attack the bile acid—taurine bond.
[0049] Only one out of the 16 strains tested was able to totally deconjugate the TCA: the Bifidobacterium infantis Bi 6.
[0050] The results of the dehydroxylation experiments (Table II) show that only one (Bi 4) out of the 16 strains is able to completely dehydroxylate GCA. Six strains did not dehydroxylate at all: YS 52; SF 2; SF 4; LA 3; LA 10; and Bi 6. The other strains were able to dehydroxylate GCA but not completely, ranging from 9% to 90%. As to TCA, seven strains do not dehydroxylate it at all: YS 52; SF 3; LA 3; LA 10; LB 1; LB 7; and LB 77. One strain, Bi 6, dehydroxylated TCA completely; the other strains dehydroxylated TCA according to varying percentages.
TABLE I Percentage of deconjugation of GCA and TCA by bacterial cultures after 48 hours of incubation ACCESSION BACTERIUM NO. GCA % TCA % Streptococcus thermophilus YS 46 I-1668 9 9 Streptococcus thermophilus YS 48 I-1669 17 11 Streptococcus thermophilus YS 52 I-1670 0 0 Streptococcus faecium SF 2 100 3 Streptococcus faecium SF 3 I-1671 27 0 Streptococcus faecium SF 4 100 12 Lactobacillus acidophilus LA 3 100 80 Lactobacillus acidophilus LA 10 100 95 Lactobacillus bulgaricus LB 1 I-1664 9 0 Lactobacillus bulgaricus LB 3 I-1665 20 12 Lactobacillus bulgaricus LB 7 I-1666 14 0 Lactobacillus bulgaricus LB 77 I-1667 20 0 Bifidobacterium infantis Bi 2 80 15 Bifidobacterium infantis Bi 3 90 10 Bifidobacterium infantis Bi 4 100 26 Bifidobacterium infantis Bi 6 0 100
[0051] [0051] TABLE II Percentage of dehydroxylation of GCA and TCA by bacterial cultures after 48 hours of incubation ACCESSION BACTERIUM NO. GCA % TCA % Streptococcus thermophilus YS 46 I-1668 9 9 Streptococcus thermophilus YS 48 I-1669 17 11 Streptococcus thermophilus YS 52 I-1670 0 0 Streptococcus faecium SF 2 0 3 Streptococcus faecium SF 3 I-1671 27 0 Streptococcus faecium SF 4 0 12 Lactobacillus acidophilus LA 3 0 0 Lactobacillus acidophilus LA 10 0 0 Lactobacillus bulgaricus LB 1 I-1664 9 0 Lactobacillus bulgaricus LB 3 I-1665 20 12 Lactobacillus bulgaricus LB 7 I-1666 14 0 Lactobacillus bulgaricus LB 77 I-1667 20 0 Bifidobacterium infantis Bi 2 80 15 Bifidobacterium infantis Bi 3 90 10 Bifidobacterium infantis Bi 4 100 26 Bifidobacterium infantis Bi 6 0 100
[0052] These strains have been deposited with the CNCM, Collection Nationale de Cultures de Microorganismes, Institut Pasteur, 28 rue du Dr Roux, 75724 Paris Cédex 15, France, under the following accession numbers:
Streptococcus thermophilus YS 46: I-1668 Streptococcus thermophilus YS 48: I-1669 Streptococcus thermophilus YS 52: I-1670 Streptococcus faecium SF 3: I-1671 Lactobacillus bulgaricus LB 1: I-1664 Lactobacillus bulgaricus LB 3: I-1665 Lactobacillus bulgaricus LB 7: I-1666 Lactobacillus bulgaricus LB 77: I-1667
[0053] The following strains are on the contrary kept at the Centro Ricerche Sitia-Yomo S.p.A.,—strada per mercino 3-ZELO BUON PERSICO (MILAN)—ITALY, distinguished by the below-reported identifiers:
Streptococcus faecium SF 2: SF 2 Streptococcus faecium SF 4: SF 4 Lactobacillus acidophilus LA 3: LA 3 Lactobacillus acidophilus LA 10: LA 10 Bifidobacterium infantis Bi 2: Bi 2 Bifidobacterium infantis Bi 3: Bi 3 Bifidobacterium infantis Bi 4: Bi 4 Bifidobacterium infantis Bi 6: Bi 6
[0054] These results demonstrate that the majority of the strains tested by us have a low capability to deconjugate the bile acids and that there are strains that do not deconjugate at all. This observation is surprising in that it has not been known that the lactic acid bacteria deconjugated the biliary salts. Furthermore, it is evident that the enzymes of the strains are selective for the specific bile acid bound on the side chain. In this study, the clearest example is offered by the Bifidobacterium infantis Bi 6. This strain is not able to deconjugate the glycine-conjugated bile acid but is able to totally deconjugate the taurine-conjugated bile acid. Some other strains (LB 1, LB 7, LB 77, and SF 3) are unable to deconjugate TCA but are able to deconjugate GCA to a certain extent.
[0055] To conclude, strains have been discovered that have a weak or zero capability to deconjugate and dehydroxylate.
Example 2
[0056] Three healthy volunteers were tested for their content of bile acids following treatment with a lactobacilli preparation containing 1×10 11 cells of Streptococcus thermophilus YS 52 per gram for a daily total of 6 g for 28 days. Before beginning the treatment and after 12 hours starvation, the subjects were intubated and the gallbladder bile, following stimulation with ceruletide, was collected and frozen at −80° C. The gallbladder contraction was assessed by echography and the position of the tube, in the second portion of the duodenum was checked by Rx (fluoroscopy).
[0057] After a 4 week treatment, the subjects underwent a second intubation and collection of bile. The bile samples were then tested for their content of some bile acids as previously described. The results are shown in Table III.
TABLE III Patient #1 Patient #2 Patient #3 Bile Acid Before After Before After Before After Glychenodeoxycholic 32 15 22 15 28 12 Glycodeoxycholic 6 5 9 2 4 3 Glycoursodeoxycholic 1 5 1 7 1 4 Taurocholic 9 26 15 25 12 21 Taurodeoxycholic 1 3 5 8 3 9
[0058] This experiment is a confirmation of what is shown in Example No. 1, that is: a lower deconjugation in one of the primary bile acids if bacteria being the object of the present invention are administered. The achieved result is a longer maintenance of the primary bile acids in the enterohepatic circulation.
[0059] The properties of the bile acids are reported in the note to Table III. Thus, according to these results the administration of selected strains of bacteria can reduce the detergency property and therefore the cytolytic activity of the bile acids.
Example 3
[0060] Fourteen patients with chronic hepatitis were treated with a bacterial preparation containing Streptococcus thermophilus YS 46 and YS 48 (two strains), and Lactobacillus bulgaricus LB 1, LB 7, and LB 77 (three strains). Each strain had been brought to a concentration of 150×10 9 cells per gram before being mixed with the others, to prepare a mixture containing the same parts by weight of each strain. 6 grams per day of said mixture were administered for 28 days. Liver enzymes were measured before and after the treatment, and the results are shown in Table IV.
TABLE IV Influence of the Treatment with the Bacterial Mixture on Liver Enzymes Aspartate Transaminase (AST; SGOT) and alanine transaminase (ALT; SGPT) AST (SGOT) ALT (SGPT) Patient Before After Before After #1 92 59 102 46 #2 89 67 96 42 #3 174 86 97 39 #4 121 91 102 66 #5 116 81 111 55 #6 156 87 94 76 #7 163 66 69 37 #8 78 64 122 57 #9 109 39 87 86 #10 166 70 102 48 #11 56 24 118 62 #12 131 83 96 79 #13 137 86 94 74 #14 84 87 144 114 Mean 119 71 102 63 Standard deviation 36 19 17 21 Significance Student p < 0.001 p < 0.001 t test for paired data
[0061] Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | Strains of bacteria characterized by exhibiting: (a) a 7α-dehydroxylase activity of less than 50%, and (b) a bile acid deconjugation activity of less than 50%, and descendants, mutants and derivatives thereof preserving activities (a) and (b); and a pharmaceutical composition using one or more of such strains and use of same for preventing and treating diseases associated with or caused by an altered metabolism of bile acids. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 12/342,483, filed Dec. 23, 2008 (now issued as U.S. Pat. No. 7,897,183).
FIELD OF THE INVENTION
The present invention relates to combinations of herb extracts which provide synergistic antioxidant effects when used in personal care products including body washes, lotions, liquid hand soaps, sunscreens, shampoos, and the like. The invention also relates to the methods for preparing skin care preparations incorporating such combinations of herb extracts, as well as the methods for caring for the skin utilizing such preparations.
BACKGROUND
The use of various antioxidant compositions for counteracting the deleterious effect of free radicals upon cells of the human body is widely studied. Free radicals are implicated in a wide variety of diseases of the human body. Referring particularly to diseases of the skin, the presence of free radicals on the skin results from a number of conditions, including over-production of free radicals within the cell itself, or exposure to external forces such as ultraviolet rays, coupled with an inability of the cell itself to defend against the over-production. The resulting excess of free radicals is known to be the cause of various skin disabilities, such as wrinkling, lack of elasticity, and generalized aging, and there is a need to fortify and supplement the various antioxidant mechanisms in the body.
Many compositions have been proposed and used in the past for providing the desired antioxidant effect, including Vitamin E (tocopherol), Vitamin A (beta-carotene), Vitamin C (ascorbic acid), Trolox (a Vitamin E analog), and the like. In addition, certain plant extracts have been reported as having antioxidant properties, including extracts from birch Betula platyphylla) (JP-A-10-046143) and various plant extracts obtained by extraction, with water or a lower alcohol or an aqueous lower alcohol solution, of plants such as hibiscus, aloe, rhubarb, osei (polygonati rhizoma), bearberry leaf, enmeiso (plectranthi herba), yobaihi (nyricae cirtex), pueraria root, cnidium rhizome, atractylodes lancea rhizome, mentha leaf, glycyrrhiza, peony root, coix seed, sin'i (magnoliae flos), cinnamon bark, houttuynia herb, coptis rhizome, moutan bark, gentian, nutgall, swertia herb, geranium herb, phellodendron bark, dried ginger, scutellaria root, chulling (poly porus), garlic, sage, oregano, rosemary, laurel, celery, thyme, tarragon, nutmeg, mace, clove, Japanese horseradish, savory, basil, red pepper, roasted bean, black tea, green tea, persimmon leaf, coffee, horsetail, henon bamboo, mugwort, Cynostemma species, low striped bamboo, matrimony vine, Cyrtomium species, and shiitake mushrooms (JP-A6-024937). [See US published patent application Publication No. 2004/0028643].
Personal care products such as body washes, lotions, liquid hand soaps, sunscreens, shampoos, and the like ordinarily contain a variety of additives designed to provide performance enhancing benefits such as moisturizing, fragrance, colorant, anti-inflammatory, and anti-irritant properties, and thus these personal care products provide a convenient vehicle for also applying antioxidants directly to the skin. Botanical extracts are a source for many of the above performance enhancing properties and accordingly are conventionally found as additives to the personal care products. To keep the number of additives within reasonable bounds with respect to any particular skin care product, it would be desirable to use herb extracts that provide not only one or more of the performance enhancing properties but also an antioxidant property, and, more particularly, it would be beneficial to find combinations of herb extracts that provide synergistic antioxidant effects. That is, it would be useful to provide formulations of different herb extracts that would function synergistically to increase the total antioxidant activity of the combined extracts in excess of their individual contributions.
SUMMARY OF THE INVENTION
In accordance with one embodiment, the present invention comprises mixtures of herb extracts which exert synergistic antioxidant effect and comprise the herb licorice and at least one other herb selected from the group consisting of ginger, kudzu, sophora, and thyme.
In accordance with another embodiment, the invention comprises a skin care preparation comprising a base which is medicinally acceptable for dermal application and which contains an antioxidant effective mixture of the herb licorice and at least one other herb selected from the group consisting of ginger, kudzu, sophora, and thyme. The invention also comprises a method for the preparations of such skin preparation.
In accordance with another embodiment, the invention comprises a method for caring for the skin comprising applying to the skin a composition comprising an admixture of a base and an antioxidant effective mixture of the herb licorice and at least one other herb selected from the group consisting of ginger, kudzu, sophora, and thyme.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an XY scatter chart depicting the synergistic and non-synergistic results from the use of various concentration ratios of ginger/licorice extract mixtures.
FIG. 2-A is an XY scatter chart depicting the synergistic and non-synergistic results from the use of various concentration ratios of kudzu/licorice extract mixtures, in which the kudzu and licorice are in powder form, obtained from China.
FIG. 2-B is an XY scatter chart depicting the synergistic and non-synergistic results from the use of various concentration ratios of kudzu/licorice extract mixtures, in which the kudzu and licorice are in liquid extract form obtained from Symrise GMBH & Co., KG., Holzminden, Germany.
FIG. 3 is an XY scatter chart depicting the synergistic and non-synergistic results from the use of various concentration ratios of sophora/licorice extract mixtures.
FIG. 4 is an XY scatter chart depicting the synergistic and non-synergistic results from the use of various concentration ratios of thyme/licorice extract mixtures.
DETAILED DESCRIPTION OF THE INVENTION
This detailed description of various exemplary embodiments of the invention makes reference to exemplary compositions and methods. While these embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may also be realized, and that logical and processing changes may be made without departing from the spirit and scope of the invention. Thus, the detailed description herein is present for the purposes of illustration only and not of limitation.
In the development of the present invention, it was discovered that certain mixtures of extracts of the herb licorice with extracts of other herbs such as ginger, kudzu, sophora, and thyme provide a synergistic antioxidant effect when prepared within certain ranges of concentration ratios. The detailed description of this discovery with respect to each herb mixture (i.e., licorice/ginger, licorice/kudzu, licorice/sophora, and licorice/thyme) will be taken up separately in the sections to follow:
Mixtures of Licorice and Ginger
Licorice is an herb extract obtained from the root of the Glycyrrhiza glabra plant, which is indigenous to many subtropical climes, including China, Greece, Spain, Turkey, and Iraq. It is mentioned throughout history not only as a candy and food ingredient but also as a natural remedy for a wide range of ailments, including use for anti-inflammatory effect. The licorice extracts used in the present study were obtained from two different sources. The first was a powder extract ordered through Nankai University in China from Shaanxi Hua Teng Biology Project Co. Ltd. The second was a liquid extract obtained on the market from Symrise GMBH & Co., KG., Holzminden, Germany, under the name Actipone® Licorice Root. In the present specification and claims, the extract will be referred to either as “licorice” or as “licorice (powder)” or as “licorice (liquid)”, as may be applicable.
Ginger is an herb extract obtained from the rhizome of the perennial plant Zingiher officinale , which is indigenous to a number of Asian and Eurasian areas, including China, India, Indonesia, etc. It is mentioned throughout history not only as a candy and food ingredient but also as a natural remedy for a wide range of ailments, including use for anti-inflammatory effect. The ginger extracts used in the present study were obtained from two different sources. The first was a powder extract ordered through Nankai University in China from Sha anxi Hua Teng Biology Project Co. Ltd. The second was a liquid extract obtained on the market from Symrise GMBH & Co., KG., Holzminden, Germany under the name Actipone® Ginger. In the present specification and claims, the extract will be referred to either as “ginger” or as “ginger (powder)” or as “ginger (liquid)”, as may be applicable.
In the development of the present invention, the measurement of antioxidant activity was made using the oxygen radical absorbance capacity (ORAC) assay described in the publication by Huang, D.; Ou, B.; Hampshe-Woodill, M.; Flanagan, J. A.; and Prior, R. I., entitled “High-throughput assay of oxygen radical absorbance capacity (ORAC) using a multichannel liquid handling system coupled with a microplate fluorescence reader in 96-well format”, 2002 J. Agric. Food Chem., 50, 4437-4444. In these measurements, for each herb extract, the fluorescence decay curves of Na 2 Fl induced by AAPH in the presence of Trolox standards was evaluated. The ORAC measurement was performed at 30° C. on a Synergy™ HT multi-detection microplate reader (Bio-Tek Instruments, Inc., Winooski, Vt.) with an excitation wavelength of 485±20 nm and emission wavelength of 530±20 nm. The plate reader was controlled by software KC4 3.4.
In these measurements, an 8.0×10 −5 mM fresh Na 2 Fl solution was made daily by diluting the stock solution in 75 mM phosphate buffer (pH 7.4). AAPH (0.414 g) was completely dissolved in 10 ml of 75 mM phosphate buffer (pH 7.4) to a final concentration of 150 mM and was kept in an ice bath. Trolox standard was prepared as follows: 0.0125 g of Trolox was dissolved in 10 ml MeOH solution to give a 0.5M stock solution. The stock solution was diluted with the same phosphate buffer to 50, 25, 12.5 and 6.25 μM, i.e. 12.5, 6.25, 3.13, and 1.56 μg/ml working solutions. These samples were used in each test as control. In each test, samples were freshly prepared by dissolving into 75 mM phosphate buffer (pH 7.4) to make stock solution and then diluting, and the phosphate buffer solution was tested as blank.
In the course of the work leading to the present invention, mixtures of licorice and ginger in a number of varying concentration ratios were tested for antioxidant effectiveness using the ORAC assay method. The fluorescence decay curves of Na 2 Fl induced by AAPH in the presence of Trolox standards for each herb extract and the combination of herb extracts were plotted after each test. Their area under the curve (A.U.C.) was calculated. The net A.U.C. was calculated as A.U.C. sample −A.U.C. blank . The net A.U.C. from the combination of herb extracts and the sum of net A.U.C. from each herb extract were listed in table and also plotted in diagram. The results of such testing for a first group of mixtures, using licorice (powder) and ginger (powder) obtained from China are set forth in the following Table 1-A:
TABLE 1-A
Licorice (Powder) and Ginger (Powder)
Ginger
Licorice
(Net − Sum)/
Conc.
Conc.
Net
Sum of each
Sum * 100
μg/ml
μg/ml
A.U.C.
herb
Net − Sum
%
10
5
14.98
12.66
2.32
18.33
30
5
28.74
25.3
3.44
13.60
5
10
17.68
17.32
0.36
2.08
5
15
22.54
22.6
−0.06
−0.27
10
15
25.67
26.22
−0.55
−2.10
30
15
36.18
38.86
−2.68
−6.90
15.88
5.18
17.59
15.71
1.88
11.97
5
3.25
10
6.87
30
19.51
5
5.79
10
14.07
15
19.35
Blank
9.52
It will be noted that, in the above Table 1-A, a positive percentage number in the (Net−Sum)/Sum*100 column indicates that the mixtures possesses synergistic effect, while a negative percentage number indicates non-synergistic effect.
A second group of licorice/ginger mixtures, but with concentration ratios differing from the first, was submitted to the same ORAC testing, with the results being shown in the following Table 1-B:
TABLE 1-B
Licorice (Powder) and Ginger (Powder)
Ginger
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
AU.C.
herb
Sum
%
3
0
6.79
1.21
15
0
11.78
6.2
35
0
18.88
13.3
0
3
8.13
2.55
0
6
10.56
4.98
0
12
15.69
10.11
3
3
10.42
4.84
3.76
1.08
28.72
15
3
15.41
9.83
8.75
1.08
12.34
35
3
23.29
17.71
15.85
1.86
11.74
3
6
12.45
6.87
6.19
0.68
10.99
15
6
17.38
11.8
11.18
0.62
5.55
35
6
24.47
18.89
18.28
0.61
3.34
3
12
17.9
12.32
11.32
1
8.83
15
12
22.89
17.31
16.31
1
6.13
35
12
31.58
26
23.41
2.59
11.06
Blank
5.58
It will be noted that, in the above Table 1-B, all numbers in the (Net−Sum)/Sum*100 column are positive numbers, indicating that all concentration ratios provided synergism.
A third group of licorice/ginger mixtures, but with concentration ratios differing from the first two, was submitted to the same ORAC testing, with the results being shown in the following Table 1-C:
TABLE 1-C
Licorice (Powder) and Ginger (Powder)
Ginger
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
3
0
6.25
0.8
5
0
7.1
1.65
10
0
9.23
3.78
35
0
19.59
14.14
0
3
7.41
1.96
0
5
8.92
3.47
0
10
12.46
7.01
0
13.42
17.85
12.4
3
3
9.39
3.94
2.76
1.18
42.75
5
3
10.33
4.88
3.61
1.27
35.18
35
3
23.29
17.84
16.1
1.74
10.81
3
5
10.98
5.53
4.27
1.26
29.51
5
5
13.05
7.6
5.12
2.48
48.44
10
5
14.05
8.6
7.25
1.35
18.62
5
10
15.79
10.34
8.66
1.68
19.40
10
10
17.85
12.4
10.79
1.61
14.92
3
13.42
17.36
11.91
13.2
−1.29
−9.77
5
13.42
17.19
11.74
14.05
−2.31
−16.44
blank
5.45
It will be noted that, in the above Table 1-C, a positive percentage number in the (Net−Sum)/Sum*100 column indicates that the mixtures possesses synergistic effect, while a negative percentage number indicates non-synergistic effect.
To summarize the synergistic and non-synergistic findings in the above studies, the synergistic ratios are tabulated below in Table 1-D, and the non-synergistic ratios are set out below in Table 1-E:
TABLE 1-D
Synergistic Licorice/Ginger Concentration ratios
Ginger
Licorice
μg/ml
μg/ml
10
5
30
5
5
10
15.88
5.18
3
3
15
3
35
3
3
6
15
6
35
6
3
12
15
12
35
12
5
3
3
5
5
5
10
10
TABLE 1-E
Non-synergistic Licorice/Ginger Concentration ratios
Ginger
Licorice
μg/ml
μg/ml
5
15
30
15
10
15
3
13.42
5
13.42
The data of Tables 1-D and 1-E have been incorporated in an XY scatter chart which is presented in this application as FIG. 1 . It will be noted that the concentration ratios found to be synergistic are located within the area marked A on the chart.
To summarize all of the foregoing, in the embodiment of the invention involving mixtures of licorice and ginger, the concentration ratios which have been found to be synergistic are within the range of 3.0 μg/ml≦C Ginger ≦35.0 μg/ml, 3.0 μg/ml≦C Licorice ≦12.0 μg/ml.
Mixtures of Licorice and Kudzu
In the embodiment involving mixtures of licorice and kudzu, the licorice is the herb extract obtained from the root of the Glycyrrhiza glabra plant, which is described in more detail in the previous section. Kudzu is an herb extract obtained from the plant Pueraria lobata , which is native to China and Japan but has been transplanted in many other countries of the world, including the United States. It is described as having numerous medicinal uses, particularly in traditional Chinese medicine. The kudzu extracts used in the present study were obtained from two different sources. The first was a powder extract ordered through Nankai University in China from Sha anxi Hua Teng Biology Project Co. Ltd. The second was a liquid extract obtained on the market from Symrise GMBH & Co., KG., Holzminden, Germany under the name Actipone® Pueraria Root. In the present specification and claims, the extract will be referred to either as “kudzu” or as “kudzu (powder)” or as “kudzu (liquid)”, as may be applicable.
In the development of the licorice/kudzu embodiment of the present invention, the measurement of antioxidant activity was made using the oxygen radical absorbance capacity (ORAC) assay, which is described in detail in the preceding section relating to the licorice/ginger embodiment.
In the course of the work leading to the present invention, mixtures of licorice and kudzu in a number of varying concentration ratios were tested for antioxidant effectiveness using the ORAC assay method to obtain net A.U.C. values, and the results of such testing for a first group of mixtures, using licorice (powder) and kudzu (powder) obtained from China. are set forth in the following Table 2-A:
TABLE 2-A
Licorice (Powder) and Kudzu (Powder)
Kudzu
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
1.03
4.8
14.66
9.51
7.88
1.63
20.69
2.06
4.8
19.31
14.16
12.23
1.93
15.78
3.09
4.8
23.42
18.27
16.36
1.91
11.67
1.03
9.6
18.79
13.64
11.58
2.06
17.79
2.06
9.6
23.15
18
15.93
2.07
12.99
3.09
9.6
26.22
21.07
20.06
1.01
5.03
1.03
0
9.34
4.19
2.06
0
13.69
8.54
3.09
0
17.82
12.67
0
4.8
8.84
3.69
0
9.6
12.54
7.39
Blank
5.15
It will be noted that, in the above Table 2-A, all numbers in the (Net−Sum)/Sum*100 column are positive numbers, indicating that all concentration ratios provided synergism
A second group of powder licorice/kudzu mixtures, but with concentration ratios differing from the first, was submitted to the same ORAC testing, with the results being shown in the following Table 2-B:
TABLE 2-B
Licorice (Powder) and Kudzu (Powder)
Kudzu
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
3.05
3
18.37
13.26
13.4
−0.14
−1.04
5.08
3
28.7
23.59
20.11
3.48
17.30
8.13
3
37.24
32.13
28.64
3.49
12.19
3.05
10
25.81
20.7
20.36
0.34
1.67
5.08
10
31.45
26.34
27.07
−0.73
−2.70
8.13
10
39.47
34.36
35.6
−1.24
−3.48
3.05
15
27.76
22.65
23.68
−1.03
−4.35
5.08
15
33.36
28.25
30.39
−2.14
−7.04
8.13
15
41.18
36.07
38.92
−2.85
−7.32
3.05
0
16.65
11.54
5.08
0
23.36
18.25
8.13
0
31.89
26.78
0
3
6.97
1.86
0
10
13.93
8.82
0
15
17.25
12.14
Blank
5.11
It will be noted that, in the above Table 2-B, a positive percentage number in the (Net−Sum)/Sum*100 column indicates that the mixtures possesses synergistic effect, while a negative percentage number indicates non-synergistic effect.
To summarize the synergistic and non-synergistic findings in the above two studies relating to mixtures of powdered licorice and kudzu, the synergistic ratios are tabulated below in Table 2-C, and the non-synergistic ratios are set out below in Table 2-D:
TABLE 2-C
Synergistic Licorice/Kudzu Concentration ratios
(Powdered Extracts from China)
Kudzu
Licorice
μg/ml
μg/ml
1.03
4.8
2.06
4.8
3.09
4.8
1.03
9.6
2.06
9.6
3.09
9.6
5.08
3
8.13
3
3.05
10
TABLE 2-D
Non-synergistic Licorice/Kudzu Concentration ratios
(Powdered Extracts from China)
Kudzu
Licorice
μg/ml
μg/ml
3.05
3
5.08
10
8.13
10
3.05
15
5.08
15
8.13
15
The data of Tables 2-C and 2-D have been incorporated in an XY scatter chart which is presented in this application as FIG. 2-A , relating to powdered kudzu and licorice extracts from China. It will be noted that the concentration ratios found to be synergistic are located within the area marked A on the chart.
To summarize the above data for the embodiment of the invention involving mixtures of powdered kudzu and licorice extracts from China, the concentration ratios which have been found to be synergistic are within the range of 1.0 μg/ml≦C Kudzu ≦8.0 μg/ml, 3.0 μg/ml≦C Licorice ≦10.0 μg/ml.
In addition to the above two groups, third and fourth groups of licorice/kudzu mixtures, but with the herbal extracts in liquid form (from Symrise), were submitted to the same ORAC testing. The results for the third group are shown in the following Table 2-E:
TABLE 2-E
Licorice (Liquid) and Kudzu (Liquid)
Kudzu
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
3.56
6.92
21.97
16.72
14.8
1.92
12.97
4.75
6.92
25.54
20.29
18.17
2.12
11.67
7.12
6.92
32.21
26.96
24.57
2.39
9.73
3.56
13.84
26.26
21.01
19.12
1.89
9.88
4.75
13.84
29.33
24.08
22.49
1.59
7.07
7.12
13.84
34.96
29.71
28.89
0.82
2.84
3.56
0
15.8
10.55
4.75
0
19.17
13.92
7.12
0
25.57
20.32
0
6.92
9.5
4.25
0
13.84
13.82
8.57
blank
5.25
It will be noted that, in the above Table 2-E, all numbers in the (Net−Sum)/Sum*100 column are positive numbers, indicating that all concentration ratios provided synergism.
The results for the fourth group of licorice/kudzu mixtures, with the herbal extracts in liquid form (from Symrise), are shown in the following Table 2-F:
TABLE 2-F
Licorice (Liquid) and Kudzu (Liquid)
Kudzu
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
1.78
18.45
19.46
13.39
15.82
−2.43
−15.36
1.78
13.84
20.72
14.65
13.24
1.41
10.65
1.78
1.73
13.11
7.04
6.24
0.8
12.82
3.56
27.68
34.27
28.2
26.06
2.14
8.21
3.56
13.84
25.45
19.38
18.7
0.68
3.64
7.12
6.92
29.94
23.87
22.58
1.29
5.71
7.12
3.46
28.59
22.52
20.48
2.04
9.96
14.24
27.68
57.11
51.04
48.66
2.38
4.89
14.24
13.84
48.31
42.24
41.3
0.94
2.28
14.24
1.73
41.25
35.18
34.3
0.88
2.57
18.98
18.45
55.67
49.6
51.07
−1.47
−2.88
18.98
3.46
53.44
47.37
42.43
4.94
11.64
18.98
1.73
50.71
44.64
41.49
3.15
7.59
1.78
0
11.31
5.24
3.56
0
16.77
10.7
7.12
0
24.61
18.54
14.24
0
39.37
33.3
18.98
0
46.56
40.49
0
1.73
7.07
1
0
3.46
8.01
1.94
0
6.92
10.11
4.04
0
13.84
14.07
8
0
18.45
16.65
10.58
0
27.68
21.43
15.36
Blank
6.07
It will be noted that, in the above Table 2-F, a positive percentage number in the (Net−Sum)/Sum*100 column indicates that the mixtures possesses synergistic effect, while a negative percentage number indicates non-synergistic effect.
To summarize the synergistic and non-synergistic findings in the third and fourth groups relating to mixtures of liquid licorice and kudzu, the synergistic ratios are tabulated below in Table 2-G, and the non-synergistic ratios are set out below in Table 2-H:
TABLE 2-G
Synergistic Licorice/Kudzu Concentration ratios
(Liquid Extracts from Symrise)
Kudzu
Licorice
μg/ml
μg/ml
3.56
6.92
4.75
6.92
7.12
6.92
3.56
13.84
4.75
13.84
7.12
13.84
1.78
13.84
1.78
1.73
3.56
27.68
3.56
13.84
7.12
6.92
7.12
3.46
14.24
27.68
14.24
13.84
14.24
1.73
18.98
3.46
18.98
1.73
TABLE 2-H
Non-synergistic Licorice/Kudzu Concentration ratios
(Liquid Extracts from Symrise)
Kudzu
Licorice
μg/ml
μg/ml
1.78
18.45
18.98
18.45
The data of Tables 2-G and 2-H have been incorporated in an XY scatter chart which is presented in this application as FIG. 2-B , relating to liquid kudzu and licorice extracts from Symrise. It will be noted that the concentration ratios found to be synergistic are located within the area marked A on the chart.
To summarize the above data for the embodiment of the invention involving mixtures of liquid kudzu and licorice extracts from Symrise, the concentration ratios which have been found to be synergistic are within the range of 1.5 μg/ml≦C Kudzu ≦19.0 μg/ml, 1.5 μg/ml≦C Licorice ≦28.0 μg/ml.
Mixtures of Licorice and Sophora Flower
In the embodiment involving mixtures of licorice and sophora flower, the licorice is the herb extract obtained from the root of the Glycyrrhiza glabra plant, which is described in more detail in previous sections. Sophora flower is the dried flower of the Japanese pagoda tree (Sophora japonica), which is native to Japan, China, Korea and other Eastern Asia countries It is described as having numerous medicinal uses, particularly in traditional Chinese medicine, including use as an anti-inflammatory agent. The sophora flower extracts used in the present study were obtained from Symrise GMBH & Co., KG., Holzminden, Germany under the name Actipone® Sophora Flower. In the present specification and claims, the extract will be referred to either as “sophora” or as “sophora flower.”
In the course of the work leading to the present invention, mixtures of licorice and sophora in a number of varying concentration ratios were tested for antioxidant effectiveness using the ORAC assay method to obtain net A.U.C. values, and the results of such testing for a first group of mixtures, using licorice (liquid) and sophora (liquid) obtained from Symrise are set forth in the following Table 3-A:
TABLE 3-A
Licorice (Liquid) and Sophora (Liquid)
Sophora
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
6.69
6.92
18.1
12.29
10.53
1.76
16.71
8.92
6.92
21.41
15.6
12.79
2.81
21.97
13.38
6.92
25.69
19.88
17.16
2.72
15.85
6.69
13.84
22.77
16.96
14.35
2.61
18.19
8.92
13.84
24.5
18.69
16.61
2.08
12.52
13.38
13.84
29.29
23.48
20.98
2.5
11.92
6.69
0
12.42
6.61
8.92
0
14.68
8.87
13.38
0
19.05
13.24
0
6.92
9.73
3.92
0
13.84
13.55
7.74
Blank
5.81
It will be noted that, in the above Table 3-A, all numbers in the (Net−Sum)/Sum*100 column are positive numbers, indicating that all concentration ratios provided synergism.
A second group of licorice/sophora mixtures, but with concentration ratios differing from the first, was submitted to the same ORAC testing, with the results being shown in the following Table 3-B:
TABLE 3-B
Licorice (Liquid) and Sophora (Liquid)
Sophora
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
1.67
0
7.78
2.08
3.34
0
8.46
2.76
6.69
0
10.58
4.88
13.38
0
17.65
11.95
26.75
0
29.6
23.9
0
1.73
6.62
0.92
0
3.46
7.42
1.72
0
6.92
9.59
3.89
0
13.84
13.43
7.73
0
27.68
20.86
15.16
1.67
27.68
25.57
19.87
17.24
2.63
15.26
1.67
6.92
12
6.3
5.97
0.33
5.53
1.67
1.73
8.48
2.78
3
−0.22
−7.33
3.34
27.68
26.95
21.25
17.92
3.33
18.58
3.34
6.92
13.46
7.76
6.65
1.11
16.69
3.34
3.46
11.18
5.48
4.48
1
22.32
6.69
13.84
20.85
15.15
12.61
2.54
20.14
6.69
3.46
14.44
8.74
6.6
2.14
32.42
6.69
1.73
13.22
7.52
5.8
1.72
29.66
13.38
27.68
35.62
29.92
27.11
2.81
10.37
13.38
6.92
21.65
15.95
15.84
0.11
0.69
26.75
13.84
45.33
39.63
31.63
8
25.29
26.75
1.73
30.62
24.92
24.82
0.1
0.40
Blank
5.7
It will be noted that, in the above Table 3-B, a positive percentage number in the (Net−Sum)/Sum*100 column indicates that the mixtures possesses synergistic effect, while a negative percentage number indicates non-synergistic effect.
A third group of licorice/sophora mixtures, but with concentration ratios differing from the first two, was submitted to the same ORAC testing, with the results being shown in the following Table 3-C:
TABLE 3-C
Licorice (Liquid) and Sophora (Liquid)
Sophora
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
0
27.68
24.43
18.92
0
39.54
32.97
27.46
0
55.35
45.57
40.06
1.67
0
6.64
1.13
6.69
0
11.21
5.7
26.75
0
29.03
23.52
1.67
27.68
25.16
19.65
20.05
−0.4
−2.00
1.67
39.54
33.2
27.69
28.59
−0.9
−3.15
1.67
55.35
46.56
41.05
41.19
−0.14
−0.34
6.69
39.54
38.05
32.54
33.16
−0.62
−1.87
6.69
55.35
50.3
44.79
45.76
−0.97
−2.12
26.75
27.68
48.65
43.14
42.44
0.7
1.65
Black
5.51
It will be noted that, in the above Table 3-C, a positive percentage number in the (Net−Sum)/Sum*100 column indicates that the mixtures possesses synergistic effect, while a negative percentage number indicates non-synergistic effect.
To summarize the synergistic and non-synergistic findings in the above three studies, the synergistic ratios are tabulated below in Table 3-D, and the non-synergistic ratios are set out below in Table 3-E:
TABLE 3-D
Synergistic Licorice/ Sophora Concentration ratios
Sophora
Licorice
μg/ml
μg/ml
6.69
6.92
8.92
6.92
13.38
6.92
6.69
13.84
8.92
13.84
13.38
13.84
1.67
27.68
1.67
6.92
3.34
27.68
3.34
6.92
3.34
3.46
6.69
3.46
6.69
1.73
13.38
27.68
26.75
13.84
26.75
1.73
26.75
27.68
TABLE 3-E
Non-synergistic Licorice/ Sophora Concentration ratios
Sophora
Licorice
μg/ml
μg/ml
1.67
1.73
1.67
27.68
1.67
39.54
1.67
55.35
6.69
39.54
6.69
55.35
The data of Tables 3-D and 3-E have been incorporated in an XY scatter chart which is presented in this application as FIG. 3 . It will be noted that the concentration ratios found to be synergistic are located within the area marked A on the chart.
To summarize all of the foregoing, in the embodiment of the invention involving mixtures of licorice and sophora, the concentration ratios which have been found to be synergistic are within the range of 1.5 μg/ml≦C sophora ≦27.0 μg/ml, 1.5 μg/ml≦C Licorice ≦28.0 μg/ml.
Mixtures of Licorice and Thyme
In the embodiment involving mixtures of licorice and thyme, the licorice is the herb extract obtained from the root of the Glycyrrhiza glabra plant, which is described in more detail in previous sections. Thyme is a well-known herb, obtained from the leaves of the Mediterranean perennial plant, Thymus vulgaris . It is described in the literature as having numerous culinary and medicinal uses, including use as an antiseptic. The thyme extracts used in the present study were obtained from Symrise GMBH & Co., KG., Holzminden, Germany. In the present specification and claims, the extract will be referred to either as “thyme” or as “thyme (liquid).”
In the course of the work leading to the present invention, mixtures of licorice and thyme in a number of varying concentration ratios were tested for antioxidant effectiveness using the ORAC assay method to obtain net A.U.C. values, and the results of such testing for a first group of mixtures, using licorice (liquid) and thyme (liquid) obtained from Symrise are set forth in the following Table 4-A:
TABLE 4-A
Licorice (Liquid) and Thyme (Liquid)
Thyme
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
2.98
6.92
19.1
13.06
12.67
0.39
3.08
4.48
6.92
23.43
17.39
16.34
1.05
6.43
8.95
6.92
33.54
27.5
26.38
1.12
4.25
2.98
13.84
23.15
17.11
16.87
0.24
1.42
4.48
13.84
26.8
20.76
20.54
0.22
1.07
8.95
13.84
36.47
30.43
30.58
−0.15
−0.49
2.98
27.68
30.56
24.52
24.44
0.08
0.33
4.48
27.68
34.14
28.1
28.11
−0.01
−0.04
8.95
27.68
43.52
37.48
38.15
−0.67
−1.76
2.98
0
14.72
8.68
4.48
0
18.39
12.35
8.95
0
28.43
22.39
0
6.92
10.03
3.99
0
13.84
14.23
8.19
0
27.68
21.8
15.76
blank
6.04
It will be noted that, in the above Table 4-A, a positive percentage number in the (Net−Sum)/Sum*100 column indicates that the mixtures possesses synergistic effect, while a negative percentage number indicates non-synergistic effect.
A second group of licorice/thyme mixtures, but with concentration ratios differing from the first, was submitted to the same ORAC testing, with the results being shown in the following Table 4-B:
TABLE 4-B
Licorice (Liquid) and Thyme (Liquid)
Thyme
Licorice
Sum of
(Net −
Conc.
Conc.
Net
each
Net −
Sum)/Sum * 100*
μg/ml
μg/ml
A.U.C
A.U.C.
herb
Sum
%
0
1.73
6.83
1.32
0
3.46
8.03
2.52
0
27.68
24.43
18.92
2.24
12.2
6.69
4.48
18.02
12.51
8.95
28.04
22.53
12.79
35.52
30.01
2.24
1.73
13.57
8.06
8.01
0.05
0.62
2.24
3.46
15.64
10.13
9.21
0.92
9.99
2.24
27.68
34
28.49
25.61
2.88
11.25
4.48
1.73
19.52
14.01
13.83
0.18
1.30
4.48
3.46
20.89
15.38
15.03
0.35
2.33
8.95
3.46
29.88
24.37
25.05
−0.68
−2.71
12.79
3.46
37.02
31.51
41.45
−9.94
−23.98
black
5.51
It will be noted that, in the above Table 4-B, a positive percentage number in the (Net−Sum)/Sum*100 column indicates that the mixtures possesses synergistic effect, while a negative percentage number indicates non-synergistic effect.
To summarize the synergistic and non-synergistic findings in the above two studies, the synergistic ratios are tabulated below in Table 4-C, and the non-synergistic ratios are set out below in Table 4-D:
TABLE 4-C
Synergistic Licorice/Thyme Concentration ratios
Thyme
Licorice
μg/ml
μg/ml
2.98
6.92
4.48
6.92
8.95
6.92
2.98
13.84
4.48
13.84
2.98
27.68
2.24
1.73
2.24
3.46
2.24
27.68
4.48
1.73
4.48
3.46
TABLE 4-D
Non-synergistic Licorice/Thyme Concentration ratios
Thyme
Licorice
μg/ml
μg/ml
8.95
13.64
4.48
27.68
8.95
27.68
8.95
3.46
12.79
3.46
The data of Tables 4-C and 4-D have been incorporated in an XY scatter chart which is presented in this application as FIG. 4 . It will be noted that the concentration ratios found to be synergistic are located within the area marked A on the chart.
To summarize all of the foregoing, in the embodiment of the invention involving mixtures of licorice and thyme, the concentration ratios which have been found to be synergistic are within the range of 2.0 μg/ml≦C Thyme ≦9.0 μg/ml, 1.5 μg/ml≦C Licorice ≦28.0 μg/ml.
In the practice of the invention, the plant extract combinations mentioned above may be included in any suitable skin care bases medicinally acceptable for dermal application, including various base formulations such as liquids, creams, gels, foams, lotions, body washes, liquid hand soaps, shampoos, antiperspirants, deodorants, and the like. Such base formulations conventionally contain known skin care ingredients, such as found in “CFTA Cosmetic Ingredient Handbook,” J. M. Nikitakis, ed., The Cosmetic, Toiletry and Fragrance Association, Inc., Washington, D.C. (1988), incorporated herein by reference. Such ingredients include, but not by way of limitation, numerous enhancing elements, such as alcohols, oleaginous substances, surfactants, preservatives, perfumes, emollients, colorants, humectants, thickening agents, skin care agents, water-soluble polymers, chelating agents, pH adjusting agents, foaming agents, antimicrobial agents, vitamins, and the like.
Examples of the above-mentioned surfactants include, but are not limited to, lauryl sulfates, octyl sulfates, 2-ethylhexyl sulfates, lauramine oxides, decyl sulfates, tridecyl sulfates, cocoates, lauryl sulfosuccinates, lauryl sarcosinates, lauryl ether sulfates (1 and 2 moles ethylene oxide), myristamine oxide, ricinoleates, cetyl sulfates, alkyl glucosides, and similar surfactants.
Examples of the above preservatives include benzoic acid salts, salicylic acid salts, sorbic acid salts, dehydroacetic acid salts, parahydroxybenzoic acid esters, benzalkonium chloride, 2,4,4′-trichloro-2′-hydroxydiphenyl ether, 3,4,4′-trichlorocarbanilide, hinokitiol, resorcinol, and ethanol.
Examples of humectants include glycerin, sodium pyrrolidone carboxylate, and the like. Examples of foam stabilizers include cetyl alcohol, cetearyl alcohol, stearic acid, and the like. Examples of skin care agents include guar gum, hydroxyethylcellulose, hydroxypropylmethylcellulose, polyethylene glycol, hydrolyzed wheat protein, polyoxyethylene stearyl ether, and the like.
The actual formulation of the skin care consumer products incorporating the plant extract combinations of the present invention is through standard methods of manufacturing. All the liquid formulations are easily made in batch mixtures, with addition of water usually first, such that the liquid is above the mixing impeller within the tank. Then the specialty chemicals, such as the surfactants are added, followed by the dyes, preservatives, plant extract combinations, etc. The methods of manufacture are well known.
While numerous exemplary embodiments of the invention have been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention set forth in the appended claims and their legal equivalents. | The present invention comprises mixtures of herb extracts which exert synergistic antioxidant effect and comprise the herb licorice and at least one other herb selected from the group consisting of ginger, kudzu, sophora, and thyme. Skin care preparations incorporating such herb extract mixtures, and their methods of preparation and use, are also claimed. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for scanning documents with high resolution. Also, the present invention relates to an image scanning and copying apparatus of the type in which an original such as a document is two-dimensionally scanned to produce image signals and an image is formed by driving a plurality of printing elements such as ink jet heads by means of the image signals.
2. Description of the Prior Art
Recently, a remarkable progress has been made in the image scanning and copying apparatus. At present, aiming at further development of the technique, many efforts are being made to increase the resolution of image detection and print to speed up the image detecting and printing operation and to simplify the signal processing system used in the course of image detection and printing.
The printing system most widely used in the above mentioned type of image forming apparatus uses an array of printing elements arrayed in one single row. The array of printing elements is moved in the direction normal to the row of the printing elements to two-dimensionally scan a document and then form an image thereof by only one scanning. However, this conventional printing system has a disadvantage. It is impossible for this system to record such image which has a higher resolution than the pitch of the printing elements. For example, when ink jet nozzles are used as the printing elements, the possible minimum space between nozzles is 0.25 mm for any array of ink jet nozzles available according to the prior art. Therefore, the maximum recording resolution attainable by it is 4 image points/mm. Such printing resolution is obviously not enough to record images contained in common documents. The resolution desired for this purpose is at least 12 image points/mm. To realize this objective, it is also required to provide a detection apparatus which is able to detect high resolution image point signals.
A high resolution copying apparatus has been disclosed in U.S. Pat. No. 4,112,469 (Japanese Patent Application laid open No. 136,835/1978). The known apparatus uses a sensor array comprising N (in number) photo diodes arranged at regular intervals. The sensor array detects an original document in a manner of interlaced scanning with high resolution. Recording is carried out using a printing head comprising N nozzles arrayed in regular intervals in the same interlaced fashion as used at the time of detection scanning to effect high resolution recording.
SUMMARY OF THE INVENTION
To scan the entire two-dimensional area of a document using a one-dimensional sensor array there is required such scanning optical system which moves the sensor array image on the document in the direction normal to the array some distance corresponding at least to the width of the document. As will be easily seen, such scanning optical system has to have a very high scanning speed to meet the requirement of high speed recording. Since the technique of two-dimensional sensor array has been developed rapidly in these years, it is desirable to moderate the high speed required for scanning optical system by using the two-dimensional sensor array. However, to realize it there remain some problems to be solved. The main problems to be mentioned concern the following two points:
Firstly, it needs a detecting system which is able to detect image points in a high resolution corresponding to the desirable printing resolution while using a two-dimensional sensor array. Generally speaking, the number of image points to be detected to meet the desirable printing resolution is far larger than the number of sensor elements in a two-dimensional sensor array or the image resolution point pitch of an image is smaller than the possible minimum sensor element pitch. Therefore, it is required to provide such detecting apparatus which detects all the image resolution points using an interpolation technique. In this case, the interpolation technique used therein must be convenient to the printing system then used. In other word, the interpolation technique preferably used therein is of the type which allows the use of a simplified signal processing system.
Secondly, therefore, it is required to simplify the signal processing system. The signal processing system provisionally stores image point signals from the two-dimensional sensor array and then rearranges them for interlaced printing. There is need to provide apparatus which uses a most suitable image detecting and printing system for simplification of the signal processing part.
Accordingly, it is an object of the invention to provide an image scanning apparatus and method having the advantage of high resolution.
It is another object of the invention to provide an image scanning apparatus and method having the advantage of simplified scanning mechanism by employing a two-dimensional sensor array.
It is a further object of the invention to provide an image detecting and copying apparatus and method having the advantages of high resolution and no need of particular memory and signal rearrangement processing apparatus while using a two-dimensional sensor array.
Other and further objects, features and advantages of the invention will appear more fully from the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows an embodiment of the invention;
FIG. 2 shows an example of the mask used therein with the image of document formed thereon;
FIG. 3 shows the read-out mechanism of two-dimensional sensor array;
FIG. 4 illustrates the process of recording by a printing head; and
FIG. 5 illustrates an example of correction relating to some inclination of scanning line for printing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the apparatus shown in FIG. 1, a reduced image of a document 1 is formed on a mask 3 through an optical system comprising a first scanning mirror 4, an image forming lens system 2 and a second scanning mirror 5. The scanning mirrors 4 and 5 are mounted rotatably with rotary motors 24 and 25 respectively. The scanning mirrors deflect the beam coming from the document so as to move the document image on the mask 3 in two directions orthogonal to each other, that is, in longitudinal direction and in transverse direction on the surface of the mask respectively. The reduced image of the document 1 and the mask 3 are further focused on the detecting area of a two-dimensional sensor array 7 through a relay lens 6. The two-dimensional sensor array 7 comprises a number of sensor elements arranged in M rows and N lines to form a matrix. The area on which the image of two-dimensional region of the document to be scanned and the image of the mask are formed, is nearly coincident with the entire detecting area of the sensor array. Therefore, if the mask be absent, then the document will be detected each resolution point by each sensor element. Here, one resolution point is one small area given by dividing the document area by M×N.
Assuming that the number of desired image resolution points contained in a document is s·M in traverse direction and t·N in longitudinal direction, it is required to detect a smaller area as unit image resolution point. The smaller area as unit image resolution point is given by further dividing the above given small area ##EQU1## by s×t. The mask 3 has small apertures arranged in M rows and N lines corresponding to the arrangement of sensor elements in the two-dimensional sensor array mentioned above. The size of each the small aperture is nearly equal to the size of each the image resolution point of an image of the document 1 formed on the mask 3. Every one of the small apertures makes the light from the above said smaller element areas of the document fall on every corresponding sensor element. When detection of the document is carried out using the above arrangement, the surface of the document is detected at M×N sampling points. Hereinafter, an image of the M×N sampling points detected at once by one self scanning of the two-dimensional sensor array is referred to as element image.
As described above, the number of desirable image resolution points is s·M in traverse direction and t·N in longitudinal direction provided that the smaller area defined above be taken as unit desirable image resolution point. The number of sampling points which can be sampled once by the two-dimentional sensor array is M×N. As seen from it, the two-dimensional sensor array detects those resolution points interlaced at intervals of s points in traverse direction and t points in longitudinal direction every time. Positional relation among sensor elements 9, images of mask apertures 8 and images of resolution points of document 10 on the detecting area of the two-dimentional sensor 7 is illustrated in FIG. 2.
In the position of images of apertures shown in FIG. 2, M×N image resolution points are firstly detected by the two-dimensional sensor and therefore M×N signals of firstly detected image resolution points are produced. These element image signals are introduced into a distributor 13 (FIG. 1).
To assist in better understanding of the manner of operation of the shown apparatus, the read-out mechanism of a two-dimensional sensor will be described briefly hereinafter.
Two-dimensional sensors known in the art can be classified in several groups according to the difference in type of read-out. FIG. 3 shows one type of the known two-dimensional sensor which is generally called frame transfer type of two-dimensional sensor. The two-dimensional sensor 7 is composed of a sensing part 20, a storing (memory) part 21 and a shift register part 22. In conformity with the previous description, the sensing part comprises M×N sensor elements and the storing part has the same number of bits. Element image signals photo-electrically converted at the sensing part 20 are frame transferred to the storing part 21 which stores the signals in the corresponding bits.
Among the signals stored in the storing part 21, those signals constituting one line in traverse direction (M bits) are driven by transfer clock issued from a control system 12 (FIG. 1) through the shift register part 22 to sequentially read out the signals to the exterior. The distributor 13 distributes these signals one by one sequentially to driving systems 15 1 , 15 2 . . . 15 M of a recording head 14, as shown in U.S. Pat. No. 3,322,064 (FIG. 1). The recording head is disposed opposed to a recording paper 17 set on a drum 16 and comprises M ink jet nozzles 14 1 , 14 2 , . . . 14 M regularly arranged on a straight line at intervals of s image resolution points of an image to be recorded. Here, it should be noted that the size of one image resolution point on the recorded image may be different from that of the document according to the magnification for recording then used. The ink jet nozzles 14 1 , 14 2 . . . 14 M are driven by the driving systems 15 1 , 15 2 . . . 15 M respectively.
During the time of the signals of one line being recorded on the recording paper by the above nozzles, the drum 16 is driven into rotation at uniform speed by the rotary motor 19. The rotation angle of the drum during the time is preset to a value corresponding to t resolution points of the recorded image relative to the first nozzle 14 1 . In this position, the element image signals in the second line stored in the storing part 21 are applied sequentially to the nozzles 14 1 , 14 2 . . . 14 M in the same manner as that for the first line signals and recording of the second line signals is carried out on the recording paper. This operation of recording is repeated N times for one complete revolution of the drum to complete recording of the whole first element image in N lines.
In the apparatus shown in FIG. 1, the function of the scanning mirror 4 is to scan the document image on the mask 3 in longitudinal direction. The rotary motor 24 with which the scanning mirror 4 is connected is precisely controlled by the control system 12 in such manner that the inclination of the scanning mirror 4 may be changed by a very minute angle just enough to shift the image on the mask 3 by one image resolution point per one revolution of the drum 16. Therefore, signals of the second element image which is shifted from the first element image by one image resolution point have been already transferred to the storing part and prepared for reading out when the drum 16 completes one revolution to record the first element image. Read-out of the second element image signals is started when the drum 16 finishes its one revolution and the first nozzle 14 1 comes to a position advanced by one image resolution point from the position for recording the first element image. Recording the second element image is carried out in the same manner as that of the first one.
The signal for starting the recording operation is obtained from a rotary encoder 18 directly connected with the drum 16, as shown in U.S. Pat. No. 3,192,854 (FIGS. 1 and 9). The rotary encoder 18 issues one reference pulse per one revolution of the drum 16. The pulse signal is delivered to the control system 12 and forms a recording start signal. For example, when the n-th element image is to be recorded, a recording start signal is given to the shift register part 22 of the two-dimensional sensor 7 and the recording control system 13 after (n-1) image resolution point signals are counted over from the time of input of the above pulse signal.
FIG. 4 illustrates the position of recorded first and second element images together. Synchronizing signal for reading out and printing the image resolution point signals in every line is also obtained from the rotary encoder 18.
By sequentially recording t element images in this manner there is obtained a record of image composed of a large number of image resolution points closely arranged with the desirable resolution in longitudinal direction. For this longitudinal image recording, the scanning mirror 4 conducts one scanning on the document in the longitudinal direction. In other words, t revolutions of the drum 16 correspond to one scanning and the width of one scanning corresponds to the distance by which the document image on the mask 3 is shifted by t image resolution points.
As shown in FIG. 5, the recorded image 32 of one line lies on a line inclined by ##EQU2## relative to the base line when the recording was carried out by the recording head 14 positioned in a position 33 normal to the direction of rotation of the drum 16. This undesirable inclination of line can be prevented by disposing the head 14 inclined by ##EQU3## relative to the rotation direction 31 of the drum as suggested by the phantom 34. When the position of the recording head is corrected in this manner there can be obtained a record line lying on a line normal to the rotation direction 31.
Scanning in traverse direction is carried out by the scanning mirror 5 connected with another rotary motor 25 in the same manner as that of the longitudinal scanning described above. Scanning speed in traverse direction on the mask 3 is at the pitch of one image resolution point per t revolutions of the drum 16. Also, the recording head 14 is moved in the direction along the drum shaft at the same resolution point pitch by the motor 26 through a screw member 27. Therefore, as soon as the first step for recording t element images in longitudinal direction comes to end, the second step for recording the next t element images shifted by one image resolution point relative to those of the first step is started under the control by the control system 12. In this manner, s steps of scanning and recording are carried out repeatedly. When the s steps of scanning and recording are all completed, a complete image composed of s·M×t·M image resolution points is obtained on the recording paper 17.
Scanning of the document image in longitudinal direction by scanning mirror 4, scanning of the document image in traverse direction by scanning mirror 5 and scanning of the recorded image in traverse direction by recording head 14 may be of uncontinuous, namely step-by-step system or of continuous system. From a technical point of view, a continuous system is preferable.
Now, the relation between scannings orthogonal to each other is described.
Let the sensor detection clock frequency be fc/sec, then repeating frequency of the recording head is fR=fc/M and the rotational speed of drum is ##EQU4##
In case that the scanning mirrors are rotated stepwise, the step frequency is fc/tMN for scanning mirror 4 and is fc/tsMN for scanning mirror 5. Therefore, the time required to record a sheet of document is T=tsMN/fc sec.
As an example, the following concrete data are given:
M=320, N=256, t=s=10 and fc=2.73 MHz.
For the above conditions,
the number of recorded image resolution points: 3200×2560;
recording time: 3 seconds;
drum rotational speed: 2000 rpm;
recording head frequency: 8.53 KHz;
step frequency of scanning mirror 4: 3.33 Hz and;
step frequency of scanning mirror 5: 0.333 Hz.
As a further example, such case may be considered that the document to be recorded is of A4 format size, namely 294 mm in width×210 mm in length, focusing magnification of the image forming lens system 2 is 1/6 and focusing magnification of the relay lens 6 is 1/5. In this case, the pitch of image resolution points on the document is 83.3 μm and that on the mask is 13.8 μm. Therefore, the size of small apertures on the mask 3 is about 14 μmφ and from the condition of t=s=10 the pitch of apertures is about 140 μm. These apertures appear on the two-dimensional sensor as images of 28 μm in pitch. This means that a two-dimensional sensor comprising 320×256 in number of sensor elements arranged at a pitch of 28 μm enables to carry out the high quality detection described above.
In the embodiment shown in FIG. 1, the relay lens 6 and two-dimensional sensor 7 are disposed behind the mask 3. However, another arrangement can be used in the scope of the invention. For example, a mask having small apertures may be attached directly to the two-dimensional sensor. Also, such two-dimensional sensor may be used which has sensor elements whose detection area is of such shape and size as given by reducing the sensor element pitch by 1/s in traverse direction and by 1/t in longitudinal direction. In this case, each sensor element has a detecting area corresponding to each image resolution point. If such two-dimensional sensor is used, the shift of the relative position between the document image and the two-dimensional sensor can be effected without using the scanning mirrors 4 and 5. It may be accomplished by moving the two-dimensional sensor by s steps in traverse direction and by t steps in longitudinal direction while keeping the document image stationary. Also, in the arrangement shown in FIG. 1, it is possible to move the mask 3 while keeping the scanning mirrors 4 and 5 in fixed positions. But, this is not preferable. In general, the sensor element used in a two-dimensional sensor has a detecting area only on a part of the element and the remaining part is non-sensitive area containing transfer portion and overflow drain portion. Therefore, when the mask is moved, detection of image becomes impossible at the non-sensitive part of sensor element.
Printing elements used in the apparatus according to the invention is never limited to ink jet nozzles particularly shown in the above embodiment. Thermal heads or heads for forming latent images also may be used. Further, it is not always necessary to scan the entire surface of a document at one time. The area of document may be divided into many sections so that scanning can be carried out section by section. In this case, the recording head is not required to have the same width as that of the recording medium.
As will be understood from the foregoing, the present invention permits provision of a novel type of scanning and detecting apparatus. An original image is detected by a two-dimensional sensor while sampling the image resolution points. Signals of sampled image points are printed by a printing head comprising many printing elements at the positions corresponding to the sampling positions. Detecting and printing operations are repeated while sequentially shifting the relative position between the original image and the two-dimensional sensor as well as the relative position between the writing head and the printing medium. Thus, a complete image of an original is printed with high image quality by using an interpolation.
Also, the present invention permits provision of an image forming apparatus for which the signal processing system can be simplified. There is no need of using particular memory apparatus and signal rearranging apparatus for processing image point signals read out from the two-dimensional sensor.
Moreover, since the output signals from the two-dimensional sensor appear in a form similar to that of signals from a common television camera, the output signals can be processed in a simple manner by connecting the outline of the apparatus according to the above embodiment to the signal processing system of a television system. The apparatus according to the invention is excellent in versatility.
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 the foregoing and other changes in form and details can be made therein without departing from the spirit and scope of the invention. | This invention relates to an apparatus and method for scanning and duplicating documents with high resolution. The apparatus herein disclosed includes an array of printing nozzles and a photosensor comprising sensor elements the number of which per line is smaller than the full number of desired image resolution points and which are arranged two-dimensionally. Small apertures are disposed optically conjugate with said photosensor in such manner that light from the desirable resolution points may fall on the corresponding individual sensor elements through a focusing lens. Through an optical system comprising another focusing lens and two rotary mirrors, an image of the document is formed on the mask. The image of document on the mask is moved in two orthogonal directions while the two mirrors being rotated sequentially to scan the document and detect image points of desirable resolution. Signals obtained therefrom are used to operate the printing nozzles. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of Patent Cooperation Treaty (PCT) Application No. PCT/CN2004/001210, filed on Oct. 25, 2004, entitled, A SYSTEM AND METHOD FOR TESTING THE SUBSCRIBER'S LINE, which claims priority to Chinese Patent Application 200310123620.6, filed on Dec. 12, 2003, all of the disclosure of both applications are hereby incorporated by reference in their entirety.
FIELD OF THE TECHNOLOGY
The present invention relates to testing technique in network communication, more particularly to a system for testing subscriber lines in network communication and method thereof.
BACKGROUND OF THE INVENTION
With the development of broadband access technology, Data Subscriber Loop (DSL) technology that is used for subscriber loop access is gradually becoming a main and widely applied broadband access technology. Subscriber lines are laid for common narrowband telephone service. However, frequency band and speed of DSL is 10 to 1000 times greater than that of common narrowband telephone service. Furthermore, development of DSL service is affected due to some problems concerning with subscriber lines, such as long-term laying, poor maintenance, large environment interference and long distance. In order to satisfy requirements for opening line pre-selection and breakdown maintenance of DSL service, subscriber line testing technique has gradually being developed.
At the present time, subscriber line testing technique has been highly valued by both device manufactures and telecom service providers, henceforth applied in a large scale.
Generally, a broadband line testing module for implementing subscriber line testing is placed in a Digital Subscriber Line Access Multiplexer (DSLAM) end. The broadband line testing module is connected to the subscriber lines to be tested, evaluating line quality and judging line breakdown by using different broadband testing techniques, thereby implementing single-terminal broadband testing for subscriber lines, as is shown in FIG. 1 .
The object of subscriber line testing is to test those subscriber lines loading DSL. However, for the existence of Remote Terminal Unit (RTU) in user end, when breakdown is tested, there is no way to confirm whether the breakdown is from the subscriber line or RTU, thereby affecting precision of the present subscriber line testing technique, even disabling some certain subscriber line testing techniques. Consequently, when testing with the present subscriber line testing technique, the subscriber is often telephoned and required to manually disconnect RTU from the subscriber line; after completion of testing subscriber line procedure, the subscriber is telephoned again to connect RTU up. The RTU includes RTU of Asymmetrical Digital Subscriber Loop (ADSL), Very-high-speed Digital Subscriber Loop (VDSL), or Single-line-pair High-bit-rate Digital Subscriber Loop (SHDSL).
SUMMARY OF THE INVENTION
The present invention provides a system and a method for testing subscriber lines, with which subscriber line testing precision is guaranteed and subscriber lines can be periodically tested without manual operation.
The technical scheme of the present invention is implemented as follows.
A system for testing subscriber lines comprises a broadband line testing control module and a remote terminal subscriber access control module located at a subscriber line between the broadband line testing control module and a remote terminal unit, wherein
said broadband line testing control module sends a signal of disconnecting the subscriber line to the remote terminal subscriber access control module, and tests the subscriber line;
said remote terminal subscriber access control module receives said signal from the broadband line testing control module, and controls the remote terminal unit to disconnect from or connect to the subscriber line based on said signal.
Said broadband line testing control module comprises:
a broadband line testing module, for sending a signal of disconnecting subscriber line, implementing performance testing for subscriber lines and obtaining testing results after the remote terminal unit is disconnected from the subscriber line; and
a remote terminal subscriber control module, for receiving the signal of disconnecting subscriber line from the broadband line testing module and forwarding it to the remote terminal subscriber access control module.
Said remote terminal subscriber access control module comprises:
a switch control module, for receiving the signal from the broadband line testing control module, and generating a control signal and transmitting said control signal; and
a remote terminal subscriber control switch, for receiving said control signal from the switch control module and disconnecting the remote terminal unit from the subscriber line based on said control signal.
Said switch control module comprises a timer circuit, and said timer circuit is triggered based on the signal sent by the broadband line testing control module, and determines time-out time based on the testing required time value which is carried in this signal; when overrunning the defined time-out time, the timer circuit notifies the switch control module to send the remote terminal subscriber control switch a control signal of setting it at off status;
said remote terminal subscriber control switch controls the remote terminal unit to connect to the subscriber line after receiving said control signal of setting the remote terminal subscriber control switch at off status from the switch control module.
Said remote terminal subscriber access control module is a relay.
Said broadband line testing control module is located in a Digital Subscriber Line Access Multiplexer (DSLAM);
said remote terminal subscriber access control module is located at the subscriber line between a splitter in user end and the remote terminal unit, or located at the subscriber line between the splitter in user end and the DSLAM.
A method for testing subscriber lines based on the above-mentioned comprises the following steps of:
A. a broadband line testing control module sends a signal of disconnecting subscriber line to a remote terminal subscriber access control module;
B. the remote terminal subscriber access control module disconnects a remote terminal unit from the subscriber line after receiving said signal of disconnecting subscriber line; and
C. the broadband line testing control module tests the subscriber line.
Said signal is transmitted through a message based on G994.1 protocol.
The method further comprises before step A:
the broadband line testing control module sends a handshake message to the remote terminal unit, and determines whether said remote terminal unit supports the testing based on the returned message from the remote terminal unit, if yes, executes step A; otherwise, ends this processing.
Said signal in step A carries a testing required time value;
the method further comprises in step B:
after receiving the signal, the remote terminal subscriber access control module triggers a timer, and determines a time-out time based on the testing required time value which is carried in said signal;
when overrunning the time-out time, accesses the remote terminal unit to the subscriber line.
The method further comprises in step B:
when disconnecting the remote terminal unit from the subscriber line, said remote terminal subscriber access control module returns a response message to the broadband line testing control module;
the method further comprises before step C:
the broadband line testing control module receives the returned response message from the remote terminal subscriber access control module, and executes step C after delaying a defined time period.
Said sending a signal to a remote terminal subscriber access control module in step A is implemented through terminal managing channels of DSLAM.
It can be seen from the above-mentioned technical schemes, in the present invention, a remote terminal subscriber access control module is added at the subscriber line between an RTU and a broadband line testing control module, in this way, when the broadband testing control module starts to implement subscriber line testing, remote controlling RTU to automatically disconnect from the subscriber line can be realized through remotely controlling the switch status of the remote terminal subscriber access control module, and automatic connection between the RTU and the subscriber line can be restored after completion of subscriber line testing. Therefore, the problem of poor testing precision or unable to perform corresponding test due to the existence of RTU in subscriber line is effectively avoided. Meanwhile, since remote control of RTU's accessing to or disconnected from subscriber line is implemented in the present invention, the subscriber line testing performed by the broadband testing control module needs no manual operation, which is greatly convenient for periodically testing subscriber lines by DALAM end and recording subscriber line health file, henceforth in favor of real-time inspection of subscriber line quality and fast positioning of subscriber line breakdown.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating system structure for testing subscriber lines according to the prior art.
FIG. 2 is a schematic diagram illustrating brief system structure for testing subscriber lines according to the present invention.
FIG. 3 is a schematic diagram illustrating detailed system structure for testing subscriber lines according to the present invention.
FIG. 4 is a flowchart illustrating the method for testing subscriber lines according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in detail hereinafter with reference to the accompanying drawings.
According to the embodiments of the present invention, RTU is connected with the subscriber line via a relay. A broadband line testing control module in DSLAM remotely controls off/on status of this relay, thereby controls RTU to connect to or disconnect from the subscriber line, making it convenient for corresponding subscriber line testing.
As shown in FIG. 2 , a relay is added between the RTU and the subscriber line in an exemplary embodiment of the present invention. When the subscriber line needs testing, the broadband line testing control module in DSLAM instructs the relay to switch its status, making RTU disconnect from the subscriber line. After overrunning a time-out time set by the DSLAM, the relay automatically switches its status again and restores the connection with subscriber line. So the RTU can be reconnected to the subscriber line after the testing and be operated normally.
The relay according to a preferred embodiment of the present invention can be set either on the subscriber line between the splitter at user side and the RTU, or on that between the splitter at user side and the DSLAM. The relay shown in FIG. 2 is set on the subscriber line between the splitter at user side and the RTU. If the relay is added on the subscriber line between the splitter at user side and the RTU, when the connection between this subscriber line and RTU is broken by the relay, the subscriber line is still connected to devices such as a splitter and a telephone that will affect the testing precision of this subscriber line. In contrast, if the relay is added on the subscriber line between the splitter at user side and the DSLAM, when the connection between this subscriber line and the RTU is broken by the relay, this subscriber line will not be connected to any device, hence high testing precision can be obtained.
In the following embodiment according to the present invention, the relay is set on the subscriber line between the splitter at user side and the RTU.
As shown in FIG. 3 , a system for testing subscriber lines according to an exemplary embodiment of the present invention includes a broadband line testing control module and a remote terminal subscriber access control module which is placed between the broadband line testing control module and the RTU.
The broadband line testing control module is used to notify the remote terminal subscriber access control module to disconnect the RTU from the subscriber line when the subscriber line needs testing and start subscriber line testing. The control signals sent to the remote terminal subscriber access control module from the broadband line testing control module can either be inputted manually, or be automatically generated according to relevant condition. For example, the control signals for disconnecting the RTU from the subscriber line are periodically generated in order to test the subscriber lines periodically.
The broadband line testing control module further includes a broadband line testing module and a remote terminal subscriber control module.
The broadband line testing module is adapted to send a signal to the remote terminal subscriber control module so as to notify the remote terminal subscriber control module to disconnect the RTU from the subscriber line when the subscriber line needs testing, and to implement various performance test for the subscriber lines and hence obtains corresponding test results after the RTU has been disconnected from the subscriber line.
The remote terminal subscriber control module is adapted to send control signals to the remote terminal subscriber access control module through subscriber lines after receiving the signal for notifying subscriber line testing from the broadband line testing module. The control signals includes the control signals for controlling the RTU to disconnect from the subscriber lines, as well as the time period required for broadband testing which is used to determine the time point to reconnect itself to the subscriber lines by the RTU.
In the exemplary embodiment of the present invention, a remote terminal subscriber access control module is provided for receiving control signals from the broadband line testing control module, and controlling the RTU to connect to or disconnect from the subscriber lines based on the received signals. The remote terminal subscriber access control module further includes a switch control module and a remote terminal subscriber control switch.
The switch control module is used to receive signals from the broadband line testing control module, generate corresponding control signals and send the control signals to the remote terminal subscriber control switch, so as to control the off/on status of the remote terminal subscriber control switch, thereby controlling the RTU to connect to or disconnect from the subscriber lines.
The remote terminal subscriber control switch is used to switch the on off state based on the control signals from the switch control module. If the on state is required, the RTU disconnects from the subscriber lines. In contrast, if the off state is required, the RTU connects to the subscriber lines.
The switch control module may include a timer circuit, which is triggered based on the received signal from the remote terminal subscriber control module. The switch control module determines corresponding time-out time according to the information carried by the signal, and sends a control signal for asking the remote terminal subscriber control module to change its status to the remote terminal subscriber control module when the timer in the timer circuit overruns. As to the broadband line testing module of the system provided in the present invention, the time period required for testing is carried in the signal sent to the remote terminal subscriber control module only when it is required to perform subscriber line testing. In this way, at the user end, when the timer overruns, the switch control module can automatically control the remote terminal subscriber control switch to return to normal status, namely reconnecting the RTU to the subscriber lines.
The remote terminal subscriber access control module can be a relay or any other device with similar function to that of a relay.
In the system for testing subscriber lines in network communication, the broadband line testing control module is set in the DSLAM; the remote terminal subscriber access control module is located between the subscriber line at user end and the RTU, or set inside the RTU.
As shown in FIG. 4 , a method for testing subscriber lines in network communication based on the above system includes the following steps.
In step 41 , when it is determined that the subscriber line needs testing, the broadband line testing control module sends a handshake message to the RTU, and receives the returned response message to judge whether this testing is supported by the RTU.
Before testing, G.994.1 standard is executed to perform handshake operation between the broadband line testing control module and the RTU. The broadband line testing control module and the RTU exchange the message indicating whether testing switch is supported through G994.1 Protocol.
In step 42 , the broadband line testing control module determines whether this testing is supported by the RTU according to the returned response message from the RTU, if yes, step 43 will be executed for the RTU supporting this testing, otherwise step 46 will be executed.
If the RTU supports testing switch, the seventh bit of “Identification field-Npar (1)” of Capability List Request (CRL) in G.994.1 is set at 1; meanwhile a command for indicating that RTU supports testing switch is defined in “Non-standard field” in G.994.1 frame. While at DSLAM end, if the DSLAM is to perform testing switch handshake, the seventh bit of “Identification field-Npar (1)” of Capability List (CL) is set at 1, meanwhile a command for indicating that DSLAM requests the RTU to perform testing switch and simultaneously notifies the RTU with the elapse time between switch off and switch back to the normal mode is defined in “Non-standard field” in G.994.1 frame.
After G.994.1 protocol is executed, if the seventh bit of the NPar(1) which is received by the broadband line testing control module in the DSLAM from the RTU is 1, the broadband line testing control module reads the command in “Non-standard field”, if the command indicates that RTU supports this testing switch, step 43 will be executed, otherwise step 46 will be executed.
If the signal sent by the broadband line testing control module in DALAM from the RUT is not a CLR frame, it is necessary for the broadband line testing control module to send the RTU a CLR frame request message for requesting the RTU to send a CLR frame. After receiving the CLR frame, the broadband line testing control module implements the above processing.
In step 43 , the broadband line testing control module sends a control signal bearing the time period for testing to the remote terminal subscriber access control module.
The above-mentioned control signal can be sent to the remote terminal subscriber access control module by means of a message based on G.994.1 protocol.
The above-mentioned control signal is used to ask the RTU to perform testing switch, namely to disconnect from the subscriber line, and to notify the RTU with a switch restoring time, namely the time point to reconnect the RTU back to the subscriber line. The above-mentioned control signal is a CL command sent from the DSLAM, including a switch starting command and a switch time in “Non-standard field” of the frame.
In step 44 , the remote terminal subscriber access control module disconnects the RTU from the subscriber line after receiving the control signal.
Meanwhile, after receiving the control signal, the remote terminal subscriber access control module starts a timer and sets a time-out time according to the testing time period carried by the received control signal. When the timer overruns, the remote terminal subscriber access control module reconnects the RTU to the subscriber line,
In addition, before the remote terminal subscriber access control module disconnects the RTU from the subscriber line, step 44 may further includes the step of returning a response message to the broadband line testing control module to notify it that the RTU has been disconnected from the subscriber line.
After receiving the CL command of DSLAM, the remote terminal subscriber access control module sends an acknowledgement message (ACK (1)) to the DALAM and starts testing switch simultaneously. After the testing switch of RTU, the remote terminal subscriber access control module starts timing according to the information carried in the CL command, if the time period set in the CL command is over, the RTU is switched back to normal access status and reconnected to the subscriber line.
In step 45 , after the RTU is disconnected from the subscriber line, the broadband line testing module in the broadband line testing control module starts to test the subscriber line.
Corresponding to step 44 , after receiving the returned response message from the remote terminal subscriber access control module and after a delay, the broadband line testing module in the broadband line testing control module starts to test the subscriber line, in order to make sure that the RTU has been safely disconnected from the subscriber line, accordingly guaranteeing the precision of corresponding testing results.
In other words, after receiving ACK(1) sent by the RTU and after a delay, the broadband line testing module in the broadband line testing control module starts testing for broadband testing items.
In step 46 , this testing processing is ended.
If the broadband line testing control module in DSLAM determines that testing switch function is not supported by the RTU, it displays the information that testing switch function is not supported by the RTU when this testing processing is ended.
Under the active state of RTU, the broadband line testing control module can send “testing switch and testing switch time” command to the RTU by way of the terminal managing channels of each port of each XDSL service sub-board in the DSLAM.
In the present invention, the above-mentioned RTU can be RTU of ADSL, VDSL or SHDSL.
While the invention has been shown and described with reference to a preferred embodiment 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 as defined by the appended claims. | The present invention discloses a system for testing subscriber lines and method thereof. The system includes a broadband line testing control module and a remote terminal subscriber access control module located at a subscriber line that is located between the broadband line testing control module and a remote terminal unit. The broadband line testing control module sends a signal of disconnecting the subscriber line to the remote terminal subscriber access control module, and tests the subscriber line. The remote terminal subscriber access control module receives said signal from the broadband line testing control module, and controls the remote terminal unit to disconnect from or connect to the subscriber line based on said signal. With the system and method according to the present invention, not only the precision of subscriber line testing is guaranteed, but also the subscriber lines can be periodically tested without manual operation. | 7 |
This application is a continuation of application Ser. No. 455,605, filed Dec. 21, 1989, now abandoned.
FIELD OF THE INVENTION
This invention relates to air breathing, gas turbine engines, and more particularly, to the starting of such engines at high altitudes.
BACKGROUND OF THE INVENTION
The starting of air breathing, gas turbine engines at high altitudes presents substantial difficulties, particularly in the case of relatively small gas turbine engines. At high altitudes, the temperature of the environment is quite cold with the consequence that fuels have high viscosity making it quite difficult to atomize the fuel sufficiently to ignite properly.
Furthermore, and as is well known, in the operation of turbine engines, the higher the altitude, the lower the fuel flow required to maintain any given standard of operation. Consequently, at high altitudes, relatively low fuel flows are required and that in turn means a reduction in the pressure applied to the fuel to achieve the reduced flow rate. Thus, where the turbine fuel injectors are of the pressure atomization type, the lesser fuel pressure utilized at high altitude means insufficient pressure to cause the required degree of atomization necessary to achieve a start. If it is attempted to overcome this difficulty by increasing the pressure, frequently, expensive altitude compensation control systems for fuel flow must be added to the system and even then, there will frequently be over fueling of the engine which in turn results in hot spots once ignition is obtained.
Further, particularly in the case of relatively small turbine engines, it is necessary to utilize so-called "start injectors" in addition to main fuel injectors. Start injectors are specially designed to provide the desired degree of atomization at maximum operating altitudes and typically are used only during the starting operation. They are turned off after ignition is obtained with fuel thereafter being supplied by the main fuel injectors. Again, the use of special injectors such as start injectors undesirably adds to the cost of the engine and still may not provide the desired degree of start reliability at high altitude of, say, thirty thousand or forty thousand feet.
The present invention is directed to overcoming one or more of the above problems
SUMMARY OF THE INVENTION
It is a principal object of the invention to provide a new and improved method of starting a gas turbine engine at high altitudes. It is also a principal object of the invention to provide a new and improved, high altitude starting-turbine.
According to one aspect of the invention, the foregoing objects are achieved in a method of starting a gas turbine engine at high altitudes including the steps of injecting fuel into a combustor for the engine through a fuel tube at a relatively low fuel rate, momentarily subjecting the fuel at an injection port on a tube or upstream thereof to a blast of oxidant at an elevated pressure and which is taken from a compressed oxidant storage vessel, and igniting the fuel. In a highly preferred embodiment, this method is practiced in a gas turbine engine having a rotary compressor driven by a turbine wheel, a nozzle for directing gases of combustion at the turbine wheel and connected to the outlet of an annular combustor, a plenum in fluid communication with the compressor and disposed about the combustor, and a plurality of angularly spaced fuel injectors about the combustor. Each fuel injector includes a housing having an outlet within the combustor and an air inlet within the plenum along with a fuel tube extending within the housing into proximity to the outlet. The end of the fuel tube adjacent the outlet defines the fuel injection port and the fuel tube further may include a fuel metering formation within the fuel tube upstream of the fuel injection port.
According to one embodiment of the invention, the step of subjecting the fuel to a blast of oxidant is performed for only a few seconds. In one form of the invention, it is performed by directing oxidant toward the outlet of the housing and about the end of the fuel tube defining the port. In another embodiment of the invention, the step is performed by directing oxidant into the fuel tube downstream of the fuel metering formation and upstream of the end defining the injection port.
The invention also contemplates the provision of a high altitude starting gas turbine including a compressor, a turbine wheel, a nozzle, a combustor and a plenum all oriented as stated previously. At least one fuel injector extends into the combustor and has an outlet therein along with a first air inlet within the plenum, a fuel injecting conduit and a second oxidant inlet along with means connected to the second inlet and associated with the conduit for directing a blast of oxidant at fuel flowing through the conduit to atomize the same. The invention further includes an oxidant storage vessel for storing oxidant at an elevated pressure and a means for selectively connecting the vessel to the second inlet to provide the blast of oxidant.
In a preferred embodiment, the selective connecting means includes a pressure regulator and a flow control valve.
In one embodiment of the invention, an air conduit interconnects the plenum and the second oxidant inlet. A check valve is located in the air conduit and is disposed to permit flow through the air conduit toward the second oxidant inlet from the plenum and to prevent reverse flow. As a result of this configuration, during starting, oxidant may be supplied to the second inlet from the storage source as mentioned previously while after ignition is obtained, air may be supplied to the second oxidant inlet from the downstream side of the engine compressor to which the plenum is connected.
Other objects and advantages will become apparent from the following specification taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic, sectional view of a gas turbine engine made according to the invention;
FIG. 2 is a partial sectional view and partial schematic of one embodiment of the gas turbine engine; and
FIG. 3 is a sectional view illustrating a modified embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Exemplary embodiments of a gas turbine made according to the invention are illustrated in the drawings in the form of radial flow, air breathing gas turbines. However, the invention is not limited to radial flow turbines and may have applicability to any form of air breathing turbine.
The turbine includes a rotary shaft 10 journaled by bearings not shown. Adjacent one end of the shaft 10 is an inlet area 12. The shaft 10 mounts a rotor, generally designated 14, which may be of conventional construction. Accordingly, the same includes a plurality of compressor blades 16 adjacent the inlet 12. A compressor blade shroud 18 is provided in adjacency thereto and just radially outwardly of the radially outer extremities of the compressor blades 18 is a conventional vaned diffuser 20, all to define a rotary compressor.
Oppositely of the compressor blades 16, the rotor 14 has a plurality of turbine blades 22 which, along with the adjacent part of the rotor 14 define a turbine wheel. The body of the rotor 14 itself effectively couples the turbine wheel thus defined to the rotary compressor.
Just radially outwardly of the turbine blades 22 is an annular nozzle 24 which is adapted to receive hot gases of combustion from an annular combustor, generally designated 26. The compressor system including the blades 16, shroud 18 and diffuser 20 delivers compressed air to the annular combustor 26, and via dilution air passages 27, to the nozzle 24 along with gases of combustion. That is to say, hot gases of combustion from the combustor are directed via the nozzle 24 against the blades 22 to cause rotation of the rotor, and thus the shaft 10. The latter may be, of course, coupled to some sort of apparatus requiring the performance of useful work.
A rear turbine shroud 28 is interfitted with the combustor 28 to close off the flow path from the nozzle 24 and confine the expanding gas to the area of the turbine blades 22. The combustor 26 has a generally cylindrical inner wall 32 and a generally cylindrical outer wall 34. The two are basically concentric and merge to a necked down area 36 which serves as an outlet from an interior annulus 38 of the combustor 26 to the nozzle 24. A third wall 39, generally concentric with the walls 32 and 34, extends generally radially to interconnect the walls 32 and 34 and to further define the annulus 38.
Opposite of the outlet 36 and adjacent the wall 39, the interior annulus 38 of the combustor 26 includes a primary combustion zone 40 in which the burning of fuel primarily occurs. Other combustion may, in some instances, occur downstream from the primary combustion area 40 in the direction of the outlet 36. As mentioned earlier, provision is made for the injection of dilution air through the passages 27 into the combustor 26 downstream of the primary combustion zone 40 to cool the gases of combustion to a temperature suitable for application to the turbine blades 22 via the nozzle 24. However, in some instances, where other provision for cooling the combustor 26 is made, the dilution air passages 27 may be omitted.
In any event, it will be seen that the primary combustion zone 40 is an annulus or annular space defined by the generally radially inner wall 32, the generally radially outer wall 34, and the radially extending wall 39.
An annular wall 44 of L-shaped section as seen in FIG. 1 is connected to a radially inner, annular wall 45 and both are in generally concentric relation to the corresponding walls of the combustor 26 from which they are spaced. The walls 44 and 45 serve as a case for the combustor 26 and define a plenum in fluid communication with the outlet of the diffuser 20 which contains and directs compressed air from the compressor system to the combustor 26.
Mounted on the wall 44, and extending through the wall 34 are injectors, generally designated 46.
Though not shown herein, according to a preferred embodiment of the invention, there will be a plurality of injectors 46 equally angularly spaced about the axis of rotation 48 of the shaft 10. The injectors 46 extend into the primary combustion zone by means of aligned apertures 50 and 52 respectively in the walls 34 and 44 as seen, for example, in FIGS. 2 and 3.
With reference to FIG. 2, each injector 46 includes a generally cylindrical housing 54 terminating in a radially inwardly directed elbow section 56. Opposite the elbow section 56, the housing 54 has a peripheral retaining flange 58 which may be sealed by a gasket 60 against the mounting surface 62 on the exterior of the radially outer wall 44.
That part of the housing 54 disposed between the walls 34 and 44 is provided with one or more openings 64, 66 which open to the plenum between the walls 34 and 44. Thus, compressed air from the compressor may flow through the holes 64, 66 to the interior of the housing 54.
Within the interior of each housing 54 there is disposed a somewhat J-shaped tube 70. The radially outer end 72 of the tube 70 is in fluid communication with a fuel manifold 74 connected to the fuel system for the engine. The radially inner end 76 of the tube 70 is angled to correspond with the elbow section 56 of the housing 54 and to be centered about a reduced diameter outlet opening 78 therein. Optionally, a fuel swirler 80 may be located within the tube 70 in proximity to the end 76 which serves as an injector nozzle or fuel port.
Well upstream of the port 76, and in close adjacency to the manifold 74, the tube 70 may include an internal orifice 81 which acts as a fuel metering orifice for fuel flow through the tube 70.
The angle of the elbow section 56 and the end 76 of the tube 70 is such that both fuel and air will enter the primary combustion zone 40 generally tangentially. Provision may also be made for the introduction of dilution air into the periphery of the primary combustion zone 40 in a tangential direction by the provision of a series of axial lines of apertures 84 and axially elongated cooling strips 86 as illustrated in both FIGS. 2 and 3.
The tangential injection of fuel and combustion air via the injectors 46 as well as tangential introduction of dilution air as just described provides for a high degree of circumferential swirl within the primary combustion zone 40 and thus is highly desirable, though not absolutely necessary, in practicing the invention since it minimizes the number of injectors required to provide an even distribution of mixed air and fuel. This feature of the invention eliminates hot spots even if one or more of the injectors should clog. Thus, the invention lends itself readily to use in relatively small turbine engines which, because of their relatively small size, have utilized extremely small fuel injection passages in their fuel injectors which are highly subject to clogging. Individual passage size for a given engine can be increased by reducing the number of injectors, thereby allowing each injector to have a larger fuel passage. Any resulting tendency to develop hot spots is eliminated because the swirl of burning fuel in the primary combustion zone 40 provides even temperature distribution throughout during normal operation.
The injectors 46 are basically air blast atomization injectors. That is to say, the compressed air from the compressor moving through the constricted opening 78 of the housing 54 as a result of the fluid communication established by the openings 64 and 66 with the plenum connected to the outlet of the diffuser 20 causes atomization of fuel exiting through the injection port 76 of the tube 70. This, of course, is perfectly satisfactory during normal operation of the engine when the compressor is providing compressed air to effect such air blast atomization. However, when the turbine is quiescent and must be started, other means of effecting the necessary atomization must be employed since compressed air from the compressor will not be available at this time.
As alluded to earlier, in prior art apparatus, this is effected by so-called pressure atomization systems. In large turbine engines, it may be effected through pressure atomization at main fuel injectors without the use of start fuel injectors. Conversely, in small turbine engines, one or more start injectors might be employed.
According to the present invention, which is ideally suited for use in small turbine engines, start injectors are avoided as are pressure atomization systems.
With reference to FIG. 2, each tube 70, intermediate the end 76 and the flow metering formation or orifice 81 includes a branch tube 90 which serves as a second oxidant inlet to the injector 46. The first oxidant inlet is, of course, in the form of the openings 64, 66.
According to the invention, a relatively small high pressure storage vessel or bottle 92 is provided. A pressure regulator 94 is connected to the outlet of the bottle 92 which in turn is connected to a flow control valve 96. A control system 97 which may be basically conventional and is employed in starting the engine is utilized to open or close the valve 96 as desired and the outlet side of the valve 96 is connected via a conduit 98 through the branch tube 90.
According to the invention, when a start procedure for the engine is initiated, the valve 96 is opened by the control system 97 and compressed oxidant, typically in the form of air or even molecular oxygen, from the bottle 92 is supplied to the tube 70 along with fuel. In one case, if at an altitude of forty thousand feet, an absolute pressure of 17 psi is applied to the tube 90 from the bottle 92, an oxidant velocity in excess of 500 feet per second may be obtained with the flowing oxidant which will provide excellent atomization of even extremely viscous fuels being flowed into the tube 70 from the manifold 72. It is significant to note that the branch tube 90 enters the tube 70 downstream of the fuel metering formation or orifice 81 so the application of pressurized oxidant to the tube 90 does not interfere with the desired flow of fuel from, or cause backflow toward the source because the orifice 81 provides an isolating effect.
In a worst case, typically the valve 96 need be opened only for a few seconds. Two seconds will normally be sufficient and because of the short time the valve 96 is open, the vessel 92 may be made of relatively small size, its dimensions being measured in inches rather than feet.
Once the engine is started, the improved atomization provided by the application of pressurized air to the branch tube 90 may be maintained after closure of the valve 96 if desired by means of a conduit 100 connected to the conduit 98. The conduit 100 is placed in fluid communication with the outlet 102 of the diffuser 20 (FIG. 1). Thus, once the engine is operating, compressed air from the compressor will sustain the injection of air even after the valve 96 is closed by the start control 97.
To prevent oxidant backflow during start-up, a check valve 104 is located in the line 100 between the diffuser outlet 102 and the line 98 and is disposed so as to allow flow from the diffuser outlet 102 toward the tube 90 but not the reverse.
FIG. 3 illustrates an alternative form of the invention although the same employs a number of components identical or extremely similar to those described previously. In the interest of brevity, like components have been given like reference numbers and will not be redescribed.
Concentrically about the fuel injection tube 70 and in spaced relation thereto is an oxidant tube 110. The oxidant tube 110 terminates in an annular port 112 surrounding the port 76 at the end of the fuel tube 70. The opposite end 114 of the oxidant tube 110 is in fluid communication with an oxidant manifold 116 within the housing 54 and which may be connected to the line 98 shown in FIG. 2. Operation again is essentially the same with the atomization of fuel exiting the port 76 being caused by the same being subjected to a high velocity blast of oxidant emanating from the port 112. Again, the oxidant blast is maintained only momentarily, typically for a few seconds, until ignition is achieved within the combustor by means of an igniter (not shown) of conventional construction.
From the foregoing, it will be appreciated that even at the low fuel flows encountered in small gas turbine engines at high altitudes, excellent atomization of fuel sufficient to insure reliable starts without overfueling may be obtained through use of the invention. If the storage source 92 is constructed so as to store oxidant at several thousand pounds per square inch, hundreds of starts may be obtained from a single stored charge because of the short duration of the oxidant blast utilized for enhanced atomization. Consequently, the use of expensive start injectors may be avoided as can be the use of highly sophisticated altitude compensation systems. Considerable cost savings result.
In addition, when the oxidant blast is employed with all the main injectors in an engine, poor fuel distribution from one injector to the next due to the effects of so-called "manifold head" at high altitude is avoided because of the uniformity of injection achieved by the high velocity oxidant passing through each of the injectors. | Difficulties in starting a gas turbine engine at high altitudes may be avoided by the method of starting such an engine which includes the steps of introducing fuel into the combustor (26) of the engine through at least one fuel injector (46) having an outlet (76, 78) within the combustor (26), atomizing the fuel with a burst of oxidant at elevated pressure from a source (92) of pressurized stored oxidant until ignition is obtained, and thereafter discontinuing the burst of oxidant from the source (92). | 5 |
FIELD OF THE INVENTION
[0001] This invention relates to a method of producing advanced composite materials with a substantially laminar construction.
[0000] Review of the Art Known to the Applicant(s)
[0002] Composite materials have found great application in recent decades, due in part to their ability to combine high strength with the ease of forming complex shapes. One particular class of composite materials, to which this current invention relates, uses fibres made of various materials, bonded together with a resin. The fibres themselves have an inherent strength combined with a flexibility, that allows them to be formed into complex shapes and then bound together with an appropriate resin. The strength of the composite material derives from the inherent strength of the fibres combined with the strength of the bond between them. The desirable mechanical properties of the fibres are intrinsically anisotropic, in that they lie predominantly along the direction of the fibre. However, in the manufacture of articles from such composite materials it is sometimes required that the finished article has isotropic strength characteristics. This design requirement has led to a number of technical solutions, which will be described below, each of which exhibits a number of deficiencies.
[0003] The class of composite materials to which this invention refers are known as Polymer Matrix Composites, or Fibre Reinforced Polymers. They use a polymeric resin as a continuous matrix and contain a variety of fibres. Commonly used fibres include carbon fibre, glass, aramid and boron. The overall properties of such composites result from the individual properties of the fibre and of the resin, the ratio of fibre to resin in the composite and the geometry and orientation of the fibres within the composite.
[0004] A wide range of resin types are used in the manufacture of resin-fibre composites. These resins or polymers may be thermoplastic, or more usually thermosetting. A wide range of such thermosetting polymers are used in the composite industry, polyester, vinylester and epoxy are common. Properties of the resin are chosen to be compatible with the fibres to be used in the composite. For example, it is important that the adhesive properties of the polymer are such that a strong bond is made between the fibres. In this respect, epoxy systems are regarded as offering high performance. The mechanical properties of the resin system are also important, particularly the tensile strength and stiffness of the cured polymer, as well as the shrinkage of the resin during its curing period. In this respect, again, epoxy resin systems are known to produce low shrinkage rates.
[0005] Among the range of fibres available for use in composite manufacture, three are most common in the industry. Glass fibres are typically used either as yarns (closely associated bundles of twisted filaments or strands), rovings (a more loosely associated bundle of untwisted filaments or strands), or spun yarn fibres.
[0006] Aramid fibres made from aromatic polyamides, such as those sold under the trade mark ‘Kevlar’ have high strength and low density and have found wide application in protective materials. Carbon fibres, produced by high temperature treatment of polymer fibres, have been used for the last 40 years or so and have high stiffness, tensile and compressive strength, as well as favourable corrosion-resistance properties.
[0007] Methods of construction of fibre and resin composite materials fall into two broad classes. The first of these, referred to as ‘Wet Lay-up’ involves adding liquid resin to the fibres at the stage of forming the moulded product. In this mode of processing, a relatively large resin to fibre ratio is produced, and composites of this form are recognised in the art as having inherent weakness. The second mode of construction uses pre-impregnated fibres, and is generally regarded as being superior to the wet lay-up technique. These so-called ‘pre-impregnated’ fibres are well known in the art, and will not be needlessly described here. Within this class there are three approaches that have been used, as follows:
[0000] Pre-impregnated Unidirectional and Woven Fabric
[0008] Sheets of fabric made from the required fibres may be stacked to form a desired laminate thickness. The sheets may be unidirectional—i.e. with the fibres running in one direction—or woven, with a variety of weave options. This allows a controlled orientation of the fibres so that a manufactured component can be stronger and/or stiffer in the direction of the fibre, in an analogous way to the grain of wood. The weave of the fabric itself is comprised of ‘tows’ which themselves may comprise many thousands of fibres or filaments.
[0009] The alignment and bundling of fibres into a tow allows a very strong resin bond to take place between the fibres, unlike the random fibre methods to be described below. This alignment allows the resin content of the composite to be reduced, and to be more uniformly distributed amongst the fibres.
[0010] Problems arise, however, when a homogenous construction is required, and the strength and stiffness in a manufactured article needs to be isotropic (i.e. not varying with direction), at least with respect to the major spatial axes. The use of a number of such sheets to create the required thickness in the product introduces an interlaminar weakness. Interlaminar failure and delamination significantly compromise a laminate's structural integrity and performance, and is a common failure mode for composite materials constructed in this manner.
[0011] Each ply of fabric is anisotropic in terms of its planar mechanical properties. So, in order to construct an isotropic laminate a significant number of plies are required, but the problem of interlaminar differences are inherent even though the laminate as a whole is quasi-isotropic.
[0012] The construction of a quasi-isotropic structure requires a significant number of plies which in turn requires a level of symmetry of fibre direction through the plane and sectional view of a bi-directional thickness in order to avoid distortion of the manufactured article through eg. thermal or shrinkage mechanisms. This requires increased care, and hence manufacturing costs, in the laminating process.
[0013] When this type of material is required for complex shapes with tight compound curves, specific tailoring is needed with both woven and unidirectional material. The drapebility of the fabric used is key to the success of this manufacturing technique. Individual plies are cut and spliced to enable the material to conform to the required shape. This can increase interlaminar stresses over a large area.
[0000] Chopped Random Fibre and Continuous Random Fibre
[0014] Fibre-resin composites may also be made using chopped or continuous random fibres. The use of such fibres requires less effort, and hence reduces the cost of components. The random nature of the fibre orientation means that a construction can be made with essentially isotropic properties.
[0015] However, the reduction in cross-linking between parallel fibres is very significant and reduces the overall performance of the laminate. The inherently random nature of the fibre placement causes some areas of the product to be thicker than others unless significant pressure is used to help the distribution, but this contributes further to the reduction in laminate performance as the fibres are distorted in this process.
[0016] Furthermore, the random bridging of fibres leaves large voids that get filled with resin. This increases the weight of the component. Therefore the control on resin to fibre ratio is poor which generally means the mechanical properties are worse than with pre-impregnated fabric.
[0017] Finally, the Fibre Area Weight (FAW)—i.e. the weight of a given area of a sheet or product—is not as consistent in this mode of manufacture, as may be obtained by use of pre-impregnated unidirectional or woven fabric.
[0000] Random Chopped Fibre in Moulding Compound
[0018] A final way of constructing resin-fibre laminates is by the use of random chopped fibres in a moulding compound. In a number of applications, for example in the manufacture of protective helmets, an unsaturated polyester resin moulding compound is used, reinforced with pre-impregnated glass fibre. This method usually uses comparatively short fibres, with a consequently adverse effect on the material properties. The overall performance of this type of material is recognised to be significantly worse than that produced by the methods described above.
[0019] The present invention addresses these problems of conventional resin-fibre laminate technology, and produces a laminate that is essentially anisotropic, has favourable mechanical properties in terms of strength and stiffness, and is significantly less prone to de-lamination failure.
SUMMARY OF THE INVENTION
[0020] In the broadest definition of the invention, there is provided a method of producing a laminate comprising the following steps:
[0021] (a) Forming patches from a substantially unidirectional fabric, treated with a resin
[0022] (b) Substantially randomising the orientation of said patches
[0023] (c) Distributing a plurality of said patches in layers around a former
[0024] (d) Causing said layers of patches to amalgamate by means of activation of the resin treatment.
[0025] Advantageously, the means for distributing patches in step (c) is a suction device.
[0026] Advantageously also, the means for distributing patches in step (c) is a pneumatic conveyor.
[0027] Preferably, in any of the definitions of the methods of the invention, the said patches have an average surface area no greater than 20% of the surface area of the layer formed in step (c).
[0028] More preferably, in any of the definitions of the methods of the invention, a multiplicity of patch shapes and/or sizes is employed.
[0029] Included within the scope of the invention, is a method of producing a laminate substantially as described herein, with reference to and as illustrated by any appropriate combination of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a schematic process diagram illustrating the formation of fabric patches, their randomisation, and their presentation for fiber processing.
[0031] FIG. 2 is a schematic process diagram illustrating the formation of patches, their randomisation, and subsequent conveyance to a moulding process.
[0032] FIG. 3 illustrates a range of patch shapes suitable for use in the current invention.
[0033] FIG. 4 illustrates a typical random arrangement of patches in a composite polymer.
[0034] FIG. 5 is a schematic diagram of a cross-section through a composite laminate as made by existing technology.
[0035] FIG. 6 is a schematic diagram showing a cross-section through a composite laminate made according to the method of the current invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0036] To overcome the deficiencies of existing methods of composite manufacture, the method of the present invention comprises the use of a large number of randomly-orientated patches of orientated fibres. Preferably, these are patches of unidirectional fabric, i.e. a fabric in which the majority of fibres run in one direction only. It is commonly understood in the art that such unidirectional fabrics may have a small amount of fibre or other material running in another direction, with the intention of holding the primary fibres in position. It is preferable that the unidirectional fabric used in the method of manufacture of the preferable that the unidirectional fabric used in the method of manufacture of the composite is pre-impregnated, or pre-treated, with an appropriate resin system in order to produce a high fibre to resin ratio in the final composite. This is difficult to achieve with the Wet Lay-up technique. The patches used in the manufacture of this ‘Random Stamp Laminate’ are chosen to have a size and shape appropriate to the geometry of the required final product, as will be discussed below. The laminate is then formed by layering, in an essentially random way, the patches to the required shape of the final articles. Following this layering process, the patches are compressed if required and then cured in the conventional way, appropriate to the resin system in use.
[0037] One embodiment of such a production process is illustrated in FIG. 1 . Unidirectional fabric 1 as sheet or roll material is fed into apparatus 2 comprising the means for producing the fabric patches 3 of the required range of sizes and shapes. The patches 3 are fed into apparatus such as a tumbler 4 providing means for randomly orientating the patches 3 . On leaving the tumbler 4 the randomly orientated patches 5 may fall onto a conveyer belt 6 to form a loose, randomly orientated layer 7 of patches. The randomly orientated patches 7 may then be conveniently picked up by use of a suction head 8 for transfer to a product mould by, for example, robotic means.
[0038] In an analogous way, the randomly orientated patches 5 could be fed into a hopper for eventual delivery to such a suction head device.
[0039] FIG. 2 shows another embodiment of the production process whereby the randomly orientated patches 5 are conveyed from the tumbler 4 by means of a pneumatic conveyor. Such conveyors are known for handling powdered or granular materials. Control of temperature in such a conveyor can be used to prevent patches sticking to each other, or to the conveyor, during transport. The patches may then be conveniently deposited in layers, to the required geometry, optionally with the assistance of a vacuum-forming device.
[0040] The shape and size of the patches used to form the random stamp laminate may be chosen according to the size and geometry of the object to be manufactured. Any particular object to be manufactured may use patches of a range of sizes and shapes, either distributed randomly over the surface of the object, or patches of a particular shape or size may be positioned, or orientated, at particular locations on the object to provide localised areas of specific strength characteristics, such as local anisotropy. It is to be appreciated that there is a trade off between the ability to follow a curved geometry and the strength of the composite produced. Small patches will be more able to follow complex geometries, but at the expense of the strength that derives from long fibre length.
[0041] FIG. 3 illustrates a range of suitable geometries for the patches. All the patches depicted are capable of tesselating, thus making most efficient use of the sheet or roll unidirectional fabric, although this property is not essential for operation of the present method. Referring to FIG. 3 , appropriate shapes depicted are a rectangle 10 , a parallelogram 11 , a trapezium 12 , a chevron 13 , a hexagon 14 and a curved arrow 15 . The lines in each of the shapes depicted in FIG. 3 indicate the preferred direction of the fibres in the unidirectional sheet, by providing the most efficient way to maximise the fibre length within the patch.
[0042] FIG. 4 depicts, again schematically, a small section 16 of a composite laminate made according to the method of this invention. This view, perpendicular to the plane of the randomly orientated patches 17 , shows a typical arrangement of the patches. In this instance, rectangular patches of a uniform size are depicted, but a range of sizes and shapes could equally be used as required.
[0043] A key advantage of this method of production of advanced composite materials is that the problem of delamination under stress is significantly reduced. FIG. 5 shows a schematic representation of a section through a typical six ply laminate composite made according to existing methodology. The two central plies 18 as illustrated are formed of unidirectional fabric with the fibre direction running normal to the plane of the diagram. The two outer plies 19 are similarly orientated. The two intermediate plies 20 have unidirectional fibres lying along the plane of the diagram, as indicated by the horizontal stripes. It can be seen that in this construction there are clear interlaminar ‘strata’ 21 . In the final composite, of course, these would be composed of the resin material. They are, however, a plane of weakness in the material along which delamination failure often occurs.
[0044] By contrast, FIG. 6 is a diagrammatic representation of a section through a composite made according to the method of the current invention. It will be appreciated that the diagram is schematic, and that in order to clarify the description, the patches are depicted as being thicker, shorter and more kinked than would be preferable. The diagram shows sections through a large number of patches 22 , 23 , 24 , each composed of unidirectional fabric, and each patch orientated in a random fashion as described earlier. As a result of the random way in which the patches are placed on the former, a number of features of the invention are apparent. Whilst some patches may abut each other, although with a random orientation of the fabric, others, for example those depicted as patches 24 overlap at their edges. Still further patches, such as those depicted at 23 , traverse at least part of the thickness of the composite laminate. It will be noted that unlike the traditional laminates depicted in FIG. 5 , the laminate produced by the current invention has a much less stratified structure. These features contribute in great part to the improved characteristics of the composite. The overlapping and thickness-traversing patches serve to prevent delamination, and to spread stresses throughout the structure of the composite.
[0045] The invention is defined in the claims that follow and in which the term “unidirectional fabric” is understood to encompass fabrics in which most of the fibres are aligned in substantially the same direction, and may contain fibres running in other directions with the intention of holding the primary fibres in position. Typically, in the art, more than 75% of the fibres are aligned in substantially the same direction.
[0046] The term “former” is understood to be any means of causing the spatial association of patches. The term former includes, therefore, means commonly referred to as a mould, which may contain a number of convex and concave curves. The term former also includes substantially planar surfaces.
[0047] The term “resin” is understood to include any polymeric material capable of binding the fibres of the fabric together, and “means of activation” is understood to include heat, radiation, catalysis, chemical reaction and drying.
[0048] Laminates produced according to the method of this invention are described in the co-pending application filed by our agent the same day, under the title ‘Advanced Composite Materials’. | A method of producing a laminate comprising the following steps: (a) Forming patches from a substantially unidirectional fabric, treated with a resin; (b) Substantially randomising the orientation of said patches; (c) Distributing a plurality of said patches in layers around a former; (d) Causing said layers of patches to amalgamate by means of activation of the resin treatment. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to an engine oil makeup and extended operation oil exchange system for automatically maintaining the amount of engine oil in an engine oil sump and for increasing the total volume of oil available for lubricating the engine by continuously exchanging engine oil between an oil tank containing oil and the engine oil sump during extended operation.
Engine oils, used as a lubricants, lose their initial qualities after prolonged or extended use and are no longer effective. Therefore, it is necessary to change the used engine oil after a period of time.
In conventional engine lubrication systems, an internal combustion engine powered by diesel fuel or gasoline is lubricated by lubrication oil which is distributed to moving parts of the engine susceptible to frictional wear. After a prolonged use, however, the quality of engine oil degrades and loses its effectiveness due to accumulation of combustion-generated solid debris and chemicals, accumulation of frictionally generated metallic particles and degradation of molecular weight with attendant drop in viscosity. Thus, such degradation in the quality of the lubrication oil necessitates the changing of the lubrication oil. Further, during engine operation it is necessary to maintain the amount of lubrication oil in the engine. Typically, this is solved by periodically maintaining the oil level and changing the oil as required.
In certain situations, it may be impossible to periodically maintain the oil level and quality. For example, when the engine is located in remote locations or in difficult to reach locations. Also, emergencies may occur wherein it is impossible to periodically maintain the oil level and quality.
One solution to this problem is the use of an engine oil makeup system. In some engine oil makeup systems, engine oil is periodically partially changed to maintain oil level and quality. Another type of engine oil changing system uses an engine oil exchange system, wherein engine oil is circulated to exchange used oil with fresh oil.
U.S. Pat. No. 4,105,092 discloses an engine oil makeup and exchanging system. In this engine oil makeup and exchanging system, excess oil in an engine is transferred to an oil tank at intervals by pumps during engine operation. In addition, U.S. Pat. No. 4,417,561 discloses yet another kind of oil changing system. In this oil changing system, used lubrication oil is recirculated and mixed with fuel in a fuel tank. The oil/fuel mixture is then burned in the fuel system.
The present invention offers improvements over the prior art and solves many problems associated with the prior art.
SUMMARY OF THE INVENTION
One embodiment of the present invention relates to an engine oil makeup and extended operation oil exchange system and method for automatically maintaining the amount of engine oil and for increasing the total volume of oil available for lubricating the engine by continuously exchanging engine oil between an engine oil sump and an oil tank containing oil during extended operation.
Yet, another embodiment of the present invention relates to an engine oil makeup and extended operation oil exchange system and method for automatically maintaining the amount of engine oil and exchanging engine oil between an engine and an oil tank for maintaining oil quality in the engine during extended engine operation. In this embodiment, oil is transferred from a pressurized oil source on the engine to the oil tank.
One advantage of an embodiment of the present invention is that it has two modes of operation. In a first mode, the system functions as an oil makeup system to automatically maintain the amount of engine oil in the engine oil sump. In a second mode, the system functions as both an oil makeup system and an extended operation oil exchange system which effectively increases the total volume of oil available for lubrication of the engine. In the first mode, an oil exchange shutoff valve is closed to prevent engine oil from leaving the engine, and an oil tank valve is opened to supply fresh oil by gravity flow from the oil tank through an oil tank valve to the engine oil sump. A regulator is used to regulate the amount of engine oil added to the engine oil sump so as to maintain the proper level of volume of oil in the engine oil sump. The regulator regulates the level of engine oil in the engine oil sump by closing and opening an oil supply passageway from the oil tank to engine oil sump in response to the changing level of the engine oil in the engine oil sump. Thus, the amount of engine oil in the engine oil sump is automatically maintained during the first mode. In the second mode, the oil exchange shutoff valve is opened to allow engine oil to flow from the engine to the oil tank. In a preferred embodiment, an additional oil filter is used to filter used engine oil flowing from the engine to the oil tank. A restriction orifice, not typically an integral part of the engine, can be used to restrict the flow of filtered oil from the oil filter to the oil tank so as to allow the desired amount of filtered engine oil to flow to the oil tank. During the second mode of operation, engine oil from the engine oil sump is pressurized in the engine and flows to the oil filter through the oil exchange shutoff valve. The filtered engine oil then flows to the oil tank. The restriction orifice between the pressurized engine oil source and the oil tank is predeterminately sized so as to maintain the proper level of oil flow to the oil tank. Thus, oil is recirculated between the engine and the oil tank while maintaining the proper oil level in the oil sump.
It is yet another advantage of an embodiment of the present invention is to provide a drain system to separately drain the engine oil sump and the oil tank or drain them together.
Yet another embodiment of the present invention relates to an engine oil makeup and extended operation oil exchange system for use with an engine having an engine oil sump, comprising:
(a) an oil tank interconnected to said oil sump by an oil passageway;
(b) means for controlling the flow of oil through said passageway so as to maintain the level of oil in said engine oil sump; and
(c) oil transfer means, including an oil exchange shutoff valve, interconnecting a pressurized oil source on said engine to said oil tank for transferring oil from the engine to the oil tank, whereby the oil is recirculated between the oil tank and the engine.
Still another embodiment of the present invention relates to an engine oil makeup and extended operation oil exchange system for use with an engine having an engine oil sump, comprising:
(a) an oil tank interconnected to said engine oil sump by an oil passageway;
(b) means for controlling the flow of oil through said passageway so as to maintain the level of oil in said engine oil sump; and
(c) means for continuously circulating oil between said oil tank and said engine upon the occurrence of a predetermined condition.
The present invention provides an extended operation oil exchange system to allow an engine to operate without maintenance for long periods of time. This is particularly advantageous where an engine is located in remote or difficult to reach locations or in the case of emergencies when it is not possible to service the engine.
These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects obtained by its use, reference should be had to the drawing which forms a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing in which like reference numerals and letters indicate corresponding parts throughout the several views,
FIG. 1 is a diagrammatic illustration of an embodiment of an engine oil makeup and extended operation oil exchange system according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an embodiment of an engine oil makeup and extended operation oil exchange system of the present invention, generally referred to be reference numeral 11, is shown in association with an engine 15 which is lubricated by engine oil in an engine oil sump 17. An oil conduit 27 interconnects an outlet 26 of an oil tank 29 containing engine oil; e.g., four gallons in one embodiment, to an inlet 18 of the oil sump 17 so as to provide an oil passageway therebetween. The oil conduit 27 includes proximate one end a regulator 31. The oil conduit 27 further includes proximate an opposite end an oil tank valve 33 proximate the outlet 26 of the oil tank 29. Fresh oil flows from the oil tank 29 through the oil tank valve 33 to the regulator 31 when the oil tank valve 33 is opened. When the oil tank valve 33 is closed, oil flow from the oil tank 29 to the regulator 31 is prohibited. As shown, the oil tank 29 is positioned at an elevation greater than the oil sump 17 so that oil flows from the oil tank 29 to the oil sump 17 due to gravity. Thus, the oil tank valve 33 can be a simple ball type valve which simply opens and closes the oil passageway.
When the oil tank valve 33 is open, the regulator 31 regulates fresh oil flow from the oil tank 29 to the oil sump 17 in response to the level of the oil in the oil sump 17 so as to maintain the desired oil level in the oil sump 17. In the preferred embodiment, the regulator 31 is a float type valve which opens and closes in response to the changing level of engine oil in the oil sump 17. One example of such a float type valve is the model LR-857 Level Regulator made by Frank W. Murphy Company. Accordingly, the regulator 31 is closed when the oil level in the oil sump 17 reaches the predetermined oil level at which the amount of engine oil in the oil sump 17 is maintained, while the regulator 31 is opened when the oil level in the oil sump 17 drops below the predetermined oil level. The regulator 31 remains opened until the oil level in the oil sump 17 raises to the desired predetermined oil level. It will be appreciated that the regulator 31 might comprise a conventional float type valve or other well known oil regulation devices.
Further in the preferred embodiment shown in FIG. 1, an oil conduit 35 connects a pressurized oil source 37 on the engine 15 with the oil tank 29 so as to provide an oil passageway therebetween. Accordingly, oil under pressure flows from the pressurized oil source 37 on the engine 15 to the oil tank 29. The pressurized oil source 37 might be at any location along the engine's oil lubrication system, where oil is being circulated under pressure by an oil pump (not shown on the FIG. 1) of the engine 15. During engine operation, oil is typically pumped under pressure throughout an engine 15 by the engine's oil pump. Thus, by simply tapping into any of the locations in the engine where oil is being circulated under pressure will provide a pressurized oil source 37. A suitable connector can be used to provide a fluid tight connection of the oil conduit 35 to the pressurized oil source 37. Disposed along the oil conduit 35 is an oil exchange shutoff valve 39 and a restriction orifice 43. The oil exchange shutoff valve 39 opens and closes the oil passageway. When the oil exchange shutoff valve 39 is opened, the oil under pressure is allowed to transfer from the engine 15 to the oil tank 29. When the oil exchange shutoff valve 39 is closed, oil is not allowed to transfer from the engine 15 to the oil tank 29. The oil exchange shutoff valve 39 is preferrably an electrically activated valve such as a solenoid activated valve. Accordingly, the oil exchange shutoff valve 39 enables and disables the exchange of oil between the engine 15 and the oil tank 29. One example of an oil exchange shutoff valve 39 which might be used is the ASCO® 8223 Series valve. An oil filter 41 is used to filter oil flowing from the engine 15 through the oil exchange shutoff valve 39 so that filtered oil flows to the oil tank 29. The oil filter 41 is in addition to the oil filtration that is normally an integral part of the engine's operation. In an alternative embodiment, the oil filter 41 need not be present. The restriction orifice 43 is used to restrict oil flow from the engine 15 and thereby restrict the rate of oil exchange between the engine 15 and the oil tank 29. This prevents oil from leaving the engine 15 too quickly, thereby ensuring that the rate of oil exchange is sufficiently restrained so as to maintain an adequate supply of oil in the engine 15 for lubrication. While it will be appreciated that the rate of oil flow may vary from engine to engine, a typical rate of oil flow might be 0.8 quarts/hour.
In the preferred embodiment shown, the engine oil sump 17 includes an outlet 16. An oil conduit 19 is attached to the outlet 16 and includes an oil pan drain valve 21 proximate the outlet 16. An oil drain pipe plug 23 is positioned proximate the end of the conduit 19. A support bracket 25 is shown as supporting the end of the conduit 19. Accordingly, oil in the oil sump 17 can be drained through the outlet 16.
In the preferred embodiment shown in FIG. 1, an oil fill cap 45 at the top of the oil tank 29 allows an operator to fill fresh oil in the oil tank 29. The oil fill cap 45 also prevents fresh oil from vaporizing. An oil level gauge 47 besides the oil fill cap 45 at the top of the oil tank 29 measures the amount of oil in the oil tank 29. An oil tank drain 28 is positioned at the bottom of the oil tank 29 for draining oil from the oil tank 29. Accordingly, oil in the oil tank 29 can be drained either through the oil tank drain 28 or through the oil sump 17 and the oil conduit 19.
In the preferred embodiment shown in FIG. 1, a controller 50 is used to monitor the hours of engine operation and, upon detection of a predetermined period of engine operation, open the oil exchange shutoff valve 39. In the embodiment shown, the controller 50 is electrically interconnected by an electrical conductor 52 to an engine's electrical system 54 and the oil exchange shutoff valve 39. In one embodiment, the controller 50 might be interconnected to a part of the engine's electrical system 54 which is only energized when the engine is running. The controller 50, in this case, monitors the amount of time that the electrical system is energized, which will correspond to the amount of time the engine is running. Upon detection of the predetermined amount of time, the controller 50 will signal the oil exchange shutoff valve 39 to open via the electrical conductor 52. It will be appreciated that a conventional controller 50 might be used. The controller 50 will contain suitable logic for activating the oil exchange shutoff valve 39 upon detection of the predetermined amount of time. While the amount of time will vary from engine to engine, a typical time of engine operation might be 300 hours. In alternative embodiments, the controller 50 might monitor the occurrence of some other predetermined condition and upon the occurrence of such condition; e.g., quality of oil in the oil sump 17, level of oil in the oil tank 29, etc., the controller 50 open the oil exchange shutoff valve 39. If the quality of oil in the oil sump 17 is monitored, a suitable sensor might be placed in the oil sump 17 to sense oil quality.
In use, when initially setting up the system, fresh engine oil is placed in the oil tank 29. The oil tank valve 33 is then opened. Fresh oil will flow under the influence of gravity to the regulator 31. The controller 50 will have initially closed the oil exchange shutoff valve 39 to prevent oil in the oil sump 17 from leaving the engine 15. Thus, the engine will initially run in the oil makeup mode. The regulator 31 regulates the amount of oil allowed to flow into the oil sump 17 until oil level in the oil sump 17 reaches the predetermined oil level and then maintains the oil at that level. Upon the occurrence of a predetermined condition, for example, a predetermined period of time of engine operation, the controller 50 opens the oil exchange shutoff valve 39 to allow oil under pressure to continuously flow from the engine 15 to the oil tank 29. Meanwhile, oil in the oil tank 29 is fed by gravity to the oil sump 17 through the regulator 31 which maintains the oil level in the oil sump 17. Thus, oil in the oil tank 29 and oil in the oil sump 17 are exchanged. The engine 15 is now in the extended operation oil exchange mode. The system will remain in the extended operation oil exchange mode until stopped by a user for an oil change. In the extended operation oil exchange mode, the volume of oil available for engine lubrication is increased.
While particular example of the usage of the present invention have been shown and described, it is apparent that changes and modifications may be made therein without departing from the gist of the present invention in its broadest aspects. The aim of the appended claims, therefore, is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | An engine oil makeup and extended operation oil exchange system and method are provided for automatically maintaining the amount of engine oil and continuously exchanging engine oil in extended operation between an engine and an oil tank. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a sensor element for opening of doors and gates, in which case a sensing field can be generated using an antenna element for the purpose of detecting people and/or static objects.
Multifarious forms and designs of such sensor elements are known and available commercially. They are used to generate a sensing field in front of a door and/or gate area and are usually arranged above doors or gates. They are also usually in the form of stationary sensors, infrared sensors or radar sensors and detect stationary objects and/or people in the sensing field in front of a door in order to keep the latter open or to open it.
Since such sensor elements have to be adjustable or have to be adjusted to different heights and widths for particular door areas in order to generate an optimized sensing field for different heights and doors and gates of different widths, a complicated control device and adjusting devices have hitherto been provided on the sensor elements in order to adjust an angle of inclination of the sensor, for example, or to carry out optical adaptation or the like, which is undesirable.
For example, as a result of doors of different heights, the sensor element, in particular a radar sensor, is often set and readjusted after installation in order to set and align a sensing field to the conditions. The setting and alignment or adjustment operation is also time-consuming and expensive.
In particular, the operation of manually installing and aligning and adjusting sensing fields in front of doors and gates involves a high level of installation and alignment outlay, which is likewise undesirable.
EP 1 508 818 A exhibits a radar sensor in which individual slot antennas are provided in the carrier element.
US 2002/036595 A1 describes an antenna in which individual antennas are arranged at the same distance from one another. An antenna array is described in EP 1 113 523 A1, in which a plurality of pin antennas are likewise arranged at equal distances around an antenna element.
The publication by Schlub R. et al.: “Dual-band six-element switched parasitic array for smart antenna cellular communications systems” ELECTRONIC LETTERS, IEE STEVENAGE, GB, vol. 36, no. 16, 3 Aug. 2000 (2000 Aug. 3), pages 1342-1343, XP006015551 ISSN: 0016-5194” describes a conventional array antenna in which only individual arrays are provided in order to influence a field in different ways. Although some antennas may be arranged in different lengths, it is not possible to accurately determine a clear delimitation and boundary of a field.
The citation MURATA M ET AL.: “Planar active Yagi-like antenna” ELECTRONICS LETTERS, IEE STEVENAGE, GB, vol. 36, no. 23, 9 Nov. 2000 (2000 Nov. 9), pages 1912-1913, XP006015913 ISSN: 0013-5194 discloses an antenna in which the antennas are inserted into conductor tracks in a planar structure. Said antenna does not have any separate pins.
The present invention is based on the object of providing a sensor element for opening of doors and gates, in which the length and width of a sensing field can be exactly preset in order to ensure sufficient protection and a sufficient sensing field for opening of doors and gates for doors and gates of a particular width at an installation height or passage height which can be determined and selected.
In this case, the intention is to dispense with manual setting-up and readjustment, in which case only the sensor element has to be installed at a determinable height above or beside doors and gates in order to ensure an optimum sensing field in front of the door and/or gate.
SUMMARY OF THE INVENTION
This object is achieved by the features of a sensor element for opening of doors and gates, in which case a sensing field can be generated using an antenna element for the purpose of detecting people and/or static objects, characterized in that the antenna element has a flat antenna unit, at least one pin-like antenna projecting approximately perpendicularly from the flat antenna unit.
In the present invention, it has proved to be particularly advantageous to form an antenna element as a flat antenna unit, at least one antenna in the form of a pin antenna projecting from the flat antenna unit itself.
The width of a sensing field can be defined by preferably arranging two or more individual pin antennas beside one another.
Reflectors which are correspondingly arranged above the antenna and directors which are arranged below the antenna additionally make it possible to exactly determine and align a length of the sensing field on a background for a predefined installation height.
The sensor element is thus individually aligned for the required installation situation as regards the width and height of the gate or door by means of the corresponding pin-like arrangement and dimensioning.
In this case, the antenna, the reflector and the director are preferably arranged above one another and project perpendicularly from a reference plane of the flat antenna unit.
Appropriate selection of a length of the reflector, antenna and director makes it possible to exactly define and restrict the field of the antenna. In this case, the scope of the present invention should also include the fact that a plurality of arrangements of the reflector, antenna and underlying director are arranged beside one another, a width of the sensing field being able to be determined and aligned using a distance between two or more antennas, in particular underlying director are arranged beside one another, a width of the sensing field being able to be determined and aligned using a distance between two or more antennas, in particular two or more arrangements of the reflector, antenna and director.
A plurality of sensing fields of different sizes and widths can also be generated by using a plurality of arrangements which can also be connected to one another below one another. This should likewise be within the scope of the present invention.
The practice of producing different lengths of the sensing field by varying different lengths of the individual reflectors or antennas and directors should also likewise be considered. The invention shall not be restricted to this.
The reflector, antenna and director are preferably above one another, in which case the fact that a plurality of reflectors can be arranged above the antenna in different arrangements and one or more directors may also be arranged below the antenna may also be considered. The invention shall not be restricted to this.
In this case, one or more receiving antennas may be provided beside the antenna. Only the transmitting antenna itself as well as the receiving antenna are electrically connected to a respective radio-frequency circuit. The reflector and director are preferably connected to ground, if necessary by means of additional circuits.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention emerge from the following description of preferred exemplary embodiments and with reference to the drawing, in which:
FIG. 1 a shows a diagrammatically illustrated plan view of a sensor element for opening of doors and gates;
FIG. 1 b shows a diagrammatically illustrated side view of the sensor element in the installed state according to FIG. 1 a;
FIG. 2 a shows a diagrammatically illustrated plan view of a further exemplary embodiment of a further sensor element according to FIGS. 1 a and 1 b;
FIG. 2 b shows a diagrammatically illustrated plan view of a further exemplary embodiment of the sensor element according to FIGS. 1 a and 1 b;
FIG. 2 c shows a diagrammatically illustrated plan view of yet another exemplary embodiment of a sensor element according to FIGS. 1 a and 1 b.
DETAILED DESCRIPTION
According to FIG. 1 a , a sensor element R 1 according to the invention has an antenna element 1 which is in the form of a flat antenna unit 2 . In this case, pin-like antennas 3 which are preferably arranged beside one another project from a reference plane E of the flat antenna unit 2 which may be in the form of a flat base plate, printed circuit board, substrate or the like.
The antenna 3 preferably projects perpendicularly from the flat antenna unit 2 , but also projects at an angle if necessary, and is electrically operated in order to generate a sensing field 4 .
The at least one antenna 3 which is in the form of a pin is preferably installed orthogonal to the flat antenna unit 2 and is designed and dimensioned in a manner corresponding to a Marconi antenna, in particular is in the form of an asymmetrical λ/4 dipole. The antenna 3 is preferably electrically operated actively as the actual antenna in order to generate the sensing field 4 .
The antenna 3 may be installed, for example, on a wall 5 or above a door 6 or gate or else at any other desired locations. It illuminates a sensing field 4 which, as shown in FIGS. 1 a and 1 b , may extend from the door 6 to the floor 7 , for example. The contour of the sensing field 4 may be of any desired type and size.
In order to determine and set a length L E of the sensing field 4 , it has proved to be advantageous in the present invention to arrange at least one reflector 8 above the antenna 3 .
In order to also limit the field in order to obtain a desirable “endfire” characteristic, at least one director 9 may be arranged in a pin-like manner below the antenna 3 . The reflector 8 and director 9 are likewise of pin-like design, the reflector 8 and director 9 preferably lying on a common vertical to the antenna 3 , as shown in the exemplary embodiment according to FIG. 1 a.
The reflector 8 and director 9 are preferably connected to ground directly or indirectly, if necessary by means of an additional circuit. The reflector 8 and director 9 are likewise of pin-like design and analogously project approximately perpendicularly from the antenna 3 . Like the antenna 3 as well, the reflector and director may likewise have a round, oval, square or polygonal cross section and preferably project perpendicularly from the flat antenna unit 2 .
However, the scope of the present invention should also include the fact that the antenna 3 as well as the reflector 8 and director 9 are oriented at an angle, that is to say greater or less than 90°, to the surface of the flat antenna unit 2 or project from the latter.
An opening angle φ with respect to the floor 7 can be set and determined by means of a corresponding length L of the reflector 8 relative to the antenna 3 and of the director 9 relative to the antenna 3 in order to set a desired length L E of the sensing field 4 .
In this case, the length of the reflector 8 may be less than, equal to or greater than a length of the antenna 3 . The same applies to the director 9 . As is also clear from FIG. 1 a of the present invention, a width B E of the sensing field 4 of the sensor element R 1 can be determined by virtue of the fact that a plurality of arrangements D 1 , D 2 comprising the reflector 8 , the underlying antenna 3 and the director 9 arranged below the latter are preferably at a distance A 1 from one another on a vertical.
A width B E of the sensing field 4 and/or a width angle α can be set or changed, in particular by virtue of the distance between the two antennas 3 in the arrangements D 1 , D 2 .
In this case, it is not absolutely necessary for the reflector 8 and director 9 to be provided or to be perpendicularly arranged above one another in a correspondingly vertical manner. They may also be arranged outside a vertical in order to produce, for example, a different size or contour of the sensing field 4 . For example, one or the other director 9 or reflector 8 may be dispensed with or a plurality of reflectors 8 and/or directors 9 may be provided below and/or above the at least one antenna 3 . This should likewise be within the scope of the present invention.
In addition, it is conceivable to set a horizontal distance A between the reflector 8 and antenna 3 and/or a distance A between the antenna 3 and director 9 as desired in order to influence the length L E and/or width B E of the sensing field 4 on the floor and/or to influence the opening angle φ and the width angle α.
Furthermore, the antenna element 1 , in particular the flat antenna unit 2 , as indicated in FIG. 1 a , may be assigned at least one receiver antenna 10 which is preferably arranged beside the arrangements D 1 and/or D 2 at the same height as the antenna 3 and/or reflector 8 and director 9 . The receiver antennas 10 are preferably on a vertical parallel to the arrangement D 1 and/or D 2 and are in the form of perpendicularly projecting pins as a receiver antenna 10 on the same flat antenna unit 2 . The receiver antennas 10 are preferably arranged at a lateral distance from the other antennas 3 , the reflector 8 and the director 9 .
A sensor element R 2 is shown in the exemplary embodiment of the present invention according to FIG. 2 a , the antenna element 1 being in the form of a flat antenna unit 2 , and reflectors 8 which are arranged in an area 11 above two antennas 3 , which are on a horizontal and are at a distance from one another, and are arranged in any desired area 11 above the antennas 3 being provided. They need not necessarily be arranged on a vertical to the antenna 3 .
In this case, at least one director 9 can also be provided in an area 12 below the at least one antenna 3 . This should likewise be within the scope of the present invention. A plurality of receiver antennas 10 may be provided in the flat antenna unit 2 at a distance from the arrangement of the antenna 3 as well as the reflector 8 and director 9 .
A sensor element R 3 which approximately corresponds to the abovementioned type is shown in another exemplary embodiment of the present invention according to FIG. 2 b . The difference is that only one antenna 3 or else a plurality of antennas 3 (not illustrated in any more detail in this case) may also be provided, for example, a plurality of reflectors 8 being able to be provided in an area 11 above the antenna 3 and a plurality of directors 9 being able to be provided in an area 12 below the antenna 3 in any desired arrangement. These are used to focus the field, in particular the sensing field 4 .
In this case, a length L of the individual antennas 3 and/or reflectors 8 and/or directors 9 may also vary in a corresponding manner. The same applies to their cross sections.
A sensor element R 4 , in which a plurality of arrangements D 1 , D 2 and D 3 of the antenna 3 , reflector 8 and director 9 are formed, is shown in the final exemplary embodiment of the present invention according to FIG. 2 c.
In this case, in the preferred exemplary embodiment, the reflector 8 , the underlying antenna 3 and the underlying director 9 are arranged above one another in the vertical direction according to the exemplary embodiment of the present invention 1 a and 1 b.
A corresponding further arrangement D 2 is provided beside it such that it is parallel to, and at a particular distance A 1 from, the arrangement D 1 .
A particular distance A 1 is selected between the arrangements D 1 and D 2 . In this case, a third arrangement D 3 comprising the reflector 8 , the underlying antenna 3 and the underlying director 9 may be provided, which third arrangement is aligned at a different distance A 2 from the arrangement D 1 than the arrangement D 2 .
This makes it possible to connect arrangements D 1 and D 2 at a selectable distance A 1 in order to obtain a desired sensing field 4 . At the same time, it is conceivable for only the arrangements D 1 and D 3 to be connected to one another in order to generate a sensing field 4 with a correspondingly different opening angle φ and width angle α to the combination of arrangements D 1 and D 2 .
It is also conceivable to connect the arrangements D 2 and D 3 together in order to generate yet another sensing field. This should likewise be within the scope of the present invention. This should also concomitantly include the fact that corresponding receiver antennas 10 are also provided on the antenna element 1 beside the individual arrangements D 1 , D 2 and D 3 .
Furthermore, as illustrated using dashed lines in FIG. 2 b , a separate independent receiver antenna may also be assigned to the antenna element 1 or may be provided beside the latter. The invention shall not be restricted to this. | A sensor element for opening of doors and gates, with the aim being to allow production of a detection field for identification of people and/or static objects by means of an antenna element, the antenna element is intended to have a flat antenna unit, with a pin-like antenna projecting at least approximately vertically from the flat antenna unit. | 4 |
DESCRIPTION OF THE INVENTION
[0001] The filed on which the invention is relating to The invention is relating on the mobile protection against thigh waters. It contains transportable, waterproof structural elements that can be filled or emptied with water.
PRIOR ART OF THE TECHNIQUES
[0002] From the patent DE 20213118 U1 it can be recognized a mobile protection against high waters that contains recognizable composition elements in shape of rectangular vessels that are waterproof and that can be filled or emptied by water. These vessels are composed of one floor element (plate, wall) with four side walls. The walls are made of gum elastic material. The biggest disadvantage of this protection against the high waters is that it is not waterproof. Such a made wall is unstable and water porous because of the whole gum/elastic structure of the walls. That is the reason why there is no possibility for walls to be put one over another and in such a way to increase the highness of the protective wall. Also, it is not possible, for example, the river curves to be followed only by rectangular vessels. The supporting elements, that are applied only for simulation of the curve (as it is said in DE 20213118 U1) makes the fast wall (the wall that fits closely) to be statically unstable.
TECHNICAL PROBLEM THAT IS RESOLVED BY THE INVENTION
[0003] The task of this invention is to develop mobile protection against high waters that comprises transportable, waterproof structural elements which can be filled and emptied with water. This protection shall make a stabile and waterproof protective wall, that, for example, follows one curve of river and that can be built up.
DESCRIPTION OF THE ESSENCE OF THE INVENTION
[0004] In accordance with the invention this task shall be resolved providing that the structural (constructional) elements will be attached each to other and each over other. They will make shape of rectangular vessels for rectilinear path of the protective wall, as well as a shape of top/formed segments for the curved path of the protective wall whereas each composed element comprises four inclined walls and one plate. Two of the aside walls equal each to another and two frontal walls with equal size build up, together with the floor plate, rectangular vessels. Also, that there is a frontal wall, that is directed towards the side of the high water. On the floor plate as well as on the back frontal wall of the frontal wall, on the aside wall of the back frontal wall and on the aside wall of the aside wall, that can be overlapped by using hinge/joints that are hinged on the aside and frontal walls in such a way making possible horizontally overlapping of the walls one over another. Also, it can be done between the barriers that can be built from the hinge/joints in the aside and frontal walls and where are put packing elements between the vessel wall barriers. Furthermore, the frontal walls use easy up caps in form of hanger with opposite hangers which are under inclination in relation to the aside walls that press packed aside walls in opposite of the frontal walls by means of wall sticker. In is performed in such a way that into each vessel is inserted a piece of gum, that, remooved from the asside edge, makes a vessel with a half circled packed coat which can be attached to the previous mention walls from the upper side. The walls and the floor plates of the structural elements are built by two layers: one of them is made of PE-HD/PE-LD mixture while the other is made of caoutchouc. The walls bring the layer of caoutchouc from the outer side while the floor plate brings this layer from down side. The walls are hard bounded; they are waterproof regarding each to other as well as in respect of floor plates. The compositional (structural) elements are placed on the one of the sides for bounding that is put near to outer edges and vertically put packed elements. The structural elements, that regarding to the sides are without packed elements, can be tensioned by means of hooking caps, while the key segments posses packed elements on the upper edge. The structural elements that are put each over another are connectable by hook caps in the field of the upper edge. There are connected fast and sticker each to other, while the key segments make circle reinforcement. In the middle, they created one cross sectioned reinforcement which structural elements posses supportive handles for transportation and for construction of the protective wall. Each of the structural elements that are put on the floor from the side of the high water, in the prolongation of the floor plate, has floor lips and waterproof outlet valve, that can be closed and opened and that is used for draining of the filled water. On the downside from prolongated floor plate that are over the packed profile that is desirable to be built up of ellastomer as well as on the side on which is turned the high water onto the floor plate are placed jaws. Each from the connected structural elements has passing holes of the floor plate that is attachable with one passing tube. On the down side from floor plates, each of the elements has security equipment against replacement. The inserted gum pieces in the vessels can be strength fasted with the drain valves or with the passing tube. The sub-claims from point 2 till nine show the rest of the performed forms of the invention.
[0005] Further, the invention is shown in details on the base of one performed example. The drawings that belong to this example show the details as follows.
[0006] FIG. 1 Upper view on the vessel,
[0007] FIG. 2 A part from one protective wall of the vessels,
[0008] FIG. 3 Down side of the floor plate prolongated with floor leaps,
[0009] FIG. 4 Upper view on one key segment,
[0010] FIG. 5 Frontal view on the FIG. 4
[0011] FIG. 6 Frontal view on a vessel,
[0012] FIG. 7 Frontal view on a vessel with inside directed and bended frontal wall,
[0013] FIG. 8 Back view on a vessel,
[0014] FIG. 9 Back view on vessel with inside directed and bended frontal wall,
[0015] FIG. 10 Steps of assembling walls of a vessel,
[0016] FIG. 11 Upper view of the gum sticker,
[0017] FIG. 12 Schematic cross section A-A, in accordance with FIG. 11 .
[0018] The FIG. 1 shows the upper view of one rectangular transportable vessel 1 , that can be filled or emptied with water, and which, with the key segments 2 (as a structural elements placed each near to other), build protective wall against high waters whereas they shall be put each to adhere in case of curved flow, while, in case of linear flow, on the protective wall against high water will be put rectangular vessels 1 . In purpose of increasing the highness of protective wall against high water, the structural elements can be ordered one over another, as it is shown in FIG. 2 . Each of the structural elements is built up from four vertical walls 3 , that are fasted on the floor plate 4 and that have above an opened holed room that is to be filled with water. The vessel 1 has two aside walls with equal size 3 a , 3 b and two frontal walls 3 c , 3 d with equal size, too. The structural elements that have to be attached to the floor, in the prolongation of the floor plate 4 , from the side of the high water, posse's floor lips. This leaps uses for decreasing the turning momentum in the case of extra water weigh. In purpose of developing attachment between the floor and the structural elements, each of the down sides of the prolongated floor plates 4 has one packed profile 16 that is desirably to be made of polymer (see FIG. 3 ). On the side that is turned toward the high water and from the side of the floor plate 4 are mounted jaws 17 that are used for further stabilization. The jaws comprise PE-HD-plate with impregnated steal tops. Further, in the floor leaps 14 , there are perforated holes 21 , across which are put concrete (armature) iron bars for reinforcement of the structural elements on the floor. The aside walls 3 a , 3 b and the frontal walls 3 c , 3 d can be overlapped in the direction of the floor plate 4 . As it can be seen in FIG. 10 , over the hinged/joints 5 are going to be overlapping, as follows:
[0019] The fontal wall 3 c , that is turned toward the high water, with the floor plate 4 , the frontal wall 3 d with the frontal wall 3 c , the aside wall 3 a with the frontal wall 3 d , as well as the aside wall 3 b with the aside wall 3 a.
[0020] As it can be seen from the FIG. 10 , the hinged/joints 5 of the frontal walls 3 c , 3 d and the aside walls 3 a , 3 b are placed in such a way facilitating horizontal overlapping of the walls 3 a , 3 b , 3 c and 3 d . Further, the structures, that are built up from the hinged/joints 5 in the aside walls 3 a , 3 b and the frontal walls 3 c , 3 d are ordered between the structures of the walls 3 and the wall stickers 24 of the walls 1 . In the opened vessels 1 can be inserted one gum part 6 , in accordance with FIG. 11 and FIG. 12 . The inserted gum part 6 shall be stopped across one drain valve 25 from the down vessel 1 and across the transmission tube from the upper vessel 1 into the vessel 1 that is not shown in the figure. For example, this can be happened in the down vessel 1 , across a plate (an equipment for fitting the tubes) that lays inside the drain valve 25 , whereas the connecting nut 22 shall be turned outside, against the vessel 1 of the drain valve 25 , while the fast inserted gum pieces 6 are put inside, between the plate and the vessel 1 . The upper edge of the inserted gum piece shall be pulled off over the edge of the vessel, where the gum piece 6 of the upper edge from the vessel shapes half-circled, packed coat 7 referring to one adhered vessel 1 . Further, the frontal walls 3 c , 3 d have an easy up caps in the form of hanger 26 , with inclined placed opposite hooks 27 , on the aside walls 3 a , 3 b that fast the aside walls 3 a , 3 b by means of wall jacket 24 , opposite to the frontal walls 3 c , 3 d . The walls 3 and the floor plate 4 from the structural elements are made of two-layer, namely, they are composed of one PE-HD/PE-LD-mixture and one layer of caouchouc, whereas the walls of the structural elements carry the caouchouc layer from the outside, while the floor plate 4 carries the same layer from the downside. The walls 3 and the floor plates 4 are attached each to other strength and waterproof. The structural elements have to the one of the turning sides, besides the outside edges, vertically placed packed elements 8 . The packed elements 8 are in a form of half-profile, unsolvable adhered each to other over the caouchouc layer. Opposite to the packed elements 8 , there are adhere fasted the structural elements with the sides without the packed elements 8 , by the hooked caps 9 . The edges of the walls have jacked coat 7 made of inserted gum pieces 6 and key segments 2 that carry jacket elements 10 on the upper edge in a shape of mushrooms. The structural elements are connected each to other through hooked caps 9 that is shown in FIG. 2 with possibility for their strength and densely connection. The hook caps 9 are built up as an easy up caps, which have opposite hooks 20 of the constructive element, which lies from the other side because of the security of the structural elements. The easy up cups have supplementary prolongation of the basic plate 19 at the segments 2 because of the security of the segments 2 and the vessels 1 , by means of the opposite hooks 20 . The segments 2 posses circled reinforcement 11 in the field of the upper edge. In the middle there is put one cross sectioned placed second reinforcement 12 , as it is shown in FIG. 4 . The structural elements posses carrying handle 13 in purpose of building protective wall against high waters. Each from the structural elements that can be attached has, in the floor plate, passing drilling in which one passing tube can be screwing. As it is shown in FIG. 2 , at the down side, the adhered structural elements posses security equipment against spraining 18 , In FIG. 6 and FIG. 7 are shown, the vessel 1 from the down side of the water, whereas, in FIG. 7 , the frontal wall 3 c is horizontally sprained toward inside, opposite to the floor plate 4 . Over the vessel, that is opened frontally, it can be seen the back frontal wall 3 d with its hinge/joints. The FIGS. 8 and 9 show the view of the vessel 1 seen from the back. In FIG. 9 , the frontal side 3 d is overlapped to the frontal side 3 c . From the drain valve 25 of the segment 2 , there is screwed one two inches ball valve 15 by Storz-C-clutch to Storz-C-blind attachment, while, opposite of the drain valves 25 , from each of the vessels 1 it can be screwed treaded cap 23 into the appropriate drain valve 25 . Additionally, in the invention are applied materials that are stainless and neutral to the underground waters.
Meanings of the Referred Drawings
[0000]
1 . Vessel,
2 . Segment,
3 . Walls, 3 a -Aside wall, 3 b -Aside wall, 3 c -Frontal wall, 3 d -Frontal wall,
4 . Floor plate,
5 . Hinge/joint,
6 . Inserted gum piece,
7 . Coat,
8 . Packed element,
9 . Hook cap
10 . Packed element in the kind of mushroom,
11 . Reinforcement,
12 . Reinforcement, cross-sectional placed,
13 . Carrying handle,
14 . Floor leaps,
15 . 2″ (two inches) ball valve,
16 . Packed profile,
17 . Jaws,
18 . Security equipment against straining,
19 . Prolongation of the basic plate,
20 . Opposite hooks,
21 . Outlet,
22 . Connecting nut,
23 . Threaded cap,
24 . Wall jacket,
25 . Draining valve,
26 . Easy up cap in form of hanger,
27 . Opposite inclined hooks. | The mobile protection against high waters that is contained from transportable structural elements that are water proof and that can be filled or emptied with water where the structural elements can be placed aside each to other and each over other, taking the shape of rectangular vessels ( 1 ) in case of linear flow of the protective wall against high waters and the shape of key segments ( 2 ) when the flow is curved. The hook hanger ( 9 ) represents easy up cap with opposite hooks ( 20 ) to the structural elements that lay across it. The easy up caps at the segments ( 2 ) have additional prolongation of the basic plate ( 19 ) because of the assurance of the segments ( 2 ) with the vessels ( 1 ) throughout the opposite hooks ( 20 ). The vertical jacket element ( 8 ) is in shape of half-profile, and it is unsolvable adhered over the layer of caouchouc. The jacket element ( 10 ) from the segment ( 2 ) has a profile in shape of mushroom. The jaws ( 17 ) are made of PE-HD-plate with inserted steel tops. The floor lips ( 14 ) have outlets ( 21 ) for insertion of reinforced iron bars. On the draining valve ( 25 ) from the segment ( 2 ) is screwed 2″ (two inches) ball valve ( 15 ) with Storz-C-attachment and with Storz-C-blind attachment. At the draining valve ( 25 ) from each of the vessels ( 1 ) it can be screwed by one threaded cap ( 23 ) for closing of the appropriate draining valve ( 25 ) | 4 |
CLAIM OF PRIORITY UNDER 35 U.S.C. §119
The present Application for Patent claims priority to Provisional Application No. 60/839,506 entitled “A CONSTANT POWER, VARIABLE DATA RATE TWO-WAY, MOBILE SATELLITE COMMUNICATIONS LINK” filed Aug. 22, 2006, and to Provisional Application No. 60/846,121 entitled “A CONSTANT POWER, VARIABLE DATA RATE TWO-WAY, MOBILE SATELLITE COMMUNICATIONS LINK” filed Sep. 19, 2006, which were both assigned to the assignee hereof and hereby expressly incorporated by reference herein.
BACKGROUND
1. Field
The present invention relates generally to communication systems, and more specifically to a method and apparatus for selecting a forward link and return link data rate is a constant power, variable data rate two-way, mobile satellite communications link.
2. Background
There is therefore a need in the art for an efficient constant power, variable data rate two-way, mobile satellite communications link. Typical satellite communication links are designed with excess link margin in order to overcome occasional link degradations. The result is that during normal link conditions, the link is not efficiently used, i.e., power is wasted.
SUMMARY
The present system solves the shortcomings of the prior art. In the present system, the link margin is varied by adjusting the over the air data rate in order to limit the wasted power and at the same time to improve the over the air data rate useable by each mobile terminal.
A constant fixed power is transmitted by the earth station (both the fixed earth station network operation center and the mobile terminals). The modulation used in both links is such that the receiving terminal can accumulate the received power until enough energy is received to demodulate the signal correctly. The receiving terminal feeds back information to the transmitter including the signal strength it measures which determines at what data rate it can demodulate. The transmitter remembers this information so that next time it is to send data to the receiver, it uses this information to determine the data rate. In both links (network operations center to terminal and terminal to network operations center) the transmitters (and subsequently the receivers) are able to send (receive) multiple different data rates, thus minimizing the wasted link power while simultaneously keeping the transmitter power fixed.
The present invention contains novel features such as the network operations center and terminal measure the forward link (FL) and return link (RL) carrier power to noise power spectral density ratio (C/No), neither the network operations center nor terminal get constant feedback from the network operations center/terminal, the network operations center sends a short “ping message” to a terminal to get a current FL C/No reading if the terminal has not been heard from recently, the network operations center and terminal use data rate selection algorithms as a best guess to choose the packet data rate to minimize excess link margin for both the initial packet transmission and subsequent retransmissions and the network operations center and terminal change the modulation symbol rate (not the power level) to create the packet data rate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart showing the FL message packet transmission;
FIG. 2 is a flow chart describing the method for determining the packet data rate;
FIG. 3 is an example of a table of FL data rates;
FIG. 4 is a flow chart of the preferred data rate determination for the RL message; and
FIG. 5 is an example of a RL data rate table.
DETAILED DESCRIPTION
The purpose of the presently disclosed embodiments, hereinafter referred to as the Millennium System, is to drastically increase bandwidth efficiency (and thereby drastically reduce transponder cost) and capacity of the communications link between a network operation center (NOC) or hub to a Millennium data module (MDM). The Millennium System will maintain compatibility with other systems, such as OmniTRACS®, and interfaces to the dispatch centers and resident applications.
The Millennium forward link consists of variable rate data frames that are directed to terminals based on their ability to receive. Terminals receiving a strong signal will be sent data frames at a higher rate, whereas terminals receiving a weaker signal will be sent frames at a lower data rate. The subsequent sections describe the rate selection algorithm.
FIG. 1 is a flow chart showing the FL message packet transmission. The NOC receives a customer originated message to be delivered 10 to a customer mobile terminal and segments it (if necessary) into one or more Protocol Data Units (PDUs). If the terminal has not been in communication with the NOC for T RP — PingThreshold sees or longer and the message length is greater than or equal to L RP — PingThreshold bytes, then the NOC sends a “Ping” 12 PDU to the mobile unit. If the Ping is sent 14 a Ping PDU is created, and prepared for transmission 16 to the mobile unit. The forward link data rate used to send the Ping PDU is determined 18 as is the return data rate to be used by the terminal for the reply. The last known RL C/No from that terminal is also computed and inserted into the PDU. After the Ping is transmitted, the NOC waits a predetermined time for a response from the terminal 20 . Next a determination is made whether the NOC has received the Ping response from the mobile terminal 22 . If the predetermined time lapses and there is no response 24 from the terminal, the NOC resends the Ping 26 if the maximum number of attempts has not been reached 28 . The data rate to send the Ping is recomputed 18 and the process repeats until either the maximum number of attempts is reached 28 in which case the message delivery is deemed foiled 30 , or the terminal responds.
When the NOC receives the Ping reply PDU 32 , it measures the RL C/No level of the received signal and stores it in its database for later use. The Ping reply PDU also contains the FL C/No level the terminal most recently measured. The NOC extracts that value and stores it in its database, also 34 . The NOC then prepares for transmission the original message PDU 36 . If a Ping is not necessary 40 or original message PDU in sent 36 , the NOC computes the FL data rate to use for transmitting the PDU using the most recently saved FL C/No levels. The NOC also computes the RL data rate to be used by the terminal for its acknowledgment reply 38 . The RL C/No to send to the terminal is also computed for it to use in its RL data rate selection algorithm. After the message PDU is transmitted, the NOC waits a predetermined time for a response from the terminal 42 . Next, the NOC determines whether an acknowledgement (Ack) has been received from the terminal 44 . If the predetermined time lapses and there is no response from the terminal 46 , the NOC resends the message PDU 48 if the maximum number of transmission attempts has not been reached 50 . If the maximum number of transmissions has been reached 52 , the message delivery is deemed a failed delivery 54 . The data rate used to retransmit the PDU is recomputed and the process repeats until either the maximum number of attempts is reached, or the terminal responds. If the NOC receives an acknowledgement from the terminal that it received the forward link message 56 , the NOC saves the measured RL C/No of that signal and the FL C/No that is contained in the received PDU 58 . After the acknowledgement is received, the NOC declares the message delivery to be successful and notifies the sender 60 .
FIG. 2 is a flow chart describing the method for determining the packet data rate procedure as indicated in steps 18 and 38 of FIG. 1 . The first step is to initiate or enter into the system 62 . Using a look-up table with the transmission count as the index, the next step is to find the FL (M r — FL ) and RL (M r — RL ) retransmission margin value 64 . Calculate the total forward link (M total — FL ) and return link margin (M total — RL ) 66 values as:
M total — FL =M r — FL +M p — FL +M m — FL +M b — FL
Where:
M r — FL is forward link re-transmission margin. M p — FL is forward link priority margin, M m — FL is forward link message type margin. M m — FL is forward link balance margin.
M total — RL =M r — RL +M p — RL +M m — RL +M b — RL
Where:
M r — RL is return link re-transmission margin. M p — RL is return link priority margin. M m — RL is return link message type margin. M b — RL is return link balance margin
Next a determination is made whether the terminal has been heard from 68 . If the NOC has never received any packets from the mobile terminal before 70 , the NOC uses pre-determined, configurable values for default FL and RL C/N 0 values 72 . If the NOC has received packets from the mobile terminal before 74 . The NOC uses the last saved values for the FL and RL C/N 0 values for that terminal 76 . The NOC then subtracts the total forward link margin (M total — FL ) and total return link margin (M total — RL ) from the FL and RL C/N 0 values 78 to get estimated FL and RL C/N 0 values, as defined by:
Estimated FL C/N 0 =(Last Known FL C/N 0 )− M total — FL
Estimated RL C/N 0 =(Last Known RL C/N 0 )− M total — RL
Finally, the estimated FL and RL C/N 0 values are used to look-up FL and RL data rates to use for the packet. The RL data rate is used by the mobile terminal for the packet response. The NOC measured R/L C/N 0 is also sent to the terminal in the packet 80 , so that the terminal can make subsequent R/L data rate determinations wherein the systems returns 82 to the appropriate steps of FIG. 1 .
An example of FL data rates for selection is shown in the table of FIG. 3 . In this particular embodiment, the data rate table is configurable and can be expanded up to 31 FL data rates. This limitation is based on the available number of Walsh Codes, which are identified by the receiver to identify the data rates.
FIG. 4 is a flow chart showing the return link message packet transmission. As shown in FIG. 4 , the mobile terminal receives a customer originated message to be sent or delivered to NOC 100 and segments it (if necessary) into one or more Protocol Data Units (PDUs). The terminal calculates the margin 102 to use when determining the RL data rate as:
PDU Margin= M p +M m +M b +M ( i ) retx
Where:
M p =PDU priority margin M m =PDU type margin M b =Balance margin M(i) retx =The ith retransmit schedule margin
Depending on whether the terminal has received a PDU from the NOCl since it powered on 104 , the terminal takes one of two actions.
If the terminal has not received 106 any PDUs from the NOC since it powered on, the terminal uses the system default value of FL_to_RL_CNo_Difference it has received from the NOC in the broadcasted System Parameters message 108 in its next calculation. If the terminal has received 110 a PDU from the NOC since it powered on, the terminal uses the latest value of FL_to_RL_CNo_Difference 112 that it has previously computed using the RL_CNo feedback in the last PDU from the NOC in its next calculation.
The terminal then calculates an estimated RL C/No level 114 as:
Estimated RL C/N 0 =FL C /No−FL_to_RL — C No_Difference−PDU Margin
Where:
FL C/No=The FL C/No the terminal is currently measuring
The terminal converts the estimated RL C/No to a data rate 116 to use when transmitting the PDU through a table look-up. The terminal creates the RL PDU and inserts the recently measured FL C/No into the PDU header 118 for the NOC to use in its FL data rate determination calculations. The PDU is transmitted and the terminal waits for a response from the NOC 120 . The terminal also saves the recently measured FL C/No. The terminal waits a predetermined time for the NOC response 122 . Depending on whether a response is received, the terminal performs one of two actions. If the terminal does not receive 124 a response from the terminal and if the maximum number of transmit attempts has not been reached 126 , the terminal re-transmits or resends the PDU 128 after computing a new estimated RL C/No and PDU data rate. If the maximum number of transmission attempts has been reached 128 , the terminal drops the message 130 .
If the terminal has received the NOC's response 132 , it extracts the last RL C/No level 134 the NOC measured from the response message. The terminal uses that RL C/No level and the previously saved FL C/No to compute a new value of FL_to_RL_CNo_Difference. The terminal drops the message and considers it successfully delivered 136 .
An example of RL data rates for selection is shown in the table of FIG. 5 . In this particular embodiment, the data rate table is configurable and can be expanded up to 16 RL data rates.
Those of skill in the art would understand that information and signals may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof.
Those of skill would further appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in Random Access Memory (RAM), flash memory, Read Only Memory (ROM), Electrically Programmable ROM (EPROM), Electrically Erasable Programmable ROM (EEPROM), registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | A method an apparatus for selecting a forward link and return link data rate for a constant power, variable data rate two-way, mobile satellite communications link. The forward link and return link signal strength (in the form of carrier power to noise power spectral density ratio) is measured, cataloged, and the values are used for the data rate selection. In addition, a ping can be sent by the network operation center to the mobile unit and the response to the ping is used for updating the information of both forward link and return link signal strength, so the chance of wrong data rate selection can be reduced. Multiple re-transmission attempts combined with gradually increased re-transmission margin ensures the proper data rate decision can be eventually achieved even with occasionally inaccurate signal strength information. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Serial No. 60/447,984, filed on Feb. 15, 2003, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an automated control system for operating a drawworks or similar hoisting means during a back reaming operation.
BACKGROUND OF THE INVENTION
[0003] In the petroleum industry, the apparatus and machinery used to drill wells is commonly known as a drilling rig or a rig. On these rigs are means of rotating the drill pipe, the most popular and successful of which is a device known as a top drive system. The popularity and proliferation of top drive systems within the oilfield has greatly enhanced the capability of the industry's drillers and operators to handle drill pipe operations in safe and beneficial manners.
[0004] One such operation is “back reaming” wherein the operator hoists a drill pipe out of a borehole while simultaneous pumping drilling mud and rotating the drill pipe, thus avoiding the build-up of frictional forces between the drill pipe and the borehole that may lead to the drill pipe being jammed in the borehole. Until recently this back-reaming process has been done either completely manually or has involved the use of complicated controls within the hoisting equipment.
[0005] For example, in the manual process, the operator engages a hoisting means by engaging a clutch and then manually manipulating a hoisting throttle, either a hand or foot throttle, to slowly and carefully hoist the drill pipe out of the borehole. However, during this operation, the driller must simultaneously monitor the hookload, and the rotating torque or standpipe pressure (if using a downhole mud motor) for indications that the pipe is in danger of jamming in a lateral direction or a rotational direction, respectively.
[0006] Alternatively, in another process, the operator may be required to operate a control system that is connected to the hoisting means. In such a system, upon a command from the operator, the control system activates the hoisting means to slowly hoist the pipe out of the borehole. However, the driller must still monitor the hookload, the rotating torque and/or the standpipe pressure for indications of that the drill pipe may be in danger of jamming in the borehole.
[0007] In addition, a problem with both of these processes is that many hoisting systems cannot tolerate holding a drill pipe without movement for an extended period of time, a situation that can occur when a drill pipe does jam in the borehole. Thus, each of these processes relies on the operator's judgment to avoid equipment damage. Accordingly, a need exists for an improved control system that allows for greater control of the back reaming process while reducing operator burden.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a control system for the automated operation of a drawworks during a “back reaming” operation. In one embodiment the control system is connected to an operator control unit to allow a driller to enter maximum values to be reached during the reaming operation for one or more specified reaming parameters. During the reaming operation, the control system continuously monitors the specified reaming parameters and compares the measured values to the limits or maximum values input by the operator. When any of the maximum values are exceeded, a control signal is sent to the drawworks to reduce the speed of the hoisting.
[0009] In another embodiment, the specified reaming parameters may be selected from any or all of the pull on the drill bit (POB), the rate of hoisting (ROH), and the drilling torque. In still another embodiment, the speed of hoisting is controlled by the application of a drawworks brake assembly.
[0010] In one embodiment, the present invention is an automated method for controlling a back reaming operation of a drilling rig. The method includes providing a hoisting system that moves a drill pipe during a back reaming operation at a hoisting speed and a hoisting torque. The hoisting system includes at least one back reaming parameter sensor for measuring a corresponding at least one back reaming parameter. The method further includes comparing a predetermined value of the at least one back reaming parameter with the measured value for the at least one back reaming parameter; and initiating a braking assembly that resists the hoisting torque of the hoisting system when the measured value of the at least one back reaming parameter equals the predetermined value of the at least one back reaming parameter.
[0011] In another embodiment, the present invention is an automated method for controlling a back reaming operation of a drilling rig. The method includes providing a drawworks system that moves a drill pipe during a back reaming operation at a hoisting speed and a hoisting torque. The hoisting system comprises at least one back reaming parameter sensor for measuring a corresponding at least one back reaming parameter. The method further includes providing an operator control unit that allows an operator to input a predetermined value of the at least one back reaming parameter therein; and providing a control system that compares the predetermined value of the at least one back reaming parameter with the measured value for the at least one back reaming parameter, wherein the control system initiates a braking assembly that resists the hoisting torque of the drawworks system when the measured value of the at least one back reaming parameter equals the predetermined value of the at least one back reaming parameter.
[0012] In yet another embodiment, the present invention is a system that controls a back reaming operation of a drilling rig that includes a hoisting system that moves a drill pipe during a back reaming operation at a hoisting speed and a hoisting torque. The hoisting system comprises at least one back reaming parameter sensor for measuring a corresponding at least one back reaming parameter. An operator control unit allows an operator to input a predetermined value of the at least one back reaming parameter therein. A back reaming parameter sensor obtains the measured value of the at least one back reaming parameter. A control system monitors the at least one back reaming parameter. A braking assembly resists the hoisting torque of the drawworks system when the measured value of the at least one back reaming parameter equals the predetermined value of the at least one back reaming parameter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
[0014] [0014]FIG. 1 is a schematic representation of a drilling rig and a drawworks/brake control system according to the present invention;
[0015] [0015]FIG. 2 is a block diagram of the drawworks/brake control system of FIG. 1 including a signal flow diagram; and
[0016] [0016]FIG. 3 is a schematic representation of the drawworks/brake control system of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0017] As shown in FIGS. 1-3, the invention is directed to a drawworks/brake control system 110 (hereinafter “control system 110 ”) for the automated operation of a drawworks 50 or similar hoisting means during a “back reaming” (hereinafter “reaming”) operation.
[0018] As shown in FIG. 1, in one embodiment of the current invention the control system 110 is connected to an operator control unit 115 . A driller or operator enters into the control unit 115 maximum values to be reached during the reaming operation for one or more specified reaming parameters. For example, the reaming parameters may include any or all of the pull on the drill bit (POB), the rate of hoisting (ROH), and the drilling torque. The operator then initiates the reaming operation.
[0019] During the reaming operation, the control system 110 continuously monitors the POB, ROH and/or the drilling torque through various sensors 90 , 100 and 104 , and compares the measured values to the limits or maximum values input by the operator. When any of the maximum values are exceeded, a brake assembly 70 is activated via a control signal 109 from the control system 110 to reduce the speed of the hoisting. In such an embodiment, the brake assembly 70 modulates the speed of hoisting during the reaming operation by applying a braking torque that resists the hoisting torque of the drawworks 50 so as to maintain the limits set by the operator for POB, ROH and/or the drilling torque.
[0020] [0020]FIG. 1 shows a schematic representation of the control system 110 of the current invention interconnected to a conventional drilling rig. In the depicted embodiment, a derrick 10 supports, at an upper end thereof, a crown block 15 . A rope arrangement 17 connects the crown block 15 to a traveling block 20 , or load bearing part, for supporting a hook structure 25 . The hook structure 25 is connected to and supports a top drive assembly 12 , which in turn is connected to a drill string 13 . The drill string 13 includes one or more drill pipes and a drill bit 14 that produces a borehole 16 in a drilling operation upon rotation by the top drive assembly 12 . The drawworks 50 is then used to hoist the drill string 13 out of the borehole 16 during a reaming operation.
[0021] The drawworks 50 is attached to a hoisting line 30 , that assists the drawworks 50 in hoisting the drill string 13 during the reaming operation. The hoisting line 30 is securely fixed at one end to the ground by means of a dead line 35 and a dead line anchor 40 . The other end of the hoisting line 30 forms a fast line 45 that is attached to the drawworks 50 .
[0022] In the embodiment shown in FIG. 1, the drawworks 50 includes one or more motor(s) 55 , such as an electrical, diesel or other appropriate motor, and a transmission 60 connected to a cylindrical rotatable drum 65 for wrapping and unwrapping the fast line 45 as required for operation of the associated crown block 15 and traveling block 20 during drilling and reaming operations. In such an embodiment, the rotatable drum 65 is also referred to as a winding drum or a hoisting drum. Although one embodiment of a hoist system is shown in FIG. 1 it should be understood that other hoist systems capable of controllably raising a drill pipe could be utilized with the automated reaming control system of the current invention.
[0023] As shown in FIG. 1, a plurality of positioning sensors, such as proximity switches 102 in the derrick 10 or an encoder 100 that is affixed to the drawworks drive shaft 85 , may be used to determine the position of the traveling block 20 for additional safety and control during the reaming process. In such an embodiment, an output control signal 107 or 105 , indicting the position of the traveling block 20 is sent from the proximity switches 102 or the encoder 100 , respectively, to the control system 110 . The actual speed and position of the traveling block 20 may then be used to ensure safe operation of the hoist during reaming. Although in one embodiment the positioning sensors are proximity switches 102 , it should be understood that other means for determining the position of the traveling block 20 could be utilized with the automated reaming control system of the current invention.
[0024] Although any brake capable of automated control may be utilized in the current invention, as shown in FIG. 1, the brake assembly 70 preferably includes a primary friction brake 80 , typically a band type brake or a caliper disk brake, an auxiliary brake 75 , such as an eddy current type brake or a friction plate brake, and an emergency brake 78 . The brake assembly 70 is connected to the drawworks 50 by a drive shaft 85 of the drawworks 50 . The brake assembly 70 is controlled by the control system 110 . Again, although any suitable actuator may be utilized in the current invention, typically the brake 70 of the current invention is actuated either hydraulically or pneumatically, using, for example, a pneumatic cylinder that is applied by rig air pressure that is modulated by control signals 109 issued by the control system 110 by way of, for example, an electronically controlled air valve.
[0025] As discussed above, to provide reaming monitoring signals to the control system 110 , a number of sensors may be utilized in the current invention. In the embodiment depicted in FIG. 1, a load sensing device 90 , such as a strain gage or a hydraulic load cell is affixed to the dead line 35 , and produces an output control signal 95 indicating the tension in the dead line 35 and consequently, the load carried by the traveling block 20 or POB. This POB measurement from the load sensing device 90 is provided sent from the strain gage 90 to the control system 110 . Various tension measuring devices may be employed to indicate the tension conditions on the line 35 . In one embodiment, as shown in FIG. 1, the actual hook load or POB is calculated using the load sensing device 90 input in conjunction with the number of lines strung and a calibration factor. Alternatively, a conventional load cell, hydraulic tension transducers or other load measuring device may be associated with the derrick 10 to provide the output control signal 95 representative of the load carried by the traveling block 20 .
[0026] Alternatively, or in addition, the system may also be provided with a sensor for monitoring the rate of hoisting. In such an embodiment, as shown in FIG. 1, a measuring device, such as an encoder 100 , for example, is affixed to the drawworks drive shaft 85 . In such an embodiment, an output control signal 105 , representative of the speed of rotation of the rotatable drum 65 as the drum 65 rotates to pull in or pay out the fast line 45 and as the traveling block 20 rises or descends, is sent from the encoder 100 to the control system 110 . Using such an encoder, the frequency of the signal may be used to measure the velocity of the traveling block 20 movement, typically, by calculating the actual drum 65 speed and ultimately the traveling block 20 speed based on lines strung, the diameter of the drum 65 , the number of line wraps and the line size. Alternatively, the velocity of the traveling block 20 movement may be calculated from the change in the vertical position of the traveling block 20 . In such a system, the ROH can be calculated from the velocity of the traveling block 20 . In addition, the proximity switches 102 may be utilized to confirm the measurements taken by the encoder 100 .
[0027] Finally, as shown in FIG. 1, alternatively, or in addition, the drilling torque may be monitored. The drilling torque may be measured by sensing the torque on the top drive or rotary table, such as by a torque sensor 104 or as reported by a top drive motor drive 112 or a rotary table drive 113 . In such an embodiment, an output control signal 108 indicating of the drilling torque is sent from the torque sensor 104 or from the drive 112 or 113 to the control system 110 . Alternatively, the drilling torque can be obtained by measuring the standpipe pressure when a downhole drilling motor is used.
[0028] Referring to FIGS. 1-3, the control system 110 is in signal connection with the brake assembly 70 to provide brake control signals 109 , and continuously receives output control signals 95 , 105 , and 108 from the load sensing device 90 , the encoder 100 , and the torque sensor 104 , respectively, wherein each of the output control signals 95 , 105 , and 108 is an electrical, digital or other appropriate signal. The control system 110 is also in signal communication with an operator control unit 115 located on or near the derrick 10 such that the operator can provide appropriate maximum values for the specified reaming parameters to be monitored. Alternatively, a separate workstation (not shown), located, for example, in an equipment room on or near the derrick 10 , can be connected to the control system 110 to provide an additional user interface and configuration signals.
[0029] In one embodiment, as depicted in FIG. 2, the operator control center 115 or man-machine interface preferably includes an industrial processor driven monitor 160 wherein the operator or driller can set and control the specified reaming parameters. For example, the operator can enter the maximum values to be reached during the reaming operation for any or all of the pull on the drill bit (POB), the rate of hoisting (ROH), and the drilling torque.
[0030] As shown in FIG. 2, the control system 110 includes a programmable controller (the drawworks PC 155 ), such as a programmable logic controller, a single board computer or an equivalent, to which are input the measured reaming values from the various sensors, and the respective operator defined maximum values from the operator control center 115 . The programmable controller 155 then compares the values and outputs appropriate control signals to the braking system and the drawworks that and are interfaced between the drive system 120 using, for example, a serial communication connection 150 such as, for example, an optical linkage and/or hard-wired linkage.
[0031] In the embodiment shown, two or more remote programmable controllers (PC) input/output (I/O) units 145 are used to control the brake assembly 70 (including, as shown in FIG. 2 any or all of the disc brake 80 , the parking brake 75 , and the emergency brake 78 ) of the drawworks 50 and the drawworks processor 155 , although any suitable interface may be used. A processor 160 is also connected to the control system 110 for providing input and output of the operator values, operating parameters and calculated values during the performance of various drilling rig operations.
[0032] Although not necessary, the control system 110 may also be connected to the motor(s) 55 of the drawworks through the drive system 120 . The motor(s) 55 may be an alternating current (ac) motor or a direct current (dc) motor and the drive system 120 is an ac or a dc drive, respectively. The drive system 120 may further include, for example, a controller 125 , such as a programmable controller (PC) and one or more motor drives 130 connected to an ac bus 135 for providing control of the motor.
[0033] As discussed above, and shown in FIG. 3, the control system 110 of the current invention may includes an auto back reaming (ABR) mode that the operator initiates by engaging a drawworks clutch, i.e. a high 2 B or a low 2 A clutch. Engaging the clutch 2 A or 2 B while the ABR is enabled (such as while auto-drilling) commands the control system 110 to activate the drive system 120 and the brake assembly 70 .
[0034] During operation in the ABR mode, the control system 110 senses when the operator activates either the low or high clutch control, which in turn activates low and high clutch solenoids 7 g or 7 e, respectively. Signals from the activated clutch solenoids 7 g or 7 e and/or pressure sensors 7 D on the low 2 A or a high 2 B are then communicated to the control system 110 CPU, which senses the operator's intent to back ream.
[0035] Once the drawworks clutch 2 is engaged, the control system 110 calculates the amount of torque needed to be supplied from the drawworks motor(s) 55 , and utilizes an output signal 7 F to control the torque command selector 9 , which in turn outputs a torque input 120 C to the drawworks drive 120 . The drawworks motor(s) 55 in turn produces torque, which exceeds that required to hold the load of the traveling block 20 stationary. The starting torque is calculated as the static hookload plus the operator entered maximum POB value.
[0036] The control system 110 then utilizes control signals from the various sensors 7 C to calculate and monitor the reaming parameters, and these values are compared versus the limits on those parameters input by the operator, to ensure that the back reaming operation is performed within the operator limits. If the measured values from the sensors match or exceed the limits input by the operator, the CPU sends a signal to the brake actuator, which in turn controls the braking system 70 to apply a torque to resist the hoisting torque of the drawworks motor(s) 55 and control the rate of hoisting of the drill string, to in turn maintain the limits input by the operator for ROH, POB, and/or the drilling torque. The CPU commands the braking system 70 to apply a torque that resists the hoisting torque of the drawworks motor(s) 55 such that the hoisting speed is reduced until the relevant maximum value is no longer exceeded, and then commands the brake actuator to reduce the resisting torque of the brake system 70 to allow the drawworks motor(s) 55 to increase the speed of hoisting.
[0037] For example, if while hoisting and back reaming, the top drive motor torque exceeds the limit input by the operator for drilling torque due to a tight hole condition, the CPU commands the brake actuator to control the brake assembly 70 to apply the brake to reduce the rate of hoisting to allow the drill motor torque to decrease as it drills through the tight area more slowly. This is possible because of the smooth proportional control of the brake assembly 70 and its sufficient capacity to produce more torque than the drawworks motor(s) 55 provides in this mode.
[0038] If stopping the drawworks motor(s) 55 completely is required to prevent the reaming system from exceeding one or more of the limits for the specified reaming parameters input by the operator, the control system 110 sends a torque command 7 F to the torque command selector 9 , which in turn sends a torque command 120 C from the drive system 120 to reduce the torque produced by the drawworks motor(s) 55 to zero. This prevents damage to the motor and allows safe operation.
[0039] When the control system 110 is not in the ABR mode, the drawworks torque command will come from a manual hand or foot throttle, or an equivalent device.
[0040] In an alternative embodiment other controls may be used by the operator to command hoisting torque while the braking system is still used for speed control of the hoisting.
[0041] As described above, the control system continuously monitors specified back reaming parameters and compares the measured values to the limits or maximum values input by the operator for the specified back reaming parameters. When any of the maximum values are meet or exceeded, a control signal is sent to the drawworks to reduce the speed of the hoisting. However, although the above description has focused on the monitoring of specific back reaming parameters, measured by specific back reaming parameter sensors, the monitored back reaming parameters can be any one or any combination of: weight on bit, hoisting torque, hoisting speed, drilling mud flow, drilling mud pressure, and formation cutting condition of mud screens within the drilling mud. These back reaming parameters can be measured by back reaming parameter sensors including any one or any combination of: strain gauges, proximity sensors/switches, cameras, gyroscopes, encoders, and magnetic pick ups/switches.
[0042] The preceding description has been presented with references to presently preferred embodiments of the invention. Persons skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structures and methods of operation can be practiced without meaningfully departing from the principle, spirit and scope of this invention, such as various changes in the size, shape, materials, components, circuit elements, wiring connections, as well as other details of the illustrated circuitry and construction. Accordingly, the foregoing description should not be read as pertaining only to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope. | A system that controls a back reaming operation of a drilling rig is provided that includes a hoisting system that moves a drill pipe during a back reaming operation at a hoisting speed and a hoisting torque. The hoisting system comprises at least one back reaming parameter sensor for measuring a corresponding at least one back reaming parameter. An operator control unit allows an operator to input a predetermined value of the at least one back reaming parameter therein. A back reaming parameter sensor obtains the measured value of the at least one back reaming parameter. A control system monitors the at least one back reaming parameter. A braking assembly resists the hoisting torque of the drawworks system when the measured value of the at least one back reaming parameter equals the predetermined value of the at least one back reaming parameter. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a rescue sled for picking up and transporting persons who may be involved in water and ice accidents, of the type which is buoyant, and can be towed over ice and snow with a person strapped thereon.
2. Description of the Prior Art
Various devices have been proposed as rescue equipment for rescuing persons trapped on thin ice, or stranded on a flooded river or creek. A situation where a person ventures out onto thin ice and breaks through, or is unable to return is common and presents a difficult scenario for rescue personnel. The rescue equipment must be capable of easy movement over the ice, must be easily grasped by the person, and then moved over ice and/or snow to return the victim to safety.
Rescue equipment must be lightweight, it must be easily deployable and capable of supporting a person, useful on ice or water or snow, and be transportable in an ambulance or other rescue vehicle.
Various pieces of equipment have been proposed, such as those shown in the U.S. Patents to Paden et. al. U.S. Pat. No. 2,735,690; Rickenbacker U.S. Pat. No. 4,170,367; Eisenhauer U.S. Pat. No. 4,347,635; Cashmere U.S. Pat. No. 4,561,664; Brooks, Jr. U.S. Pat. No. 4,571,195; Kraft U.S. Pat. No. 4,717,362; Nixon et. al. U.S. Pat. No. 5,473,784; Daouk U.S. Pat. No. 5,499,416; Glydon et. al. U.S. Pat. No. 5,658,179; Ziff U.S. Pat. No. D216,530; Diemond et. al. U.S. Pat. No. D219,463; and Helms U.S. Pat. No. D322,770.
Ice rescue equipment is also offered by Marsars, 17 Terrill Ave., Hamilton, N.J. 08619 but none of the available equipment is useful for the wide variety of situations that rescue personnel face.
The rescue sled of the invention is useful in snow, ice and water rescue operations, is easily transportable and provides many other positive advantages.
SUMMARY OF THE INVENTION
This invention relates to a rescue sled for use by rescue personnel who are involved in ice or water rescue operations for picking up and transporting persons.
The principal object of the invention is to provide a rescue sled for use in picking up and transporting persons.
A further object of the invention is to provide a rescue sled which can support a person on water or ice.
A further object of the invention is to provide a rescue sled that has rungs so that it may be used as a ladder.
A further object of the invention is to provide a rescue sled that can be used in multiples.
A further object of the invention is to provide a rescue sled that can be pulled behind a boat.
A further object of the invention is to provide a rescue sled that can travel over snow.
A further object of the invention is to provide a rescue sled that can be ferried over water.
A further object of the invention is to provide a rescue sled that is easy to make, durable and long lasting in use.
A further object of the invention is to provide a rescue sled that can be deployed by one person.
Other objects and advantageous features of the invention will be apparent from the description and claims.
DESCRIPTION OF THE DRAWINGS
The nature and characteristic features of the invention will be more readily understood from the following description taken in connection with the accompanying drawings forming part hereof in which:
FIG. 1 is a top perspective view of the rescue sled of the invention;
FIG. 2 is a bottom perspective view of the rescue sled of FIG. 1 .
FIG. 3 is a top plan view of the rescue sled of FIG. 1;
FIG. 4 is a vertical sectional view taken approximately on the line 4 — 4 of FIG. 3 .
FIG. 5 is a vertical sectional view taken approximately on the line 5 — 5 of FIG. 3, and,
FIG. 6 is a vertical sectional view taken approximately on the line 6 — 6 of FIG. 3 .
It should, of course, be understood that the description and drawings herein are merely illustrative and that various modifications and changes can be made in the structures disclosed without departing from the spirit of the invention.
Like numerals refer to like parts throughout the several views.
DESCRIPTION OF THE PREFERRED EMBODIMENT
When referring to the preferred embodiment, certain terminology will be utilized for the sake of clarity. Use of such terminology is intended to encompass not only the described embodiment, but also technical equivalents which operate and function in substantially the same way to bring about the same result.
Referring now more particularly to FIGS. 1-6 of the drawings, the rescue sled 10 is therein illustrated.
The sled 10 includes a body of multipiece molded construction with an outer skin 12 of polyethylene, filled with plastic foam 13 , preferably polyurethane foam, which imparts buoyancy to the sled.
The sled 10 is of rectangular configuration with a deck 14 , a rounded front end 15 , which is prow shaped, with straight sides 16 , and a rear end 17 , which is also rounded, but to a lesser degree than front end 15 .
The sled 10 has a plurality of holes 18 therein adjacent the front end 15 and rear end 17 , three being illustrated, which can receive a rope or ropes (not shown) for towing or to fasten to another sled (not shown).
The sled 10 adjacent the sides 16 is provided with a plurality of rectangular holes 20 on each side, four being illustrated. The holes 20 can receive straps (not shown), which can be used to secure a person (not shown) to the sled 10 for transport.
The sled 10 has a plurality of transversly extending hand holds 25 , which are in the deck 14 , four being shown, which permit the sled to be used as a ladder.
The sled 10 has a bottom 26 which has a pair of spaced ribbed runners 27 extending longitudinally, which are rectangular in shape with sloped ends 28 , to assist the sled in traveling over ice or snow.
In use the sled 10 can be slid on the runners 27 across snow or ice, and to the location of the person to be rescued (not shown). If the ice cannot support the person's weight then the person can grab onto one of the hand holds 25 , and climb onto the deck 14 of the sled 10 . The holes 18 may have a rope or ropes (not shown) therein to enable rescue personnel to pull the sled 10 and person (not shown) to safety, with the sled capable of supporting the person whether the sled is in the water, on the ice or on snow. If the person is stranded on an island, or a vehicle in the water, the sled can be ferried over the water to the person and then returned to safety.
It will thus be apparent that the objects of the invention have been achieved. | A rescue sled for picking up victims of water or ice accidents and transporting them to safety, which sled can be carried in the back of an ambulance or other vehicle. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2014-0150916, filed on Nov. 3, 2014, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The following disclosure relates to a method of synthesizing silver nanoparticles having a uniform size.
BACKGROUND
[0003] Unlike silver generally used in real life, chemical, physical, and optical properties of nano-sized silver particles are significantly different from each other according to a shape and a size, and unexpected properties may be exhibited. Therefore, silver nanoparticles have proven to be high efficient in various fields such as a sensor, a catalyst, an electronic circuit, a photonics, and the like, by using properties of the silver nanoparticles.
[0004] A most important factor for using and commercializing the silver nanoparticles as described above is synthesis of particles having a uniform shape and size. Methods for synthesizing silver nanoparticles in a liquid phase have been widely known. The methods may be roughly divided into a method of synthesizing silver nanoparticles in a hydrophilic solvent and a method of synthesizing silver nanoparticles in a hydrophobic solvent.
[0005] More specifically, in the method of synthesizing silver nanoparticles in a hydrophilic solvent, water or alcohol is mainly used as the solvent, and an oxidized silver precursor is reduced using NaXH 4 (X=B or A1), hydrazine, or the like, which is a strong reducing agent. In the method of synthesizing silver nanoparticles in a hydrophilic solvent, there are various limitations in view of mass-production, non-uniform shape and sizes, and the like.
[0006] In order to solve the problems as described above, many researchers developed a method of synthesizing uniform silver nanoparticles in a hydrophobic solvent. A method of mixing a paraffin solvent, a silver precursor, and an amine molecule serving as a surfactant and a reducing agent, or a molecule containing two or more hydroxyl groups corresponding to a separate reducing agent with each other and inducing a chemical reaction for nanoparticles has been mainly used. Uniform silver nanoparticles may be synthesized through the chemical reaction in this hydrophobic solvent, but in a process of dissolving the silver precursor, which is hydrophilic, nanoparticles are partially already formed, such that non-uniform nanoparticles may be formed.
[0007] For example, a method of synthesizing silver nanoparticles having a size of 1 to 40 nm by using a silver precursor, a heterogeneous metal precursor, and alkyl amine has been disclosed in Korean Patent Laid-Open Publication No. 10-2009-0012605. However, in this method, dissociation and reduction reactions are carried out at a single temperature of 150° C. or less, such that size uniformity of the silver nanoparticles may be slightly deteriorated.
[0008] That is, the methods known in the art have problems in view of uniformity and reproducibility. Therefore, in order to synthesize significantly uniform silver nanoparticles on a large scale, a method capable of synthesizing silver nanoparticles through a simple synthesis process, having reproducibility, and satisfying a low cost synthesis should be developed.
RELATED ART DOCUMENT
Patent Document
[0009] (Patent Document 1) Korean Patent Laid-Open Publication No. 10-2009-0012605
[0010] (Patent Document 2) Korean Patent Publication No. 10-0790457
SUMMARY
[0011] An embodiment of the present invention is directed to providing a method of synthesizing silver nanoparticles having uniform size distribution on a large scale with high reproducibility.
[0012] In one general aspect, a method of synthesizing silver nanoparticles includes:
[0013] a) a nucleation step of reacting a composition containing a silver precursor, a heterogeneous metal precursor, and an amine-based compound at 30 to 120° C. to form a nucleus; and
[0014] b) a growth step of reacting the composition containing the nucleus formed therein at 155 to 350° C. to grow the nucleus.
[0015] In step a), the reacting of the composition may be performed for 30 to 90 minutes.
[0016] In step b), the reacting of the composition containing the nucleus formed therein may be performed for 1 to 4 hours.
[0017] In step b), a reaction temperature may be raised by heating at a heating rate of 5° C./min or more from step a).
[0018] The composition may contain 5 to 20 wt % of the silver precursor, 0.001 to 2 wt % of the heterogeneous metal precursor, and 78 to 95 wt % of the amine-based compound based on the entire composition.
[0019] The silver precursor may be AgNO 3 , AgNO 2 , Ag(CH 3 CO 2 ), AgCl, Ag 2 SO 4 , AgClO 4 , Ag 2 O, or a mixture thereof.
[0020] The heterogeneous metal precursor may be a zinc (Zn) precursor, an iron (Fe) precursor, a copper (Cu) precursor, a tin (Sn) precursor, or a mixture thereof.
[0021] The zinc (Zn) precursor may be Zn(acac) 2 , Zn(CH 3 CO 2 ) 2 , ZnCl 2 , ZnBr 2 , ZnI 2 , ZnSO 4 , Zn(NO 3 ) 2 , or a mixture thereof.
[0022] The amine-based compound may be oleylamine, propylamine, butylamine, hexylamine, octylamine, decylamine, dodecylamine, hexadecylamine, octadecylamine, or a mixture thereof.
[0023] The silver nanoparticles may have an average diameter (D A ) of 5 to 20 nm.
[0024] Hereinafter, the present invention will be described in detail.
[0025] The present invention is characterized in that the reaction for synthesizing silver nanoparticles having a uniform size is performed through two steps, that is, the nucleation step and the growth step of the formed nucleus.
[0026] The silver nanoparticles having a uniform size may be synthesized by uniformly growing the nucleus after primarily forming the nucleus. In order to synthesize the uniform silver nanoparticles as described above, usage of the heterogeneous metal precursor and a reaction temperature at each of the steps are significantly important.
[0027] That is, the silver nanoparticles may be synthesized so as to have a uniform size by using a small amount of heterogeneous precursor and controlling the reaction temperature to thereby suppress growth at the time of nucleation and suppress nucleation at the time of growth of the nucleus.
[0028] To this end, it is preferable that at the time of raising the reaction temperature to the growth step after nucleation, unnecessary nucleation is suppressed by increasing the heating rate to maximally decrease a temperature change time.
[0029] The nucleation step will be described in detail.
[0030] The nucleation step is a step of forming the nucleus by reacting the composition containing the silver precursor, the heterogeneous metal precursor, and the amine-based compound. In this step, the reaction temperature and time, concentrations of the heterogeneous metal precursor and the silver precursor, and the like, are important.
[0031] The heterogeneous metal precursor is used at a content of 0.001 to 2 wt % in the entire composition in order to allow the uniform silver nanoparticles to be synthesized, and in the case in which the heterogeneous metal precursor is reacted at 50 to 120° C., more preferably 70 to 100° C., it is possible to form the nucleus while suppressing growth. The growth is suppressed as described above, thereby making it possible to suppress size distribution from being board due to growing the formed nucleus ahead of time.
[0032] As the heterogeneous metal precursor, for example, any one selected from the zinc (Zn) precursor, the iron (Fe) precursor, the copper (Cu) precursor, the tin (Sn) precursor, or the mixture thereof may be used. More specifically, as zinc (Zn) precursor, any one selected from Zn(acac) 2 , Zn(CH 3 CO 2 ) 2 , ZnCl 2 , ZnBr 2 , ZnI 2 , ZnSO 4 , Zn(NO 3 ) 2 , or the mixture thereof may be used, but the present invention is not limited thereto.
[0033] In addition, in the nucleation step, an amount of the formed nucleus may be adjusted depending on the reaction time. For example, the reaction time may be preferably 30 to 90 minutes, more preferably 40 to 80 minutes, but is not particularly limited thereto. That is, it is preferable to control the reaction time in consideration of the concentration of the silver precursor, sizes of silver nanoparticles to be synthesized, and the like.
[0034] However, when the reaction time is excessively increased, undesired growth of the nucleus may occur, or silver ions are excessively consumed to form the nucleus, such that the nucleus may not sufficiently grow in a subsequent step.
[0035] It is preferable that the silver precursor according to the present invention is used at a content of 5 to 20 wt % in the entire composition, and in view of nucleation, it is effective to use the silver precursor in the above-mentioned range. In the case in which the concentration of the silver precursor is excessively low, the nucleus may not be suitably formed, and in the case of using an excessively large amount of silver precursor, dissociation may not be smoothly performed, which is not suitable.
[0036] Any silver precursor may be used without a particular limitation as long as it provides silver ions. For example, any one selected from AgNO 3 , AgNO 2 , Ag(CH 3 CO 2 ), AgCl, Ag 2 SO 4 , AgClO 4 , Ag 2 O, or a mixture thereof may be used.
[0037] Next, the amine-based compound according to the present invention, which serves as a solvent, a surfactant, a reducing agent, and the like, is used at a content of preferably 78 to 95 wt % in the entire composition. When the amine-based compound is used in the above-mentioned range, the silver precursor may be easily dispersed and dissociated, and silver particles may be effectively reduced.
[0038] As the amine-based compound, any one selected from oleylamine, propylamine, butylamine, hexylamine, octylamine, decylamine, dodecylamine, hexadecylamine, octadecylamine, or a mixture thereof may be used, but the present invention is not limited thereto.
[0039] In the nucleation step, the stirring may be simultaneously performed so that dispersion and dissociation are more evenly generated, and the stirring is performed at preferably 100 to 1000 rpm, more preferably 300 to 800 rpm. When the stirring is performed at the above-mentioned range, nucleation may not be inhibited.
[0040] The growth step will be described in detail.
[0041] This step is a step of synthesizing the silver nanoparticles having a uniform size and shape by uniformly growing the nucleus formed in the nucleation step. In this step, the reaction temperature, the heterogeneous metal precursor, and the like, are important.
[0042] In this step, the heterogeneous metal precursor may suppress formation of a new nucleus and induce uniform growth of the formed nucleus, unlike the nucleation step. To this end, it is preferable that the reaction is performed at a temperature of 155° C. or more. In the case of a growth reaction is performed at a temperature lower than 155° C., a new nucleus is formed together with growth of the nucleus, such that the particles may become significantly non-uniform. The reaction temperature may be preferably 155 to 350° C., and more preferably 155 to 250° C. Since the amine-based compound is volatilized at 350° C. or more and accordingly, growth of the particles does not proceed, the reaction temperature may be adjusted depending on the kind of used compound.
[0043] The heterogeneous metal precursor induces the silver nanoparticles having a significantly uniform size to be synthesized at a temperature of 155° C. or more as described above, such that spherical silver nanoparticles having an average diameter (D A ) of 5 to 20 nm may be synthesized, but the present invention is not limited thereto.
[0044] In this case, the synthesized silver nanoparticles may have a diameter satisfying the following Equation 1, such that the silver nanoparticles according to the present invention may have significantly uniform size distribution.
[0000] [Equation 1]
[0000] D A −0.7 nm≦ D≦D A +0.7 nm
[0045] Here, D is a diameter of each of the silver nanoparticles, and D A is the average diameter of the silver nanoparticles.
[0046] Therefore, during the temperature change time from the nucleation step to the growth step, it is important to rapidly raise the reaction temperature so that nucleation and growth do not simultaneously occur. The reaction temperature is raised at a heating rate of preferably 5° C./min or more, more preferably, 8° C./min or more, and an upper limit of the heating rate is not separately restricted. However, actually, when the upper limit of the heating rate is 50° C./min or less, it may be easy to adjust the reaction temperature, but the present invention is not limited thereto.
[0047] In the case in which the heating rate is less than 5° C./min or less, as the temperature is slowly raised, temperature distribution becomes board, and nucleation and growth may simultaneously occur, such that the size of the silver nanoparticles becomes non-uniform as shown in FIG. 3 .
[0048] Further, while raising the temperature in a heating process, the entire temperature of the reaction solution is constantly raised by temporarily performing the stirring at a significantly rapid rate, such that growth may further uniformly occur. For example, the stirring may be performed at 1000 to 2000 rpm, more preferably, 1200 to 1500 rpm.
[0049] In the growth step, a reaction time is not particularly limited, but it is preferable that the reaction time is, for example, 1 to 4 hours. The reaction time may be adjusted in consideration of sizes of silver nanoparticles to be synthesized, a concentration of the remaining silver ion, and the like.
[0050] In addition, the stirring may be simultaneously performed in a range in which growth of the nucleus is not inhibited. For example, the stirring is performed at preferably, 50 to 500 rpm, more preferably 100 to 400 rpm. The stirring is performed in the above-mentioned range, which is effective for uniform growth of the silver nanoparticles.
[0051] The method of synthesizing silver nanoparticles according to the present invention may further include a purification step.
[0052] After the reaction solution is cooled to room temperature after the growth step, alcohol, an organic solvent, or a mixture thereof is added thereto and centrifuged, thereby making it possible to obtain precipitates. This centrifugation step may be performed one time or more, such that by-products and the excessive amount of amine-based compound may be removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 is a transmission electron microscope photograph of silver nanoparticles synthesized according to Example 1 of the present invention.
[0054] FIG. 2 is an x-ray diffraction (XRD) pattern of the silver nanoparticles synthesized according to Example 1 of the present invention.
[0055] FIG. 3 is a transmission electron microscope photograph of silver nanoparticles synthesized at a heating rate of 3° C./min.
DETAILED DESCRIPTION OF EMBODIMENTS
[0056] Hereinafter, a method of synthesizing silver nanoparticles according to the present invention will be described in more detail through the following Examples. However, the following Examples are only to specifically explain the present invention, but the present invention is not limited thereto and may be implemented in various forms.
[0057] In addition, unless defined otherwise in the specification, all the technical and scientific terms used in the specification have the same meanings as those that are generally understood by those who skilled in the art. The terms used in the specification are only to effectively describe a specific Example, but are not to limit the present invention.
[0058] Further, the accompanying drawings to be described below are provided by way of example so that the idea of the present invention can be sufficiently transferred to those skilled in the art to which the present invention pertains. Therefore, the present invention is not limited to the drawings to be provided below, but may be modified in many different forms. In addition, the drawings to be provided below may be exaggerated in order to clarify the scope of the present invention.
[0059] In addition, unless the context clearly indicates otherwise, it should be understood that a term in singular form used in the specification and the appended claims includes the term in plural form.
[0060] Physical properties of the silver nanoparticles prepared in the following Examples and Comparative Examples were measured as follows.
Confirmation of Synthesis of Silver Nanoparticles
[0061] Synthesis of silver nanoparticles was confirmed using an X-ray diffractometer (XRD, Rigaku D/MAX-RB diffractometer at 12 kW with a graphite-monochromatized Cu-Kα radiation at 40 kV and 120 mA).
Measurement of Size and Shape
[0062] Sizes and shapes of the silver nanoparticles were confirmed using a transmission electron microscope (TEM, Philips F20 Tecnai operated at 200 kV).
EXAMPLE 1
[0063] After a composition containing 1 g of AgNO 3 , 10 mg of Zn(acetylacetonate) 2 , and 10 mL of oleylamine was put in a 50 ml vial and heated to 80° C. while stirring at 500 rpm to dissociate the silver precursor, followed by reaction for 1 hour, thereby forming a nucleus. Then, a reaction temperature was raised to 155° C. at a heating rate of 9° C./min, and a reaction was performed for 3 hours while stirring at 300 rpm, thereby growing the nucleus. After the reaction was terminated, the reaction solution was cooled to room temperature.
[0064] 10 mL of ethanol was added to the reaction solution of which the temperature became room temperature, and centrifugation was performed at 3,000 rpm for 10 minutes, thereby obtaining precipitates. In order to remove by-products and an excessive amount of oleylamine, 5 mL of toluene and 10 mL of ethanol were added to the precipitates and then centrifuged at 3,000 rpm for 10 minutes, thereby obtaining silver nanoparticles having an average diameter of 8.3 nm.
EXAMPLES 2 TO 5
[0065] All of the processes were the same as those in Example 1 except that a temperature during a growth step was different as shown in Table 1.
COMPARATIVE EXAMPLES 1 AND 2
[0066] All of the processes were the same as those in Example 1 except that a temperature during a growth step was different as shown in Table 1.
[0067] (In Table 1, D A is an average diameter of the silver nanoparticles, and D is a diameter of each of the silver nanoparticles.)
[0068] As shown in Table 1, in the cases of the silver nanoparticles of Examples 1 to 5 in which the growth occurred at a reaction temperature of 155 to 200° C., at the time of observing the silver nanoparticles using the TEM, silver nanoparticles having a significantly uniform size were observed. On the contrary, it may be appreciated that in the case of the silver nanoparticles of Comparative Examples 1 and 2 in which the growth occurred at a reaction temperature lower than 155° C., since nucleation simultaneously occurred at the time of growth, the sizes of the particles were not uniform but were significantly different.
[0069] Further, in Examples 1 to 5, the silver nanoparticles were synthesized with a high yield of 90% or more, and at the time of observing sizes of the silver nanoparticles, it may be confirmed that about 95% or more of the silver nanoparticles have an average diameter of ±1.3 nm or less, but the silver nanoparticles of Comparative Examples 1 and 2 had larger size distribution.
[0070] When the same process as in the method of synthesizing silver nanoparticles according to the present invention was repeated 20 times, similar results were obtained at a rate of 950 or more. That is, the silver nanoparticles having a significantly uniform size and high yield were synthesized, such that high reproducibility was shown.
EXAMPLE 6
[0071] After a composition containing 200 g of AgNO 3 , 2 g of Zn(acetylacetonate) 2 , and 2 L of oleylamine was put in a 10 L reactor and heated to 80° C. while stirring at 500 rpm to dissociate the silver precursor, followed by reaction for 1 hour, thereby forming a nucleus. Then, a reaction temperature was raised to 155° C. at a heating rate of 9° C./min, and a reaction was performed for 3 hours while stirring at 300 rpm, thereby growing the nucleus. After the reaction was terminated, the reaction solution was cooled to room temperature.
[0072] 2 L of ethanol was added to the reaction solution of which the temperature became room temperature, and centrifugation was performed at 3,000 rpm for 10 minutes, thereby obtaining precipitates. In order to remove by-products and an excessive amount of oleylamine, 1 L of toluene and 1 L of ethanol were added to the precipitates and then centrifuged at 3,000 rpm for 10 minutes, thereby obtaining silver nanoparticles having an average diameter of 8.2 nm. At this time, a yield was 90% or more.
[0073] In Example 6, since the same processes as in Example 1 were performed except for increasing the scale to 200 times the scale in Example 1 to synthesize the silver nanoparticles on a large scale, similar results to those in Example 1 could be obtained, and significantly uniform silver nanoparticles could be synthesized. That is, it was confirmed that the silver nanoparticles may be easily synthesized on a large scale.
[0074] In the method of synthesizing silver nanoparticles according to the present invention, the significantly uniform and fine silver nanoparticles may be synthesized by reacting the composition containing the silver precursor, the heterogeneous metal precursor, and the amine-based compound through multi-step processes.
[0075] In addition, the method of synthesizing silver nanoparticles according to the present invention may have high reproducibility. | Provided is a method of synthesizing silver nanoparticles including: a) a nucleation step of reacting a composition containing a silver precursor, a heterogeneous metal precursor, and an amine-based compound at 30 to 120° C. to form a nucleus; and b) a growth step of reacting the composition containing the nucleus formed therein at 155 to 350° C. to grow the nucleus. According to the present invention, significantly uniform and fine silver nanoparticles may be synthesized with high reproducibility on a large scale. | 1 |
BACKGROUND
The present invention relates generally to the field of engines, and more particularly, to a timing plate for use with a crankshaft.
Conventional timing plates are used in association with crankshafts to monitor crank angle. Conventional timing plates are often affixed to some portion of the crankshaft and rotate with the crankshaft. A crank angle sensor monitors the timing plate and thereby monitors the rotation, and crank angle, of the crankshaft.
Some conventional timing plates are bolted onto a portion of the crankshaft. For example, International Publication Number WO 2008/093656 shows a conventional timing plate bolted to a portion of a crankshaft journal. The bolt affixes the conventional timing plate to the crankshaft and ensures the conventional timing plate will rotate with the crankshaft.
Using bolts to affix the conventional timing plate to the crankshaft, however, adds mass to the crankshaft. The additional mass of the bolts must also be accounted for when statically and dynamically balancing the crankshaft.
There exists a need in the art for a timing plate that reduces the need for additional mass to be added to the mass of the crankshaft.
SUMMARY
In one aspect, the invention provides an engine comprising: a crankshaft connected to at least one piston by a connecting rod, the crankshaft configured to rotate about a crankshaft axis; the crankshaft including a first axial portion that lies on the crankshaft axis and is substantially symmetric about the crankshaft axis; a timing plate having a central hole and a plurality of indicia on a periphery portion of the timing plate; the timing plate including at least one protruding portion extending in a direction along the crankshaft axis; wherein first axial portion of the crankshaft extends through the central hole of the timing plate; wherein the crankshaft includes at least one receiving portion configured to receive the at least one protruding portion; and wherein the timing plate is configured to move along the crankshaft axis.
In another aspect, the invention provides an engine comprising: a crankshaft connected to at least one piston via a connecting rod, the crankshaft being configured to rotate about a crankshaft axis; and a timing plate having a central hole and a plurality of indicia on a periphery portion of the timing plate, wherein: the crankshaft includes a first axial component that lies on the crankshaft axis and is substantially symmetric about the crankshaft axis, the first axial component of the crankshaft extends through the central hole of the timing plate, the timing plate includes at least one protruding portion extending in a direction along the crankshaft axis, the crankshaft includes at least one receiving portion configured to receive the at least one protruding portion, the protruding portion and the receiving portion are removably mated, the timing plate and the crankshaft rotate with substantially the same speed, and the timing plate floats about the first axial component when the timing plate and the crankshaft rotate.
In another aspect, the invention provides an engine comprising: a crankshaft connected to at least one piston via a connecting rod, the crankshaft being configured to rotate about a crankshaft axis; and a timing plate having a central hole and a plurality of indicia, wherein: the timing plate has at least one protruding portion extending in a direction along the crankshaft axis, the crankshaft has at least one receiving portion configured to receive the at least one protruding portion, the timing plate and the crankshaft rotate with substantially the same speed, and the timing plate is associated with the crankshaft via a connecting system, the connecting system consisting essentially of the at least one protruding portion being received by the at least one receiving portion.
Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
FIG. 1 is a top view of an engine of a motor vehicle;
FIG. 2 is an isometric view of an exemplary embodiment of a crankshaft;
FIG. 3 is a side view of an exemplary embodiment of a crankshaft;
FIG. 4 is a front view of an exemplary embodiment of a timing plate;
FIG. 5 is an exploded view of an exemplary embodiment of a timing plate and a crankshaft journal side wall;
FIG. 6 is a side view of a portion of a crankshaft showing a crankshaft journal and an exemplary embodiment of a timing plate mated together;
FIG. 7 is a side view of a portion of a crankshaft showing a crankshaft journal and an exemplary embodiment of a timing plate;
FIG. 8 is a representative view of the relative difference in mass between a conventional crankshaft with a connected timing plate and an exemplary embodiment of a crankshaft;
FIG. 9 is an isometric view of an alternate embodiment of a crankshaft;
FIG. 10 is a front view of an alternate embodiment of a timing plate including a thrust surface;
FIG. 11 is a cross-section of an alternate embodiment of a timing plate including a thrust surface taken along line A-A of FIG. 10 ; and
FIG. 12 is a side view of a portion of a crankshaft showing a crankshaft journal and an alternate embodiment of a timing plate including a thrust surface mated together.
DETAILED DESCRIPTION
FIG. 1 illustrates a front region of an embodiment of a motor vehicle 101 . Motor vehicle 101 may be any type of motor vehicle known in the art. The term “motor vehicle” as used throughout this specification and claims refers to any moving vehicle that is capable of carrying one or more human occupants and is powered by any form of energy. The term “motor vehicle” includes, but is not limited to: cars, trucks, vans, minivans, SUVs, motorcycles, scooters, boats, personal watercraft, and aircraft.
In some embodiments, motor vehicle 101 may include one or more engines. The term “engine” as used throughout this specification and claims refers to any device or machine that is capable of converting energy. In some cases, potential energy is converted to kinetic energy. For example, energy conversion may include a situation where the chemical potential energy of a fuel or fuel cell is converted into rotational kinetic energy or where electrical potential energy is converted into rotational kinetic energy. Engines may also include provisions for converting kinetic energy into potential energy. For example, some engines include regenerative braking systems where kinetic energy from a drive train is converted into potential energy. Engines may also include devices that convert solar or nuclear energy into another form of energy. Some examples of engines include, but are not limited to: internal combustion engines, electric motors, solar energy converters, turbines, nuclear power plants, and hybrid systems that combine two or more different types of energy conversion processes.
In this embodiment, motor vehicle 101 may include an engine 102 . In an exemplary embodiment, engine 102 may be an internal combustion engine. In some cases, engine 102 may be a piston engine including any number of cylinders. In other cases, engine 102 may be a rotary engine. In other embodiments, engine 102 may be an electric motor. In still other embodiments, engine 102 may be any type of engine, as discussed above. In some embodiments, motor vehicle 101 and engine 102 may be further associated with additional components, including, but not limited to a power train system, as well as other components necessary for a motor vehicle to operate.
In some embodiments, engine 102 may include a number of pistons associated with one or more cylinders. In an exemplary embodiment, engine 102 may include a single piston for each cylinder. The plurality of pistons and corresponding cylinders may be of any type of piston and/or cylinders known in the art. In some embodiments, the plurality of pistons and cylinders may be arranged in a V-shaped configuration within engine 102 . In other embodiments, the plurality of pistons and cylinders may be arranged within engine 102 in an inline or straight configuration. In different embodiments, the plurality of pistons and cylinders may be arranged within engine 102 in any arrangement known in the art.
In some embodiments, fuel may be injected into the cylinders and may be ignited to create pressure in the cylinders. The pressure in the cylinders may cause the pistons associated with the cylinders to move. In some cases, the movement of the pistons may be a reciprocating motion.
In some embodiments, engine 102 may include a crankshaft 301 . Crankshaft 301 may be any type of crankshaft known in the art. In an exemplary embodiment, crankshaft 301 may be associated with the plurality of pistons via a plurality of connecting rods. In one embodiment, the plurality of connecting rods may connect the plurality of pistons to crankshaft 301 . Crankshaft 301 may translate a reciprocating motion of the plurality of pistons into rotational motion.
Generally, the timing of the firing to ignite fuel in the cylinders, the motion of the pistons, and the rotation of crankshaft 301 may be synchronized, such as with a timing belt, gear, or chain.
FIGS. 2 and 3 illustrate an exemplary embodiment of crankshaft 301 . In some embodiments, crankshaft 301 may be associated with one or more components. In one embodiment, crankshaft 301 may include a flywheel 303 , a damper 305 , a plurality of crankshaft journals 309 , a plurality of main bearing journals 317 , and a timing plate 321 . In some embodiments, crankshaft 301 may define a crankshaft axis 307 along the length of crankshaft 301 . For convenience, throughout this description the term “flywheel side” refers to positions proximate to a flywheel, including flywheel 303 . Similarly, the term “damper side” refers to a side closer to a damper on crankshaft 301 , including damper 305 . For example, a damper side of timing plate 321 is visible in FIG. 2 . Crankshaft 301 may generally be considered to extend from a flywheel side to a damper side.
For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term “axial,” as used throughout this detailed description, refers to a direction along an axis defined by crankshaft axis 307 . The term “radial,” as used throughout this detailed description, refers to any direction extending radially outward from crankshaft axis 307 .
Generally, crankshaft 301 may have a mass that is substantially the sum of the masses of each component included with crankshaft 301 . In some cases, the components of crankshaft 301 may have irregular shapes and, therefore, uneven distributions of mass. Designers of crankshaft 301 may strive to balance the mass of crankshaft 301 , for example, to reduce vibrations, bending of crankshaft 301 , wear and tear on the bearing and journal surfaces, and other typically undesirable effects. The balancing of the mass of crankshaft 301 is often done both statically, i.e., when crankshaft 301 is not moving, and dynamically, i.e., when crankshaft 301 is rotating.
Crankshaft static balance, as generally understood in the art, may be achieved by equally distributing a mass of crankshaft 301 around crankshaft axis 307 . In some cases, any crankshaft element spaced radially from crankshaft axis 307 may be balanced by another crankshaft element of substantially equal mass on a radially opposite side of crankshaft axis 307 . A statically balanced crankshaft at rest is intended to remain at rest and not rotate unless acted on by an outside force.
Crankshaft dynamic balance, as generally understood in the art, may be achieved by balancing all centrifugal forces at every point acting on crankshaft 301 , during rotation of crankshaft 301 around crankshaft axis 307 . Crankshaft dynamic balance may prevent unequal forces from acting on any portion of crankshaft 301 during rotation. Additionally, crankshaft dynamic balance may prevent vibration in crankshaft 301 during rotation.
In some embodiments, statically and dynamically balancing crankshaft 301 may be achieved by balancing every mass located on crankshaft 301 against another substantially similar mass. In some cases, statically and dynamically balancing crankshaft 301 may be a time consuming and expensive process. In some embodiments, removing components from crankshaft 301 may reduce the mass of crankshaft 301 and ease the balancing process. Accordingly, eliminating various crankshaft components, or combining multiple components into a single component without reducing the functionality of crankshaft 301 , may assist with the balancing process.
In the various embodiments discussed herein, timing plate 321 may be provided to float between crankshaft components to assist in the balancing process by eliminating a mechanical connector, such as a bolt, typically used to attach a timing plate to the adjacent crankshaft components. Prior to discussing the details of timing plate 321 , a general discussion of typical crankshaft components is set forth below.
In some embodiments, crankshaft 301 may include components configured to reduce vibrations or other characteristics associated with the reciprocating motion of the plurality of pistons. In one embodiment, crankshaft 301 may include flywheel 303 . In some embodiments, flywheel 303 may store rotational energy to provide a smother engine rotation. In some cases, flywheel 303 may be provided to eliminate or reduce a pulsation created by the reciprocating motion of the plurality of pistons. Flywheel 303 may be any type of flywheel known in the art. Additionally, in some embodiments, flywheel 303 may be also associated with any type of transmission system of motor vehicle 101 , which transmission systems are well known in the art.
In one embodiment, crankshaft 301 may also include damper 305 . Damper 305 may be any type of damper known in the art. In some embodiments, damper 305 may include a harmonic balancer. In other embodiments, damper 305 may include a torsional damper. In some cases, damper 305 may add mass to the damper side of crankshaft 301 to balance a mass of flywheel 303 on the flywheel side. In other cases, damper 305 may be provided to reduce vibrations associated with the motion of engine 102 . In an exemplary embodiment, damper 305 and flywheel 303 may be located on opposite ends of crankshaft 301 .
In some embodiments, crankshaft 301 may include components configured to assist with the rotation of crankshaft 301 within engine 102 . In some embodiments, crankshaft 301 may include main bearing journals 317 . In an exemplary embodiment, main bearing journals 317 may be arranged along crankshaft axis 307 . Main bearing journals 317 may be any type of bearing journal known in the art. In some embodiments, main bearing journals 317 may be associated with a plurality of bearings. In an exemplary embodiment, the plurality of bearings may be configured to hold crankshaft 301 in place within engine 102 . With this arrangement, the plurality of bearings may allow crankshaft 301 to rotate about crankshaft axis 307 .
In various embodiments, crankshaft 301 may have any number of main bearing journals 317 . The plurality of main bearing journals 317 may also be placed at various locations on crankshaft 301 . The number of main bearing journals 317 and the placement of main bearing journals 317 may be chosen based on criteria known in the art. In an exemplary embodiment, the number and placement of main bearing journals 317 on crankshaft 301 may be chosen to properly balance crankshaft 301 . In this embodiment, crankshaft 301 includes three main bearing journals 317 , one located at each end on the flywheel side and the damper side, as well as one located in the middle of crankshaft 301 . In other embodiments, crankshaft 301 may include fewer or greater number of main bearing journals 317 . Additionally, in other embodiments, the placement and arrangement of main bearing journals 317 on crankshaft 301 may vary.
In some embodiments, crankshaft 301 may include crankshaft journals 309 . Crankshaft journals 309 may generally provide a surface on crankshaft 301 on which bearings located within engine 102 may ride. In some embodiments, crankshaft journals 309 may include a number of components. In an exemplary embodiment, each crankshaft journal 309 may include two crankshaft journal side walls connected at one end by a crankpin 313 .
Crankpin 313 may be any type of crankshaft pin known in the art. Crankpin 313 may be made of any material known in the art. In some embodiments, crankpin 313 may be associated with the connecting rod of a piston. Crankpin 313 may serve as the connection point between the piston and crankshaft 301 . With this arrangement, crankpin 313 may allow energy from the connecting rod to be transferred to crankshaft 301 . In some embodiments, crankpin 313 may be spaced radially apart from crankshaft axis 307 . The radial spacing may allow crankpin 313 to accommodate the reciprocal motion of the piston while allowing crankshaft 301 to rotate about crankshaft axis 307 .
In some embodiments, crankpin 313 may lie between two crankshaft journal side walls. In some embodiments, each crankshaft journal side wall may have a damper side face and a flywheel side face. In one embodiment, crankpin 313 may be associated with a damper side face of one crankshaft journal side wall and associated with a flywheel side face of another crankshaft journal side wall.
In some embodiments, crankshaft journal side walls may include a first portion proximate crankpin 313 and a counterweight portion. In an exemplary embodiment, the counterweight portion of the crankshaft journal side wall may be spaced radially away from crankpin 313 . With this arrangement, the counterweight portion of the crankshaft journal side wall may balance crankshaft journal 309 with respect to crankshaft axis 307 .
In various embodiments, crankshaft journal side walls may be of any shape, configuration, and material known in the art. The shape, configuration, and material of crankshaft journal side walls may be chosen based on factors including, but not limited to: the desired number of crankshaft journals, an intended balance of crankshaft 301 , an intended operational speed of crankshaft 301 , and the type of engine.
In some embodiments, crankshaft journals 309 may include one or more types of crankshaft journal side walls. Referring again to FIG. 2 , in this embodiment, crankshaft journal side walls may include a tapered side wall 315 . Tapered side wall 315 may have a generally non-symmetrical ovoid shape with a greater amount of mass at one end than the other. Additionally, in some embodiments, crankshaft journal side walls may also include an elliptical side wall 311 . Elliptical side wall 311 may have a generally symmetrical ovoid shape with approximately equal amounts of mass at either end. In other embodiments, crankshaft journals 309 may include one or more types of crankshaft journal side walls of similar or different shapes.
As shown in FIG. 3 , in an exemplary embodiment, each crankshaft journal 309 may include tapered side wall 315 and elliptical side wall 311 connected at one end by crankpin 313 . In an exemplary embodiment, two tapered side walls 315 may be associated with a shared elliptical side wall 311 . Shared elliptical side wall 311 may be associated with one crankpin 313 on the flywheel side face and another crankpin 313 on the damper side face.
In some embodiments, a plurality of crankshaft journal side walls, including one or more of tapered side wall 315 and/or elliptical side wall 311 , may be associated with multiple crankshaft components including other crankpins and bearing journals. In an exemplary embodiment, main bearing journal 317 may be associated with two crankshaft journal side walls located approximately in the middle of crankshaft 301 . In this embodiment, main bearing journal 317 may be associated with the damper side face of one tapered side wall 315 and the flywheel side face of another tapered side wall 315 .
In other embodiments, one or more crankshaft journal side walls may be associated with crankshaft components located at each end of crankshaft 301 on the flywheel side and the damper side, including one or more of main bearing journals 317 , flywheel 303 , and other crankshaft components. In one embodiment, a first crankshaft journal side wall 323 may be located adjacent to timing plate 321 at damper side of crankshaft 301 . In this embodiment, first crankshaft journal side wall 323 may be a tapered side wall. In other cases, first crankshaft journal side wall 323 may have any shape. In an exemplary embodiment, first crankshaft journal side wall 323 may be configured to mate with timing plate 321 , as further discussed below.
FIGS. 4 and 5 illustrate an exemplary embodiment of a timing plate that may be associated with a crankshaft. In some embodiments, timing plate 321 may be configured to reduce the total mass of crankshaft 301 . In an exemplary embodiment, timing plate 321 may reduce the total mass of crankshaft 301 by eliminating a connecting element, such as a bolt, between timing plate 321 and crankshaft 301 . In some embodiments, timing plate 321 may be configured to synchronize the movement of crankshaft 301 with other components and/or systems associated with engine 102 , including, but not limited to timing control of an ignition system and/or a fuel injection system, as is well known in the art. In some embodiments, timing plate 321 may be used in engines which do not employ other typical mechanisms to coordinate crankshaft motion and timing control, such as timing belts or chains.
FIG. 4 shows a frontal view of an embodiment of timing plate 321 . In this embodiment, timing plate 321 may have a central hole 501 , a plurality of timing elements 503 , and at least one protruding portion 507 . In an exemplary embodiment, an axial portion of crankshaft 301 may extend through central hole 501 in timing plate 321 . The term “axial portion” refers to a crankshaft element lying on crankshaft axis 307 . In some embodiments, the axial portion may be symmetric about crankshaft axis 307 . In an exemplary embodiment, the axial portion may have a substantially circular cross-section with respect to crankshaft axis 307 . In one embodiment, main bearing journal 317 may extend through central hole 501 , as shown in FIGS. 2 and 3 , described above.
In some embodiments, central hole 501 may be configured to allow the axial portion of crankshaft 301 to pass through timing plate 321 . In some cases, central hole 501 may be substantially circular. In an exemplary embodiment, central hole 501 may have a slightly larger diameter than a diameter of the axial portion. With this arrangement, timing plate 321 may be configured to rotate around the axial portion of crankshaft 301 . In one embodiment, timing plate 321 may be configured to move freely or float around the axial portion of crankshaft 301 extending through central hole 501 .
In some embodiments, timing plate 321 may be configured to rotate with crankshaft 301 . In some cases, timing plate 321 may rotate at substantially the same speed as crankshaft 301 . Each full rotation of crankshaft 301 includes the crankshaft rotating through 360 degrees. At any given time, crankshaft 301 may be at a particular angle between 1 to 360 degrees in the rotation. This angular position of crankshaft 301 at a given time may be referred to as the “rotational angle” or “crank angle.”
In some embodiments, motor vehicle 101 may monitor the crank angle using a crank angle sensor (not shown). In some embodiments, engine 102 may include additional components configured to be used in conjunction with a crank angle sensor, including, but not limited to a timing plate. In an exemplary embodiment, timing plate 321 may be associated with a crank angle sensor that may be configured to read or sense indicia on timing plate 321 . In some cases, the crank angle sensor may be an optical sensor. In other cases, the crank angle sensor may be a magnetic sensor. In various embodiments, timing plate 321 may be associated with any type of crank angle sensor known in the art.
In some embodiments, the crank angle sensor may detect the rotational angle of crankshaft 301 . The crank angle sensor may be connected to electronic control unit associated with engine 102 for supplying signals corresponding to the rotational angle of crankshaft 301 . In some embodiments, the crank angle sensor may generate a pulse at various predetermined rotational angles of crankshaft 301 corresponding to various rotational angles of crankshaft 301 and/or pistons within engine 102 . In various embodiments, the signals supplied from the crank angle sensor may be used by one or more systems associated with engine 102 , including, but not limited to an ignition system and/or a fuel injection system, for timing control operations associated with fuel injection timing, ignition timing, and other controls, as well as determining the rotational speed of engine 102 .
In some embodiments, the crank angle sensor may monitor one or more timing elements 503 on timing plate 321 to determine the crank angle. In various embodiments, the crank angle sensor may monitor timing elements 503 using any method known in the art. In some cases, timing elements 503 may rotate with timing plate 321 . With this arrangement, timing elements 503 may rotate at substantially the same speed as crankshaft 301 . By monitoring the plurality of timing elements 503 , the crank angle sensor may determine the crank angle of crankshaft 301 during rotation.
In various embodiments, timing elements 503 may be any type of indicia or structure capable of creating a detectable contrast on the surface of timing plate 321 . In some embodiments, timing elements 503 may include markings spaced at known angular positions about timing plate 321 . In other embodiments, timing elements 503 may include gear teeth spaced around a circumference of timing plate 321 . In still other embodiments, timing elements 503 may include hash marks formed on a periphery surface of timing plate 321 . In various embodiments, timing elements 503 may include combinations of any or all of these different types of timing elements.
In some embodiments, timing plate 321 may include an element gap 505 . Element gap 505 may be a region lacking timing elements 503 . In some embodiments, element gap 505 may be positioned to correspond to a crank angle of zero. In other embodiments, element gap 505 may correspond to a top dead center position of one or more pistons within engine 102 when timing plate 321 is positioned in an initial position. In other embodiments, element gap 505 may correspond to any desired crank angle position of crankshaft 301 and/or position of one or more pistons within engine 102 . In other embodiments, timing plate 321 may include more than one element gap corresponding to different crank angle positions.
In some embodiments, element gap 505 may be used to calibrate timing plate 321 and/or provide an indicator of a full rotation of timing plate 321 . In an exemplary embodiment, element gap 505 may be used by the crank angle sensor to provide a top dead center signal or other signal associated with a predetermined rotational angle of crankshaft 301 to one or more systems associated with engine 102 , including, but not limited to an ignition system and/or a fuel injection system, for timing control operations associated with fuel injection timing, ignition timing, and other controls, as well as determining the rotational speed of engine 102 .
In some embodiments, timing plate 321 may include one or more components that may be configured to mate, or otherwise removably associate, timing plate 321 with crankshaft 301 . In an exemplary embodiment, timing plate 321 may include a protruding portion 507 . In various embodiments, protruding portion 507 may be any shape. In some cases, protruding portion 507 may be a geometric shape, including, but not limited to prisms, cones, pyramids, cylinders, as well as other geometric shapes. In other cases, protruding portion 507 may be an irregular shape. In an exemplary embodiment, protruding portion 507 may be a substantially rectangular prism, as further described below.
FIGS. 5 through 7 further illustrate protruding portion 507 of timing plate 321 associated with one or more portions of crankshaft 301 . Referring now to FIG. 5 , an exploded view of crankshaft 301 is illustrated. FIG. 5 illustrates a damper side of first crankshaft journal side wall 323 and a flywheel side of timing plate 321 .
As shown in FIG. 5 , in this embodiment, protruding portion 507 is a substantially rectangular prism. Protruding portion 507 may generally be defined by a protruding length L and a protruding width W. In this embodiment, protruding length L may be measured in the radial direction of timing plate 321 . Similarly, protruding width W may be measured in a direction perpendicular to protruding length L. Additionally, protruding portion 507 may extend in the axial direction. In this embodiment, protruding portion 507 may generally be defined by a height H in the axial direction. In this embodiment, height H may extend from a surface of timing plate 321 to a tip 521 of protruding portion 507 .
In various embodiments, timing plate 321 may have any number of protruding portions 507 . In an exemplary embodiment, timing plate 321 may include one protruding portion 507 . In other embodiments, timing plate 321 may include two protruding portions 507 . In still other embodiments, timing plate 321 may include four protruding portions 507 . As shown in FIGS. 4-7 , timing plate 321 has one protruding portion 507 .
In various embodiments, one or more protruding portions 507 may be disposed on timing plate 321 in numerous patterns or arrangements. In some embodiments, multiple protruding portions 507 may be disposed symmetrically or asymmetrically on timing plate 321 . In some embodiments, one or more protruding portions 507 may be disposed at varying radial distances between center hole 501 and an outermost periphery of timing plate 321 .
In some embodiments, one or more portions of crankshaft 301 may be configured to mate or associate with a portion of timing plate 321 . In an exemplary embodiment, one or more portions of a component associated with crankshaft 301 may be configured to mate or associate with protruding portion 507 . In one embodiment, crankshaft 301 may include a receiving portion 509 that may be configured to receive protruding portion 507 of timing plate 321 . In an exemplary embodiment, receiving portion 509 may be a cavity in a surface of crankshaft 301 . In one embodiment, receiving portion 509 may be a cavity in an axial facing surface 325 of crankshaft 301 . In an exemplary embodiment, axial facing surface 325 may be adjacent to timing plate 321 . In one embodiment, axial facing surface 325 may face tip 521 of protruding portion 507 of timing plate 321 . As shown in FIGS. 5-7 , receiving portion 509 is a cavity in axial facing surface 325 of first crankshaft journal side wall 323 .
In various embodiments, receiving portion 509 may define a cavity of any shape. In some cases, receiving portion 509 may be a geometric shape, including, but not limited to prisms, cones, pyramids, cylinders, as well as other geometric shapes. In other cases, receiving portion 509 may be an irregular shape. In an exemplary embodiment, receiving portion 509 may be a substantially rectangular prism shaped cavity. In one embodiment, receiving portion 509 may be configured to substantially correspond to a shape of protruding portion 507 . In this embodiment, receiving portion 509 and protruding portion 507 are both substantially rectangular prism shaped. In other embodiments, receiving portion 509 and protruding portion 507 may be other similar shapes, including, but not limited to substantially cylindrical shaped. In other embodiments, receiving portion 509 and protruding portion 507 may be different shapes. For example, in one embodiment, protruding portion 507 may be substantially cylindrical shaped, while receiving portion 509 may be substantially rectangular prism shaped.
In some embodiments, receiving portion 509 may extend into crankshaft 301 in the axial direction. In an exemplary embodiment, receiving portion 509 may be defined by a depth D in the axial direction within first crankshaft journal side wall 323 . In this embodiment, depth D may extend from axial facing surface 325 to a receiving portion bottom 531 .
In various embodiments, depth D of receiving portion 509 may be larger, smaller or equal to height H of protruding portion 507 . In an exemplary embodiment, depth D of receiving portion 509 may be substantially equal to height H of protruding portion 507 . Referring now to FIG. 6 , in this embodiment, depth D of receiving portion 509 is substantially equal to height H of protruding portion 507 . With this arrangement, timing plate 321 may sit approximately flush against axial facing surface 325 when depth D of receiving portion 509 equals or is larger than height H of protruding portion 507 .
In some embodiments, receiving portion 509 may also be defined by width and length dimensions. In an exemplary embodiment, receiving portion 509 may be defined by a receiving length LR and a receiving width WR. Receiving length LR may be measured in the radial direction. Receiving width WR may be measured in a direction perpendicular to receiving length LR.
In some embodiments, the dimensions of receiving portion 509 may be configured to allow protruding portion 507 to mate with receiving portion 509 . In some embodiments, protruding length L may be smaller or substantially equal to receiving length LR. In some embodiments, protruding width W may be smaller or substantially equal to receiving width WR. As shown in FIGS. 5-7 , receiving length LR is larger than protruding length L and receiving width WR is substantially equal to protruding width W. In various embodiments, receiving length LR and receiving width WR, along with depth D, described above, may be any desired size. In some embodiments, receiving length LR and receiving width WR of receiving portion 509 may be chosen so as to substantially correspond to the dimensions of protruding portion 507 . In other embodiments, receiving length LR and receiving width WR may be larger than the dimensions of protruding portion 507 . In some embodiments, the dimensions of receiving portion 509 may be larger than the dimensions of protruding portion 507 to allow for adjustment of the position of timing plate 321 relative to crankshaft 301 .
In various embodiments, crankshaft 301 may include any number of receiving portions 509 . In some embodiments, crankshaft 301 may include an equal number of receiving portions 509 and protruding portions 507 . In other embodiments, crankshaft 301 may include multiple receiving portions 509 disposed at various locations on crankshaft 301 . In some cases, one or more receiving portions 509 may correspond to particular rotational angles of crankshaft 301 and/or pistons within engine 102 . In some embodiments, different receiving portions 509 located on crankshaft 301 may allow for adjustment of the position of timing plate 321 relative to crankshaft 301 . As shown in FIGS. 4-7 , crankshaft 301 includes one protruding portion 507 and one receiving portion 509 .
FIGS. 5 and 6 illustrate an exemplary embodiment of protruding portion 507 mating with receiving portion 509 to thereby attach, or temporarily associate, timing plate 321 with crankshaft 301 . In some embodiments, protruding portion 507 may mate, or otherwise temporarily associate, with receiving portion 509 during operation of crankshaft 301 . In an exemplary embodiment, the mating of protruding portion 507 and receiving portion 509 may connect timing plate 321 to crankshaft 301 . With this arrangement, timing plate 321 may be configured to rotate with crankshaft 301 . When crankshaft 301 rotates during crankshaft operation, first crankshaft journal side wall 323 will rotate along with crankshaft 301 . In this embodiment, receiving portion 509 will rotate with first crankshaft journal side wall 323 . With this arrangement, receiving portion 509 will rotate with rotation of crankshaft 301 .
In some embodiments, as receiving portion 509 associated with a portion of crankshaft 301 rotates, the rotation may cause a receiving portion side wall 533 of receiving portion 509 to contact a protruding portion side wall 523 of protruding portion 507 that has been mated with receiving portion 509 . With this arrangement, rotational force may be transferred from receiving portion side wall 533 to protruding portion side wall 523 . The rotational force may then be transferred to the remainder of timing plate 321 . With this arrangement, timing plate 321 may rotate with crankshaft 301 . In an exemplary embodiment, timing plate 321 may rotate at substantially the same speed as crankshaft 301 .
FIGS. 6 and 7 illustrate cross-sections of crankshaft 301 in the region around first crankshaft journal side wall 323 and timing plate 321 . FIGS. 6 and 7 further illustrate the nature of the connection between timing plate 321 and crankshaft 301 formed by the mating of protruding portion 507 and receiving portion 509 . In some embodiments, mating protruding portion 507 to receiving portion 509 may allow timing plate 321 to rotate along with crankshaft 301 , while allowing timing plate 321 freedom of movement along the axial direction.
As shown in FIG. 7 , in an exemplary embodiment, the temporary association between timing plate 321 and crankshaft 301 caused by mating of protruding portion 507 to receiving portion 509 may allow timing plate 321 to move away from crankshaft 301 . In some embodiments, the removable association between timing plate 321 and crankshaft 301 may allow timing plate 321 to move freely or “float” on an axial portion of crankshaft 301 extending through central hole 501 . In one embodiment, timing plate 321 may slide along main bearing journal 317 , in the axial direction, away from first crankshaft journal side wall 323 . With this arrangement, timing plate 321 may be allowed to detach from a mating or temporary association with crankshaft 301 .
In contrast, conventional timing plates may be bolted to the crankshaft. Bolting the conventional timing plate to the crankshaft allows the conventional timing plate to rotate with the crankshaft. This arrangement, however, increases the total mass of the crankshaft due to the added mass of the bolts. Additionally, the mass of the bolts must also be balanced, both statically and dynamically on the crankshaft. The present embodiments of timing plate 321 , described herein, are configured to rotate along with crankshaft 301 without using such bolts or other similar connecting elements.
Referring now to FIG. 8 , a representative view of the relative difference in mass between a conventional crankshaft with a connected timing plate and an exemplary embodiment of a crankshaft is shown. In an exemplary embodiment, by mating or otherwise temporarily associating timing plate 321 to crankshaft 301 using protruding portion 507 and receiving portion 509 , as described above, the total mass of crankshaft 301 may be smaller than a conventional crankshaft.
FIG. 8 shows a balance scale having a first balance plate containing an exemplary embodiment of timing plate 321 associated with crankshaft 301 by the mating of protruding portion 507 and receiving portion 509 . On a second balance plate, a conventional timing plate 805 is connected to a conventional crankshaft 801 by two bolts 803 . In this embodiment, conventional crankshaft 801 may be substantially the same as crankshaft 301 , other than the addition of two bolts 803 that connect conventional timing plate 805 to conventional crankshaft 801 . FIG. 8 shows that the additional mass of bolts 803 may cause the combination of conventional crankshaft 801 and conventional timing plate 805 to have a greater mass than crankshaft 301 associated with timing plate 321 . It should be understood that the amount of mass reduced by the present embodiment of crankshaft 301 associated with timing plate 321 shown in FIG. 8 is merely exemplary. In various embodiments, the amount of mass reduced may depend on a number of different factors, including the number of bolts connected to the conventional crankshaft, as well as materials used for making individual components of the crankshafts.
FIG. 9 illustrates an alternate embodiment of a crankshaft 901 . In some embodiments, crankshaft 901 may be associated with one or more components, including one or more components substantially similar to components associated with crankshaft 301 , discussed above. In one embodiment, crankshaft 901 may include a flywheel 903 , a damper 905 , a plurality of crankshaft journals 909 , a plurality of main bearing journals 917 , and a timing plate 921 . In some embodiments, crankshaft 901 may define a crankshaft axis 907 along the length of crankshaft 901 . In some embodiments, crankshaft 901 may be supported by one or more bearings 941 and a flanged bearing 931 .
In some embodiments, crankshaft 901 may include components configured to reduce vibrations or other characteristics associated with the reciprocating motion of the plurality of pistons. In one embodiment, crankshaft 901 may include flywheel 903 . In some embodiments, flywheel 903 may store rotational energy to provide a smother engine rotation. In some cases, flywheel 903 may be provided to eliminate or reduce a pulsation created by the reciprocating motion of the plurality of pistons. Flywheel 903 may be any type of flywheel known in the art. Additionally, in some embodiments, flywheel 903 may be also associated with any type of transmission system of a motor vehicle, which transmission systems are well known in the art.
In one embodiment, crankshaft 901 may also include damper 905 . Damper 905 may be any type of damper known in the art. In some embodiments, damper 905 may include a harmonic balancer. In other embodiments, damper 905 may include a torsional damper. In some cases, damper 905 may add mass to the damper side of crankshaft 901 to balance a mass of flywheel 903 on the flywheel side. In other cases, damper 905 may be provided to reduce vibrations associated with the motion of an engine. In an exemplary embodiment, damper 905 and flywheel 903 may be located on opposite ends of crankshaft 901 .
In some embodiments, crankshaft 901 may include components configured to assist with the rotation of crankshaft 901 within an engine. In some embodiments, crankshaft 901 may include main bearing journals 917 . In an exemplary embodiment, main bearing journals 917 may be arranged along crankshaft axis 907 . Main bearing journals 917 may be any type of bearing journal known in the art. In some embodiments, main bearing journals 917 may be associated with a plurality of bearings. In an exemplary embodiment, main bearing journals 917 may be associated with one or more bearings 941 and flanged bearing 931 . In one embodiment, bearings 941 and flanged bearing 931 may hold crankshaft 901 in place within an engine. In this embodiment, bearings 941 and flanged bearing 931 may allow crankshaft 901 to rotate about crankshaft axis 907 .
In various embodiments, bearings 941 and flanged bearing 931 may be any type of bearing known in the art. In one embodiment, bearings 941 and/or flanged bearing 931 may be a plain bearing. In another embodiment, one or more of bearings 941 and/or flanged bearing 931 may be a thrust bearing. In additional embodiments, bearings 941 and/or flanged bearing 931 may be a combination of one or more types of bearings. In an exemplary embodiment, flanged bearing 931 may include a flange 933 . In some cases, flanged bearing 931 may include flange 933 disposed on one or more of damper side and flywheel side of flanged bearing 931 . In other cases, flanged bearing 931 may include flange 933 on only one side. In an exemplary embodiment, flange 933 may further include a bearing thrust surface 935 . In some cases, bearing thrust surface 935 may be disposed on one or more of damper side and flywheel side of flange 933 . In other cases, flange 933 may include bearing thrust surface 935 on only one side.
In some embodiments, crankshaft 901 may include crankshaft journals 909 . Crankshaft journals 909 may generally provide a surface on crankshaft 901 on which bearings located within an engine may ride. In some embodiments, crankshaft journals 909 may include a number of components including one or more components substantially similar to components associated with crankshaft journals 309 , discussed above. In an exemplary embodiment, each crankshaft journal 909 may include two crankshaft journal side walls connected at one end by a crankpin 913 . Crankpin 913 may be any type of crankshaft pin known in the art. In an exemplary embodiment, crankpin 913 may be substantially similar to crankpin 313 , discussed above.
In some embodiments, crankpin 913 may lie between two crankshaft journal side walls. In some embodiments, each crankshaft journal side wall may have a damper side face and a flywheel side face. In one embodiment, crankpin 913 may be associated with a damper side face of one crankshaft journal side wall and associated with a flywheel side face of another crankshaft journal side wall.
In an exemplary embodiment, crankshaft journals 909 may include one or more crankshaft journal side walls, including a tapered side wall 915 and an elliptical side wall 911 . Tapered side wall 915 and elliptical side wall 911 may be substantially similar to, respectively, tapered side wall 315 and elliptical side wall 311 , discussed above. In other embodiments, crankshaft journals 909 may include one or more types of crankshaft journal side walls of similar or different shapes. The function and operation of crankshaft journals 909 is substantially similar to crankshaft journals 309 described above, and will not be further discussed here.
Additionally, as shown in FIG. 9 , in one embodiment, timing plate 921 , as described in more detail below, may be located proximate a first crankshaft journal side wall 923 . In some embodiments, first crankshaft journal side wall 923 may be substantially similar to first crankshaft journal side wall 323 , discussed above.
Referring now to FIG. 10 , a frontal view of an alternate embodiment of timing plate 921 is shown. In this embodiment, timing plate 921 may have a central hole 1111 , a plurality of indicia 1103 , at least one protruding portion 1107 , and a thrust surface 1109 . In some embodiments, timing plate 921 may also include a plurality of holes 1121 designed to reduce the mass and/or balance of timing plate 921 . In various embodiments, plurality of holes 1121 may include one or more types or shapes of holes and may be arranged on timing plate 921 in any symmetrical or asymmetrical configuration as desired to affect the mass and/or balance of timing plate 921 .
In various embodiments, indicia 1103 may be any type of indicia known in the art. In some embodiments, indicia 1103 may be substantially similar to timing elements 503 , discussed above. In some embodiments, indicia 1103 may include gear teeth spaced around a circumference of timing plate 921 . In other embodiments, indicia 1103 may include markings spaced at known angular positions about timing plate 921 . In still other embodiments, indicia 1103 may include hash marks formed on a periphery surface of timing plate 921 . In various embodiments, indicia 1103 may include combinations of any or all of these different types of indicia. The function and operation of indicia 1103 on timing plate 921 may be substantially similar as explained above in regard to timing elements 503 . Additionally, indicia 1103 may be used by one or more systems associated with a motor vehicle, for example, using a crank angle sensor, to determine a crank angle or rotational angle of a crankshaft, as discussed in detail above.
In some embodiments, timing plate 921 may also include an element gap 1105 . Element gap 1105 may be a region on the periphery of timing plate 921 that lacks indicia 1103 . In an exemplary embodiment, element gap 1105 may be substantially similar to element gap 505 , discussed above. In other embodiments, timing plate 921 may include multiple element gaps. In still other embodiments, timing plate 921 may not include any element gaps.
In an exemplary embodiment, an axial portion of crankshaft 901 may extend through central hole 1111 in timing plate 921 . In some embodiments, the axial portion may be symmetric about crankshaft axis 907 . In an exemplary embodiment, the axial portion may have a substantially circular cross-section with respect to crankshaft axis 907 . As shown in FIG. 9 , in one embodiment, a first main bearing journal 927 , associated with flanged bearing 931 , may extend through central hole 1111 .
In some embodiments, central hole 1111 may be configured to allow the axial portion of crankshaft 901 to pass through timing plate 921 . In some cases, central hole 1111 may be substantially circular. In an exemplary embodiment, central hole 1111 may have a slightly larger diameter than a diameter of the axial portion. With this arrangement, timing plate 921 may be configured to rotate around the axial portion of crankshaft 901 . In one embodiment, timing plate 921 may be configured to move freely or float around the first main bearing journal 927 of crankshaft 901 extending through central hole 1111 .
In some embodiments, timing plate 921 may include one or more components that may be configured to mate, or otherwise removably associate, timing plate 921 with crankshaft 901 . In an exemplary embodiment, timing plate 921 may include one or more protruding portions 1107 for mating with a receiving portion associated with crankshaft 901 . As shown in FIG. 11 , described below, in this embodiment, timing plate 921 may include two protruding portions 1107 . The nature of the mating between the protruding portion and the receiving portion may be substantially the same as discussed above with regard to the embodiment shown in FIGS. 4-7 . In one embodiment, protruding portions 1107 may be substantially semi-circular shapes. In other embodiments, protruding portions 1107 may be any shape, including, but not limited to prisms, cones, pyramids, cylinders, as well as other geometric shapes or irregular shapes.
In an exemplary embodiment, one or more portions of a component associated with crankshaft 901 may be configured to mate or associate with protruding portions 1107 . In one embodiment, crankshaft 901 may include one or more receiving portions that may be configured to receive protruding portions 1107 of timing plate 921 . In an exemplary embodiment, the receiving portions may be cavities in a surface of crankshaft 901 . In one embodiment, the receiving portions may be substantially similar to receiving portion 509 , discussed above.
In various embodiments, the receiving portions may define cavities of any shape. In an exemplary embodiment, the receiving portions may be a substantially rectangular prism shaped cavity. In this embodiment, receiving portions may be sized and dimensioned so as to substantially accept receiving portions 1107 within the cavities. In one embodiment, receiving portions and protruding portions 1107 may be different shapes. In one embodiment, protruding portions 1107 may be substantially semi circular shaped, while the receiving portions may be substantially rectangular prism shaped. In other embodiments, the receiving portions may be configured to substantially correspond to a shape of protruding portions 1107 . In other embodiments, the receiving portions and protruding portions 1107 may be other shapes, as discussed above.
Referring now to FIG. 11 , a cross-section of timing plate 921 taken along line A-A from FIG. 10 is illustrated. In this embodiment, protruding portions 1107 may include semi-circular cross-sectional shapes. As discussed above, in other embodiments, the shapes of protruding portions 1107 may vary.
FIG. 11 also illustrates a cross-sectional view of thrust surface 1109 . The term “thrust surface,” as used in this description and claims, refers to two opposing surfaces placed in close proximity to each other (in the crankshaft axis direction) with a layer of fluid, typically motor oil, between the two thrust surfaces to dampen axial motion. In some embodiments, thrust surface 1109 may be any type of thrust surface known in the art. In an exemplary embodiment, thrust surface 1109 may be a raised portion of the surface of one side of timing plate 921 . As shown in FIG. 11 , in this embodiment, thrust surface 1109 is raised a distance T in the axial direction from the remainder of a surface of timing plate 921 . In one embodiment, thrust surface 1109 may be disposed proximate one or more portions of flanged bearing 931 .
In various embodiments, flanged bearing 931 may be any type of bearing known in the art, as discussed above. In this embodiment, flanged bearing 931 may serve two functions. In one case, flanged bearing 931 may support crankshaft 901 within the engine, while allowing crankshaft 901 to rotate, in the same manner as bearings 941 . In another case, flanged bearing 931 may also absorb axial crankshaft movement. In an exemplary embodiment, flanged bearing 931 may include one or more flanges 933 having bearing thrust surfaces 935 , as described above.
Referring now to FIG. 12 , a side view of a portion of crankshaft 901 is illustrated showing the spatial relationship between bearing thrust surface 935 and thrust surface 1109 of timing plate 921 . In this embodiment, timing plate 921 may be disposed on first main bearing journal 927 between crankshaft journal 909 and flanged bearing 931 . In an exemplary embodiment, thrust surface 1109 may extend axially towards flanged bearing 931 . In one embodiment, thrust surface 1109 may be radially disposed on timing plate 921 so as to substantially align with flange 933 of flanged bearing 931 . With this arrangement, bearing thrust surface 935 associated with flange 933 , may be disposed opposite thrust surface 1109 of timing plate 921 .
In some embodiments, during operation of the engine, oil may be placed in the space or gap between flange 933 and timing plate 921 . The oil may fill the space or gap between bearing thrust surface 935 and thrust surface 1109 . With this arrangement, the axial motion of crankshaft 901 may be dampened or absorbed by the oil, as is known in the art.
In some embodiments, associating thrust surface 1109 with a portion of timing plate 921 may reduce the number of components necessary in crankshaft 901 . Specifically, in one embodiment, disposing thrust surface 1109 on timing plate 921 may combine two functions into a single component. With this arrangement, reducing the number of components may reduce mass and complexity in the engine.
While various embodiments have been described, the description is intended to be exemplary, rather than limiting. It will be apparent to those of ordinary skill in the art, that many more embodiments and implementations are possible that are within the scope of the claims. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims. | An engine timing plate is disclosed that is generally positioned between a crankshaft surface and a main journal. The engine timing plate is not bolted or otherwise secured to either the crankshaft surface or the main journal. Instead, the timing plate “floats” between the two surfaces. The timing plate includes protruding portion that mates or temporarily associates with a receiving portion disposed on the crankshaft. The timing plate also generally includes a raised surface forming an integrated thrust surface that may engage with, but not necessarily interlock with, one or both of the crankshaft surface and the main journal. Thus, the rotational motion of the crankshaft maintains the relative position of the timing plate with respect to the crankshaft surface and/or the main journal without the use of standard mechanical connectors, such as bolts. | 5 |
This invention relates to an apparatus for, and to a method of, applying to the surface of a cellulosic sheet material, such as paper or board, a coating composition comprising a particulate inorganic pigment and an adhesive in an aqueous medium. More particularly, but not exclusively, the invention is concerned with the production of what is usually known as ultra-lightweight coated papers, i.e. papers coated with not more than 9 g. of dry coating composition per square metre of paper surface per side of paper.
BACKGROUND OF THE INVENTION
Inorganic pigments which have been found most suitable for incorporation in coating compositions for producing ultra-lightweight coated papers are minerals of the layer lattice silicate type of which kaolin clay is the most widely used, but coating compositions may also comprise other layer lattice silicate minerals such as talc. These layer lattice silicate minerals generally crystallise in the form of flat plates which may be relatively easily cleaved apart along a plane parallel to the face of the plates. If the coating applied to the surface of a sheet of cellulosic material is light in weight, it follows that the thickness of the dry coating will be small. It has been found that, if a coating is to possess good opacity, gloss and printing properties, the particles of the layer lattice silicate mineral in the coating composition should generally be of high aspect ratio, in other words the ratio of the longest dimension measured across the face of the particle to the thickness of the particle should be large, and the particles should be generally oriented with the plane of the plates parallel to the surface of the cellulosic material. Layer lattice silicate minerals generally exist in the form of particles consisting of stacks or clusters of plate-like crystals and the aspect ratio of the particles of such a mineral may be increased by cleaving apart the plates to provide a particulate material which consists predominantly of individual plates.
However, paper coating compositions containing a high proportion of particles of high aspect ratio suffer from the disadvantage that their rheological properties are generally poor, i.e. a paper coating composition containing a high percentage by weight of such particles tends to be highly viscous and to exhibit rheological dilatancy, i.e. the viscosity of the composition increases with the rate of shear applied to the composition. One way of overcoming this disadvantage would be to reduce the percentage by weight of particulate silicate mineral in the paper coating composition but such a measure would introduce other disadvantages, viz:
1. the cost of drying the coated material would be increased because the quantity of water to be evaporated per unit weight of pigment applied is increased;
2. the aqueous medium would tend to migrate rapidly into the cellulosic sheet material leaving the platelet particles immobilised in an orientation which may be far removed from the optimum orientation in which the plane of the plates are parallel to the surface of the cellulosic material; and
3. the particles would tend to collapse in random orientation into relatively large holes or fissures between fibres of the cellulosic sheet material with the result that the upper surface of the coating, when dried, would not be sufficiently smooth to receive a good print impression.
It is therefore desirable to use a coating composition containing the highest possible percentage by weight of particulate silicate mineral of high aspect ratio to produce an ultra-lightweight coated paper.
A widely used method of coating webs of cellulosic material utilises apparatus which includes a spring steel blade which in use extends across the web of cellulosic material to be coated and is biased into contact with the web, the web being generally supported on a slightly resilient curved surface, such as a roll faced with an elastomeric material. The blade generally makes an acute angle with the tangent to the curved supporting surface along the line of contact of the blade with the surface and is in a trailing attitude with respect to the direction of motion of the web. For obvious reasons such a blade is known as a "trailing blade" and an apparatus using such a blade is generally known as a "trailing blade paper coating apparatus". In one method of coating cellulosic material using a trailing blade paper coating apparatus an aqueous coating composition is introduced into a trough of which the floor and back are formed by the blade and its supporting structure, the sides are formed by suitable dams, and the front of the trough is closed by the web of cellulosic material on the curved support. In another method, an aqueous coating composition is applied to the web upstream of the trailing blade by a suitable applicator, such as a rotating roll or brush in contact with the moving web or by means of spray jets. In either method the trailing blade serves to remove surplus coating composition and to smooth and level the coating. If a coating composition, which is supported on a moving web of cellulosic material and contains a high percentage by weight of particles which are predominantly of high aspect ratio, is constrained to pass at high velocity beneath a trailing blade, the coating is suddenly exposed to conditions of very high shear and, as a result of the poor rheological properties of the coating composition (by virtue of the random orientation of particles of high aspect ratio), there tend to occur sudden changes in the velocity of flow of the composition beneath the blade and in the clearance between the blade and the web with the result that the coating is unevenly applied.
It is an object of the present invention to provide an apparatus for, and a method of, applying to a cellulosic sheet material a substantially smooth and level coating, even at a small thickness, of a composition which contains a relatively high percentage by weight of particles which are predominantly of high aspect ratio.
SUMMARY OF THE INVENTION
Accordingly, in one aspect, the present invention provides a trailing blade paper coating apparatus which comprises means providing a resilient curved surface for supporting a moving web of cellulosic material, an applicator for a paper coating composition and a trailing blade which in use is biased towards and in contact with the moving web of cellulosic material, and which further includes a flexible blade mounted so that, in operation of the trailing blade paper coating apparatus, the flexible blade is in contact with a web of cellulosic material to be coated at a location which is upstream relative to the trailing blade and downstream relative to the applicator for the coating composition.
In another aspect, the present invention provides a method of coating a web of cellulosic material with a coating composition comprising a particulate pigment material and an adhesive in an aqueous medium, which method comprises applying said coating composition to the surface of a moving web of a cellulosic material, passing the web and applied coating composition between a resilient supporting member and a trailing blade one edge of which is biased towards the supporting member, characterised in that the web and its applied coating are acted upon, at a position upstream relative to the trailing blade, by a flexible blade.
The flexible blade employed in the apparatus and method of the present invention should be constructed and mounted so that when it is in contact with a web of cellulosic material its free edge flexes sufficiently to be substantially tangential to the web at the point of contact. The flexible blade is advantageously made of a plastics materials, such as polytetrafluoroethylene or poly(vinyl chloride), although an elastomeric material, such as a natural or synthetic rubber, can be used. It may also be possible to employ a thin, flexible metallic material. In one embodiment the flexible blade is retained, for example clamped, along one edge in suitable retaining means and its free edge is arranged to contact the web supported on a curved surface substantially tangentially. More generally, the flexible blade should be mounted in a manner such that it applies enough pressure to limit the weight of wet paper coating composition which is allowed to pass beneath the flexible blade to not more than 10% by weight in excess of the amount which is required to give the final desired dry coating weight. Preferably, the flexible blade is itself supported near to the retaining means by a curved former, for example a resilient bar, which may advantageous be a length of flexible, plastomeric or elastomeric tubing.
The flexible blade is preferably mounted so that, in operation, the distance between the lines of contact of the flexible blade and the trailing blade with the web of cellulosic material is such that the time taken for a fixed point on the web to travel between the two lines of contact at the normal operating speed of travel of the web is not larger than 15 milliseconds. For example, on an industrial paper coating machine which normally runs at a speed of 1500 m.min -1 (meters per minute) the time taken to travel between the two blades is 10 ms (milliseconds) if the blades are 25 cm apart. In one embodiment of the invention the trailing blade and/or the flexible blade are movable relative to each other to enable the time taken for a fixed point on the web to travel between the two lines of contact of the flexible blade and the trailing blade to be adjusted.
It is believed that the flexible blade of a trailing blade paper coating apparatus in accordance with the invention functions by applying to the coating composition on the surface of the web a gradually increasing shear which causes particles, especially those in the form of platelets having a high aspect ratio, in the coating composition to orient themselves with the plane of the platelet parallel to the surface of the web. As a result, the coating composition passing under the trailing blade has its particles preoriented and a much smoother flow of coating composition under the trailing blade is possible. It is therefore possible to use coating compositions containing pigment particles of high aspect ratio at a higher percentage by weight of pigment in the composition than is possible with conventional trailing blade coating apparatus. It is also possible to increase the pressure under which the trailing blade is biased against the resilient supporting member, and trailing blade pressures up to about twice those used in conventional trailing blade paper coating apparatus are practicable. As a result, very thin coatings having a coat weight in the range of from 2 to 3 g.m -2 per side are obtainable. A further consequence of the preorientation of the particles is that the particles, substantially all of which are oriented with the platelets parallel to the surface of the paper, pack closely together in, or bridge across, any relatively large holes or fissures between the fibres of the cellulosic material, and remain oriented by virtue of the high viscosity of the composition, with the result that a smooth, level coating having good opacity, gloss and printing properties is obtainable.
DESCRIPTION OF EMBODIMENTS
For a better understanding of the invention, and to show more clearly how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
FIG. 1 shows diagrammatically part of one embodiment of a trailing blade paper coating apparatus in accordance with the invention; and
FIGS. 2 and 3 show diagrammatically part of another embodiment of a trailing blade paper coating apparatus in accordance with the invention.
Referring first to FIG. 1, there is shown a web of paper 1 supported on a steel roll 2 which is provided with a facing 3 of an elastomeric material. The roll 2 is rotated so as to advance the web in the direction shown by the arrow 4. A flexible blade 5, made of polytetrafluoroethylene, is clamped along one edge to a supporting member 6 and the free edge 7 of the blade contacts the moving web substantially tangentially to the roll 2. Along that edge of the supporting member 6 facing the roll there is secured a length of polyethylene tubing 8, part of the curved outer surface of which supports and defines the curvature of the flexible blade 5. A trailing blade 11 made of thin spring steel is biased against the web by means not shown.
In operation, a coating composition 9, which comprises a layer lattice silicate mineral having particles of high aspect ratio and an adhesive in suspension in water, is introduced into a trough 10 which is defined by the web 1, the flexible blade 5, the supporting member 6 and two dams (not shown). The trailing blade 11 serves to remove excess coating composition and to smooth and level the coating. The distance "d" between the lines of contact of the flexible blade 5 and trailing blade 11 is 6 cm which, for a speed of travel of the web of 400 m.min -1 , gives a time of travel between the two blades of 9 ms. This is a typical spacing between the blades but many other configurations are possible although it is preferred that the time of travel of the coated web between the flexible blade and trailing blade does not exceed 15 ms.
Turning now to FIGS. 2 and 3, there is shown a coating head which has been designed for use in conjunction with a laboratory scale, trailing blade paper coating apparatus of the type described in British patent specification No. 1,032,536. The coating head comprises two side walls 12 and 13 which are held in the desired parallel relationship with one another by nut and bolt assemblies 14 in rigid tubular sleeves 15. The forward facing edges 16 of the side walls are curved to confirm to the periphery of the roll 2 (corresponding to the backing roll 4 shown in FIG. 1 of British patent specification No. 1,032,536) of the laboratory scale trailing blade paper coating apparatus and are faced with strips of poly(tetrafluoroethylene) of thickness 1.6 mm. A trailing blade 11 of thin, spring steel is clamped between steels jaws 25 attached to a substantially rectangular holder 17 which is fixed in place by means of screws 18 passing through holes 19 in the side walls. A flexible blade 5 made of polytetrafluoroethylene and having a thickness of 0.16 mm is clamped with a length of 16 mm of the blade protruding in a holder 20 of dog leg shape which is pivotally connected to the side walls by a nut and bolt assembly 26. The angle of the holder 20 is adjustable by means of a screw 21 provided with a knurled knob 22, the screw co-operating with a threaded block 23 which is fixed in place by means of a nut and bolt assembly 24. The side walls, blade holders and sleeves 15 are made from the material known as "TUFNOL" (Registered Trade Mark) which is formed by impregnating a textile material with a phenolformaldehyde resin. The sleeves 15 are made of nylon.
The invention is further illustrated by the following Examples.
EXAMPLE 1
Examples of a gravure printing base paper were coated with a rotogravure paper coating composition prepared according to the following formulation:
______________________________________ Parts byIngredient Weight______________________________________Pigment 100Sodium polyacrylate dispersing agent 0.3Self-thickening acrylic copolymer 4.8latex adhesiveSodium hydroxide to pH 9Water to appropriate fluidity______________________________________
The following four pigments were used:
A. A kaolin clay having a particle size distribution such that 6% by weight of particles had an equivalent spherical diameter larger than 10 μm, 40% by weight of particles had an equivalent spherical diameter smaller than 2 μm and 25% by weight of particles had an equivalent spherical diameter smaller than 1 μm;
B. A kaolin clay having a particle size distribution such that 4% by weight of particles had an equivalent spherical diameter larger than 10 μm, 82% by weight of particles had an equivalent spherical diameter smaller than 2 μm and 60% by weight of particles had an equivalent spherical diameter smaller than 1 μm;
C. 90% by weight of Pigment B+10% by weight of muscovite mica consisting predominantly of particles having diameters in the range from 5 μm to 50 μm; and
D. 70% by weight of Pigment B+30% by weight of the same mica as was used in Pigment C.
Samples of the base paper were coated with compositions containing each of the four pigments by means of:
Type 1. A conventional trailing blade coating head comprising a single spring steel blade; and
Type 2. A coating head according to the invention and as shown in FIGS. 2 and 3 comprising a trailing blade of thin spring steel and a flexible, preorientating blade of polytetrafluoroethylene of thickness 1.6 mm.
The coating heads were mounted on a "HELI-COATER" (Registered Trade Mark) laboratory scale paper coating apparatus of the type described in British Patent Specification No. 1,032,536 and the drum was rotated at a speed such that the paper attached to the drum passed beneath the blades at a speed of 400 meters per minute. Before coating, the percentage by weight of total dry solids in each paper coating composition was determined and the viscosity was measured by means of a Brookfield Viscometer with a spindle speed of 100 rpm. Coatings were applied to the base paper to give weights of dry coating varying in the range from about 4 to about 11 gm -2 by varying the pressure applied to bias the coating head against the drum. Each coating was thermally dried and the gloss of the dry coating was measured according to TAPPI Standard No. T480 ts-65 and the gravure printing quality was tested by the method described in the article "Realistic paper tests for various printing processes" by A Swan published in "Printing Technology" vol 13, No. 1, April 1969, pages 9-12 and in British patent specification No. 2,058,734.
Before testing, the samples of coated paper were calendered at a line pressure of 500 lb per linear inch (89 kg per cm) for 10 passes at 65° C. For each combination of coating composition and coating head there were estimated, by interpolation, the gloss and gravure printing quality results which corresponded to a dry coating weight of 7 gm -2 . In the case of gravure printing quality the lowest figure represents the best result. The results obtained are set forth in Table I below:
TABLE I______________________________________ TAPPI GravurePigment/coating % by wt Viscosity gloss printinghead combination of solids (mPa.s) units quality______________________________________A1 (comparative) 60.1 1580 43 4A2 (invention) 61.9 2480 46 2.5B1 (comparative) 56.9 1640 61 7.5B2 (invention) 58.1 2280 59 5.5C1 (comparative) 58.2 1660 54 7.5C2 (invention) 60.1 2450 57 4.5D1 (comparative) 59.1 1680 49 7.5D2 (invention) 61.2 2500 53 3______________________________________
These results show that use of the coating head in accordance with the invention makes it possible to use compositions of greater solids concentration and thus reduce the amount of water which must be thermally evaporated during drying of the coated paper. A further advantage of the higher solids concentration and thus higher viscosity is that the time during which water from the composition drains into the base paper is reduced and therefore the particles in the composition are more likely to retain the orientation given to them as they pass beneath the pre-orientating flexible blade. It can also be seen from these results that the use of the coating head of the invention gives improved gravure printing quality and, in most cases, improved gloss. These improvements become more pronounced as the proportion of high aspect ratio particles, i.e. the proportion of mica particles between about 5 μm and about 50 μm in size is increased.
EXAMPLE 2
Samples of a web offset printing base paper were coated on the laboratory scale trailing blade paper coating apparatus at a paper speed of 400 meters per minute with a composition prepared according to the following formulation:
______________________________________ Parts byIngredient weight______________________________________Pigment 100Sodium polyacrylate dispersing agent 0.3Styrene butadiene latex adhesive 12Sodium carboxymethylcellulose 1Sodium hydroxide to pH 9Water to appropriate fluidity______________________________________
The pigment comprised 90% by weight of a kaolin clay, having a particle size distribution such that 1% by weight of particles had an equivalent spherical diameter larger than 10 μm and 80% by weight of particles had an equivalent spherical diameter smaller than 2 μm, and 10% by weight of the same mica as was used in Example 1.
The pigment was coated on to samples of paper using coating heads of both Type 1 and Type 2 as described in Example 1 above. In the case of the Type 1 coating head water was added to the composition to give a viscosity of 1500 mPas as measured by means of the Brookfield Viscometer at a spindle speed of 100 rpm and the percentage by weight of total dry solids in the composition was found to be 60%. In the case of the Type 2 coating head, water was added to give a viscosity of 2000 mPas or a solids concentration of 63% by weight.
Coatings were applied at varying blade pressures to give dry coating weights in the range from about 3 to about 9 gm -2 . Each sample of coated paper was thermally dried and calendered at a line pressure of 89 kg per cm for 10 passes at 65° C. and the gloss was measured according to TAPPI Standard No. T 480 ts-65. The gloss corresponding to a dry coating weight of 5 gm -2 was found in each case by interpolation. The results obtained are set forth in Table II below:
TABLE II______________________________________Coating TAPPIhead gloss units______________________________________Type 1 (comparative) 39Type 2 (invention) 47______________________________________ | A trailing blade paper coating apparatus is disclosed which comprises means providing a resilient curved surface for supporting a moving web of cellulosic material, an applicator for a paper coating composition and a trailing blade which in use is biased towards and in contact with the moving web of cellulosic material, and which further includes a flexible blade mounted so that, in operation of the trailing blade paper coating apparatus, the flexible blade is in contact with a web of cellulosic material to be coated at a location which is upstream relative to the trailing blade and downstream relative to the applicator for the coating composition. A method is also disclosed and claimed. | 3 |
RELATED APPLICATIONS
This application claims the benefit of Korean Patent Application No. 10-2012-0133609, filed on Nov. 23, 2012, which is hereby incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
The present invention relates to a navigation system, and, more specifically, to a device and method for actively generating intersection guidance information for turning using geometry information of a map.
BACKGROUND OF THE INVENTION
The related art includes the Korean Laid-Open Patent Publication No. 10-2008-0104548, entitled “Method for guiding intersection using point of interest and navigation system thereof.” The above related art makes use of POI (Point of Interest) information to improve turning guidance information using surrounding POI information of an intersection.
FIG. 1 illustrates a block diagram of a navigation system for intersection guidance in the related art. Referring to FIG. 1 , the navigation system includes a route calculation unit 20 , a storage 30 , a user interface unit 40 , a display unit 50 , a voice output unit 60 , and a controller 70 .
The storage 30 includes map data for the whole country and a map database that constructs route guidance data associated with the map data. In this case, intersection guidance information may be generated using values that have been investigated and fixed previously. That is, when there is an intersection on the map data, the navigation system displays an arrow, for example, in an intersection area indicating a turning direction. However, the intersection guidance navigation system has a problem in that the system can not actively generate the intersection guidance information and merely provided the guidance information stored previously as it.
SUMMARY OF THE INVENTION
In view of the above, the present invention provides a device and method for actively generating intersection guidance information that is needed for a client to turn in real time by analyzing geometry data (e.g., area information of building, more specifically, polygon data, etc) on a map while providing route navigation services.
Further, the present invention provides a device and method for generating intersection guidance information, capable of storing and managing data smaller than those in the related art, by actively generating the intersection guidance information while providing a route navigation service, instead of using guidance information for intersections stored previously.
Further, the present invention provides a device and method for generating intersection guidance information based on changed environment information around the intersections so that the intersection guidance information is adaptively generated while providing the route navigation services.
In accordance with an aspect of the present invention, there is provided a device for generating intersection guidance information, which includes: a route setting unit configured to receive a route up to a destination; a candidate area detecting unit configured to search for a turning point on the searched route, and detect a surrounding area of the searched turning point as a candidate area; a candidate POI (point of interest) area detecting unit configured to detect a POI area as a candidate POI area, at least a portion of the POI area being included in the candidate area; a guidance POI area selecting unit configured to calculate distance between the candidate POI area and the turning point, search a candidate POI area whose distance calculated is shortest, and select the searched candidate POI area as a guidance POI area; and guidance information generating unit configured to generate guidance information for an intersection including the guidance POI area.
In the exemplary embodiment, wherein the guidance information further comprises at least one of a distance from a current position to the intersection, and turning direction information at the intersection.
In the exemplary embodiment, wherein the candidate area detecting unit sets the searched turning point, and a first point and a second point that are set apart from the searched turning point at a predetermined distance, and detects as a candidate area an internal area of an arbitrary closed curve that passes through all of the turning point, and the first and second points.
In the exemplary embodiment, wherein the turning direction information comprises at least one of a left turn, a right turn, a U-turn, a P-turn and a rotary turn.
In the exemplary embodiment, wherein the guidance POI area selecting unit calculates distance between the candidate POI area and the turning point, and selects as a guidance POI area a candidate POI area whose distance calculated is shortest.
In the exemplary embodiment, wherein the guidance POI area selecting unit selects the guidance POI area in consideration of at least one of a client's position, a client's moving direction and a final destination.
In the exemplary embodiment, wherein the route setting unit receives a route that is searched from an external device or a route that is searched internally and sets the searched route as input data to generate guidance information.
In the exemplary embodiment, wherein when the candidate POI area detecting unit did not detect the candidate POI area, the candidate area detecting unit sets a third point and a fourth point that are apart from the turning point at a distance determined previously, the third and fourth points being different from the first point or the second point, and detects as a candidate area an internal area of an arbitrary closed curve that passes through all of the turning point, the third point, and the fourth point.
In accordance with an embodiment of the present invention, there is provided a method for generating intersection guidance information performed by a server, which includes: searching a route up to a destination; searching for a turning point on the route to detect as a candidate area a surrounding area of the searched turning point; detecting a POI (Point Of Interest) area as a candidate POI area, at least a portion of the POI area being included in the candidate area; calculating distance between the candidate POI area and the turning point, searching for a candidate POI area whose distance calculated is shortest, and selecting the searched candidate POI area as a guidance POI area; and generating guidance information for a intersection including the guidance POI area.
In the exemplary embodiment, wherein the guidance information further comprises at least one of a distance from a current position to the intersection, and turning direction information at the intersection.
In the exemplary embodiment, wherein said detecting a surrounding area of the searched turning point as a candidate area comprises: setting the searched turning point and a first point and a second point that are set apart from the searched turning point at a predetermined distance; and detecting as a candidate area an internal area of an arbitrary closed curve that passes through all of the turning point, and the first and second points.
In the exemplary embodiment, wherein the turning direction information comprises at least one of a left turn, a right turn, a U-turn, a P-turn and a rotary turn.
In the exemplary embodiment, wherein said selecting the searched candidate POI area as a guidance POI area comprises: calculating distance between the candidate POI area and the turning point, and selecting as a guidance POI area a candidate POI area whose distance calculated is shortest.
In the exemplary embodiment, the method further comprising: when not detecting a candidate POI area in said detecting the candidate POI area, determining whether to detect a candidate POI area in order to detect the candidate area, wherein said detecting the candidate POI area comprises detecting another candidate area different from the candidate area detected previously.
In the exemplary embodiment, wherein said selecting the searched candidate POI area as a guidance POI area comprises: selecting a guidance POI area in consideration of at least one of a client's position, a client's moving direction and a final destination.
As set for the above, the present invention may provide a device and method for generating intersection guidance information that is needed for a client to turn in real time by analyzing geometry data on a map while providing route navigation services.
Further, the present invention may provide a device and method for generating intersection guidance information, capable of storing and managing data smaller than those in the art, by generating the intersection guidance information while providing a route navigation service, without using guidance information for intersections stored previously.
In addition, the present invention may provide a device and method for generating intersection guidance information based on changed environment information around the intersections since the guidance information of intersections is generated while providing the route navigation services.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of embodiments given in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a block diagram of a navigation system for an intersection guidance in the related art;
FIG. 2 illustrates a block diagram of a device for generating intersection guidance information in accordance with an exemplary embodiment of the present invention;
FIG. 3 is a flowchart illustrating a method for generating intersection guidance information in accordance with an exemplary embodiment of the present invention;
FIG. 4 shows a searched route provided by a device for generating intersection guidance information in accordance with an exemplary embodiment of the present invention;
FIG. 5 shows a candidate area provided by a device for generating intersection guidance information in accordance with an exemplary embodiment of the present invention;
FIG. 6 shows candidate POI areas provided by a device for generating intersection guidance information in accordance with an exemplary embodiment of the present invention; and
FIG. 7 shows candidate areas detected by a device for generating intersection guidance information in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The advantages and features of exemplary embodiments of the present invention and methods of accomplishing them will be clearly understood from the following description of the embodiments taken in conjunction with the accompanying drawings. However, the present invention is not limited to those embodiments and may be implemented in various forms. It should be noted that the embodiments are provided to make a full disclosure and also to allow those skilled in the art to know the full scope of the present invention. Meanwhile, it should be noted that the terminologies used herein is merely intended to describe the embodiments and do not limit the scope of the present invention.
A device and method for generating intersection guidance information in accordance with an exemplary embodiment of the present invention relates to a device and method for generating guidance information utilizing POI information around intersections when generating information to guide turning points on intersections among links of searched route. Since current maps around intersections are used without using guidance information stored previously when providing route guidance services, it is possible to provide guidance information changed as buildings around intersections and situations are changed.
FIG. 2 illustrates a block diagram of a device 100 for generating intersection guidance information in accordance with an exemplary embodiment of the present invention.
The device 100 for generating intersection guidance information includes a route setting unit 110 , a candidate area detecting unit 120 , a candidate POI area detection area 130 , a guidance POI area selecting unit 140 , and a guidance information generating unit 150 .
The route setting unit 110 receives a route up to an intended destination and sets it as input data to generate guidance information. The route may be transferred from external devices or may be generated inside the device. The external devices used to transfer searched route may be a navigation system, a smart phone and a PC. The results produced from the route navigation may be provided as illustrated in FIG. 4 together with a map.
The candidate area detecting unit 120 searches a turning point at an intersection on the searched route, and detects surroundings of the turning point as a candidate area. The detection of the candidate area is intended to generate intersection guidance information using POI areas, which are detected by the candidate POI area detecting unit 130 based on geometry data on a map, within the detected candidate area. The detected candidate area may be an area shaped in a triangle whose one apex becomes the turning point and whose two segments becomes both routes connected to the turning point. Further, the detected candidate area may be an internal area of an arbitrary closed curve (for example, a triangle, a circle, an ellipse, a lozenge, a tetragon, etc) which passes through both of two points that are apart from the turning point at a predetermined distance.
When the candidate POI area is not detected through the candidate POI area detecting unit 130 , the candidate area may be newly set by differently setting the two points that are apart from the turning point at a predetermined distance.
The candidate POI area detecting unit 130 detects one or more POI areas within a candidate area. The candidate POI area detecting unit 130 detects one or more POI areas that contained in the boundary of the candidate area or partially overlaps the candidate area, among the POI areas within the candidate area. The detected candidate POI area may be plural. When at least two POIs are detected, one POI area may be selected in consideration of a client's current position (e.g., driver's current position). The candidate POI area detecting unit 130 may detect candidate POI areas 610 to 640 as illustrated in FIG. 6 . When the candidate POI areas are not detected at all, it may be performed to detect candidate area again.
The guidance POI area selecting unit 140 selects a guidance POI area used to generate intersection guidance information. The guidance POI area selecting unit 140 selects as a guidance POI area a POI area nearest to a turning point among the candidate POI area detected by the candidate POI area detecting unit 130 . The POI information of the guidance POI area selected by the guidance POI area selecting unit 140 is used to generate intersection guidance information.
When at least two POI areas are selected by the guidance POI area selecting unit 140 , one POI area may be selected as a guidance POI area in consideration of a client's position, a moving direction and a final destination.
The guidance information generating unit 150 generates guidance information using POI information of the guidance POI area. The guidance information may include guidance POI area information and turning direction information, for example, such as ‘turn right centering around a guidance POI area at a guidance POI area 100 m ahead’. The turning direction information may be a right turn, a left turn, a P-turn, a U-turn, a rotary turn, etc. The guidance information generated may be guided in a voice message or a text message.
FIG. 3 is a flowchart illustrating a method for generating intersection guidance information in accordance with an exemplary embodiment of the present invention.
The method for generating intersection guidance information may include steps of searching routes (Block S 320 ), detecting a candidate area (Block S 330 ), detecting a candidate POI area (Block S 340 ), determining whether to detect a candidate POI area (Block S 350 ), selecting a guidance POI area (Block S 360 ), and generating guidance information (Block S 370 ).
At the step of searching routes (Block S 320 ), a server or local device searches routes up to a destination. The searched route is provided as illustrated in FIGS. 4 and 7 together with a map.
The step of detecting a candidate area (Block S 330 ) includes detecting a candidate area including a POI area from a map before detecting POI area information that can be used to generate guidance information. The candidate area refers to a surrounding area of a turning point, which may be a triangle area of which an apex is the turning point and whose two segments are routes connected to the turning point. Alternatively, the candidate area may be an internal area of an arbitrary closed curve that passes through all of arbitrary two points that are apart from the turning point at predetermined distances and a turning point.
As illustrated in FIG. 5 , reference numerals 500 and 510 may be candidate areas with respect to each turning point.
The step of detecting a candidate POI area (Block S 340 ) includes detecting a candidate POI area that overlaps the candidate or is a space within the candidate area. The candidate POI area may be a space that is wholly included in the candidate area or whose portion is included in the candidate area. The step of detecting the candidate POI area (Block S 340 ) includes detecting a candidate POI area as illustrated in FIG. 6 . The number of the detected candidate POI areas may be 0 or more.
The step of determining whether to detect the candidate POI area (Block S 350 ) includes determining whether the candidate POI area was detected. At the step of determining whether to detect the candidate POI area (Block S 350 ), when the number of the candidate POI area is zero, the step proceeds to the step of detecting a candidate area (Block S 330 ) where a candidate area may be detected again. In this case, it may be is possible to set as a candidate area another area that is not overlapped with an internal area of the closed curve mentioned above.
The step of selecting the guidance POI area (Block S 360 ) includes selecting a guidance POI area used to generate intersection guidance information. The step of selecting a guidance POI area (Block S 360 ) includes selecting as a guidance POI area a candidate POI area that is nearest to the turning point among the candidate POI areas. The step of selecting the guidance POI area (Block S 360 ) may include selecting the guidance POI area using distance between the candidate POI area and the turning point. The step of selecting the guidance POI area (Block S 360 ) may include selecting the guidance POI area using distance between each apex or center and the turning point.
The step of selecting the guidance POI area (Block S 360 ) may include selecting as the guidance POI area one POI area in consideration of a client's position, a moving direction and a final destination when at least two POI areas are selected.
The step of generating the guidance information (Block S 370 ) includes generating guidance information using POI information of the POI area and turning direction information at an intersection. The turning direction information of the guidance POI area may include a right turn, a left turn, a rotary turn, a P-turn, and a U-turn.
The intersection guidance information generated by the device and method for generating guidance information in accordance with an exemplary embodiment of the present invention may be utilized in a navigation system, a smart phone, an Internet path finding Website, and the like. The intersection guidance information may be provided in a voice message or text message.
FIGS. 4 to 6 illustrate searched routes, candidate areas and candidate POI areas provided by a device for generating intersection guidance information in accordance with an exemplary embodiment of the present invention.
Referring to FIG. 4 , the searched route 400 may be illustrated together with a map. As a result of analyzing the searched route as illustrated, a turning point-1 410 and a turning point-2 420 are searched for.
Referring to FIG. 5 , two points that are apart from the detected turning point-1 410 at a predetermined distance are selected, and an internal area of an arbitrary closed curve that passes through both turning points-1 and -2 is detected as a candidate area. The distance between the turning points 1 and 2 may be an arbitrary positive number.
Spaces that have a portion overlapped with the detected candidate area 500 are detected as candidate POI areas. Referring to FIG. 6 , two candidate POI areas 630 and 640 are detected.
Distances between each of the candidate POI areas 630 and 640 and a turning point 410 are calculated. Distances between each apex or center of the candidate POI areas 630 and 640 and the turning point-1 410 may be calculated.
FIG. 7 shows candidate areas detected by a device for generating intersection guidance information in accordance with an exemplary embodiment of the present invention. Here, the arrow indicates a route, and the route includes a turning point 700 . The device and method for generating intersection guidance information in accordance with the present invention detects a candidate area again when a candidate POI area is not detected. In this case, as illustrated in FIG. 7 , the candidate area may be detected in the order of 710 , 720 , 730 and 740 . Further, the candidate area may be detected in the order of 710 , 740 , 730 , and 720 . There is no limitation in the order of candidate area detection. The shape of the candidate area is not limited to a tetragon but may be an arbitrary closed curve (e.g., a circle, an ellipse, a triangle, a lozenge, a trapezoid, etc).
The device and method for generating intersection guidance information in accordance with an exemplary embodiment of the present invention may be utilized in a map indicating an interior space as well as a common map. The POI area refers to a space divided logically according to usage in a map, which indicates an interior space, or a space divided into a shop, a bank, an office, etc. in a map indicating an exterior space.
Further, in the device and method for generating intersection guidance information in accordance with an exemplary embodiment of the present invention, the guidance POI area is not limited to shops and stores positioned at 1st floor but may be selected as POI information of shops and stores positioned at 2nd floor or higher.
While the invention has been shown and described with respect to the embodiments, the present invention is not limited thereto. It will be understood by those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims. | A device for generating intersection guidance information, which includes: a route setting unit configured to receive a route up to a destination; a candidate area detecting unit configured to search for a turning point on the searched route, and detect a surrounding area of the searched turning point as a candidate area; a candidate POI area detecting unit configured to detect a POI area as a candidate POI area, at least a portion of the POI area being included in the candidate area; a guidance POI area selecting unit configured to calculate distance between the candidate POI area and the turning point, search a candidate POI area whose distance calculated is shortest, and select the searched candidate POI area as a guidance POI area. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority of Korean Patent Application No. 10-2012-0157254, filed on Dec. 28, 2012, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field
[0003] Exemplary embodiments of the present invention relate to semiconductor design technology, and more particularly, to a pulse signal generation circuit for adjusting a pulse width of an input pulse signal and outputting an output pulse signal having the changed pulse width.
[0004] 2. Description of the Related Art
[0005] A semiconductor memory device, such as double data rate synchronous DRAM (DDR SDRAM), includes a variety of internal circuits for performing a variety of operations. One of the internal circuits is a pulse signal generation circuit for generating a pulse signal.
[0006] FIG. 1 is a circuit diagram of a conventional pulse signal generation circuit.
[0007] Referring to FIG. 1 , the pulse signal generation circuit includes a delay unit 110 and an output unit 120 .
[0008] The delay unit 110 incorporates a predetermined amount of delay into an input pulse signal SIG_IN and outputs a delayed signal. The amount of delay incorporated by the delay unit 110 is one of important factors that determine a pulse width of an output pulse signal SIG_OUT. The output unit 120 generates the output pulse signal SIG_OUT in response to a signal SIG_A inverted from the input pulse signal SIG_IN and the signal SIG_B from the delay unit 110 .
[0009] FIG. 2 is a timing diagram illustrating the operation of the pulse signal generation circuit of FIG. 1 , where the amount of delay of the delay unit 110 is indicated by ‘DY’.
[0010] Referring to FIGS. 1 and 2 , the delay unit 110 delays the input pulse signal SIG_IN by the amount of delay DY and outputs the signal ‘SIG_B’. The output pulse signal SIG_OUT is generated in response to the signal ‘SIG_A’ and the signal ‘SIG_B’. As can be seen from the figure, the pulse width of the output pulse signal SIG_OUT is equal to the pulse width of the input pulse signal SIG_IN plus the amount of delay DY.
[0011] With the recent development of the process and design technologies of semiconductor memory devices, a semiconductor memory device operates at a very high speed, which requires a clock signal having a high frequency. This means that the pulse width of the clock signal needs to become smaller. A clock signal provides a reference in the operation to a semiconductor memory device. That is, a semiconductor memory device internally generates a pulse signal with reference to the pulse width of a clock signal.
[0012] As described above, as the pulse width of a clock signal becomes smaller, the pulse width of a pulse signal becomes smaller. Accordingly, the following concerns arise.
[0013] According to prior art, for generation of a pulse signal, the amount of delay DY of the delay unit 110 has to be smaller than the pulse width of the input pulse signal SIG_IN. If the amount of delay DY of the delay unit 110 is greater than the pulse width of the input pulse signal SIG_IN, the output pulse signal SIG_OUT has two pulses. For this reason, the amount of delay DY must be designed very precisely for generation of the pulse signal as the pulse width of a clock signal becomes smaller.
[0014] However, the design of a pulse signal generation circuit is becoming more difficult because an influence due to a PVT (process, voltage, and temperature) and a gradual decrease in the pulse width of the input pulse signal SIG_IN should be reflected to a design of an inverter chain in the delay unit.
SUMMARY
[0015] Embodiments of the present invention are directed to providing a pulse signal generation circuit capable of adjusting a pulse width of an output pulse signal in response to variation of a pulse width of an input pulse signal.
[0016] In accordance with an embodiment of the present invention, a pulse signal generation circuit may include a control signal generator configured to generate at least one control signal according to a pulse width of a input pulse signal, and a pulse signal generator configured to control a pulse width of an input pulse signal in response to a control signal and to generate an output pulse signal with the controlled pulse width. The control signal controls the pulse width of the output pulse signal.
[0017] The pulse signal generator preferably may include a plurality of delay units configured to incorporate a preset delay time into the input pulse signal and a pulse output unit configured to output the output pulse signal in response to output signals of the plurality of delay units.
[0018] In accordance with another embodiment of the present invention, a pulse signal generation circuit may include a first edge detection unit configured to detect the deactivation edge of an input pulse signal having a pulse width defined by an activation edge and the deactivation edge, a shifting unit configured to shift the input pulse signal in response to the output signal of the first edge detection unit, a second edge detection unit configured to detect the deactivation edge of the output signal of the shifting unit, and a pulse generation unit configured to generate an output pulse signal in response to the input pulse signal and the output signal of the second edge detection unit.
[0019] The pulse generation unit preferably may be set in response to the input pulse signal and reset in response to the output signal of the second edge detection unit.
[0020] In accordance with yet another embodiment of the present invention, an operating method of a pulse signal generation circuit may include detecting a second activation edge of an input pulse signal having a pulse width defined by a first activation edge and the second activation edge, delaying the input pulse signal by a time corresponding to the second activation edge, and generating an output pulse signal having a pulse width defined by the input pulse signal and a result signal by the delaying of the input pulse signal by a time corresponding to the second activation edge.
[0021] The delaying of the input pulse signal by a time corresponding to the second activation edge preferably may shift the input pulse signal by a time corresponding to the second activation edge.
[0022] In accordance with yet another embodiment of the present invention, a pulse signal generation circuit may include a pulse signal generator configured to sequentially shift an input pulse signal by a preset amount, and to generate an output pulse signal based on the input pulse signal and at least one delay signal that is a sequentially shifted version of the input pulse signal, and a control signal generator configured to control the sequential shift based on the deactivation edge of the input pulse signal.
[0023] The pulse signal generation circuit in accordance with one embodiment of the present invention may generate a stable output pulse signal by adjusting a pulse width of an output pulse signal in response to a pulse width of an input pulse signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a circuit diagram of a conventional pulse signal generation circuit.
[0025] FIG. 2 is a timing diagram illustrating the operation of the pulse signal generation circuit shown in FIG. 1 .
[0026] FIG. 3 is a block diagram of a pulse signal generation circuit in accordance with an embodiment of the present invention.
[0027] FIG. 4 is a timing diagram illustrating the operation of the pulse signal generation circuit shown in FIG. 3 .
[0028] FIG. 5 is a circuit diagram illustrating a rising/falling edge detection unit shown in FIG. 4 .
[0029] FIG. 6 is a circuit diagram illustrating a rising edge detection unit shown in FIG. 4 .
[0030] FIG. 7 is a circuit diagram illustrating an activation section control unit shown in FIG. 4 .
[0031] FIG. 8 is a circuit diagram illustrating an activation control unit shown in FIG. 4 .
[0032] FIG. 9 is a block diagram illustrating a pulse signal generation circuit in accordance with another embodiment of the present invention.
[0033] FIG. 10 is a timing diagram illustrating the operation of the pulse signal generation circuit show in FIG. 9 .
DETAILED DESCRIPTION
[0034] Exemplary embodiments of the present invention will be described below in more detail with reference to the accompanying drawings. The present invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. Throughout the disclosure, reference numerals correspond directly to the like numbered parts in the various figures and embodiments of the present invention. In addition, a singular form may include a plural form as long as it is not specifically mentioned in a sentence.
[0035] FIG. 3 is a block diagram of a pulse signal generation circuit in accordance with an embodiment of the present invention.
[0036] Referring to FIG. 3 , the pulse signal generation circuit includes a pulse signal generator 310 and a control signal generator 320 .
[0037] The pulse signal generator 310 generates an output pulse signal SIG_OUT in response to a plurality of activation control signals e.g. SIG_EN 1 , SIG_EN 2 , and SIG_EN 3 (hereinafter referred as SIG_EN 1 , SIG_EN 2 , and SIG_EN 3 ) by controlling the pulse width of an input pulse signal SIG_IN. The control signal generator 320 generates the plurality of activation control signals SIG_EN 1 , SIG_EN 2 , and SIG_EN 3 that are activated based on rising and falling edge of the input pulse signal SIG_IN.
[0038] The pulse signal generator 310 includes a plurality of delay units 311 for incorporating a preset delay time into the input pulse signal SIG_IN and a pulse output unit 312 for outputting the output pulse signal SIG_OUT based on the output signals e.g. SIG_N 2 and SIG_N 3 (hereinafter referred as SIG_N 2 and SIG_N 3 ) of the delay unit 311 and the input pulse signal SIG_IN.
[0039] The control signal generator 320 generates the activation control signals SIG_EN 2 and SIG_EN 3 for controlling the pulse signal generator 310 and includes a first control signal generation unit 321 for generating the activation control signal SIG_EN 1 , a second control signal generation unit 322 for generating the second activation control signal SIG_EN 2 , and a third control signal generation unit 323 for generating the third activation control signal SIG_EN 3 . The structures and operations of the first to third control signal generation units 321 , 322 , and 323 are described in detail with reference to FIGS. 5 to 8 .
[0040] FIG. 4 is a timing diagram illustrating the operation of the pulse signal generation circuit shown in FIG. 3 .
[0041] Referring to FIG. 4 , when the input pulse signal SIG_IN is inputted, a rising/falling edge detection unit 321 A generates a first rising detection signal SIG_R 1 according to the rising edge of the input pulse signal SIG_IN and generates a first falling detection signal SIG_F 1 according to the falling edge of the input pulse signal SIG_IN. An activation section control unit 321 B shifts the activation control signal SIG_EN 1 from a logic ‘LOW’ to a logic ‘HIGH’ in response to the first falling detection signal SIG_F 1 , and from a logic ‘HIGH’ to a logic ‘LOW’ in response to the first rising detection signal SIG_R 1 . The other activation control units 322 B and 323 B are reset in response to the first rising detection signal SIG_R 1 . That is, the second and third activation control signals SIG_EN 2 and SIG_EN 3 outputted from the activation control units 322 B and 323 B shift to a logic ‘HIGH’.
[0042] Meanwhile, the input pulse signal SIG_IN is delayed by a first delay unit 311 A by a preset time and outputted as an output signal SIG_N 2 to the next delay unit or a second delay unit 311 B. A rising edge detection unit 322 A generates a second rising detection signal SIG_R 2 according to the rising edge of the output signal SIG_N 2 from the first delay unit 311 A at which the activation control signal SIG_EN 1 inputted to the activation control unit 322 B maintains a logic ‘LOW’, and the second activation control signal SIG_EN 2 generated from the activation control unit 322 B maintains a logic ‘HIGH’. Accordingly, a second delay unit 311 B transfers the delayed input pulse signal SIG_IN or an output signal SIG_N 3 from the first delay unit 311 A to a next stage with another preset delay time.
[0043] A series of the operations described above are performed until a time point of the falling edge of the input pulse signal SIG_IN. The output pulse signal SIG_OUT is generated in response to the output signals SIG_N 2 , SIG_N 3 , SIG_N 4 and SIG_N 5 that are generated during the activation of the input pulse signal SIG_IN. The pulse signal generation circuit in accordance with one embodiment of the present invention may detect the falling edge of the input pulse signal SIG_IN and generate the output pulse signal SIG_OUT having a pulse width based on a result of the detection, which means that the pulse width of the output pulse signal SIG_OUT according to the embodiment of the present invention may be adjusted in response to variation of the pulse width of the input pulse signal SIG_IN.
[0044] FIG. 5 is a circuit diagram of the rising/falling edge detection unit 321 A shown in FIG. 4 .
[0045] Referring to FIG. 5 , the rising/falling edge detection unit 321 A generates the first rising detection signal SIG_R 1 having a predetermined pulse width according to the rising edge of the input pulse signal SIG_IN and generates the first falling detection signal SIG_F 1 having a predetermined pulse width according to the falling edge of the input pulse signal SIG_IN.
[0046] FIG. 6 is a circuit diagram of the rising edge detection unit 322 A shown in FIG. 4 . The rising edge detection unit 322 A has substantially the same structure and operation as each of the rising edge detection units of the plural control signal generators shown as an example 322 , and 323 shown in FIG. 4 .
[0047] Referring to FIG. 6 , the rising edge detection unit 322 A generates the second rising detection signal SIG_R 2 having a predetermined pulse width according to the rising edge of the output signal SIG_N 2 inputted from the first delay unit 311 A.
[0048] FIG. 7 is a circuit diagram of the activation section control unit 321 B shown in FIG. 4 .
[0049] Referring to FIG. 7 , the activation section control unit 321 B generates the activation control signal SIG_EN 1 that shifts to a logic ‘LOW’ in response to the first rising detection signal SIG_R 1 and shifts to a logic ‘HIGH’ in response to the first falling detection signal SIG_F 1 .
[0050] FIG. 8 is a circuit diagram of the activation control unit 322 B shown in FIG. 4 . The activation control unit 322 B has the same structure and operation as each of the activation control units of the plural control signal generators shown as an example 322 and 323 in FIG. 4 .
[0051] Referring to FIG. 8 , the activation control unit 322 B generates the second activation control signal SIG_EN 2 that shifts to a logic ‘HIGH’ in response to the first rising detection signal SIG_R 1 and shifts to a logic ‘LOW’ in response to the activation control signal SIG_EN 1 or the second rising detection signal SIG_R 2 .
[0052] FIG. 9 is a block diagram of a pulse signal generation circuit in accordance with another embodiment of the present invention.
[0053] Referring to FIG. 9 , the pulse signal generation circuit includes a first edge detection unit 910 , a shifting unit 920 , a second edge detection unit 930 , and a pulse generation unit 940 .
[0054] The first edge detection unit 910 generates a first falling detection signal SIG_F 1 according to the falling edge of an input pulse signal SIG_IN. The shifting unit 920 shifts the input pulse signal SIG_IN with preset amount of shift in response to the first falling detection signal SIG_F 1 to generate the shifted input pulse signal or a output signal SIG_S. The second edge detection unit 930 generates a second falling detection signal F 2 according to the falling edge of the output signal SIG_S of the shifting unit 920 . The pulse generation unit 940 generates an output pulse signal SIG_OUT in response to the input pulse signal SIG_IN and the second falling detection signal F 2 .
[0055] FIG. 10 is a timing diagram illustrating the operation of the pulse signal generation circuit shown in FIG. 9 .
[0056] Referring to FIGS. 9 and 10 , first, the first edge detection unit 910 to which the input pulse signal SIG_IN is inputted generates the first falling detection signal SIG_F 1 according to the falling edge of the input pulse signal SIG_IN. The shifting unit 920 shifts the input pulse signal SIG_IN with preset amount of shift in response to the first falling detection signal SIG_F 1 . The second edge detection unit 930 generates the second falling detection signal F 2 according to the falling edge of the output signal SIG_S of the shifting unit 920 .
[0057] The pulse generation unit 940 generates the output pulse signal SIG_OUT that is set to a logic ‘HIGH’ in response to the rising edge of the input pulse signal SIG_IN, and reset to a logic ‘LOW’ in response to the second falling detection signal F 2 .
[0058] The pulse signal generation circuit in accordance with the present embodiment of the present invention may delay the input pulse signal SIG_IN through a shifting operation by the falling edge of the input pulse signal SIG_IN and generate the output pulse signal SIG_OUT by adding a pulse signal, which is generated through the delay, to the input pulse signal SIG_IN.
[0059] As described above, the pulse signal generation circuit in accordance with one embodiment of the present invention may control the pulse width of the output pulse signal SIG_OUT by a pulse width of the input pulse signal SIG_IN. Accordingly, even when the input pulse signal SIG_IN has a small pulse width, the output pulse signal SIG_OUT may be stably generated.
[0060] Accordingly, there may be advantages in that a stable output pulse signal may be generated and a semiconductor device using a stable output pulse signal may secure a reliable circuit operation.
[0061] An operation of the pulse signal generation circuit in accordance with an embodiment of the present invention may include a step of detecting a second activation edge of an input pulse signal SIG_IN having a pulse width defined by a first activation edge and the second activation edge, a step of delaying the input pulse signal SIG_IN by a time corresponding to the second activation edge, and a step of generating an output pulse signal SIG_OUT having a pulse width defined by the input pulse signal SIG_IN and an output signal in the delaying of the input pulse signal SIG_IN by a time corresponding to the second activation edge. The pulse width of the output pulse signal SIG_OUT may be longer than the pulse width of the input pulse signal SIG_IN. At the step of delaying the input pulse signal SIG_IN, the input pulse signal SIG_IN may be shifted by a time corresponding to the second activation edge.
[0062] The locations and types of the logic gates and the transistors illustrated in the aforementioned embodiments may be differently implemented depending on the polarity of an input signal.
[0063] While the present invention has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. | The present invention relates to a pulse signal generation circuit for changing a pulse width of an input pulse signal and outputting an output pulse signal having the changed pulse width. In an aspect, the pulse signal generation circuit may include a control signal generator configured to generate at least one control signal according to a pulse width of a input pulse signal and a pulse signal generator configured to control a pulse width of an input pulse signal in response to a control signal and to generate an output pulse signal with the controlled pulse width. The control signal controls the pulse width of the output pulse signal. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Under 35 U.S.C. 120, this application is a Continuation application and claims priority to U.S. application Ser. No. 14/555,521, filed Nov. 26, 2014, entitled “THEFT DETERRENT DEVICE AND METHOD OF USE,” which claims priority to U.S. Provisional Patent Application No. 62/032,499 by co-inventors Shahriar Ilislamloo and Andisheh Sarabi, filed on Aug. 1, 2014, entitled “Method and Apparatus for Protecting a Portable Device”, all of which are incorporated herein by reference in their entireties.
[0002] This application is related to U.S. patent application Ser. No. ______ (Docket No. 5469P), filed on Nov. 26, 2014, entitled “THEFT DETERRENT DEVICE AND METHOD OF USE”, and U.S. patent application Ser. No. ______ (Docket No. 5469C), filed on Dec. 17, 2015, entitled “THEFT DETERRENT DEVICE AND METHOD OF USE”, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0003] The present invention relates generally to protecting a device against tampering or theft and more particularly to theft deterrence for protecting a device against tampering or theft.
BACKGROUND OF THE INVENTION
[0004] Theft deterrent devices have become increasingly popular for protecting devices from intrusion. In large part, this is due to the variety and wide scope of applications offered for use by portable devices in addition to smaller form factors. Costly portable devices, such as electronics, are particularly vulnerable because they are transportable yet they often carry store users' private and sensitive information that if fallen into the wrong hands can have devastating effects, such as identity theft. On the other hand, the convenient portability of devices undesirably contributes to the ease of unwarranted intrusion, theft, or intentional and unintentional tampering. Anti-tampering or anti-deterrent techniques are therefore required.
[0005] Currently, theft and/or tampering-deterrent devices do not serve their purpose well. They tend to be ineffective in that they can be easily bypassed, inflexible in that their use is limited, and unreliable. They often fail to alert users of tampering and/or theft because simply stated, they lack adequate capability. For example, by the time the user is alerted of the loss of its device, the portable device (or object) has long been taken or already damaged.
[0006] Security-enhancement devices are generally best suited for a particular type of device and lack universal applicability in protecting different types of portable devices. Security devices that offer a suitable measure of protection tend to be large in size, unreliable, and often too inconvenient to be useful to the average individual.
[0007] Therefore, the need arises for a theft and tampering-deterrent device to protect a user's portable device (or object) from damage, tampering, and/or theft.
SUMMARY OF THE INVENTION
[0008] A portable theft deterrent device is disclosed. The theft deterrent device comprises a lock detection mechanism. The lock detection mechanism includes a plurality of connectors and an opening therethrough. The lock detection mechanism includes a keypad. The keypad enables and disables the lock detection mechanism when a correct key code is entered. The lock detection mechanism includes a first active circuit therein coupled to the plurality of connectors. Wherein when the lock detection mechanism is coupled to an electrical path via at least one connector of the plurality of connectors and the first active circuit detects an interruption in the electrical flow in the electrical path, the lock detection mechanism provides an alert.
[0009] These and other objects and advantages of a system and method in accordance with the present invention will become apparent to those skilled in the art after having read the following detailed description of the various embodiments illustrated in the several figures of the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows an anti-theft/tampering device 10 , in accordance with an embodiment.
[0011] FIG. 2 shows further details of the device 10 with the key 14 shown detached from the lock 12 .
[0012] FIG. 3 shows one of numerous applications of the device 10 , in accordance with a method and embodiment.
[0013] FIG. 4 shows, in conceptual form, a high-level block diagram of relevant portions of the internal structures of the lock 12 and key 14 , in accordance with an embodiment.
[0014] FIGS. 5 and 6 show a flow chart of some of the relevant steps performed by the lock and key for handshaking.
[0015] FIGS. 7, 8 a , 8 b , 9 , 11 a , 11 b , 12 a and 12 b show various applications of the device 10 , in accordance with methods and embodiments.
[0016] FIG. 10 a shows a cross sectional side view of the inside of the lock 12 essentially without a detection feature.
[0017] FIG. 10 b shows a cross sectional side view of the inside of the lock 12 with a tampering detection feature. FIG. 10 c shows an isolated view of the detection feature.
[0018] FIG. 13-15 show flow charts of some of the relevant operational steps performed by the lock and key.
[0019] FIG. 16 shows exemplary screenshots on a mobile device of various parameters and status reported by the device 10 .
DETAILED DESCRIPTION
[0020] The present invention relates generally to protecting a user object against tampering or theft and more particularly to protecting a portable user object against tampering or theft. A portable user object in one embodiment could comprise an electronic device such as laptop, smart phone, digital camera, hand held television, recorder, tablet, phablet or the like. In another embodiment the portable user object could comprise any object with an opening such as luggage, briefcase and the like. In the following description of the embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration of the specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized because structural changes may be made without departing from the scope of the present invention. It should be noted that the figures discussed herein are not drawn to scale and thicknesses of lines are not indicative of actual sizes.
[0021] A deterrent device, shown, discussed and contemplated using the various illustrative embodiments of the invention, can be classified by the following: the manner in which such a device is anchored; the type of object such a device protects; the type of connections between such a device and the object and the method of alerting a user of such a device of undesirable intrusion, such as theft tampering or theft attempts.
[0022] Various embodiments are generally made of two distinct physical parts, an activity-deterrent notification lock and a user monitor key that when physically and communicatively coupled together, effectively protect a host of portable devices (or objects) using an anchoring technique.
[0023] The deterrent devices of the various embodiments protect a user's portable device against tampering or theft by use of a deterrent notification lock and in some embodiments, a user monitoring key. The deterrent notification lock can operate work as a standalone unit or in conjunction with the user monitoring key, which notifies the user of the status of the device being protected. The deterrent notification lock is either directly or virtually secured to the device being protected. This lock is also separately or in conjunction with securing the device, anchored to a relatively unmovable object to anchor the device being protected to a relatively unmovable object. The anchoring can be performed virtually, in some embodiments.
[0024] Once the deterrent lock is anchored and the device being protected is secured by the deterrent notification lock, the user is notified generally of the change-in-location (or lack thereof) or the change-in-status of the device via the user monitoring key and/or locally by its own alert system. Further, the user can be alerted in the event of the strength of the communication signal between lock and key becoming degraded. The degradation can occur due to distance between the lock and the key or low battery/power or any other interference such as noise. The unintentional leaving of the device behind will trigger the notification due to the increase in the distance between the lock and the key. The user can also be notified of any tampering of the device being protected. In the case where the deterrent lock is anchored and the device being protected is secured through the deterrent notification lock without the use of the user monitoring key, the tampering and deterrence are still reported locally.
[0025] A user can further be notified of tampering and attempted theft through a remote connection, such as through the Internet.
[0026] In some embodiments, the deterrent notification lock operates as a standalone unit, without the user monitoring key. In such embodiments, the user is alerted of tampering attempts by a sound, such as a beep, horn or the like when in local vicinity of the device but at the price of lowered security relative to the above scenario. In other embodiments, any malfunction of the lock, either through failure or outside tampering, is detected by the user monitoring key while in the case presented above, the user monitoring key cannot necessarily detect failure or tampering.
[0027] In some embodiments, instead of a dedicated device, such as the user monitoring key, a general-purpose device may be employed to monitor the device being protected, such as a mobile or smart phone. In this case, the phone communicates using standard wireless/wired communication means, such as Bluetooth or a cable connection.
[0028] Portable devices that are electrically-powered (active devices), such as without limitation, computers and phones, in addition to non-powered devices (passive devices), such as without limitation, luggage and briefcases, are effectively, reliably, and flexibly secured using the anchoring technique of the various methods and embodiments.
[0029] Alternatively, a number of portable devices that are physically and/or electrically connected to each other are secured.
[0030] Use of the deterrent device, in certain configurations and in conjunction with other devices, expands beyond the scope of security and protection measures. As an example, electrically-powered devices, such as but not limited to, smart phones are not only protected but can also be charged using the deterrent device, according to various embodiments and associated methods.
[0031] Furthermore, in an illustrated embodiment, shown and discussed below, the user monitoring key securely communicates and remotely interfaces with the lock. The user monitoring key can remotely interact with the user through a network. The network could be either a public or private such as the worldwide web. For example, an alarm, an indicator or any other suitable means of alerting can be used by the key and the lock to inform those in close proximity and alert a remotely-located user of an undesirable activity.
[0032] In accordance with methods and apparatus of various embodiments, to prevent tampering, the user is notified of disturbance to the object being protected, i.e. the protected device. The same holds true for disturbance to the site in which the object is being remotely protected.
[0033] In alternate embodiments, rather than protection and security, certain environmental parameters may be monitored by the deterrent device, parameters such as temperature, humidity, fire or other types of factors-of-interest that are appropriate for tracking and monitoring. Results of such monitoring can be reported to an externally situated device, such as a smart phone, computer, or any other remotely or locally-situated monitor.
[0034] Other exemplary applications of the deterrent device are protection of peripheral devices such as mouse or keypad of a corresponding laptop or the laptop itself, whether by (cable) wire or wirelessly. Undesired changes to protected devices, such as tampering by un-plugging the mouse or keyboard or typing on the keyboard or attaching a new peripheral device or the movement of the mouse, is detected through wire or wireless transmission and can be reported accordingly.
[0035] Out-of-range detection is yet another application of embodiments of the deterrent device. Out-of-range detection is done by loss of communication or reduction of signal strength below a tolerable level between the key and the lock, or malfunctioning of either one. Alternatively, a threshold may be programmably (or statically) set below which communication between the lock and the key is considered effectively lost. The inability of the key and the lock to properly communicate with each other is typically reported to the user by the key, and in some embodiments, by the lock. The inability of the key and the lock to properly communicate with each other can be due to low signal strength or battery outage or the distance between the lock and the key or some noise interference or a combination of the above. Since the tampering with anchoring and securing are detected by monitoring the electrical flow in the corresponding electrical paths, any power outage in these paths will be treated as a failure. In a securing electrical path, in the case of the device being protected having low battery voltage or out of power, this condition will be treated as tampering with the securing electrical path and it will be notified remotely and locally. In an anchoring electrical path, in the case of the lock having low battery voltage or being out of power, this condition will similarly be treated as tampering with the anchoring electrical path. However, the user monitor key will be alerted due to reporting of low battery voltage or the interruption of periodical communication signals between the lock and the key due to power outage in the lock.
[0036] In some embodiments, the relative distance between the lock and the key is monitored. As the distance grows, the user is notified.
[0037] The deterrent device is an effective technique for non-hostile situations as well. By way of an example, where the user has secured his/her laptop and for some reason, leaves the location of the laptop but forgets to take the laptop, the key can be used to alert the user upon the user going beyond the range tolerated by the communication capabilities of the lock and the key. The user is therefore given a chance to go back and pick up the laptop before getting too far away from it.
[0038] It should be noted that the examples provided herein, such as those above, are merely some of many others and needless to say too numerous to list. To describe the features of systems and methods in accordance with the present invention in more detail refer now to the following description in conjunction with the accompanying Figures. Referring now to FIG. 1 , deterrent device 10 is shown in accordance with an embodiment. Device 10 is shown to include two parts, a (user) monitoring key 14 and deterrent notification lock 12 . The lock 12 is shown to include a tampering-resistant opening 18 , a lock-to-device connector 16 , an indicator 23 , and a communication pad 22 . In one embodiment, the key 14 is physically attached to the lock 12 through a lock-to-key connection 20 .
[0039] It is understood that while the device 10 is shown in the figures of this patent document to have generally a rectangular shape, other suitable shapes are contemplated. In an embodiment, the device 10 is made generally of plastic but can be made of any other suitable material.
[0040] Lock communication pad 22 and indicator 23 are shown situated on a top surface of the lock 12 ; however, other suitable areas of the lock 12 may be used to house the indicator 23 and pad 22 . The housing can also include a LCD or other displays of communication with the user or other input devices such as a touchpad. A tampering-resistant opening 18 is shown to extend from a longest side of the lock 12 through the interior of the lock through to an opposite side thereof. Again, other suitable locations for the opening 18 are contemplated.
[0041] A security-bound connector 16 is shown protruding from a side of the lock 12 for establishing physical connection 20 with cable and/or a device, such as a phone charger. While shown to appear as a space between the lock 12 and the key 14 , the connection 20 is nearly non-existent, with the side of each of the lock and the key facing each other are flush against one another. As shown in subsequent figures, each of the lock 12 and key 14 have a connector protruding therefrom that are used to physically connect one to the other and situated at a location within the connection 20 .
[0042] During operation of the device 10 , when the lock 12 and the key 14 are connected 20 , the lock 12 electrically synchronizes with the key 14 . Synchronization may include handshaking between the lock and the key and is further described below relative to flow chart figures.
[0043] Upon completion of synchronization, the lock 12 and the key 14 can begin to effectively communicate with one another even when they are not physically coupled. Upon completion of the lock-key synchronization, the key 14 may be physically re-located away from the lock 12 up to distances that are within the signal-range of the device 10 . Upon the detection of an intrusion of the protected device by the lock 12 , the lock 12 reports the intrusion to the key 14 and the key 14 alerts the user. Anchoring serves to physically fix the lock 12 , within the confines of an anchoring cable, to a non-readily movable object, various examples of which are provided below and shown in subsequent figures.
[0044] Alternatively, the lock 12 may be a stand-alone device, not accompanied by the key 14 . In this embodiment, the lock 12 is physically connected to the portable device being protected, through its connector and connected, via another connector, to a connector of a laptop, and used to locally alert a user. That is, upon unauthorized disconnection of the lock 12 from the device being protected, the lock 12 announces the disconnection, via a sound alarm or other desirable reporting means.
[0045] FIG. 2 shows further details of the device 10 , in accordance with an embodiment. In FIG. 2 , the key 14 and the lock 12 are shown physically detached from one another. The lock 12 is shown to include an anchor-bound connector 26 , in addition to the lock indicator 23 . The key 14 is shown to have a key connector 28 , a key communication pad 30 and a key indicator 32 . When physically coupled, connectors 26 and 28 form the connection 20 (shown in FIG. 1 .)
[0046] Through the key communication pad 30 , the user communicates with the key and effectively controls its operation. For example, operations can be initiated by the user by use of the key communication pad 30 . In an embodiment, the lock 12 receives start-of-operation and end-of-operation commands from the key 14 . These commands cause, for example, the start of deterring tampering and later the ending of deterring tampering of the electronic device. In another embodiment the key communication pad may have more than one key or implemented by a touchpad or LCD.
[0047] The lock communication pad 22 is generally utilized by the user to communicate initiation of operations or relaying of various attributes. A contemplated use of the communication pad 22 is for password-protected operations. When the user enters a password via the communication pad 22 , signaling the beginning of a particular operation, the lock is triggered to start a particular operation. As discussed above, the key communication pad 30 is utilized in a similar manner by the user. Other applications of the communication pad 22 are contemplated according to design choices by a designer of the device 10 .
[0048] In accordance with various embodiments, the communication pad 22 may be realized through a push-button, touchpad, a keypad, or other mechanisms that assist the user in notifying the device 10 of various information, such as parameters and passwords. An illustrative embodiment of the communication pad 22 , in the form of a keypad, is shown in FIGS. 1 and 2 and those to follow.
[0049] In an embodiment, key indicator 32 is implemented in the form of a light and flashes or lights up with one or more distinct colors to indicate the presence of pre-determined information or in response to an alert or an alarm, as detected by the lock 12 .
[0050] The opening 18 is essentially a hole or void extending through the two longer sides of the device 12 although, as earlier noted, in other embodiments, the opening 18 may extend through the shorter two sides of the device 12 . Alternatively, the opening 18 may protrude externally from a side of the lock 12 . Yet alternatively, the opening may be the shape of a square or rectangle and extend vertically between the top and bottom surfaces of the device 10 and horizontally between the two sides of the device with a minimum size of the opening 18 being desirably large enough to allow a connecting cable to pass through it yet small enough to prevent the object being protected to pass therethrough.
[0051] The connectors 26 and 28 can physically mate through means other than those shown or described herein, based on, for example, design choices. Without loss of generality, in an embodiment, the connectors 26 and 28 are Universal Serial Bus (USB) connectors. The number of connectors and their types can be customized toward a particular application such as having a RS232 family or circular phone connectors family or different type of USB Adaptors.
[0052] In some embodiments, the lock 12 has a connector on either side, as shown in FIG. 1 , one of which—connector 16 —allows the lock to monitor or protect a portable device/object. However, the lock 12 is hardly limited to protecting only one device and can rather, with the use of more than one connector on one side, reliably protect/monitor more than one device or anchored by more than one object.
[0053] FIG. 3 shows one of numerous applications of the device 10 , in accordance with a method and embodiment. In this particular example, a laptop 36 , mouse 38 , and/or keyboard 40 are devices under protection.
[0054] The lock 12 is shown anchored, through connectors 26 and 27 , to an example of an anchoring object, i.e. the chair 42 , thereby securing the three portable devices, the mouse 38 , the laptop 36 , and the keyboard 40 . More specifically, the keyboard 40 and the mouse 38 are shown connected to the laptop 36 and the laptop 36 is shown connected to the lock 12 through the connector 16 . By virtue of their connection to the laptop 36 , the keyboard 40 and the mouse 38 are monitored/protected by the lock 12 because the laptop 36 can communicate with the lock 12 and report thereto, the presence or absence of the three devices to the lock 12 . It is noted that an effective anchoring object is one that is not readily removed or picked up. In fact, the more securely an anchoring object is secured, such as to the floor or ground, the increased effectiveness of the device 10 in protecting a portable object.
[0055] In FIG. 3 , the chair 42 is used as an anchoring object, as it is in a fixed or stationary position (affixed to the floor) and cannot be easily moved. The laptop 36 , mouse 38 and/or keyboard 40 , on the other hand, are portable therefore requiring protection. The security of the laptop/mouse/keyboard is monitored by the device 10 and if the device 10 detects an undesirable intrusion, the device 10 remotely reports the same, through use of the lock 12 , to the key 14 .
[0056] The exemplary anchoring object of FIG. 3 , i.e. chair 42 , need not be permanently or fully stationary and instead only need be a structure that is not easily moveable. The anchoring object also has a shape allowing for the passage of a physical cable through a part of it, such as the opening 48 , in FIG. 3 . Obviously, the less portable an anchoring object, the greater the effectiveness of protecting a device.
[0057] In FIG. 3 , the lock 12 is shown physically anchored to the chair 42 through an anchoring cable 46 . The cable 46 is generally flexible allowing it to loop through the area pointed to by the pointer 48 , in FIG. 3 . As shown in FIG. 3 , the cable 46 connects at one of its ends to one of the connectors (connector 27 ) of the lock 12 , then it is looped through the opening 48 and then connected to another connector (connector 26 ) of the lock 12 therefore forming a physical loop from and to the lock 12 through the area pointed by pointer 48 . Analogously, an electrical loop also forms as a result of the physical loop.
[0058] That is, in the embodiment of FIG. 3 , the lock 12 is shown to have two connectors, connectors 26 and 27 . Connector 26 physically connects to one end of the cable 46 while an opposite end of the cable 46 physically connects to the connector 27 with this physical connection forming an electrical closed loop from and to the electrical circuitry within the lock 12 . Namely, the flow of electrical current is continuous when the foregoing physical loop is formed and when the physical connection, i.e. the loop, is disrupted, the flow of current stops. It is through monitoring of this current flow in conjunction with the current continuing to flow through the internal circuitry of the lock 12 and the electrical path from cable 44 to the laptop 36 , that the lock 12 detects tampering/intrusion. In another embodiment, the cable 44 can be eliminated by connecting the lock 12 directly to the laptop 36 via connector 16 .
[0059] It is noteworthy to say that which end of the cable 46 connects with which connector of the connectors 26 and connector 27 is irrelevant. In fact, such as shown in the embodiment of FIG. 3 , the lock 12 may have more than two connectors, connectors 26 and 27 , used for securing more than one device, such as the combination of the laptop/mouse/keyboard. In other embodiments, the lock 12 employs connectors 26 and 27 to anchor to more than one anchoring object and not just the chair 42 . For instance, two chairs can serve as anchoring objects. As a matter of convenience, the connectors 26 and 27 are shown to be the same type of connectors, in FIG. 3 , but they need not be. It should, however, be possible to physically mate the connectors 26 and 27 to either end of the cable 46 .
[0060] In yet other embodiments, the laptop/mouse/keyboard of FIG. 3 are secured in a cascaded manner. For example, the mouse 36 and the keyboard 40 are secured by the laptop 36 ; a second laptop (not shown) may also be secured by the laptop 36 and securing its own set of keyboard and mouse (not shown).
[0061] Alternatively, the laptop can be monitored for any contact or typing. For example, if the laptop is being monitored and an unauthorized individual starts typing, for example, a password to try to gain access to the laptop, the device 10 can detect the same and report it to the user through the key. In an embodiment, the laptop 36 and the lock 12 communicate through their respective connectors (or “ports”) and a cable. Alternatively, the laptop 36 and the lock 12 communicate together wirelessly, i.e. Bluetooth, or any other suitable means.
[0062] In an alternative embodiment, detection of undesirable activity is performed by execution of specialized software/firmware that is installed onto a laptop. In this instant example, any changes to the connectors or the keyboard of the laptop 36 are detected by the execution of the installed software on the laptop. The detected intrusion information is then communicated to the lock 12 , by the software/firmware of the laptop 36 and then passed on to the key 14 by the lock 12 . The user accordingly, becomes aware of the tampering. This tampering can be communicated to lock 12 via the securing cable 44 or wirelessly via Bluetooth and/or Wi-Fi or other wireless means.
[0063] In the manner described above and shown in FIG. 3 , the lock 12 is physically and electrically anchored to the chair 42 . Physical anchoring is described above. Electrical anchoring is done by connecting the cable 46 , at one of its ends, to the connector 26 and pulling the cable 46 through the area pointed to by the pointer 48 to connect to the connector 27 . In this manner, assuming the lock 12 is properly operating, the relevant part of the detection circuit (not shown in FIG. 3 ) of the lock 12 is ‘closed’ because current flows through the cable 46 . It is noted that the cable 46 need not necessarily loop through the area pointed to by the pointer 48 and rather merely requires some kind of structure through which it can physically loop coming out to connect back with the lock 12 . One way to describe the loop is as follows. An anchoring cable employed for forming the loop travels through a location of the anchoring object that is essentially an opening or a pole extending between top and bottom surfaces such that the cable loop is smaller than the perimeter of the top and bottom surfaces to prevent the anchoring cable to travel passed the top and bottom surfaces. In the case of the pole, the cable wraps around the pole and in the case of the opening, which is a part of the anchoring object, the cable passes through the opening. In both examples of the pole and the opening, the cable connects to the lock at one of its ends while at another one of its ends, it also connects to the lock but through a connector that is distinct from the connector used to connect the one end of the cable to the lock. Alternatively, other configurations of the opening and cable for forming a loop are discussed and shown below. It is noted that the anchoring strength of the anchoring object is generally based on the permanency (ability to remain unmovable) of the anchoring object as well as the sturdiness of the space (or “opening”) of the anchoring object.
[0064] Upon tampering or removal of the laptop 36 , such as cutting of the cable 44 , this electrical path ‘opens’. An ‘open’ connection results in the detection circuit of the lock 12 detecting the absence of current flow. To this end, the lock 12 senses an electrical disconnection of the path that is formed by the cable 44 and remotely reports this disconnection to the key 14 . An exemplary reporting technique/mechanism may be setting off of a sound alarm by the lock 12 thereby activating the indicator 23 . Another example is the key setting off a sound alarm and activating the indicator 32 . The key 14 may report tampering to the user by any other suitable means, such as, without limitation, vibration.
[0065] The laptop 36 is not secured until the device protection via cable 44 physically links the laptop 36 , through the connector 16 , to form an electrical path between the lock 12 and the laptop 36 , much like the anchoring object, in that current flows through the cable 44 and back to the lock 12 where the lock's detection circuitry detects interruption of current flow. The cable 44 can be eliminated if connector 16 is connected directly to laptop 36 . The mouse 38 and/or keyboard 40 may be similarly secured because tampering of the ports of the laptop 36 is detected by the lock 12 .
[0066] As earlier mentioned, any other device coupled to the connectors of the laptop 36 can be protected. Further and as previously mentioned, the lock 12 can alert the key 14 of tampering/theft through wireless communication. An example of wireless communication is in accordance with protocol defined by the industry-recognized standard, Zigbee.
[0067] The key 14 and the lock 12 are each capable of communicating with a user personal device wirelessly or otherwise. For instance and without limitation, a user personal device may communicate wirelessly with the key and/or the lock, through Bluetooth, or through a computer to which the key or lock are physically or remotely coupled.
[0068] The electrical path is interrupted if any of the following occur in the example of FIG. 3 : 1) the connection of the cable 44 to the connector 16 is removed; 2) the connection of the cable 44 to the laptop 34 is removed; 3) the cable 44 is cut between laptop 34 and the connector 16 ; 4) the connection of the cable 46 to either of the connectors 26 and 27 is removed; or 5) the cable 46 is cut between the connectors 26 and 27 .
[0069] In various embodiments, notification of an electrical path interruption, as well as tampering of the device being protected is stored in an Electrically Erasable Programmable Read-Only Memory (EEPROM), which is physically located inside of the lock 12 . In the event, the lock is out of power, the user has sufficient knowledge of all events that preceded the power outage when power is restored later.
[0070] The operation described herein regarding the embodiment of FIG. 2 , except communication with the key 14 , applies to the embodiment of FIG. 3 .
[0071] FIG. 4 shows in conceptual form, a high-level block diagram of relevant internal portions of the lock 12 and key 14 , in accordance with an embodiment. The lock 12 is shown to include lock communication pad 22 , lock indicator 23 , lock standard wired communication unit 53 , lock keypad control block 61 , lock battery control block 65 , key-bound wired communication unit 51 , lock processor 50 , key-bound wireless communication unit 52 , opening tampering detection unit 69 , lock alerting control unit 63 , lock power control unit 62 , lock sensor unit 58 , lock connector unit 56 , lock standard wireless communication unit 54 , and connectors 16 , 26 and 27 . The lock processor 50 is shown to include a buffer 57 that is used by the processor 50 for storing data, discussed in further detail below.
[0072] An example of the unit 53 is a universal receiver/transmitter (UART/i2c) with others anticipated. An example of the unit 54 is Bluetooth or Wi-Fi with others anticipated. More specifically, the unit 54 is used by the lock 12 to communicate, by using Bluetooth or Wi-Fi, with the device being protected or a gateway to the Internet.
[0073] The key 14 is shown to optionally include the pad 30 , the indicator 32 , a key standard wired communication unit 83 , a key standard wireless communication unit 84 , a key processor 80 , a key keypad control unit 68 , a key battery control block 85 , a lock-bound wired communication unit 81 , a lock-bound wireless communication unit 82 , key alerting control unit 87 , a key power control unit 89 , key connector unit 86 , and key connector 28 . The key processor 80 is shown to include a key buffer 88 , which is used by the processor 80 to store data, discussed in further detail below.
[0074] The physical location of each of the structure/blocks shown in FIG. 4 are not indicative of their actual physical positions. For example, connector 16 , while it can be, need not be located on the same side of the device 12 as the connectors 26 and 27 .
[0075] The lock processor 50 is shown coupled to the units 53 , 54 , 56 , 58 , 62 , 63 , 69 , 52 , and 51 , and serves as the master-mind for the lock 12 . The processor 50 instructs the structures to which it is coupled to take actions, or not, and communicates information (or data) from one structure to another and other relevant functions.
[0076] The unit 56 is shown coupled to the connectors 16 , 26 and 27 . The detection unit 69 houses the opening 18 as well as the opening-tampering notification device 67 that is shown wrapped around the outside of all of the sides of the opening 18 . The cable 46 of FIG. 3 is poked through the opening 18 in certain applications that provide the user with added convenience, such as that shown by the embodiment of FIG. 9 . As earlier stated, the opening 18 is optional.
[0077] Information from the user is received, through the communication pad 22 , by the lock communication pad control unit 61 and ultimately communicated to the processor 50 . The lock battery control block 65 and power control unit 62 provide power to the electrical circuits of the lock 12 . Lock alerting control unit 63 determines when to alert the user. An alert to the user may be in the form of a sound alarm or a visual alarm, such as a LED/LCD. In applications that require it, the control unit 62 determines when to start and when to stop charging an electronic device. It also provides power to the key 14 through connection 20 .
[0078] The unit 54 enables the lock 12 to wirelessly communicate with an external device, such as a laptop. The block 51 processes communication that is transmitted or received through a physical connection with key 14 as opposed to wirelessly, whereas, the unit 52 does the same through wireless communication.
[0079] The unit 56 receives input from the outside through the connectors 16 , 26 , and 27 and passes on the received input to the processor 50 for processing. It also provides communication back to the outside from the processor 50 .
[0080] In FIG. 4 , the key 14 is shown to include structures analogous to those of the lock. The processor 80 , analogous to processor 50 , is the master-mind for the key 14 .
[0081] FIGS. 5 and 6 show flow charts of some of the relevant steps performed by the lock and key during handshaking. FIG. 5 shows the flow chart 100 of the relevant steps performed by the lock 12 and key 14 during handshaking, in accordance with an embodiment.
[0082] At step 102 , handshaking begins and physical authentication between the key 14 and lock 12 starts at step 104 . Physical authentication is verification of the key 14 to be the expected mating device, in addition to the generation of a wireless communication encryption key as well as a password generation, all of which are employed for activation of the current session. The password and wireless communication encryption key are collectively herein referred to as “credential data”. A new ‘session’ begins each time the key and the lock are physically connected to each other for the purpose of the activation of an event. In an embodiment, each time a new session starts, a new password and encryption key are generated. Alternatively, a new session need not trigger the generation of a new password and encryption key, rather, the frequency of such generation can be a design choice. However, it should be appreciated that this frequency may affect the strength of the security associated with the device 10 .
[0083] It is noted that as part of the security offered by the device 10 , the wireless communication encryption key and the password, generated during handshaking, are generated on-the-fly using a random number generator and not predetermined.
[0084] Referring still to FIG. 5 , in the above-noted manner, the lock 12 authenticates the key 14 . At 106 , a determination is made of whether or not physical authentication passes and if so, the process moves onto the step 110 , whereas, if it fails (the key or lock are not as expected), the process moves onto the step 108 at which time the user of the device 10 is notified of the failure.
[0085] At step 110 , wireless electronic authentication is initiated between the key 14 and lock 12 . That is, upon the key 14 being physically disconnected from the lock 12 , it is carried to a place remote from the lock 12 and electronic authentication, using wireless transmission, is conducted by them (at step 110 ). Electronic authentication is determined to pass or not at step 112 and if it fails, the user is notified at step 108 , otherwise, the process continues to step 114 where the key 14 and the lock 12 are activated in that they can fully perform, either individually or collectively, the functions intended for them to perform. In FIG. 5 , the solid lines indicate steps performed solely by the lock 12 whereas the dashed lines indicate steps performed by both the key 14 and the lock 12 . In both cases, the steps are generally performed by a processor with other circuitry located internally to each of the lock and key, which are shown and discussed relative to subsequent figures.
[0086] The flow chart 120 of FIG. 6 shows further details of the activation and handshake steps of FIG. 5 . In FIG. 6 , the dashed lines indicate corresponding steps/decisions performed by the key 14 and the solid lines indicate corresponding steps/decisions performed by the lock 12 . For example, the step 122 and all of the steps/decisions shown thereafter on the left side of the page, i.e. 140 , 142 , 144 , 146 , 148 , and 150 are performed by the key 14 and the remaining steps/decisions shown in FIG. 6 , are performed by the lock 12 .
[0087] Starting at 122 , physical communication credentials exchange and wireless validation between the key and the lock starts as follows.
[0088] The key 14 performs the step 140 , which is to provide its credentials to the lock 12 via its standard wired connection. Credentials may be saved in a credential-buffer, which is a memory location in the key processor 80 , such as the buffer 88 , for saving the credential data. Credential data include a signature identifying the key that is physically connected to the lock and used for authentication by the lock. Examples of other credential data are an encryption key that makes the wireless communication between the key and the lock secure and a termination key that ensures the correct termination command is being used. This step is performed when the lock 12 and the key 14 are physically connected 20 , such as shown in FIG. 1 .
[0089] Next, at step 142 , the key 14 awaits receipt of an activation command from the lock 12 and at 144 , a determination is made by the key 14 as to whether or not the awaited activation command is received and if so, the process continues to step 146 , otherwise, the process goes back to and continues from step 142 . Upon receipt of the activation command, at step 146 , radio-frequency (RF) communication starts between the lock 12 and key 14 using the wireless communication encryption key of the credential data that has been transferred from the lock 12 to the key 14 in step 140 . As previously noted, the generation of a unique wireless communication encryption key for the activation of a session increases the level of security of the wireless communication between the key 14 and the lock 12 .
[0090] Next, at step 148 , the key 14 sends a handshake message to the lock 12 through RF transmission. Upon sending the handshake message, the key 14 awaits an acknowledgment of its handshake message from the lock 12 , at 150 . Once acknowledgment is received by the key, the handshake and activation process is completed.
[0091] At step 124 , performed by the lock 12 , a pseudo-random number is generated as the wireless communication encryption key and another random number is generated as the password, the credential data, employed for the particular activation session that is currently underway. RF communication is initiated by the lock 12 at step 126 using the generated encryption key. The credentials data are then transmitted to the key through wired (physical) connection at step 128 .
[0092] Next, at 130 , the lock 12 determines whether or not the transmission of step 128 is successful and if so, the lock 12 executes step 132 , otherwise, it executes step 128 until the credential data transfer is successful.
[0093] At step 132 , an activation command is sent to the key 14 to activate the key and at 134 , receipt of the handshake message from the key is awaited. This is the handshake message of step 148 . Upon receipt of the handshake message from the key 14 , at step 136 , the lock 12 sends an acknowledgment to the key 14 . This is the acknowledgment the key awaits at 150 .
[0094] In the case where the lock 12 operates as a stand-alone unit, without the key 14 , activation is initiated either by setting up a new password for the session via the keypad 22 or using the current password. The user can use the keypad 22 to provide the necessary commands to operate the device including of a command indicating the stand alone mode being employed.
[0095] In some embodiments, operation of the user monitor key can be performed by the lock 12 communicating wirelessly with portable device, such as a smart device. In an alternative configuration, communication can be consummated through a cable connection.
[0096] FIGS. 7-9 and 11-12 show various exemplary applications of the device 10 in accordance with methods and embodiments.
[0097] In FIG. 7 , the application 160 is securing the luggage 162 . In this example, the chair 42 is used as the anchor mechanism, as it is hard to move. At airports, for instance, benches are permanently affixed to the floor and cannot be readily removed. In this sense, they serve as good candidates for anchoring. The key 14 is remotely located relative to the lock 12 and communicates with the lock 12 wirelessly.
[0098] The cable 44 is connected at one end to one of the connectors, i.e. the connector 26 , of lock 12 and connected, at an opposite end to another connector, i.e. the connector 16 , of the lock 12 . From the connector 26 to the connector 16 , it travels through the space of the headrest of the chair 42 to and through the carrying apparatus of the luggage 162 . Alternatively, the cable can be made to go through the handle of the luggage. In this manner, the cable 44 causes a closed electrical loop from the connector 26 to the connector 16 thereby allowing current to flow therethrough. Current further flows through the lock 12 . Once this electrical path is established, it is monitored and if detected by the first active circuit in the lock 12 to be interrupted, the lock 12 alerts the key 14 of the same.
[0099] The electrical loop is interrupted if any of the following occur in the example of FIG. 7 : 1) the connection of the cable 44 to the connector 26 is removed; 2) the connection of the cable 44 to the connector 16 is removed; 3) the cable 44 is cut between the connectors 16 and 26 ; or 4) the lock 12 is cut in a manner that cuts the opening-tampering notification device 67 , shown in FIG. 4 .
[0100] An undesirable removal of the luggage 162 would have to involve disconnecting the cable 44 from the connector 16 or in any other manner disconnecting the cable 44 or breaking the physical loop the cable 44 forms through the chair 42 and the lock 12 . Accordingly, the mechanism of FIG. 7 acts as a deterrent against malfeasance of the luggage 162 and in this manner protects the luggage. In the event of a malfeasance, the user is immediately alerted and can act quickly to save the luggage.
[0101] Upon detecting tampering, the lock 12 signals the key 14 , which alerts the user. An embodiment of an alert is a flashing light indicator 32 . As previously noted, numerous other types of indication are contemplated and too many to list here.
[0102] In the case of a standalone lock 12 , without key 14 , the same can be performed but excluding communication with the key 14 .
[0103] FIG. 8 a shows an exemplary application of the device 10 where the lock 12 secures the device being protected, i.e. the laptop 36 , wirelessly (or “virtually”). In this manner, the cable 44 need not go through any part of the laptop as it did in the application of FIG. 3 where the laptop 36 was connected through cable 44 to lock 12 . The chair 42 serves as an anchor and the connection of the cable 44 relative to the lock 12 is analogous to that of FIG. 7 except that the cable 44 goes through the head-rest of the chair 42 and not any part of a luggage. In the embodiment of FIG. 8 a , the range of signal matters in that the physical distance between the laptop 36 and lock 12 needs to be within the wireless capability of the lock 12 outside of which the lock 12 fails to properly communicate with the laptop 36 . In fact, it is this very feature that protects the laptop 36 against tampering or theft. That is, if the laptop is physically taken outside of the range of proper wireless communication between the lock 12 and the laptop 36 , the lock 12 treats this lack of communication with the laptop 36 as an undesirable event and wirelessly alerts the key 14 , accordingly. In an embodiment, the lock 12 not only alerts the key of the undesirable event, it also sets off some kind of an alarm for local notification.
[0104] FIG. 8 a shows an example of the protection of an active device, i.e. laptop 36 , whereas FIG. 7 shows an example of the protection of a passive device, i.e. luggage 162 .
[0105] Further shown in FIG. 8 a are relevant structures within the lock 12 that take part in the application of lock 12 shown in FIG. 8 a . These structures are emphasized, in FIG. 8 a , by showing the contents of the blocks introduced in FIG. 4 , whereas, non-active structures are shown as blank shapes.
[0106] In the case of standalone operation of lock 12 without key 14 , the same operation is valid as above with the exception of the communication with key 14 .
[0107] FIG. 8 b shows an exemplary application of the device 10 where the lock 12 is anchored virtually. In this manner, the sensor unit 58 , which may be one or more of an accelerometer, motion detector sensor or any other sensor suitable for sensing a desirable metric., detects movement of the lock 12 relative to the lock 12 's original position. In this manner, the sensor unit 58 serves as a virtual anchor for the lock 12 . Alternatively, in the case of employing a motion detector sensor, a global positioning system (GPS) may be employed. Still alternatively, instead of sensing motion, the sensor unit 58 may sense an environmental factor, such as without limitation, temperature, moisture, and pressure.
[0108] Further shown in FIG. 8 b are relevant structures within the lock 12 that take part in the application of lock 12 shown in this figure. These structures are emphasized, in FIG. 8 b , by showing the contents of the blocks introduced in FIG. 4 , whereas, non-active structures are shown as blank shapes. In the case where the lock 12 is employed in standalone mode, without use of the key 14 , the foregoing discussion applies with the exception of communicating with the key 14 .
[0109] In FIG. 9 , yet another exemplary application of the device 10 is shown with some of the relevant structures of the lock 12 and the key 14 that are active in this example, highlighted in the same fashion as the highlights of FIGS. 8 a and 8 b discussed above.
[0110] In the example of FIG. 9 , the laptop 36 is shown to be physically connected, through cable 44 , to the connector 16 of the lock 12 in a manner as follows. The chair 42 is used as an anchor and the cable 44 is connected at one end to the laptop 36 and at another end, threaded through the opening 18 . Once the cable 44 is threaded through the opening 18 , it travels through a portion of the backrest of the chair 42 , shown at 48 and thereafter connects with the connector 16 of the lock 12 . As shown in FIG. 9 , the lock 12 and key 14 communicate wirelessly, as shown and discussed relative to prior figures. As is the case with most, if not all, of the embodiments shown in the various figures of this patent document, the lock 12 can operate as a standalone unit, in the application of FIG. 9 .
[0111] Use of the opening 18 frees up the connector 26 in the application of FIG. 9 because the cable 44 connects to the lock through only one of the lock's connectors, i.e. the connector 16 , leaving connector 26 of the lock 12 and any other external connector that may be used, available. In this manner, the opening 18 allows for anchoring and securing to be done with only one cable. Whereas, in the application of the device 10 , in FIG. 9 , the opening 18 is a part of anchoring, in FIG. 3 , it is not utilized at all. Therefore, the application of FIG. 3 requires two connectors, such as connectors 26 and 27 , whereas the application of FIG. 9 only requires one connector, such as connector 16 .
[0112] Undesirable events, such as those discussed relative to previous figures, are detected by the lock 12 , in large part, due to the presence of the electrical path that starts from the laptop 36 and goes to the connector 16 . Detection is triggered in first active circuit either by the tampering with the opening 18 and/or the cable 44 . Tampering with the opening 18 is detected through configuration described in FIG. 10 . Tampering with the cable 44 entails disconnection from either connection 16 or laptop 36 or cutting the cable 44 .
[0113] Similar to FIG. 7 , cable 44 can be made to go through the handle of the luggage 162 and secure both active device 36 and passive object 162 .
[0114] In FIG. 9 , relevant structures employed for this application are shown in the drawing of the lock 12 as well as that of the key 14 . FIG. 10 a shows an internal cross section side view of the lock 12 essentially without a tampering detection feature for opening 18 . FIG. 10 b shows an internal cross section side view of the lock 12 with a tampering detection feature.
[0115] In both FIGS. 10 a and 10 b , the lock 12 is shown to include a bottom board 181 , a top board 183 , board connectors 190 - 193 , wire 187 , and wire 185 , all of which are shown located on a top surface of the top board 183 . The lock 12 is further shown to include wire 187 , which is shown located on top surface of the bottom board 181 . Wire 185 extends between the connectors 190 and 191 thereby causing electrical coupling of these connectors. Similarly, wire 187 extends between the connectors 192 and 193 .
[0116] In FIG. 10 b , wire 186 causes electrical coupling of the connector 191 with the connector 193 . Similarly, wire 184 causes electrical coupling of the connector 190 with the connector 192 . The combination of wires 184 , 185 , 186 , 187 connected to one another through the connectors 190 , 191 , 192 , 193 creates the electrical loop 67 around the opening 18 . Any cut of the opening, either on the top and bottom or the other two sides, causes an interruption of the current flow in loop 67 and is detected by the processor 50 which is connected to the loop 67 .
[0117] FIG. 10 c shows an exploded view of the loop 67 . As shown in FIG. 10 c , the loop 67 is made of a combination of the connectors 190 , 191 , 192 , 193 and wires 184 , 185 , 186 , 187 .
[0118] FIG. 11 a shows yet another exemplary application of the device 10 for deterring/protecting/monitoring of a user device. In this application, the lock 12 is anchored to the wall through its connection via the cable 214 to the charger 204 and the charger 204 being plugged 208 to the wall outlet 202 . In case, the wall outlet had a common connection interface such as USB built in, the lock 12 could directly anchor to this outlet via cable 214 .
[0119] In the configuration of FIG. 11 a , a phone 210 is secured through its connection to the lock 12 via cable 44 . If needed, the phone 210 can also get charged by the battery charger 204 through the lock 12 . In this configuration, the phone 210 can be secured while being charged. The lock 12 wirelessly reports any malfeasance related thereto to the key 14 As in the case of FIGS. 8 a , 8 b and 9 , some of the relevant portions of the inside of the lock 12 are highlighted in FIG. 11 a . In another embodiment, there can exist an internal charging system such as a charger or an adapter in the lock deterrent device. For example, the internal charging system can also have a 110V connector to be able to connect to the power outlet 202 directly or a 12V connector to be connected to a laptop charger. The lock deterrent device can charge the device being protected in two ways: either by its own battery power or through an internal or external battery charger when it is anchored to a power source 202 or external charger 204 .
[0120] In FIG. 11 a , the device being protected, the mobile device or cell phone 210 is secured through cable 44 . It could also be any other active device, such as a laptop. In the case where the lock 12 operates as a stand-alone unit, without the key 14 , the only difference is that the communication with key 14 does not take place.
[0121] The embodiment of FIG. 11 b , while shows the same anchoring as in FIG. 11 a , it shows how to secure a passive object 162 .
[0122] The embodiment of FIG. 12 a is analogous to the embodiment of FIG. 3 with the exception of the particular internal blocks of the lock 12 a that are actively in use being shown in the configuration of FIG. 12 a.
[0123] The embodiment of FIG. 12 b is analogous to the embodiment of FIG. 12 a and shows any secure path 44 or the anchored loop 46 can also secure passive objects 162 and 163 .
[0124] FIGS. 13-15 show flow charts of some of the relevant operational steps performed by the lock 12 and key 14 . At step 300 , wireless termination of the lock 12 via the key 14 begins.
[0125] In accordance with a method, termination may be done through the key in “wireless” mode. In yet another method, a password is used through the communication pad of the lock 12 to terminate and yet another method, termination is done through physically mating of the key and the lock.
[0126] After step 300 , at 302 , a determination is made as to whether or not the user 304 has entered a valid/recognized message, such as a number, through the key's communication pad and if not, the process waits until this occurs, and if so, the process continues to 316 . From 316 , the steps thereafter are performed by the key 14 and the steps from and including 306 (shown on the right side of FIG. 13 ) are done by the lock 12 . At 316 , if the key is active, the process sets a timeout counter to zero at step 318 and determines whether or not the timeout counter is at a predetermined threshold at 320 and if so, the process moves onto the step 322 , otherwise, the process goes to step 338 . At step 338 , an error is noted. At step 322 , an end-command is sent to the lock wirelessly and the process moves onto 324 , where the key waits for acknowledgment from the lock.
[0127] After step 322 , the key waits for an acknowledgment from the lock and upon receiving acknowledgment, the key ends this (termination) procedure and performs clean up or log, at step 330 . As used herein, “clean up” and “log” refer to initializing parameters at the end of the procedure to prepare for starting for a new activation.
[0128] After step 330 , at step 314 , a wait period takes place for the lock and the key to reconnect.
[0129] At 306 , a determination is made as to whether or not the lock is active and if the lock is determined to be active, the process continues to step 308 waiting for receipt of a RF-End command from the key, otherwise, the lock ignores the RF_End command from the key. After 308 , at step 310 , an acknowledgment is sent to the key. Next, at step 312 , the termination process for the lock 12 ends, much like step 330 and step 314 is performed.
[0130] FIG. 14 shows some of the steps, in flow chart form, for physical termination of the operation between the lock and key. At step 400 , the process begins. The user 304 , at some point, needs to physically connect the key to the lock, such as shown by the connection 20 in FIG. 1 . Next, at 402 , a determination is made as to whether or not the lock and key are physically connected and if so, the process moves onto either 422 or 404 depending on the steps the key or the lock perform. If the physical connection has not yet been established, the process waits until they are physically connected.
[0131] The steps and decisions shown on the right side of FIG. 14 , i.e. 404 - 416 and 420 , are generally performed by the lock 12 and the steps shown on the left side of FIG. 14 , i.e. 422 - 430 , are generally performed by the key 14 . At 404 , the lock determines whether or not it is active. Prior to being “active”, the lock is not properly operational, i.e. perform the functions it is intended to perform such as monitoring, securing, and detecting, and the like. If inactive, the process goes from 404 to the step 418 and prepares for a new session. At step 418 , the lock and the key know to start the activation process described and shown relative to FIG. 6 .
[0132] Upon determining that it is active, the step 406 is performed but only if the key has given permission to the lock to access its credential buffer. Access to the lock is typically provided through physical wire connection for increased security. Assuming access has been extended to the lock, at step 406 , the lock reads the identification password from the buffer 88 of the key to determine the authenticity of the key. This is done, in accordance with an exemplary embodiment, by using the identification password stored in the key buffer 88 and that which is saved in its own buffer 57 .
[0133] Next, the lock determines whether there is match between the identification password from the key and the password that is in its buffer 57 and when there is a match, the process moves on to the step 410 , otherwise in the event of no match, i.e. the key is not authenticated, the process moves to step 420 . At step 420 , the lock reports in intrusion (to the user 304 ), which is typically done wirelessly.
[0134] At step 410 , a password that is used to verify termination, is read from the buffer 57 and at 412 , it is verified, or not. In the case of verification, the process performs step 414 , otherwise, the process moves onto step 420 .
[0135] At step 414 , the lock reports to the key to end activation. Next, at step 416 , the lock carries out a termination process to end activation.
[0136] As to the key, at 422 , similarly to the lock, the key determines if it is active and if so, the process continues to step 424 otherwise, the process goes to step 418 . At step 424 , the key gives the lock access to its buffer 88 (shown in FIG. 4 ), via the connection 20 (shown in FIG. 1 ). This is the step necessary for the lock to perform the steps from step 406 on. Next, at step 426 and at 428 , the key 14 awaits receipt of the end of activation (step 414 ) from the lock 12 and upon receipt thereof, the key 14 performs step 430 . At step 430 , the key ends activation by carrying out a termination process, analogous to the step 416 , performed by the lock. The foregoing ends the physical wired termination process between the lock 12 and the key 14 , therefore ending this session, in accordance with an embodiment and method.
[0137] Alternatively, physical wired termination may be performed even when the key 14 is without battery power, as follows. When the lock 12 and key 14 physically mate as shown in FIG. 1 , the key then utilizes the power supplied by the lock to charge the key's battery when battery power becomes low. When the key 14 is completely out of battery power, while charging the key's back, the lock 12 can act as a power source for the key processor 80 , through the connection 20 , to ensure uninterrupted operation of the key.
[0138] In an embodiment, the key processor 80 (shown in FIG. 4 ) includes memory, such Electrically Erasable Programmable Read-Only Memory ((EEPROM). In accordance with a method, handshaking credential data is stored in the EEPROM of the key processor 80 , at the start of the session. When power is restored, the credential data is made available to the lock 12 . The foregoing process successfully effectuates termination of the lock 12 . The key also goes to the ending process and cleans up its log and prepares for next activation session. Furthermore, all information regarding tampering, intrusion, etc. are also stored in the EEPROM of the lock processor 50 . Upon loss of power by the lock, still the information will be available upon power restoration.
[0139] FIG. 15 shows some of the steps, in flow chart form, performed by the lock and key, for termination of activation via the pad 22 of the lock, at step 500 . At 502 , the lock awaits the user's entry of a user password, which the lock uses to authenticate the user 304 . Upon failure of authentication, the lock awaits entry of the correct (expected) password from the user. Upon authenticating the user 304 , the lock determines whether or not it is active at 504 and if so, step 506 is performed. At step 506 , the lock initializes a timeout counter. Timeout is during a period of time the lock awaits the expected password from the user after which the lock no longer awaits entry from the user. From 508 to step 514 , the lock waits for receiving an acknowledgment from the key in response to its transmission of end-of-command, through RF transmission. The lock then moves onto step 516 .
[0140] So as to avoid waiting indefinitely, the lock uses a threshold value to wait a predetermined amount of time for the process of acknowledgment from the key to end, as described above. The steps for doing so include steps 518 and 520 where at step 520 , the lock reports failure to receive of the key's acknowledgment, back to the key and at step 518 the lock records this problem.
[0141] Steps 524 to 530 are performed by the key, i.e. the terminating activation or termination procedure. Upon determining it is activated at 524 , the key, at 526 , waits for the end-of-command, sent by the lock at step 510 , and upon receipt thereof, it sends an acknowledgment at step 528 , to the lock and ends its termination process at step 530 .
[0142] FIG. 16 shows exemplary screenshots of a mobile device of various parameters and status reported by the device 10 . For example, the screenshot 600 shows adjustments that can be made by the user to the volume (of alert/alarm sound), password and battery status. Screenshot 602 shows various detections by the device 10 , for example, an intrusion detection at 10:17:10 AM on Jun. 6, 2014.
[0143] It is understood that the various embodiments and methods shown and discussed herein, various configurations of protecting a user object, including but not limited to, stand-alone, without use of the key 14 , may be employed. Further, in place of the key 14 , a general purpose user monitor key such as a smart device may be employed. In addition, the dedicated communication between the lock 12 and the user monitor key can be either wired or wireless. The dedicated user monitor key 14 can be used for activation start, monitoring and end operations among other functions. Furthermore, the lock 12 can use its keypad for certain operations and use the user monitor key 14 for other operations. In a case where the lock 12 operates without the user monitor key 14 , all the operations of the lock 12 can be performed solely by itself and information may be input to the lock 12 , through, for example, a keypad.
[0144] Although the invention has been described in terms of specific embodiments, it is anticipated that alterations and modifications thereof will no doubt become apparent to those skilled in the art. It is therefore intended that the following claims be interpreted as covering all such alterations and modification as fall within the true spirit and scope of the invention. | A portable theft deterrent device is disclosed. The theft deterrent device comprises a lock detection mechanism. The lock detection mechanism includes a plurality of connectors and an opening therethrough. The lock detection mechanism includes a keypad. The keypad enables and disables the lock detection mechanism when a correct key code is entered. The lock detection mechanism includes a first active circuit therein coupled to the plurality of connectors. Wherein when the lock detection mechanism is coupled to an electrical path via at least one connector of the plurality of connectors and the first active circuit detects an interruption in the electrical flow in the electrical path, the lock detection mechanism provides an alert. | 4 |
BACKGROUND OF THE INVENTION
Substituted dihydropyridines are known to be useful for reducing blood pressure, effecting dilation of the coronary vessels, and preventing urospasms. Typical of such substituted dihydropyridines are those disclosed in U.S. Pat. Nos. 3,923,818; 3,905,970; 4,044,141; 4,237,137; and 4,285,955. The substituted dihydropyridines disclosed in these patents do not include bridged ring structures.
Weller et al., [J. Org. Chem., 48, pp 3061-7 (1983)] disclose 1'-methylspiro[benzofuran-3(2H), 4'-piperdine] as a substructure of morphine which is an early intermediate in a general synthesis of morphine but not possessing exceptional analgesic activity. Weller et al. also teach the preparation of spiro [benzofuran-3(2H), 4'-(1'H)-pyridines] as potential intermediates in a synthesis of morphine but no biological activity of these compounds is reported.
Goldman [Angew. Chem. Int. Ed. Engl., 20, pp. 779-780 (1981)] teaches the preparation of spiro[benzothiophene-1-oxide, 4'-pyridines] as an intermediate in the preparation of 4,4-disubstituted 1,4-dihydropyridines.
SUMMARY OF THE INVENTION
This invention is directed to novel substituted and bridged pyridines and derivatives thereof and to methods for preparing such compounds. This invention is also directed to pharmaceutical compositions and methods of treatment for cardiovascular disorders in which high cellular concentration of Ca ++ is a factor.
DETAILED DESCRIPTION OF THE INVENTION
The specific substituted and bridged pyridine compounds of this invention are represented by the following general structural formulae (I) and (II): ##STR1## wherein:
n is 0, 1, or 2;
A is oxygen, sulfur or >NR 9 in which R 9 is hydrogen or C 1 -C 4 alkyl, and
B is --CH═CH-- or ##STR2## or
B is oxygen, sulfur or >NR 9 , and A is --CH═CH-- or ##STR3## and
R is hydrogen or C 1 -C 8 alkyl;
R 1 and R 4 independently are hydrogen, C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl or C 1 -C 8 hydroxyalkyl;
R 2 and R 3 independently are C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 8 hydroxyalkyl, C 1 -C 8 dihydroxyalkyl, C 2 -C 8 alkoxyalkyl, C 3 -C 8 alkoxy(alkoxyalkyl) or C 1 -C 8 aminoalkyl wherein the amino group is NR 5 R 6 in which R 5 and R 6 independently are hydrogen, C 1 -C 8 alkyl, C 7 -C 14 phenylalkyl or R 5 and R 6 together with the N atom form a 5 or 6 membered heterocycle selected from the group consisting of piperidinyl, morpholinyl, thiomorpholinyl, pyrrolidinyl, piperazinyl or N'-C 1 -C 4 -alkylpiperazinyl; and
X, W, Z and U independently are hydrogen, C 1 -C 8 alkyl, C 1 -C 8 alkoxy, CF 3 , cyano, nitro or halo, (i.e. fluoro, chloro or bromo) provided that at least two of X, W, Z and U are hydrogen or X and W or W and Z or Z and U together with the phenyl group to which they are attached form a naphthyl or benzoxadiazole group,
and pharmaceutically acceptable salts thereof.
The preferred compounds of this invention are those represented by the general structural formulae (I) and (II) wherein:
n is 0 or 1;
A is oxygen or sulfur and B is --CH═CH--; or
B is oxygen or sulfur and A is --CH═CH--; and
R is hydrogen;
R 1 and R 4 independently are hydrogen or C 1 -C 8 alkyl;
R 2 and R 3 independently are C 1 -C 8 alkyl or C 1 -C 8 aminoalkyl wherein the amino group is NR 7 R 8 in which R 7 and R 8 independently are hydrogen, C 1 -C 8 alkyl or C 7 -C 14 phenylalkyl; and
X, W, Z and U independently are hydrogen, C 1 -C 8 alkoxy, CF 3 , cyano, nitro or halo provided that at least two of X, W, Z and U are hydrogen.
The most preferred compounds of this invention are those preferred compounds wherein: R 1 , R 2 , R 3 and R 4 independently are C 1 -C 8 alkyl and X, W, Z and U are hydrogen.
The compounds of this invention possess asymmetric centers and thus exist in different isomeric forms. All such forms are included within the scope of this invention. Specifically, the compounds have an asymmetric center at the carbon atom to which the ester moiety, --CO 2 R 2 , is attached. Whenever that ester moiety is below the plane of the piperidine ring (i.e. down) that stereochemical configuration is denoted as the alpha (α)-isomer. Similarly, whenever that ester moiety is above the plane of the piperidine ring (i.e. up) that stereochemical configuration is denoted as the beta (β)-isomer.
Illustrative of the compounds of this invention are the following compounds of the formulae (I) and (II) which are the α-isomer, the β-isomer or mixtures thereof:
(1) Dimethyl 5,8-dihydro-4,6-dimethyl-4,8-methano-4H-thieno[2,3-a][4]benzazocine-7,13.beta. dicarboxylate [Formula (I) where n is O, A is sulfur, B is --CH═CH--, R is hydrogen, R 1 , R 2 , R 3 and R 4 are methyl and X, W, Z and U are hydrogen];
(2) Dimethyl 3a,4,6a,7-tetrahydro-4,6-dimethyl-4,8-methanoindeno[2,1-c]thieno[2,3-d]pyridine-6a,12β-dicarboxylate [Formula (II) where n is O, A is sulfur, B is --CH═CH--, R 1 , R 2 , R 3 and R 4 are methyl and X, W, Z and U are hydrogen];
(3) Dimethyl 5,8-dihydro-4,6-dimethyl-4,8-methano-4A-thieno[3,2-a][4]benzazocine-7,13.beta.-dicarboxylate [Formula (I) where n is O, A is --CH═CH--, B is sulfur, R is hydrogen, R 1 , R 2 , R 3 and R 4 are methyl and X, W, Z and U are hydrogen]; and
(4) Dimethyl 4,6a,7,12-tetrahydro-4,6-dimethyl-4,7-methano-3aH-benzo[g]furo[2,3-d]isoquinoline-6a,13β-dicarboxylate [Formula (II) where n is 1, A is --CH═CH--, B is oxygen, R 1 , R 2 , R 3 and R 4 are methyl and X, W, Z and U are hydrogen].
The pharmaceutically acceptable salts are those acid addition salts of non-toxic, pharmaceutically acceptable acids and include salts of inorganic acids such as hydrochloric, hydrobromic, hydroiodic, phosphoric, sulfuric, nitric and the like, and organic acids such as trifluoroacetic, and trichloroacetic, acetic and the like and include acids related to the pharmaceutically acceptable salts listed in Journal of Pharmaceutical Science, 66, 2 (1977) and incorporated herein by reference.
The compounds of this invention are conveniently prepared from known or readily obtainable starting materials utilizing the general synthetic pathway described below: ##STR4##
The aryl aldehyde (1), wherein n, A, B, X, W, Z and U are described above, is reacted with an appropriately substituted 3-aminopropenoate, such as methyl 3-aminocrotonate, and an appropriately substituted 3-oxo-propanoate, such as methyl acetoacetate, under the general Hantzsch reaction conditions to afford the aryl dihydropyridine compound (2).
The aryl dihydropyridine compound (2) is then treated at -10° to 50° C., preferably at ambient temperature, with between 0.5 and 5.0 equivalent, preferrably 1.0 equivalent, of a Lewis acid in an inert solvent to yield the compound of formula (I). Examples of such Lewis acids include aluminum chloride, titanium tetrachloride, trimethylsilyl trifluoromethanesulfonate and tin tetrachloride. Exemplifying the inert solvents employed in this cyclization reaction are ethers, chlorinated hydrocarbons and aromatic hydrocarbons. The preferred solvents are methylene chloride, chloroform and benzene.
As indicated above, the compounds of this invention are useful as calcium channel blockers, and thus have broad pharmacological utility in that they exhibit (i) pronounced and long-lasting vasodilating effect accompanied by an energy-sparing effect on cardiac metabolism; (ii) antiarrythmic and antianginal action on cardiac muscle; (iii) vascular spasmolytic action; (iv) antihypertensive action; (v) spasmolytic action on the smooth muscle of the gastrointestinal and urogenital tracts and the cerebrovascular and respiratory system; (vi) useful antihypercholesterolemic and antilipademic action; (vii) protection of the ischemic myocardium; (viii) inhibition of irritable bowel syndrome and esophageal spasm; and, (ix) inhibition of migraine. Some of these compounds are also useful cardiotonic agents.
The representative compounds of the present invention were found to inhibit vascular calcium contraction, reduce cardiac contractile force, inhibit calcium-mediated tracheal contraction, inhibit calcium uptake in pituitary cells, or displace triturated nitrendipine from membrane.
The compounds of the present invention can be administered in any suitable form; e.g. orally, sublingually, transdermally, or parenterally; i.e. intravenously, interperitoneally, etc. Thus, the compounds can be offered in a form (a) for oral administration e.q. as tablets in combination with other compounding ingredients customarily used such as talc, vegetable oils, polyols, benzyl alcohols, gums, gelatin, starches and other carriers; dissolved or dispersed or emulsified in a suitable liquid carrier; in capsules or encapsulated in a suitable encapsulating material; or (b) for sublingual administration; e.g., nitroglycerine tablets, lactose tablets, and the like, for rapid dissolution or high molecular weight methylcellulose tablets, carboxymethylcellulose tablets, and the like, for slower, time-releasing delivery; or, (c) for parenteral administration e.g. dissolved or dispersed in a suitable liquid carrier or emulsified.
The pharmaceutical preparations thus described are made following the conventional techniques of the pharmaceutical chemist as appropriate to the desired end product.
The ratio of active compound to compounding ingredients i.e. carrier, diluent etc. will vary as the dosage form requires. Whatever form is used, the amount of compound of the present invention administered should be sufficient to achieve the pharmaceutical and/or therapeutic effect desired or required in the patient. Generally, doses of the compounds of the invention of from about 30 to about 3000 mg per day may be used, preferably about 100 to about 1000 mg per day. Dosages may be single or multiple depending on the daily total required and the unit dosage administered. Of course, the dose will vary depending upon the nature and severity of disease, weight of the patient, and other factors which a person skilled in the art will recognize.
It is often advantageous to administer compounds of this invention in combination with angiotensin converting enzyme inhibitors and/or antihypertensives and/or diuretics and/or β-blocking agents. For example, the compounds of this invention can be given in combination with such compounds as enalapril, hydralazine hydrochloride, hyrochlorothiazide, methyldopa, timolol, and the like, as well as admixtures and combinations thereof.
Typically, the individual daily dosages for these combinations can range from about one-fifth of the minimally recommended clinical dosages to the maximum recommended levels for the entities when they are given singly. Naturally, these dose ranges can be adjusted on a unit basis as necessary to permit divided daily dosages and, as noted above, can be varied depending on the nature and severity of the disease, weight of patient, special diets and other factors.
The following Examples are provided to further illustrate the best mode currently known for preparing the compounds and compositions of this invention, but are not to be construed as limiting this invention in any manner.
EXAMPLE 1
Preparation of Dimethyl 5,8-dihydro-4,6-dimethyl-4,8-methano-4H-thieno[2,3-a][4]benzazocine-7,13.beta.-dicarboxylate and Dimethyl 3a,4,6a,7-tetrahydro-4,6-dimethyl-4,8-methanoindeno[2,1-c]thieno[2,3-d]pyridine-6a,12β-dicarboxylate
(a) 2-(2-Thienyl)benzaldehyde (1a)
To a solution of 3-bromothiophene (30 mmol) in tetrahydrofuran (20 mL) at -78° C. under nitrogen was added dropwise n-butyllithium in hexane (30 mmol). The mixture was stirred for 45 minutes and magnesium bromide etherate (45 mmol) was added portionwise. The reaction mixture was then allowed to warm to -20° C. over 45 minutes. This mixture was added to a suspension of di-μ-acetato-bis[2-(N-phenylformimidoyl)phenyl]dipalladium (15 mmol) [Onoue et al., J. Organometallic Chem., 43, pp. 431-436 (1972)] and triphenylphosphine (60 mmol) in benzene (250 mL) and the reaction mixture stirred at ambient temperature overnight. The cooled reaction mixture was quenched with 1N hydrochloric acid (175 mL), was stirred for 2.5 hours, filtered, and the phases separated. The aqueous phase was extracted with diethyl ether (2×150 mL) and the combined organic phases were washed with brine and dried over anhydrous sodium sulfate. After filtration, the solvent was removed in vacuo to give an oil which was purified by flash chromatography on silica gel eluted with ethyl acetate:hexane (3:97) to yield Compound 1a as an oil (R f =0.4).
(b) Dimethyl 2,6-dimethyl-4-[2-(2-thienyl)phenyl]-1,4-dihydropyridine-3,5-dicarboxylate (1b)
To a solution of Compound 1a (0.5 mmol) in methanol (5 mL) was added methyl acetoacetate (1.0 mmol) and concentrated ammonium hydroxide (1.0 mmol) and the reaction mixture was refluxed for 4 days. The solvent was removed in vacuo and the residue purified by flash chromatography on silica gel eluted with diethyl ether:hexane (1:1) and trituration with diethyl ether:hexane (1:2) to afford Compound 1b as a white solid (m.p. 173°-175° C.).
(c) Dimethyl 5,8-dihydro-4,6-dimethyl-4,8-methano-4H-thieno[2,3-a][4]benzazocine-7,13.beta.-dicarboxylate (1A) and Dimethyl 3a,4,6a,7-tetrahydro-4,6-dimethyl-4,8-methanoindeno[2,1-c]thieno[2,3-d]pyridine-6a,12β-dicarboxylate (1B)
To a solution of Compound 1b (0.8 mmol) in chloroform (20 mL) at ambient temperature under nitrogen was added aluminum chloride (1.0 mmol) and the resulting suspension was stirred overnight. The cooled reaction mixture was quenched in water (20 mL), made basic with saturated aqueous sodium bicarbonate and diluted with chloroform (100 mL). The organic phase was separated, washed with brine and dried over anhydrous sodium sulfate. The solvent was removed in vacuo and the residue was purified by flash chromatography on silica gel eluted with diethyl ether:hexane (2:1) to give Compound 1A (R f =0.4, m.p. 185°-193° C.) and Compound 1B (R f =0.3, m.p. 167°-173° C.).
EXAMPLE 2
Preparation of Dimethyl 5,8-dihydro-4,6-dimethyl-4,8-methano-4H-thieno[3,2-a][4]benzazocine-7,13.beta.-dicarboxylate
(a) 2-(3-Thienyl)toluene (2a)
To a solution of 2-bromotoluene (11.7 mmol) in tetrahydrofuran (25 mL) at -78° C. under nitrogen was added n-butyllithium in hexane (11.7 mmol) and the resulting yellow suspension stirred for 45 minutes at -78° C. To this suspension at -78° C. was added magnesium bromide etherate (11.5 mmol) and after stirring for 15 minutes at -70° C., the reaction mixture was allowed to warm to ambient temperature over 45 minutes. The resultant solution was added at ambient temperature to a suspension of 3-bromothiophene (11.0 mmol) and bis(1,2-diphenylphosphino)ethane nickel (II) chloride (0.05 mmol) in diethyl ether (25 mL) that has been stirred for 15 minutes. The reaction mixture was heated at reflux for 16 hours and then cooled in an ice bath. To the cooled reaction mixture was added dilute hydrochloric acid (20 mL) and then diethyl ether (50 mL). The organic phase was washed with saturated aqueous sodium bicarbonate, brine and dried over anhydrous sodium sulfate. The solvent was removed in vacuo and the residue fractionated to give Compound 2a as a clear oil (b.p. 110°-114° C./7 mm).
(b) 2-(3-Thienyl)-α-bromotoluene (2b)
To a solution of Compound 2a (7.23 mmol) in carbon tetrachloride (150 mL) was added N-bromosuccinimide (7.5 mmol) and benzoyl peroxide (0.1 g). The solution was heated at reflux and irradiated with 250 watt sunlamp for 2 hours. The cooled reaction mixture was filtered through a pad of silica gel and the silica gel washed with diethyl ether (3×75 mL). The solvent was removed in vacuo and the residue fractionated to afford Compound 2b as a clear oil (b.p. 100°-103° C./0.1 mm).
(c) 2-(3-Thienyl)benzaldehyde (2c)
To a solution of Compound 2b (1.98 mmol) in chloroform (5 mL) was added pyridine (9.88 mmol) and the reaction mixture heated at reflux for 1 hour under nitrogen. The solvent was removed in vacuo and the residue triturated with diethyl ether to give a white solid. The solid was dissolved in 95% aqueous ethanol (10 mL ) and N,N-dimethyl-4-nitrosoaniline (1.98 mmol) was added with stirring followed by the addition of sodium hydroxide (4.0 mmol) in water (3 mL). The reaction mixture was stirred for 16 hours at ambient temperature and then 6N hydrochloric acid (3 mL) was added. After 30 minutes, the solvent was removed in vacuo and the residue was diluted with water (10 mL) and extracted with diethyl ether (2×30 mL). The combined organic phases were washed with saturated aqueous sodium bicarbonate, brine and the solvent removed in vacuo to give crude Compound 2c as an oil.
(d) Dimethyl 2,6-dimethyl-4-[2-(3-thienyl)phenyl]-1,4-dihydropyridine-3,5-dicarboxylate (2d)
To a solution of crude Compound 2c (10.6 mmol) in methanol (10 mL) was added methyl acetoacetate (10.6 mmol), methyl 3-aminocrotonate (10.6 mmol) and concentrated ammonium hydroxide (1 drop). The reaction mixture was heated at reflux under nitrogen for 4 days. The solvent was removed in vacuo and the residue purified by flash chromatography on silica gel eluted with diethyl ether:hexane (2:1) and trituration with diethyl ether:hexane (1:2) to yield Compound 2d as a pale yellow solid (m.p. 164°-166° C.).
(e) Dimethyl 5,8-dihydro-4,6-dimethyl-4,8-methano-4H-thieno[3,2-a][4]benzazocine-7,13.beta.-dicarboxylate
To a solution of Compound 2d (0.83 mmol) in chloroform (20 mL) was added aluminum chloride (1.0 mmol). After stirring for 24 hours at ambient temperature under nitrogen, the reaction was quenched with water and then neutralized with saturated aqueous sodium bicarbonate. The reaction mixture was extracted with methylene chloride (3×25 mL) and the combined organic phase was washed with brine and dried over anhydrous sodium sulfate. The solvent was removed in vacuo and the residue purified by flash chromatography on silica gel eluted with diethyl ether:hexane (1:1) to give the desired compound as the hemi-hydrate (m.p. 223°-233° C.).
EXAMPLE 3
Preparation of Dimethyl 4,6a,7,12-tetrahydro-4,6-dimethyl-4,7-methano-3a H-benzo[g]furo[2,3-d]isoquinoline-6a,13β-dicarboxylate
(a) 2-Bromo-α-(3-thienyl)benzylalcohol (3a)
To a solution of n-butyllithium in hexane (2.7 mmol) and diethyl ether (2.5 mL) at -78° C. under nitrogen was added dropwise a solution of 3-bromofuran (3.0 mmol) in diethyl ether (1 mL). After stirring for 45 minutes at -78° C., to the reaction mixture was added dropwise 2-bromobenzaldehyde (2.7 mmol) in diethyl ether (1 mL). The reaction mixture was allowed to warm to ambient temperature and stirred for about 16 hours. The reaction was quenched with saturated aqueous ammonium chloride (1 mL), diluted with water (2 mL) and extracted with diethyl ether (3×10 mL). The combined organic phases were washed with water, and dried over anhydrous sodium sulfate. The solvent was removed in vacuo and the residue purified by flash chromatography on silica gel eluted with ethyl acetate:hexane (1:9) to yield Compound 3a as an oil (R f =0.4).
(b) 2-(3-Furanylmethyl)bromobenzene (3b)
Aluminum chloride (78.0 mmol) dissolved in diethyl ether (40 mL) under nitrogen was added to a suspension of lithium aluminum hydride (78.0 mmol) in diethyl ether (40 mL) under nitrogen at 0° C. To the reaction mixture was added a solution of Compound 3a (52.0 mmol) in diethyl ether (25 mL) at such a rate that reflux was maintained. After an additional 15 minutes at reflux, the reaction mixture was cooled to 0° C. and dilute 3M sulfuric acid was added dropwise until the evolution of gas stopped. The reaction mixture was then poured onto ice (100 mL) and 3N hydrochloric acid (25 mL) and then extracted with diethyl ether (2×50 mL). The combined organic phases were washed with 3N hydrochloric acid, saturated aqueous sodium bicarbonate, water and brine and then dried over anhydrous sodium sulfate. The solvent was removed in vacuo and the residue purified by flash chromatography on silica gel eluted with ethyl acetate:hexane (2:98) to afford Compound 3b as an oil (R f =0.4).
(c) 2-(3-Furanylmethyl)benzaldehyde (3c)
To a solution of Compound 3b (0.5 mmol) in tetrahydrofuran (2 mL) at -78° C. under nitrogen was added n-butyllithium in hexane (0.5 mmol). After 30 minutes, a solution of N- formylpiperidine (0.55 mmol) in tetrahydrofuran (0.5 mL) was added dropwise at -78° C. The reaction mixture was stirred for 5 hours while allowing it to warm to -10° C. The reaction was quenched with saturated aqueous ammonium chloride (1 mL) and diluted with diethyl ether (10 mL). The aqueous phase was extracted with diethyl ether (2×10 mL) and the combined organic phases were washed with saturated aqueous ammonium chloride (3×5 mL) and brine and then dried over anhydrous sodium sulfate. The solvent was removed in vacuo and the residue purified by flash chromatography on silica gel eluted with ethyl acetate:hexane (2:98) to afford Compound 3c as an oil (R f =0.2).
(d) Dimethyl 2,6-dimethyl-4-[2-(3-furanylmethyl)]phenyl-1,4-dihydropyridine-3,5-dicarboxylate (3d)
To a solution of Compound 3c (1.0 mmol) in methanol (2 mL) was added methyl acetoacetate (2.2 mmol) and concentrated ammonium hydroxide (2.2 mmol). Additional ammonium hydroxide (2 drops) was added and the reaction mixture heated to reflux for 3 hours. The solvent was removed in vacuo and the residue purified by flash chromatography on silica gel eluted with methanol:chloroform (1:99) to yield Compound 3d as a solid (m.p. 140°-143° C.).
(e) Dimethyl 4,6a,7,12-tetrahydro-4,6-dimethyl-4,7-methano-3a H-benzo[g]furo[2,3-d]-isoquinoline-6a,13β-dicarboxylate
A solution of Compound 3d (0.80 mmol) in ethanol-free chloroform (8 mL) was added to a suspension of aluminum chloride (2.4 mmol) in ethanol-free chloroform (24 mL) at ambient temperature under nitrogen. After 4 hours, the reaction was quenched with dilute aqueous sodium bicarbonate (5 mL) and then extracted with methylene chloride (2×20 mL). The combined organic phases were washed with saturated aqueous sodium bicarbonate, brine and dried over anhydrous sodium sulfate. The solvent was removed in vacuo and the residue purified by flash chromatography on silica gel eluted with methanol:chloroform (1:99) to give the desired product as a solid (m.p. 128°-131° C.).
EXAMPLES 4-20
Utilizing the general procedure of Examples 1, 2 or 3 and starting with appropriately substituted aryl aldehydes the following compounds of the formulae (I) and (II) wherein B is --CH═CH-- and R is hydrogen are prepared.
__________________________________________________________________________Compound n A R.sup.1 R.sup.2 R.sup.3 R.sup.4 X W Z U__________________________________________________________________________4 0 O Me Et Et Me H H H H5 0 S Et Et Et Et H H H H6 0 O H Me Me Et H OMe H H7 0 O Me Me Me Me H H H H8 1 O Me Et Et Me H NO.sub.2 H H9 1 O Me Me Me Me H CF.sub.3 H H10 2 O Me ##STR5## ##STR6## Me H H H H11 2 S Me Me Me Me H H H H12 1 O CH.sub.2 CHCH.sub.2 Me Me Me Cl Cl H H13 2 O CH.sub.2 OH Et Et Me H H Me H14 1 S ##STR7## Me Me Me OMe H H H15 1 O Me CH.sub.2 CHCH.sub.2 CH.sub.2 CHCH.sub.2 Me H Me H H16 2 S Me CH.sub.2 CH.sub.2 OH Me Me H Cl H H17 1 O Me Me CH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 OCH.sub.3 Me H H H F18 1 S Me CH.sub.2 CH.sub.2 NMe.sub.2 CH.sub.2 CH.sub.2 NMe.sub.2 Me H CF.sub.3 H H19 1 O Me ##STR8## Et Me H H H CN20 1 O Me ##STR9## ##STR10## Me H H H H21 1 NH Me Me Me Me H Cl H H__________________________________________________________________________
It should be noted that for the preparation of Compounds 13 and 16 the hydroxyalkyl moiety is acylated with acetic anhydride prior to cyclization and then deacylated with sodium hydroxide.
EXAMPLES 22-39
Utilizing the general procedures of Examples 1, 2 or 3 and starting with appropriately substituted aryl aldehydes the following compounds of the formulae (I) and (II) wherein A is --CH═CH-- and R is hydrogen are prepared.
__________________________________________________________________________Compound n B R.sup.1 R.sup.2 R.sup.3 R.sup.4 X W Z U__________________________________________________________________________22 0 O Me Et Et Me H H H H23 0 S Et Et Et Et H H H H24 0 O H Me Me Et H OMe H H25 0 O Me Me Me Me H H H H26 1 O Me Et Et Me H NO.sub.2 H H27 1 O Me Me Me Me H CF.sub.3 H H28 2 O Me ##STR11## ##STR12## Me H H H H29 2 S Me Me Me Me H H H H30 1 O CH.sub.2 CHCH.sub.2 Me Me Me Cl Cl H H31 2 O CH.sub.2 OH Et Et Me H H Me H32 1 S ##STR13## Me Me Me OMe H H H33 1 O Me CH.sub.2 CHCH.sub.2 CH.sub.2 CHCH.sub.2 Me H Me H H34 2 S Me CH.sub.2 CH.sub.2 OH Me Me H Cl H H35 1 O Me Me CH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 OCH.sub.3 Me H H H F36 1 S Me CH.sub.2 CH.sub.2 NMe.sub.2 CH.sub.2 CH.sub.2 NMe.sub.2 Me H CF.sub.3 H H37 1 O Me ##STR14## Et Me H H H CN38 1 O Me ##STR15## ##STR16## Me H H H H39 1 NH Et Et Et Et H H Cl H__________________________________________________________________________
It should be noted that for the preparation of Compounds 31 and 34 the hydroxyalkyl moiety is acylated with acetic anhydride prior to cyclization and then deacylated with sodium hydroxide.
EXAMPLES 40-43
Utilizing the general procedures of Examples 1, 2 or 3 and starting with the appropriately substituted aryl aldehyde the following compounds of the formulas (I) and (II) wherein R is hydrogen are prepared.
__________________________________________________________________________Compound n A B R.sup.1 R.sup.2 R.sup.3 R.sup.4 X W Z U__________________________________________________________________________40 0 O ##STR17## Me Me Me Me H OMe H H41 1 NH ##STR18## Et Et Et Et H H H Cl42 2 ##STR19## S Me Me Me Me H CF.sub.3 H H43 1 ##STR20## NH Et Me Me Et H H Me H__________________________________________________________________________
EXAMPLE 44
As a specific embodiment of a composition of this invention an active ingredient, such as dimethyl 5,8-dihydro-4,6-dimethyl-4,8-methano-4H-thieno[2,3-a][4]benzazocine-7,13.beta.-dicarboxylate is formulated to yield 5000 compressed tablets, each containing 50 mg of the active ingredient, as follows:
______________________________________Active ingredient 250 gramsStarch 70 gramsDibasic calcium phosphate hydrous 500 gramsCalcium stearate 2.5 grams______________________________________ | Novel substituted and bridged pyridine compounds useful as calcium channel blockers, pharmaceutical compositions thereof, and methods of treatment are disclosed. | 2 |
BACKGROUND OF THE INVENTION
[0001] Paper is typically treated with sizing composition to impart resistance to penetration and wetting of ink and aqueous liquid. The term “paper” in the present invention refers to all forms of paper, paperboard and related cellulosic products. There are two main categories of paper sizes: internal sizes and surface sizes. Internal sizes are added to the cellulosic or other fiber stock from which paper is later made, while surface sizes are applied to the surface of paper after the paper has been formed. Paper may be sized to a variety of degrees and for a variety of purposes. Writing paper is sized to prevent the spread of ink, while milk carton stock is sized to retain the strength of the carton and to prevent any fluid flow through the carton walls and edges.
[0002] Surface sizing has several advantages over internal sizing. Surface sizing provides substantial savings in sizing cost, since almost all of the sizing composition is retained on the surface of the treated paper. Furthermore, surface sizing imparts enhanced paper quality such as printability, in addition to resistance to liquid penetration. However, surface sizing has some drawbacks. Surface sizes are typically added in a size press, which is continuously operated at a high speed and under a high pressure. In such an operation, surface sizes may suffer from heat and mechanical shock, leading to gradually reduction of solubility and consequently formation of scum. The presence of scum reduces sizing efficiency, and the deposition of scum on the surface of paper adversely impacts the paper appearance.
[0003] The most widely used surface size is starch. However, starch sizing alone has not been effective in providing liquid resistance to paper and paperboard products. Various kinds of natural and synthetic resins have been used as surface sizing compositions in combination with starch. Some typical surface sizes are modified rosins, modified petroleum resins, polyurethane dispersion, and copolymers of styrene and vinylic monomers such as maleic anhydride, (meth)acrylic acid and its alkyl ester, and (meth)acrylamide. In particular, styrene-maleic anhydride copolymer resins are commonly used for surface sizing. However, polymeric surface sizing compositions are less effective in sizing than reactive sizes such as alkylketene dimers (AKD) and alkenylsuccinic anhydrides (ASA). U.S. Pat. No. 6,162,328 teaches that surface sizing efficiency of polymeric surface size is enhanced when it is used in combination with reactive sizes. U.S. Pat. No. 5,138,004 teaches the use of styrene-acrylic copolymers as surface sizes with improved sizing efficiency for alkaline paper. To address the scum problem resulting from heat and mechanical shock of surface size during sizing application, U.S. Pat. No. 4,030,970 discloses a surface sizing composition comprises a copolymer of (meth)acrylic ester, alkali metal salts of (meth)acrylic acid, and (meth)acrylic acid or its ammonium or lower alkyl amine salts thereof. This surface sizing compositions has high heat and mechanical stabilities and produces substantially no scum during sizing operation even after 8 hours.
[0004] Rosin-based compounds have been used for surface sizing. U.S. Pat. No. 6,048,439 discloses a modified rosin surface sizing emulsion produced by mixing emulsified rosin with a water soluble salt of an alkylene-acrylic acid copolymer. The modified rosin surface sizing emulsion has improved compatibility with an anionic starch solution, and significantly increased emulsion stability. Furthermore, the modified rosin surface sizing emulsion enhances runnability of the paper machine and reduces undesirable scum deposits on machine parts such as the dryer cans and calendar rolls. U.S. patent application No. 6,074,468 teaches a surface sizing composition comprising a thermoplastic resin, starch, and surfactant that enhances process runnability and provides sized paper with improved print properties.
[0005] Notwithstanding many surface sizing compositions are known, there is constantly a need for improved surface sizing compositions capable of improving print characteristics and enhancing process runnability. Adhesion of inks, such as toner inks, to the sized paper is one critical performance required to improve print quality. Styrene maleic copolymers and styrene acrylic copolymers are widely used surface sizes. However, they commonly generate high foam level during papermaking process that often results in troublesome processing and undesired paper appearance.
[0006] Furthermore, there is a need for surface size that is less costly, yet as efficient as the commonly used styrene-maleic anhydride copolymer surface size.
[0007] Therefore, it is an object of the present invention to provide a surface sizing composition having increased sizing efficiency, higher heat and mechanical stability, improved process runnability, and enhanced print characteristics. In particular, the present invention is to provide surface sizing composition that is less costly than styrene-maleic anhydride copolymer, yet having equal, if not improved, sizing efficiency.
[0008] Another object of the present invention is to provide a method for producing paper surface sized with the invention sizing composition.
[0009] A further object of the present invention is to provide paper sized with the invention surface sizing composition.
[0010] Other objects and advantages of the present invention will become apparent from the following detailed description.
SUMMARY OF THE INVENTION
[0011] The present invention relates to surface sizing compositions, methods for making such compositions, processes for sizing paper products using such compositions, and paper products which have been sized with such compositions. In particular, the invention relates to novel surface sizing compositions comprising rosin-based component and styrene-carboxylic copolymer.
DETAILED DESCRIPTION OF THE INVENTION
[0012] A surface sizing composition of the present invention comprises at least one rosin or rosin derivative and at least one styrene-carboxylic polymer.
[0013] In one embodiment of the present invention, a surface sizing composition comprises:
(a) about 50%-90% weight of rosin or rosin derivative; and (b) about 10%-50% weight of styrene-carboxylic polymer.
[0016] Rosins that are suitable for use in the present invention include tall oil rosin, gum rosin, wood rosin, and mixture thereof. Tall oil rosin is preferred. Rosin derivatives that are suitable for use in the process of the invention include, but are not limited to, the following: hydrogenated rosins, disproportionated rosins, formaldehyde-treated rosins, dimerized rosins, polymerized rosin, fumarated rosins, maleated rosins, styrenated rosins, phenolic-modified rosins, acrylic-modified rosins, hydrocarbon-modified rosins, rosin-vinylic copolymers, rosin salts, hydrogenated rosin salts, disproportionated rosin salts, formaldehyde-treated rosin salts, dimerized rosin salts, polymerized rosin salts, fumarated rosin salts, maleated rosin salts, styrenated rosin salts, phenolic-modified rosin salts, acrylic-modified rosin salts, hydrocarbon-modified rosin salts, rosin-vinylic copolymer salts, rosin esters, hydrogenated rosin esters, disproportionated rosin esters, formaldehyde-treated rosin esters, dimerized rosin esters, polymerized rosin esters, fumarated rosin esters, maleated rosin esters, styrenated rosin esters, phenolic-modified rosin esters, acrylic-modified rosin esters, hydrocarbon-modified rosin esters, rosin-vinylic copolymer esters, rosin amides, hydrogenated rosin amides, disproportionated rosin amides, formaldehyde-treated rosin amides, dimerized rosin amides, polymerized rosin amides, fumarated rosin amides, maleated rosin amides, styrenated rosin amides, phenolic-modified rosin amides, acrylic-modified rosin amides, hydrocarbon-modified rosin amides, rosin-vinylic copolymer amides, and mixture thereof. Preferred rosin derivatives for the present invention are fumarated rosins, maleated rosins, rosin salts, rosin esters, and rosin amides.
[0017] Styrene-carboxylic polymers suitable for the present invention include the polymerization product of: (i) at least one monomer selected from the group consisting of acrylic acid, methacrylic acid, fumaric acid, crotonic acid, itaconic acid, maleic acid, maleic anhydride, carboxylic acrylics, and their corresponding esters thereof, and (ii) at least one styrenic monomer. Preferred styrene-carboxylic polymers are styrene-acrylic copolymer and styrene-maleic anhydride copolymer.
[0018] Styrenic monomers suitable for the present invention include, but are not limited to, alpha-methyl styrene, styrene, vinyl toluene, tertiary butyl styrene, ortho-chlorostyrene and mixtures thereof.
[0019] A process for producing surface sized paper of the present invention comprises:
(a) providing an aqueous pulp suspension; (b) sheeting and drying the aqueous pulp suspension to obtain paper; (c) applying to at least one surface of the paper, a surface size composition comprising at least one rosin or rosin derivative and at least one styrene-carboxylic polymer; and (d) drying the paper.
[0024] In one embodiment of the present invention, a process for producing surface sized paper comprises:
(a) providing an aqueous pulp suspension; (b) sheeting and drying the aqueous pulp suspension to obtain paper; (c) applying to at least one surface of the paper, a surface size composition comprising about 50%-90% weight of rosin or rosin derivative and about 10%-50% weight of styrene-carboxylic polymer; and (d) drying the paper.
[0029] In one embodiment of the present invention, the invention surface sizing components were applied to the paper at the range from about 0.01% to about 0.5% by weight of solids based on total dry weight of the paper. The invention sizing component may be applied to the paper in step (c) using a variety of known application means including, but are not limited to, size press and water-box.
[0030] In one embodiment of the present invention, internal sizes such as rosin sizes, AKD and ASA may be added to the aqueous pulp suspension prior to step (b). Furthermore, other surface sizing compositions may be used for step (c) in combination with the invention surface sizing composition to enhance sizing efficiency.
[0031] In one embodiment of the present invention, the invention surface sizing compositions may further comprise other components that assist the papermaking process or enhance properties of paper such as protective colloids, starch derivatives, cellulose derivatives, polymeric materials, and surfactants. Such components may be added in the papermaking process at the same stage as the surface sizing compositions, or added separately.
[0032] The effectiveness of surface sizing was determined using Hercules Size Test (HST), which is an industry standard test for measuring degree of sizing as defined in the tappi method T530 pm-89. The HST value, in seconds, is the time taken for a color test solution to penetrate into and through the sized paper. The higher HST values, the higher paper resistance to liquid penetration, and thereby the more effective surface sizing.
[0033] Furthermore, the effectiveness of surface sizing was determined using a 2 minute Cobb Test, which is an industry standard test as defined by tappi method T441. The Cobb value, in grams/square meter, is the mass of water absorbed by the sized paper over a 2 minute period. The lower the Cobb value, the lower level of water being absorbed on the sized paper, and thereby the more effective surface sizing.
[0034] In addition, the invention surface size compositions were evaluated for toner adhesion and foam formation, the two properties that significantly impact print quality and processability of the sized paper.
[0035] The following detailed description illustrates embodiments of the present invention; however, it is not intended to limit the scope of the appended claims in any manner.
[0036] The invention surface sizing composition were evaluated and compared to other surface sizes commonly used in the industry: polyurethane colloidal dispersion JETSIZE AP15 available from Eka Chemicals, styrene maleic copolymer SCRIPSET 740 from Hercules, styrene acrylic copolymer JONREZ A-2331 from MeadWestvaco, and alcohol soluble maleic rosin ester JONREZ H-2735 from MeadWestvaco. Furthermore, sizing performance of the invention sized paper was compared to two controls: one was plain paper without surface sizing, and the other was paper surface sized with starch only.
[0037] Prior to paper application, surface sizing compositions were formulated with ethylated starch PENFORD GUM 280 from Penford at 10:90 dry weight ratio of surface size to starch. The formulated surface sizing compositions were about 10% solids.
[0038] Formulated surface sizing composition was applied to the internally sized paper having properties as listed in Table 1 , using a flooded nip size press. The sizing efficiencies of the invention surface size compositions were evaluated using HST values and Cobb values, and compared to those of known surface sizing compositions.
[0000]
TABLE 1
Basis Weight
55 g/sm
Furnish
85% hardwood, 15% softwood
Ash Content
0%
Internal Size
1 lb/ton of ASA internal size
Freeness
350 ± 25
Pick up
29 lbs/Ton
[0039] Paper surface sized with the invention surface sizing composition of Example 2 showed a HST value of 150, while the paper surface sized with starch had a HST value of only 28. The HST values of paper surface sized with styrene maleic copolymer SCRIPSET 740 and polyurethane colloidal dispersion JETSIZE AP15 were 148 and 110, respectively. (Table 2) The paper sized with the invention surface sizing composition showed high HST value approaching that of paper sized with styrene maleic copolymer SCRIPSET 740; therefore, the invention composition had high sizing efficiency that about the same level as styrene maleic copolymer.
[0000]
TABLE 2
Surface Size
HST Value
Starch
28
Surface size of Example 2
150
Styrene maleic copolymer
148
Polyurethane colloidal dispersion
110
[0040] Each sized paper was also evaluated for its sizing efficiencies based on Cobb values. (Table 3)
[0041] Paper surface sized with the invention sizing composition of Example 2 showed a Cobb value of 23, which was the same as that of paper surface sized with styrene maleic copolymer SCRIPSET 740. The Cobb value measurement confirmed that the invention surface sizing composition had about the same sizing efficiency as styrene maleic copolymer surface size.
[0000]
TABLE 3
Surface Size
Cobb Value
Starch
44
Surface size of Example 2
23
Styrene maleic anhydride copolymer
23
[0042] Furthermore, the invention surface sizing compositions were applied to the non-internally sized paper.
[0043] The paper sized with the invention surface sizing composition of Example 2 showed a HST value of 18, while the plain paper and the paper surface sized with starch each showed a HST value of only 1. (Table 4)
[0000]
TABLE 4
Surface Size
HST Value
None
1
Starch
1
Surface size of Example 2
18
Polyurethane colloidal dispersion
14
Alcohol soluble maleic rosin ester
13
Styrene acrylic copolymer
6
[0044] The paper surface sized with polyurethane colloidal dispersion JETSIZE AP15 showed a HST value of 14. The other known surface sizes alcohol soluble maleic rosin ester JONREZ H-2735 and styrene acrylic copolymer JONREZ A-2331 provided paper with HST values of 13 and 6, respectively. The paper sized with the invention surface sizing composition showed higher HST value than those sized with polyurethane colloidal dispersion and styrene-acrylic ester emulsion; therefore, the invention composition had higher sizing efficiency than those of polyurethane colloidal dispersion and styrene-acrylic ester emulsion known in the industry.
[0045] Toner adhesion property was tested for paper surface sized with the invention sizing composition of Example 2. (Table 5)
[0000]
TABLE 5
Surface Size
% Retained Optical Density
Starch
94
Surface size of Example 2
90
Styrene maleic anhydride copolymer
84
Polyurethane colloidal dispersion
79
[0046] Toner ink was applied to the sized paper using a HP LaserJet 4200tn printer. After ink application, an initial optical density of the print was measured using an E-Rite 418. Adhesive tape was then applied onto the surface of the print, followed by a 90 degree pull. The optical density of the print was measured again, and the percentage retained optical density of toner was calculated. Paper with higher toner adhesion is less affected by a 90 degree adhesion tape pull, thereby showing a higher % retained optical density compared to the paper with lower toner adhesion. The control paper surface sized with only starch showed a retained optical density of 94%, while the paper sized with the invention sizing composition of Example 2 showed a retained optical density of 90%. The paper surface sized with styrene maleic copolymer SCRIPSET 740 and polyurethane colloidal dispersion JETSIZE AP15 showed % retained optical density of 84 and 79, respectively. The invention surface sizing composition provided superior toner ink adhesion to the commonly used surface sizes.
[0047] Foaming of the invention surface sizing composition was measured and compared to those of the commonly used surface size styrene maleic copolymer SCRIPTSET 740. Each surface size was diluted to about 10% solids in a glass jars, and the resulting glass jar was shaken for 30 seconds. The level of foam in each jar (in millimeter height) was measured two minutes after shaking. Surface size with higher potential for foaming during papermaking process showed higher level of foam. The invention surface sizing composition of Example 3 showed only 9 mm of foam, compared to the commonly used styrene maleic copolymer surface size at 68 mm of foam. (Table 6). The surface sizing of the present invention showed at least 7 times reduction in foam formation compared to the known styrene maleic copolymer surface size.
[0000]
TABLE 6
Level of Foam
Surface Size
(mm height)
Surface size of Example 3
9
Styrene maleic anhydride copolymer
68
[0048] The invention surface sizing compositions showed superior toner ink adhesion and lower foaming compared to the known surface sizes, while maintaining and if not enhancing the sizing efficiency.
[0049] The foregoing description relates to embodiments of the present invention are exemplary and explanatory only and are not restrictive of the invention, as claimed. Any changes and modifications may be made therein without departing from the scope of the invention as defined in the following claims.
EXAMPLES
Example 1
Rosin Modified Polyamide
[0050] A mixture of rosin and tributylphosphite was heated to 180° C. under nitrogen gas and fumaric acid was added. The temperature was raised to 210° C. and held at that temperature for 90 minutes. A piperazine solution was gradually added to the obtained fumaric-rosin adduct over 2 hours, while the temperature was maintained at about 195-210° C. After an addition of piperazine, the temperature was increased to 220° C. Diethylene glycol was added the resin products until the acid number of resin reached 175 mg KOH/g resin. The rosin modified polyamide resin was then poured into aluminum pans and rapidly cooled.
Example 2
Rosin Amide/Styrene-Acrylic Copolymer Size
[0051] To the aqueous ammonium hydroxide containing isopropyl alcohol, rosin amide resin of Example 1 and styrene-acrylic copolymer were added. The slurry was heated to 80° C. and vigorously agitated for 2 hours. When all the solid resins were completely dissolved, the solution was cooled to 25° C. The obtained solution of rosin amide/styrene-acrylic copolymer surface size had pH of 9.5 and % solids of about 30.5%.
Example 3
Rosin Amide/Styrene-Maleic Anhydride Copolymer Size
[0052] To the aqueous ammonium hydroxide containing isopropyl alcohol, rosin amide resin of Example 1 and styrene-maleic anhydride copolymer were added. The slurry was heated to 80° C. and vigorously agitated for 2 hours. When all the solid resins were completely dissolved, the solution was cooled to 25° C. The obtained solution of rosin amide/styrene-acrylic copolymer surface size had pH of 9.0 and % solids of about 30%. | The present invention relates to surface sizing compositions, methods for making such compositions, processes for sizing paper products using such compositions, and paper products which have been sized with such compositions. In particular, the invention relates to novel surface sizing compositions comprising rosin-based component and styrene-carboxylic copolymer. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains to supporting devices such as those used for temporary warning signs and in particular to such support devices which employ adjustable legs and other adjustable components.
[0003] 2. Description of the Related Art
[0004] Frequently, a need arises to provide temporary warnings alongside vehicle roadways, pedestrian walkways and other locations. It has been found convenient to provide temporary warning systems which are readily assembled from a collapsed or small sized storage configuration of relatively small size. Temporary warning signs typically employ ground-engaging legs configured with a base to support an upright mast. Typically, when the sign stand is deployed, the ground-engaging legs form an angle with the upright mast that is usually larger than 90°. It is generally preferred that a storage configuration be provided in which the legs are selectively collapsed or folded to a position generally parallel with the upright mast, in order to provide a compact storage and size suitable for construction vehicles and the like. Examples of leg release devices may be found in commonly assigned U.S. Pat. Nos. 4,954,008 and 6,315,253. A collapsible sign stand base for use with an upright fiberglass rib is described in U.S. Pat. No. 4,694,601 and other arrangements are shown in U.S. Pat. Nos. 4,548,379; 4,593,879 and 5,340,068. Despite the favorable acceptance of these designs, improvements are continuously being sought.
SUMMARY OF THE INVENTION
[0005] Oftentimes, ground-supporting legs are formed from hollow, rectangular tubing. If possible, it is beneficial to locate components of a leg release assembly within the tubing to prevent unintentional snagging with nearby materials. Furthermore, if most all of the leg release components can be located within the tubing, and optimally a compact storage configuration can be realized. However, until the advent of the present invention, at least some of the leg release components have been mounted outside of the legs, in order to provide a rugged construction, sufficient to adequately retain locking pins in a desired position, despite rough handling associated with construction work, as well as vibrations due to wind gusts. Substantially all of the leg release components employed by the present invention are located within the hollow tubular legs. Exceptions include only the locking pin tip and a smooth actuator button.
[0006] It is an object of the present invention to provide a release device for use with support arrangements, such as those found in sign stands.
[0007] Another object of the present invention is to provide a release device for use with support legs of collapsible sign systems.
[0008] Yet another object of the present invention is to provide leg release devices which can be economically fabricated from a minimum number of inexpensive parts.
[0009] These and other objects according to principles of the present invention are provided in a sign stand assembly which is comprises of a sign panel, a support base, an upright mast joining the sign panel and support base. This support base includes a plurality of plate portions which define a locking recess, a plurality of legs that are pivotally connecting the legs to the plate portions. A locking pin carried on one leg, for movement toward and away from the locking recess defined by one leg. An actuator that has an end within said leg for pivotally engaging the pivotal connection. An opposed end with an outwardly protruding button that partially extends outside the leg and a medial portion within the leg that defines an opening for receiving the locking pin in interlocking engagement therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is perspective view of a sign stand assembly with a release mechanism according to principles of the present invention;
[0011] [0011]FIG. 2 is a perspective view thereof, with the sign stand assembly shown in a collapsed position;
[0012] [0012]FIG. 3 is a perspective view of the support base portion thereof;
[0013] [0013]FIG. 4 is a bottom plan view of the arrangement shown in FIG. 2;
[0014] [0014]FIG. 5 is a cross-sectional view taken along the line 5 - 5 of FIG. 3;
[0015] [0015]FIG. 6 is a plan view of a spring component thereof;
[0016] [0016]FIG. 7 is a plan view of a locking pin component thereof;
[0017] [0017]FIG. 8 is a plan view of an actuator component thereof;
[0018] [0018]FIG. 9 is an elevational view of the actuator component; and
[0019] [0019]FIG. 10 is a fragmentary bottom plan view of the sign stand assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to the drawings, and initially to FIG. 1, the sign stand assembly is generally indicated at 10 . Sign stand assembly includes a sign panel subassembly 12 , which includes a sign panel 14 supported by a horizontal cross member 16 and a vertical cross member 18 , preferably in the form of a fiberglass rib. The bottom portion 24 of the fiberglass rib is mounted in a rib clamping device 34 , which is supported by a vertical body member 30 . Body member 30 is in turn bolted to a bracket 36 resiliently supported by a spring 50 . With reference to FIG. 3, spring 50 is supported by a support assembly 52 including a platform portion 54 supported between side plates 84 . Side plates 84 include ear portions 56 having holes 58 to receive a bolt fastener which provides pivot support for ground-engaging legs 64 (see FIG. 1). Ears 56 further include holes 68 which, as will be seen herein, define an extended or operational configuration of the legs as illustrated in FIG. 1. Ear portions 56 also include holes 72 which define a collapsed storage position for the legs 64 , as illustrated for example in FIG. 2.
[0021] Referring to FIG. 4, ear portions 56 a , 56 b preferably form part of an integral side plate 84 while ear portions 56 c , 56 d form portions of a second side plate 86 . Preferably, side plates 84 , 86 are mirror images of one another although this feature is optional, and can be omitted, if desired. With further reference to FIG. 4, it can be seen that the legs 64 extend outwardly from outer surface portions 84 a , 86 a of side plates 84 , 86 . Pivot members in the form of bolt fasteners 92 pivotally connect legs 64 to the ear portions of side plates 84 , 86 . The legs 64 are located to one side of the ear portions with the bolt fasteners passing through the legs and ear portions. Bolt fasteners 92 have heads located adjacent the inner surfaces 84 b and 86 b . The bolt fasteners 92 extend through legs 64 and are terminated at their free ends by threaded nut fasteners 94 . As can be seen in FIG. 4, the legs 64 comprise hollow tubing and have a preferred generally square cross-sectional shape. If desired, leg 64 can have an elongated, rectangular or non-square cross-sectional shape. With reference to FIGS. 3 and 4, bolts 92 pass through holes 58 formed in the ear portions 56 of plates 84 , 86 .
[0022] With reference to FIG. 5, a release assembly is generally indicated at 102 . The release assembly 102 selectively interferes with the legs 56 to lock the legs either in the operational position shown in FIG. 1 or the storage position shown in FIG. 2. As mentioned, the legs 64 pivot about bolts 92 which are secured to the inner portions of the ears 56 .
[0023] With reference to FIG. 3, it can be seen that the holes 58 which receive the bolt fasteners 92 are located at inner portions of the ears 56 while the locking holes 68 , 72 are located at outer portions.
[0024] Referring to FIGS. 5 and 10, release assembly 102 includes a locking pin 106 having a head 108 and a tip or free end 110 . The locking pin is carried by leg 64 and preferably extends through the hollow interior of the leg. In FIG. 6, the locking pin is illustrated as extending beyond the outer surface of ear 56 for illustrative purposes. If desired, the locking pin can be configured such that the free end 110 is located at or slightly recessed below the outer surface of ear 56 .
[0025] In FIG. 5, the locking pin 106 is shown in a fully extended or locked position. In the preferred embodiment, locking pin 106 has a generally cylindrical body although other cross-sectional shapes can be employed, if desired. Referring to FIG. 7, the medial portion of locking pin 106 defines a pair of opposed locking recesses 114 , the bottom portions of which extend generally parallel to one another. Preferably, locking pin 106 has an elongated generally cylindrical configuration with the recesses 114 being located opposite one another on either side of the longitudinal axis. As will be seen herein, the recesses 114 are dimensioned for interlocking engagement with a keyhole-shaped opening in the actuator.
[0026] Referring again to FIG. 5, release assembly 102 further includes a spring member 120 . The spring member 120 is preferably of a flat spring construction having first and second ends and a medial portion between the ends. The first end 122 of the spring defines a relatively shallow recess 124 giving the spring end 122 a forked or stirrup configuration. As schematically indicated in FIG. 6, recess 124 at least partially receives bolt 92 . This arrangement is schematically indicated at the left-hand portion of FIG. 5 with spring end 122 engaging bolt 92 adjacent the threaded nut fastener located at the outside of leg 64 .
[0027] Referring again to FIG. 6, the opposed end 128 of spring 120 defines a relatively deeper recess 130 which extends toward spring end 122 . As can be seen in FIG. 6, the recesses 124 , 130 are similar to one another, being located along the longitudinal center line of spring 120 , but differ in their length.
[0028] With reference to FIG. 5, the free end 128 of spring 120 is free to move back and forth, toward and away from bolt 92 and locking pin 106 . Recess 130 is made sufficiently long so as to permit locking pin 106 to extend through recess 130 in the manner indicated in FIG. 5.
[0029] Referring again to FIG. 5, release assembly 102 further includes an actuator 150 having a generally flat bar-like body including a first end 152 with a recess 154 for receiving bolt 92 . The opposed end 158 of actuator 150 includes an upstanding button 160 having a rounded free end portion. Button 160 extends from the inside surface 150 a of actuator 150 . In the preferred embodiment, the opposed outside surface 150 b of actuator 150 is relatively flat although outside surface 150 b can take on a non-flat or profiled shape, if desired. The relatively flat surface preferred for the outside 150 b of actuator 150 allows free sliding movement of spring 120 as actuator 150 is moved throughout its range of motion.
[0030] Referring again to FIG. 8, the central portion of actuator 150 defines a keyhole-shaped slot 170 . The larger end of keyhole slot 170 receives the body of locking pin 106 allowing the locking pin to be inserted through the actuator to bring recesses 114 in contact with the actuator body. Recesses 114 cooperate with the smaller sized end of keyhole slot 170 to allow interlocking engagement between the locking pin and the actuator.
[0031] Referring again to FIG. 5, it will now be seen that the actuator 150 and spring 120 are held captive within leg 64 . Button 160 extends slightly beyond the inside surface of leg 64 while the opposite end 152 engages bolt 92 preventing dislocation of actuator 150 toward the left-hand side of FIG. 5. As button 160 is depressed, locking pin 108 is moved in the direction of arrow 166 , due to the interlocking of actuator 150 and pin 106 . As button 160 is depressed, the outer surface of the actuator pushes against spring 120 causing the spring to compress or flatten slightly, with free end 128 of the spring moving in the direction of arrow 168 . This store spring energy urging actuator 150 to return to its rest position illustrated in FIG. 5. With button 160 sufficiently depressed, the free end 110 of locking pin 106 is made to clear the plate ear portion 56 , allowing the leg to be pivoted about bolt fastener 92 , with the leg assuming its desired orientation.
[0032] The drawings and the foregoing descriptions are not intended to represent the only forms of the invention in regard to the details of its construction and manner of operation. Changes in form and in the proportion of parts, as well as the substitution of equivalents, are contemplated as circumstances may suggest or render expedient; and although specific terms have been employed, they are intended in a generic and descriptive sense only and not for the purposes of limitation, the scope of the invention being delineated by the following claims. | The sign stand assembly includes a sign panel, support base and an upright mast between the two. The support base defines a locking recess and a hollow leg is pivotally connected to a plate portion and extending from the support base. The locking pin and actuator are carried within the hollow leg with the actuator carrying an outward protruding button. The actuator includes a medial portion defining an opening to receive the locking pin in interlocking engagement therewith. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of Taiwan application serial no. 92118296, filed Jul. 4, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to a testing board and its associated circuit. More particularly, the present invention relates to a phase shift Radio Frequency (RF) signal generating circuit for DVD ROM (Digital Versatile Disc Read Only Memory) chipset in HTOL (High Temperature Operating Life) board design.
[0004] 2. Description of Related Art
[0005] Storage media has always played one of the leading roles in computer system. Significant researches are invested in storage media on variety as well as stability and high capacity. Novelties of DVD ROM are invented and manufactured as the application is highly popularized.
[0006] Generally, the driving circuit of DVD ROM is manufactured as a DVD ROM chipset in order to lower chip size and cost. For testing purpose, a DVD chipset is plugged on a testing board, and placed in testing chamber of an ambient temperature about 125° C. with proper connection to testing signal device in order to machine-test High Temperature Operating Life (HTOL).
[0007] In a testing device that is similar to HTOL test , the testing signals are mostly digital, which is not appropriate for a pick up head requiring peak-to-peak 75 mV signal swing in a Digital Versatile Disc (DVD). The reason is a DVD chipset usually suffers from phase difference between a plurality of phase-shift RF signals, thus the testing process is more difficult.
SUMMARY OF THE INVENTION
[0008] According to foregoing reasons, this invention provides a phase-shift RF signal generating circuit on a DVD ROM chipset test board in order to apply HTOL test so as to evaluate reliability of a DVD ROM chipset in this present invention.
[0009] As embodied and broadly described herein, the invention provides a phase-shift RF signal generator on a DVD ROM chipset testing board, which applies to HTOL test for DVD ROM chipset in order to evaluate reliability of which. Wherein, the DVD ROM chipset test board comprises a testing base and a phase-shift RF-signal generating circuit. The testing board has at least one chip socket to accommodate Device Under Test (DUT) chipset, and a connector to adapt a testing device. The testing device providing a frequency-variant digital input signal. As to the phase-shift RF-signal generating circuit, it is for generating first, second, third, and fourth phase-shift RF-signals for testing DVD chipset, where the first and the second phase-shift RF signals are in phase, and have a phase difference to the third and the fourth phase-shift RF-signals.
[0010] In one preferred embodiment, the phase-shift RF-signal generating circuit on the DVD chipset testing board comprises a first signal potential divider, a first high pass filter, a second high pass filter, a phase shifter, a second signal potential divider, a third high pass filter, and a fourth high pass filter.
[0011] Where the first signal potential divider is for receiving digital signals provided by testing device, and dividing voltage for output. The first high pass filter couples to the first signal potential divider to eliminate dc signal of the divided input signal so as to generate a first phase-shift RF signal. The second high pass filter as well couples to the first signal potential divider to eliminate dc signal of the divided input signal so as to generate a second phase-shift RF signal. The phase shifter is to receive the digital input signal provided by testing device, and to shift the digital input signal by a phase for output. The second signal potential divider couples to the phase shifter, in order to receive and to divide voltage of the shifted digital input signal for output. The third high pass filter couples to the second signal potential divider to eliminate dc signal of the shifted and divided digital input signal, so as to generate the third phase-shift RF signal. The fourth high pass filter couples to the second signal potential divider to eliminate dc signal of the shifted and divided digital input signal, so as to generate the fourth phase-shift RF signal.
[0012] In this preferred embodiment, each the first and the second signal potential divider of this phase-shift RF-signal generating circuit is composed of two resistors in series.
[0013] In this preferred embodiment, each the first, second, third, and fourth high pass filter of this phase-shift RF-signal generating circuit comprises a capacitor.
[0014] In this preferred embodiment, the phase shifter of the phase-shift RF signal generating circuit comprises an operating amplifier, a first resistor, a capacitor, a second resistor, and a third resistor. Wherein the operating amplifier comprises a positive input terminal, a negative input terminal and an output terminal, and the output terminal is to output phase-shifted digital input signal. One end of the first resistor couples to the digital input signal, and the other end couples to the positive input terminal of the operating amplifier. One end of the capacitor couples to the positive input terminal of the operating amplifier, and the other end couples to ground. One end of the second resistor couples to the digital input signal, and the other end couples to the negative input terminal of the operating amplifier. One end of the third resistor couples to the negative terminal of the operating amplifier, and the other end couples to the output terminal of the operating amplifier.
[0015] In the preferred embodiment, the second and the third resistor of the phase-shift RF-signal generator circuit possess identical resistance value.
[0016] In the preferred embodiment, the voltage gain of the phase shifter of the phase-shift RF-signal generating circuit is ONE, and the phase shifts by 40°.
[0017] In the preferred embodiment, the phase-shift RF-signal generating circuit generates the first, second, third and fourth phase-shift RF signals based on digital input signals provided by testing device, where the phase-shift RF signals possess a signal swing of 75 mV and a frequency of 5 MHz.
[0018] The present invention provides another method of generating phase-shift RF signals, which applies to generate a first, second, third, and fourth phase-shift RF signals based on a frequency-variant digital input signal for testing DVD chipset. The method of generating phase-shift RF-signal comprises the following steps. Firstly, receive the digital input signal, and divide voltage of the input signal for output. Secondly, eliminate dc signal of the digital input signal so as to generate the first phase-shift RF signal and the second phase-shift RF signal. Lastly, eliminate dc signal of the shifted and divided digital input signal so as to generate the third and the fourth phase-shift RF signals.
[0019] Wherein the method, the phase is shifted by 40°, and each of the first, second, third and fourth phase-shift RF signals possess signal swing of 75 mV and frequency of 5 MHz.
[0020] According to the foregoing explanation, the present invention provides a phase-shift RF-signal generating circuit which applies to a DVD chipset testing board so as to implement HTOL testing for DVD chipset.
[0021] These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
[0022] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0024] FIG. 1 illustrates a DVD ROM chipset according to one preferred embodiment of the present invention.
[0025] FIG. 2 illustrates the waveforms of phase-shift RF signals of phase-shift RF-signal generator according to one preferred embodiment of this invention.
[0026] FIG. 3 illustrates the circuit of the phase-shift RF-signal generator according to one preferred embodiment of this invention.
[0027] FIG. 4 illustrates the frequency response analysis diagram of the phase-shift RF-signal generator according to one preferred embodiment of this invention.
[0028] FIG. 5 illustrates the diagram of the DVD ROM HTOL board in one preferred embodiment of this invention.
[0029] FIG. 6 illustrates the measurement of the input waveforms of the phase-shift RF-signal generator according to one preferred embodiment of this invention.
[0030] FIG. 7 illustrates the output waveforms when the first phase-shift RF signal and the second phase-shift RF signal lead.
[0031] FIG. 8 illustrates the output waveforms when the first phase-shift RF signal and the second phase-shift RF signal lag.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Referring to FIG. 1 , a connecting diagram for testing the analog circuit of a DVD ROM chipset is shown. As depicted in FIG. 1 , a 75 mV signal swing of each the first, the second, the third, the fourth phase-shift RF signals output from optical pick-up head has to be simulated for testing the analog circuit of a DVD ROM chipset .
[0033] The first phase-shift RF signal DVDA and the second phase-shift RF signal DVDC are in phase, and the third phase-shift RF signal DVDB and the fourth phase-shift RF signal DVDD are as well in phase therein. Also, there is a phase difference between the two pairs of the in-phase signals, that is the pair of the signals DVDA and DVDC and the pair of the signals DVDB and DVDD, where the phase difference is shown in FIG. 2 .
[0034] The analog circuit of the DVD ROM chipset 100 generates an output signal TEO according to the phase difference A in between. When the first phase-shift RF signal DVDA and the second phase-shift RF signal DVDC lead the third phase-shift RF signal DVDB and the fourth phase-shift RF signal DVDD as depicted in FIG. 2 , the output voltage of signal TEO is between 1.5 V and 2.1 V. On the contrary, when the first phase-shift RF signal DVDA and the second phase-shift RF signal DVDC lag the third phase-shift RF signal DVDB and the fourth phase-shift RF signal DVDD, the output voltage of signal TEO is between 0.8 V and 1.5 V. Therefore, measuring the output signal TEO is valid to diagnose if the analog circuit of DVD ROM chipset 100 is working properly.
[0035] Referring to FIG. 3 , a phase-shift RF-signal generating circuit is shown according to one preferred embodiment of this present invention. As depicted, the phase-shift RF-signal generating circuit 300 comprises: first signal potential divider 310 , first high pass filter 340 , second high pass filter 350 , phase shifter 320 , second signal potential divider 330 , third high pass filter 340 , and fourth high pass filter 350 .
[0036] Therein, the first signal potential divider 310 is composed of resistor 311 and resistor 322 in series connection in order to obtain a voltage divided signal from 5 MHz variant digital signal Vi provided by testing device (not shown). For the testing device provides digital signals instead of a plurality of phase-shift RF signals, and for testing the analog circuit block of the DVD ROM chipset requires 75 mV signal swing, the testing device is set to output a digital square-wave input Vi possessing a signal swing of 600 mV.
[0037] The digital square-wave input signal Vi, voltage-divided by the first signal potential divider 310 feeds the first high pass filter 340 and the second high pass filter 350 composing a capacitor, so as to eliminate the dc signal along the divided signals as well as to generate first phase-shift RF signal DVDA and the second phase-shift RF signal DVDC having signal swing 75 mV.
[0038] On the other hand, the third phase-shift RF-signal DVDB and the fourth phase-shift RF-signal DVDD requiring signal swing 75 mV are to differ the first phase-shift RF signal DVDA and the second phase-shift RF signal DVDC by a phase difference of 40°. Hence, in order to obtain a phase-shifted output signal Vo differed from the input signal Vi, apply phase shifter 320 before obtaining DVDB and DVDD by applying the second signal potential divider 330 and the third and fourth high pass filter 340 and 350 .
[0039] As depicted in FIG. 3 , the phase shifter 320 receives digital input signal Vi from a testing device (not shown), and shift phase of Vi to output an output signal Vo by, for example, 40°, wherein the phase shifter 320 comprises an operating amplifier 323 , a first resistor 321 , a capacitor 322 , a second resistor 324 , and a third resistor 325 . As to the connections, one end of the first resistor 321 couples to digital input signal Vi, the other end couples to the positive input terminal of the operating amplifier 323 . Mean-while, one end of the capacitor 322 couples to the positive input terminal of the operating amplifier 323 , and the other end couples to ground. Also, one end of the resistor 324 couples to the digital input signal Vi, and the other end couples to the negative input terminal of operating amplifier 323 . As well as one end of the third resistor 325 couples to the negative input terminal of the operating amplifier 323 , and the other end couples to the output terminal of the operating amplifier 323 . Assuming the capacitance of capacitor 322 is C, and the resistance of the first resistor 321 , the second resistor 324 , and the third resistor 325 is R, then the phase-shift relation is expressed as follows.
[0040] The voltage Vp of the positive input terminal of the operating amplifier is:
Vp = Vi · { 1 + j ω C R + 1 / j ω C } = Vi 1 + j ω CR ( 1 )
[0041] In an ideal operating amplifier, the voltage of the negative input terminal of the operating amplifier 323 equals to that of the positive input terminal Vp, so that
Vo = [ Vp - Vi R ] · R + Vp = 2 Vp - Vi · 1 - j ω CR 1 + j ω CR
thus , ( 2 ) Vo Vi = 1 - j ω CR 1 + j ω CR = 1 ∠ - 2 tan - 1 ω CR ( 3 )
[0042] According to Eq. (3), the voltage gain of the phase shifter 320 is ONE, and the phase shift amount is determined by proper choice of R and C, so as to generate required phase shifted output signal Vo differed from input signal Vi.
[0043] Referring to FIG. 3 again, the resistors 331 and 332 in series compose the second signal potential divider 330 that is coupling to phase shifter 320 in order to receive phase-shifted signal Vo, as well as divide the shifted signal Vo so as to respectively feed third high pass filter 360 and fourth high pass filter 370 comprising of capacitors in order to eliminate dc signal, as well as to generate third and forth phase-shift RF signals DVDB and DVDD that have 75 mV signal swing. Therefore, the third and fourth phase-shift RF signals DVDB and DVDD differed from the first and second phase-shift RF signals DVDA and DVDC by a phase shift amount based on R C values.
[0044] Referring to FIG. 4 , a frequency response analysis diagram is illustrated herein based on the phase-shift RF-signal generating circuit in the present invention. The diagram is obtained from simulation of phase-shift RF-signal generating circuit 300 in FIG. 3 by Star-HSPICE 2001.4 simulator. According to FIG. 4 , when phase-shift RF-signal generating circuit 300 in FIG. 3 receives a digital input signal Vi having p-p value of 600 mV and frequency of 5 MHz from testing device, output signals which are the first phase-shift RF signal DVDA, the second phase-shift RF signal DVDC, the third phase-shift RF-signal DVDB, and the fourth phase-shift RF signal DVDD are obtained with 75 mV p-p voltage and 5 MHz frequency. Whereas the first phase-shift RF signal DVDA and the second phase-shift RF signal DVDC differ from the third phase-shift RF signal DVDB and the fourth phase-shift RF signal DVDD by a phase shift.
[0045] Referring to FIG. 5 , a DVD ROM chipset testing board according to one preferred embodiment of this present invention is illustrated therein. This DVD ROM chipset HTOL testing board 500 is manufactured for HTOL testing in this present invention, so as to evaluate reliability of the DVD ROM chipset based on this High Temperature Operating Life testing.
[0046] According to the figure, this DVD ROM chipset HTOL testing board 500 comprises a testing board 510 and six of phase-shift RF-signal generating circuit 300 , so as to test 6 DVD ROM chipset simultaneously. In order to collaborate between the first, the second, the third, and the fourth phase-shift RF signals DVDA, DVDC, DVDB, and DVDD, six chipset sockets were installed on testing board 520 in order to integrate the testing for DVD ROM chipsets entirely.
[0047] On the other hand, testing board 510 also provides connector 517 for connection to testing device (not shown) that provides digital input signal Vi for six of the phase-shift RF signal generating circuit 300 . As a result, six of the phase-shift RF signal generating circuit 300 generates those RF signals, which are first phase-shift RF signal DVDA, second phase-shift RF signal DVDC, third phase-shift RF signal DVDB, and fourth phase-shift RF signal DVDD, based on digital input signal Vi provided by testing device. The DVD ROM chipsets under testing are plugged therein in chipset sockets 511 , 512 , 513 , 514 , 515 , and 516 , so as to take measurement of output signal TEO in order to diagnose the DVD ROM chipsets.
[0048] Also referring to FIG. 6 , FIG. 7 , and FIG. 8 all together. The experimental measurements of waveforms of first phase-shift RF signal DVDA, second phase-shift RF signal DVDC, third phase-shift RF signal DCDB, and fourth phase-shift RF signal DVDD are shown in FIG. 6 . As to FIG. 7 , a condition of first phase-shift RF signal DVDA and second phase-shift RF signal DVDC lead third phase-shift RF signal DVDB and fourth phase-shift RF signal DVDD by a phase difference is shown. Whereas in FIG. 8 , a condition of first phase-shift RF signal DVDA and second phase-shift RF signal DVDC lag third phase-shift RF signal DVDB and fourth phase-shift RF signal DVDD by a phase difference is shown. According to FIG. 7 and FIG. 8 , when first phase-shift RF signal DVDA and second phase-shift RF signal DVDC lead third phase-shift RF signal DVDB and fourth phase-shift RF signal DVDD by a phase shift, the voltage level of output signal TEO is between 1.5 V and 2.1 V. While on the contrary first phase-shift RF signal DVDA and second phase-shift RF signal DVDC lag third phase-shift RF signal DVDB and fourth phase-shift RF signal DVDD by a phase shift, the voltage level of output signal TEO locates between 0.8 V and 1.5 V. Hereby a properly working chipset is diagnosed.
[0049] Also notice that the first and second phase-shift RF signals generated by the phase-shift RF-signal generating circuit 300 in FIG. 3 lead the third and fourth phase-shift RF signals, thus when a condition of first and second phase-shift RF signals lagging the third and fourth phase-shift RF signals is observed, nothing has to be adjusted but to switch the two pairs of RF signal inputs feeding the DVD ROM chipset. In addition, although the DVD ROM chipset HTOL testing board 500 in one preferred embodiment of this present invention configures six chipset-sockets (i.e. 511 , 512 , 513 , 514 , 515 and 516 ) for simultaneous testing, the actual quantity of chipsets to be tested can be adjusted by sizing the testing board 510 .
[0050] A phase-shift RF-signal generating method is concluded upon forgoing explanation, which provides four phase-shift RF signals for testing DVD ROM chipsets based on a frequency-variant digital input signal. This phase-shift RF-signal generating method comprises the following steps. Firstly, receive a digital input signal and divide the voltage of the signal and outputting the signal. Moreover, eliminate the dc signal composition and generate first and second phase-shift RF signals. Additionally, phase shift the digital input signal, receive the shifted digital input signal, and divide voltage of the shifted input signal. Ultimately, eliminate dc signal composition of the shifted and divided digital input signal, and generating the third and the fourth phase-shift RF signals.
[0051] Notice that the phase shift is 40°, the peak-to-peak signal swing is 75 mV and the frequency is 5 MHz for all the first, second, third, and fourth phase-shift RF signals.
[0052] In conclusion, this present invention provides a phase shift RF-signal generating circuit on DVD ROM testing board so as to be applied to testing device that only provides digital input signals in order to test DVD ROM chipsets under HTOL test.
[0053] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention covers modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. | A board for testing DVD (Digital Versatile Disc) ROM (Read Only Memory) chip-set and associated circuit for generating radio frequency signals with phase difference are provided. The circuit includes signal potential dividers, high pass filters, and a phase shifter. The circuit receives a digital input signal, which has a predetermined frequency, generated by a chip test device. The radio frequency signals with phase difference for testing the analog circuit block of DVD ROM chipset are generated according to the received digital input signal. Therefor, the high temperature operating life test for optical disc drive chips can be achieved. | 6 |
This is a continuation of application Ser. No. 413,999, filed Nov. 8, 1973, now abandoned.
BACKGROUND TO THE INVENTION
The present invention relates to conveying apparatus particularly, but not solely, for use with cutter-loader machines, in underground tunnels or in mine workings.
It is well known to construct conveying apparatus from a scraper-chain assembly which moves along a conveying surface. Thus in the so-called longwall conveyors it is known to have one or several chains connected to scraper elements or flights which are spaced apart longitudinally of the chain or chains. This assembly is entrained over drums or the like and is then circulated along a series of channel sections providing the conveying surface and defining guide channels primarily for guiding the scraper elements. It is also known to utilize cutter-loader machines employing similar forms of scraper-chain assemblies. Such machines are usually self-propelled, e.g. mounted on endless tracks, and are used for driving tunnels or winning materials such as clay or other minerals. In such machines it is usual to employ a jib which can be raised and lowered or swung from side-to-side. This jib may have cutting means at one end and may have a scraper-chain assembly moved along the body of the jib to transfer material away from the cutting means. The scraper-chain assembly can be entrained around rotatable members or drums at the ends of the jib and the cutting means can be driven indirectly by the scraper-chain assembly. Various drive arrangements have been employed with both these types of conveying apparatus. It is, for example, common, especially with longwall conveyors, to provide conventional drive motors at one side of the conveyor so that the motor and pertinent coupling project laterally from the main part of the apparatus. The drive motor is normally a heavy unit and it is usually difficult in underground working to provide sufficient space for the motor in other positions.
A general object of this invention is to provide an improved form of conveying apparatus.
A further object of the invention is to provide an improved drive system for conveying apparatus. Another object of the invention is to provide a drive system for conveying apparatus which is simple to assemble and disassemble, which utilizes minimum space and which is adaptable.
SUMMARY OF THE INVENTION
According to the invention there is provided conveying apparatus comprising a scraper-chain assembly adapted to move in a circulatory path and along at least one guide channel and an electric motor for moving said assembly, the motor having a housing which defines part of said at least one guide channel. In accordance with the invention the housing of the motor can form a structural component of the actual conveyor body. This greatly simplifies the construction of the drive system for the conveyor and ensures that no undue space is taken up by the drive system. This, moreover, allows the weight of the drive system to be more evenly distributed.
Preferably the scraper-chain assembly is entrained around rotatable members at the ends of said at least one guide channel and at least one of the rotatable members is driven by said motor to move the assembly. The rotatable members can take the form of shafts carrying sprocket wheels engaging with the chain of the scraper-chain assembly. There may be provided two oppositely-disposed guide channels part of each of the guide channels being defined by the motor housing. Each of these guide channels have a generally U-shaped cross-sectional profile with side walls and a floor surface extending between said side walls. Normally the drive motor would be coupled to a reduction-ratio gearing unit and in accordance with a further feature of the invention this gearing unit can also have a housing which also defines part of said at least one guide channel. The motor housing and gearing unit housing can be connected together at their ends and the motor housing may additionally be connected at its other end to a body section of the apparatus also defining part of the channel section or sections.
The conveying apparatus may be designed for use in an underground mine working, i.e. as a short-face or longwall conveyor, or as a jib of a cutter-loader. Preferably, in this latter regard some form of cutting means is located at one end of the jib and is driven indirectly by the scraper-chain assembly or directly by the drive motor.
It is possible to provide a drive motor and gearing unit at both ends of the apparatus and this is convenient where the power requirements cannot be met by a single motor. The housings of the motor and gearing units may have extended side walls which project above upper and lower walls to provide somewhat U-shaped guide channels. The ends of the housing may then have mating flanges which have bores for accepting fixing means such as nuts and bolts.
The invention may be understood more readily, and various other features of the invention may become apparent, from consideration of the following description.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the invention will now be described, by way of examples only, with reference to the accompanying drawings, wherein:
FIG. 1 is a side view of a jib of a cutter-loader machine employing conveying apparatus made in accordance with the invention;
FIG. 2 is a plan view of the motor of the conveying apparatus;
FIG. 3 is a side view of the motor shown in FIG. 2;
FIG. 4 is a sectional plan view of the reduction gearing unit of the conveying apparatus in conjunction with the chain-drive arrangement and cutting means, and
FIG. 5 is a sectional plan view of part of an alternative form of the chain-drive arrangement.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring initially to FIGS. 1 to 3, there is shown in FIG. 1 a jib A of a cutter-loader machine. Such a machine is well known per se and is not therefore shown in the drawings. The jib A is connected at end B to the machine. Usually the end B of the jib A would be connected to a rotatable turntable so that the jib A can swing in a lateral sense. Means such as hydraulic piston and cylinder units, would also be attached to the end B of the jib A so that by operating this means the jib A can be raised and lowered. At the free end C of the jib A there is provided cutting means in the form of a cutting cylinder or drum or in this embodiment in the form of cutting wheels. This cutting means serves to detach material from a working face. The jib A is provided with conveying apparatus made in accordance with the invention, which serves to transfer material away from the cutting means and in the direction of arrow P. The transferred material can then be taken up by further conveying means such as an additional loading jib on the machine.
The conveying apparatus on the jib A is in the form of a scraper-chain assembly, denoted 12, employing one or several endless chains to which scraper elements are attached and spaced apart along the jib A. The scraper-chain assembly 12 is entrained around a rotatable member 11 at the end B of the jib A and around a rotatable member at the end C. The rotatable member at the end C forms part of the cutting means assembly and serves to directly drive the scraper-chain assembly so that the member 11 is freely rotatable. It is however possible to effect driving of the scraper chain assembly 12 by the member 11 so that the cutting means is rotated indirectly by the scraper-chain assembly. The scraper chain assembly 12 is circulated around the rotatable members and moves along guide channels. To effect driving of the scraper chain assembly and the cutting means there is provided an electric motor 13 and a reduction-ratio gearing unit 14. The motor 13 and the gearing unit 14 have housings which combine with a body section 24 of the jib A to form the guide channels for the scraper-chain assembly and provide structural parts of the jib A. Thus, as shown in FIGS. 2 and 3, the motor 13 has its rotor 15 disposed in a stator housing 13' provided with side walls 16, 17 projecting from its upper and lower walls. These side walls 16, 17, which are arranged symmetrically in relation to the longitudinal central plane M of the housing 13', provide the guide channels denoted 18, 19, within which the scraper-chain assembly 12 is moved. The channel 18 forms part of a conveying run and the upper face 20 of the motor housing 13' forms part of the conveying floor surface along which the scrapers of the assembly 12 transfer the material. The channel 19 forms part of a return run for the assembly 12. At the ends of the motor housing 13' there are provided flanges 21 which serve for the connection of the motor housing into the jib structure. The housing for the reduction-ratio gearing unit 14 is constructed in a similar fashion with side walls forming guide channels contiguous with the guide channels 18, 19 of the motor housings and with flanges 23 at one end. The flanges 23 of the gearing unit housing mate with the flanges 21 at one end of the motor housing 13' and the flanges 21 at the other end mate with corresponding flanges 22 of the body section 24. Nuts and bolts can be inserted through aligned bores in the flanges 21, 23 and 21, 22 to effect rigid connection between the components. The body section 24 is also constructed with side walls forming guide channels contiguous with the guide channels 18, 19 of the motor housing so that the guide channels of the components serve, in common, to guide the scraper elements of the assembly 12. Thus the cross-sectional profiles of the housings of the gearing unit 14 and the motor 13 and of the body sections 24 have the same generally U-shaped configuration.
Referring now to FIG. 4, the output shaft from the motor 13 is connected by means of a torque transmission coupling 30, 31 to the input shaft of the gearing unit 14. The housing of the unit 14 is designated 40. This input shaft carries a bevel gear 32 which meshes with a bevel gear 33 carried by a second shaft extending perpendicularly to the input shaft. This second shaft also carries a spur gear 34 which meshes with a spur gear 35 carried by a third shaft extending parallel to the second shaft. A spur gear 36 carried by the third shaft meshes with an intermediate spur gear 37 supported on a short journal and also meshing with a spur gear 38. This spur gear 38 is carried by a shaft 39 which forms the drive shaft for the cutting means of the jib and the scraper-chain assembly 12, i.e. the aforesaid rotatable member. The gears 37, 38 and the associated part of the shaft 39 are mounted in a sub housing 41 connected to the housing 40 for the gearing unit 14. A bracket 45 is connected with screws 44 to an end wall of the main housing 40 and this bracket 45 supports a bearing unit for the shaft 39. This bracket 45 enables the shaft 39 and associated parts to be readily assembled and disassembled. The housing 41 accommodates a corresponding bearing unit for the shaft 39. The shaft 39 projects outwardly through its bearing unit, i.e. laterally of the jib A, and has splined portions 43 which receive detachable cutting wheels 42, i.e. wheels equipped with cutting tools, constituting the aforementioned cutting means. A sprocket 46 is mounted on the shaft 39 between its bearing units. This sprocket 46 rotates with the shaft 39 and is drivably coupled with a central single chain of the scraper chain assembly 12 to effect driving thereof. The rotatable member 11 at the end B of the jib A merely serves to reverse the scraper-chain assembly and can take the form of a drum accommodating a central sprocket for engaging the chain of the assembly 12.
As mentioned previously, the drive of the scraper-chain assembly 12 can be effected via the rotatable member 11 at the end B of the jib A. In this case, the motor 13 and the gearing unit 14 would be located at the opposite end of the jib A in a mirror-image position with the body structure 12 at the other end. FIG. 5 depicts an arrangement at the end B of the jib for driving the scraper-chain assembly 12. The gearing unit, here denoted 14' and not shown in detail, is the same as that depicted in FIG. 4. As shown in FIG. 5, the intermediate spur gear (37 FIG. 4) taking up the output from the gearing unit 14' again meshes with a spur gear 38 carried on the shaft 39 forming the aforementioned rotatable member 11. The spur gear 38, the appropriate portion of the shaft 39 and a detachable bearing unit for the shaft 39 are again located in a sub-housing 41. The housing of the gearing unit 14' has an extended side wall opposite the sub-housing 41 which locates a complementary detachable bearing unit for the shaft 39. A drive-chain sprocket 46 is carried by the central portion of the shaft 39 to rotate therewith. This sprocket 46 engages with the single central chain of the scraper-chain assembly 12.
Although in the above description a sprocket 46 is shown for driving a single chain of the scraper-chain assembly 12 the construction can be modified to accommodate a scraper-chain assembly 12 employing two laterally-spaced chains.
It is also possible for the cutting means on the jib A to be omitted and for some other separate cutting means to effect detachment of the material. In this case, the jib A constitutes the conveying apparatus which merely serves to transfer the material detached by the separate cutting means.
In another modification a drive motor 13 and a reduction-ratio gearing unit 14, 14' can be provided at each end of the jib so that the scraper-chain assembly is driven at both ends. | Conveying apparatus which may be embodied as a jib for a cutter-loader machine in tunnelling or mining applications. The apparatus employs a scraper-chain assembly which in known manner is entrained around rotatable members and is circulated within guide channels with side surfaces adjoined by a base or floor surface. An electric drive motor is coupled via reduction-ratio gearing unit to one or other of the rotatable members. The motor and the gearing each have housings joined together end-to-end and the housing of the motor is joined to at least one other body section of the apparatus. The housings and this body section have the same cross-sectional profile defining the aforesaid guide channels. | 4 |
CROSS-REFERENCE TO A RELATED APPLICATION
This application takes priority under 35 U.S.C. §119(e) of U.S. patent application Ser. No. 60/144,709 filed Jul. 20, 1999 naming Daryl Huff, et al. as inventor(s) and assigned to the assignee of the present application which is al so incorporated herein by reference for all purposes. This application is also related to the following co-pending U.S. Patent applications, which are filed concurrently with this application and each of which are herein incorporated by reference, (i) U.S. patent application Ser. No. 09/519,964, entitled “Methods and Apparatus for Automatically Generating a Routing Table in a Messaging Server” naming Belissent et al as inventors; (ii) U.S. patent application Ser. No. 09/521,282, entitled “Methods and Apparatus for Providing a Virtual Host in Electronic Messaging Servers” naming Belissent et al as inventors; (iii) U.S. patent application Ser. No. 09/520,865, entitled “Methods and Apparatus for Monitoring Electronic Mail Systems” naming Kavacheri et al as inventors; and (iv) U.S. patent application Ser. No. 09/519,948, entitled “Methods and Apparatus for Delegating Administrative Capabilities to Domains Served by Email Provider” naming Abbott et al as inventors.
FIELD OF THE INVENTION
The present invention relates in general to client/server data communication systems and, more particularly, to a mail server included in an electronic mail system for use within a client/server data processing system. More particularly still, the present invention is directed towards a method and apparatus for defining a virtual domain in an email system.
BACKGROUND OF THE INVENTION
Computer systems are well known in the art and have become a business staple and are also found in many homes. One feature available to the business world is that of using electronic mailing (email) to send and receive messages and other information to and from one another in a business setting. Similarly, home computers, such as desk tops or laptops, and other information devices, such as personal digital assistants (PDAs), allow telecommuting such that a user can connect to the user's work server and down load and upload messages.
The email system allows clients of a network system, which is maintained by a server system, to send messages or data from one user to another. In order to minimize disk space and requirements as well as to maximize functionality and consistency of the electronic mailing engine used in the network system, the engine is typically located on the server and is merely accessed by a client in order to send messages or retrieve messages to or from another user or client on the server system. In this way, the client system typically allows the user to perform such operations as composing, updating, and sending messages while the server in such a system provides, in part, a server based message repository as well as providing message transmission and reception functions for the user at the client level.
A traditional email system 100 , configured to operate in what is referred to as a consumer host mode, is illustrated in FIG. 1 . The email system 100 includes a number of consumers and/or businesses 102 - 1 (“abc.com”) through 102 -n (“xyz.gov”) each of which is coupled to a service provider (SP) 104 (“isp.net”). Traditionally, the service provider (SP) 104 provides the various consumers and/or businesses 102 with just an unprotected IP router. The consumers and/or businesses 102 also operate and maintain their own application servers, including the email server, DNS server, and (if needed) LDAP server (not shown). For their own protection, each of the consumers and/or businesses 102 must operate through a firewall that filters out undesirable packets and insulates the organization's internal network from the Internet. Notice that for many organizations, especially small ones, the email server may actually be the firewall system.
In the email system 100 , those consumers and/or businesses 102 - 1 through 102 -n who wish to read their mail must be connected to a service provider (SP) email server 106 . The SP 106 also operates an email mailbox 108 , and a DNS server 110 that provides the following services, a primary master server for the SP's own domain (ISP.net), to designate as the root server for all consumers and/or businesses, act as a primary master server for consumers and/or businesses who do not wish to maintain their own public DNS server, and as a secondary server for consumers and/or businesses who prefer to maintain their own public server.
As part of the services provided by the SP 106 , an SMTP relay host 112 that is managed by the SP offers offer a number of value added services, for which the SP may charge additional fees. In some cases, the relay host can be configured to allow the relay host to accept and hold the consumer's email when their mail server is down. However, unfortunately, the relay host imposes a significant management burden on the SP since in some cases, consumer email may live on this server for an indefinite time raising issues of backup and failure recovery. If one of the consumer servers fails because of being swamped, for example, then the consumer's email may roll over to the SP's relay host. Because of this, most SPs do not offer a relay host for those consumers and/or businesses that are hosting their own email server. The SP also provides a directory service in the form of the LDAP Directory server that is located at the consumer's site, which can be operated by the consumer. In this way, most organizations do not expose their LDAP servers to the public network for security reasons.
In the example shown in FIG. 1, a mail user in ABC, Inc. (which lawfully owns its DNS domain name abc.com, but relies on the ISP isp.net to host its email) desiring to send and receive mail uses the domain name username@abc.com even though his mailserver is really mailhost.isp.net. It also means that any user in the abc.com domain, connects to a mailhost in the domain abc.com—for example mail.abc.com—to access his/her mail.
Since the email system 100 requires a separate mail server to be supported by the SP 106 for each of the domains abc.com through xyz.gov, although well understood and easy to manage, the email system 100 is not cost effective for small domains. In addition, as the number of domains increases, the management of the individual services becomes increasingly unwieldy. Internet service providers (ISPs) have a growing interest in hosting email services for always larger and more numerous organizations. Many businesses see the ability to farm out email services as a very attractive cost-saving idea. It is therefore desirable that an email service provider be able to offer email services to multiple organizations each of which has their own virtual domain and to support the ability to define such domains in the directory and host them on a shared mail server. Thus, an email architecture that can support a single mail server which, in turn, can support many different domains associated with consumers and/or businesses is desirable.
However, when the users within a domain are granted a particular set of user level services, that set of user level services must be a proper subset of the associated allowed set of domain services.
Therefore, what is desired is a set of precedence rules that govern the granting of user level for a particular domain having a set of domain services.
SUMMARY OF THE INVENTION
To achieve the foregoing, and in accordance with the purpose of the present invention, methods for granting a user level service based upon a set of allowed domain level services is provided. In accordance with one aspect of the present invention, a method is disclosed where a requested user level service is granted or not based won a set of allowed domain level services. The user level service is requested and a subsequent determination is made whether or not the requested user level service is a member of a proper subset of the set of allowed domain level services. If the requested service is determined to be a member of the proper subset of allowed domain level services, then the requested user level service is granted. In so doing, the granted user level services becomes a member of a set of allowed user level services.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
FIG. 1 illustrates a conventional customer hosted type e-mail system.
FIG. 2 shows an Internet email system in accordance with an embodiment of the invention.
FIG. 3 shows an exemplary message store in accordance with an embodiment of the invention.
FIG. 4 shows a flowchart detailing a process whereby a virtual domain is defined in accordance with an embodiment of the invention.
FIG. 5 illustrates a flowchart that details a process that applies a set of precedence rules to the granting of user-level in accordance with an embodiment of the invention.
FIG. 6 illustrates a typical general-purpose computer system suitable for implementing the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to a preferred embodiment of the invention. An example of the preferred embodiment is illustrated in the accompanying drawings. While the invention will be described in conjunction with a preferred embodiment, it will be understood that it is not intended to limit the invention to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
The Internet has effectively lowered the cost of electronic communication. As the number of people and organizations connected to the Internet has grown, the Internet has evolved into a new channel for communication. To facilitate Internet services, Internet messaging clients and easy-to-use web browsers have provided cost-effective way of publishing and sharing information with employees inside the enterprise as well as customers, suppliers, and partners outside. Since messaging services has become crucial to enterprise infrastructure in the 1990s, organizations are seeking messaging solutions that provide a lower cost of ownership while increasing the effectiveness and reliability of their communications network. Specifically, they are evaluating the benefits of Internet standards-based messaging systems.
Broadly speaking, the invention describes an Internet standards-based messaging system having a mail server capable of offering e-mail services to multiple organizations each of which has their own virtual domain. The invention is also able to define such virtual domains in the directory and host them on a shared mail server.
The invention will now be described in terms of an internet mail server resident on a server computer coupled to a large network of mailboxes typical of a large corporate Internet system as well as a single user coupled to a large interconnected computer network such as the Internet. It should be noted, however, that the inventive mail server is well suited to any application requiring highly reliable, scalable, and efficient information transport over a large number of computers.
Referring now to FIG. 2, an Internet email system 300 in accordance with an embodiment of the invention includes an Internet mail server 301 coupled to a user mailbox 303 . In the described embodiment, the mail server 301 is a general-purpose, “store-and-forward” system for distributing computer-based mail. It should be noted that the term “store-and-forward” means that the mail server 301 automatically handles the receiving of mail messages necessitated when network links (such as those links 306 to the Internet) or other services are temporarily unavailable. In contrast to mail user agents (MUAs) that are used to create and read electronic mail messages, a transfer unit 302 included in the mail server 301 is responsible for directing messages to the appropriate network transport and ensuring reliable delivery over that transport. In a preferred embodiment, the mail server 301 includes a message store unit 304 coupled to the transfer unit 302 that is used to store messages for later transmission to the user mailbox 303 .
As shown in FIG. 3, in one implementation, the message store 304 in the mail server 301 is a dedicated data store for the delivery, retrieval, and manipulation of Internet mail messages. In a preferred embodiment, the message store works with the IMAP4 and POP3 to provide flexible and easy access to messaging. It saves any message that conforms to RFC 822 specifications, and recognizes the Multipurpose Internet Mail Extensions (MIME) content format.
In the described embodiment, the message store 304 is organized as a set of folders and user mailboxes. The mailbox 401 is a container for messages where each user has an inbox 402 where new mail arrives, and can have one or more folders 404 where mail can be stored. Folders 404 may contain other folders or mailboxes and may be arranged in a hierarchical tree. Mailboxes owned by an individual user are private folders 406 . In addition to a user owning a folder or a mailbox, a common user or group can share the ownership of a folder or mailbox as a shared folder 408 . A shared folder is similar to an email group, but instead of messages going into each member of the email group's inbox, messages addressed to the shared folder 408 go into a private folder associated with each user. It should be noted that in a preferred embodiment, the message store 304 maintains only one copy of each message. However, in those cases where the message store 304 receives a message addressed to multiple users or a group (based upon an associated distribution list), it adds a reference to the message in each user's inbox rather than having a copy of the message in each user's inbox, thereby saving disk space. In addition to the reference, the individual message's status (new, unread, replied to, deleted, and the like) is maintained per mailbox.
In the described embodiment, access to the message store 304 is multithreaded thereby allowing a single process to manage a large number of connections since each connection is handled by a thread. In this way, multithreaded access maximizes both performance and scalability by minimizing the system resources required for the management of each connection.
Referring back to FIG. 2, the delivery and routing of messages by the transfer unit 302 is based on a routing table 310 that in turn is derived from the user and group (distribution list) entries stored in a directory service unit 312 . In a preferred embodiment, the directory service unit 312 is the central repository for metainformation: user profiles, distribution lists, and other system resources based upon, in some embodiments, a dedicated Lightweight Directory Access Protocol (LDAP) directory service. This directory supports the storage of information according to a directory information tree (DIT) which is a hierarchical structure that resembles a tree with one major branch at the top and many branches and sub-branches below. The arrangement of the tree is flexible, allowing administrators to decided how to best deploy the service for their organization. For some, it may be best to arrange the tree according the actual business organizational structure or geographic structure. For others, however, a one-to-one mapping to DNS layers may be best.
The DIT also provides the flexibility to support a wide range of administration scenarios, and can be administered in either a centralized or distributed manner. Centralized administration can be implemented where one authority manages the entire DIT. This type of administration is usually used in scenarios where the entire DIT resides on one mail server.
In order to properly route a message, the transfer unit 302 must access the directory information associated with each message that it processes. However, in a preferred embodiment, rather than querying the directory service 312 directly each time it processes a message, the transfer unit 302 caches the directory information in a directory cache 314 . When the transfer unit processes a particular message, it accesses the appropriate directory information in the cache 314 . When required, the transfer unit 302 uses the directory information in the cache 314 to update the routing table 312 .
Since a directory query for each recipient of each message is time-consuming and puts a large load on the mail server 301 , by implementing the localized directory cache 314 , performance of the email server 301 is improved. In addition, since the information stored in the directory service unit 310 is not always in the format required by the transfer unit 302 , when creating the cache, the transfer unit reformats the directory information as required.
It should be noted that in most embodiments, a the transfer unit 302 can be configured to adhere to various mail delivery options which specify one or more delivery options for inbound email to a designated recipient. While inbound messages can be delivered into multiple message stores, message access servers (MAS) can read messages from only a designated one of them. The transfer unit 302 uses these to determine the targets of message delivery for all messages submitted to a particular distribution list. Such can include, but are not limited to: “autoreply”, “program” where mail is delivered to a program, “forward” where mail is forwarded to another mailbox(es), “file” where the incoming message file is appended to another file, and “shared” where mail is delivered to a shared mailbox (this is typically used to set up a shared mailbox for a distribution list).
In the context of electronic mail, protocols are generally a high-level (not necessarily network specific) language spoken between two mailers. Transports are the low-level, network specific details used to implement a protocol on a given network. Thus email messages can come in to the transfer unit 302 by any one of a variety of transports and protocols—submitted directly by a local user, via TCP/IP as an SMTP message from an Internet system, by using a dial-up modem using the PhoneNet protocol, DECnet as a MAIL-11 message, DECnet as an SMTP message, UUCP, an X.400 transport, SNA, and so on. The transfer unit 302 then routes the message out using a transport and protocol appropriate for the message's destination address.
In the described embodiment, the transfer unit 302 uses what are referred to as channels to implement specific combinations of transports and protocols. Each different transport and protocol combination has an associated transfer unit channel. The transfer unit 302 postmaster initially configures the transfer unit 302 telling it what sorts of transports and protocols are in use at his site, and what sorts of destination addresses should be routed through which sorts of channels. For instance, at sites with an Internet connection, Internet addresses are normally routed through an SMTP over TCP/IP channel; but at sites with only a UUCP connection, Internet addresses would instead be routed through a UUCP channel. Once the transfer unit 302 is so configured using configuration data stored in a configuration table (not shown), the transfer unit 302 handles message routing and delivery automatically. In this way, ordinary users need never be aware of this underlying transport and routing; that is, they simply address and send their messages and the transfer unit 302 automatically routes and delivers them appropriately.
In most embodiments, the transfer unit 302 stores messages as text files. Messages with multiple parts possibly containing different types of data) are represented as a series of text sections separated by special unique delimiter strings. In the described embodiment, the first few files in each email message are referred to as the message envelope that contains transport information. The message envelope is terminated by a line containing a boundary marker, or by a line containing two CTRL/A characters. The transfer unit 302 uses the contents of the envelope to make routing decisions. It does not use the content of the message. The content of the envelope is primarily defined by RFC 821. It includes the originator address, the recipient(s) address(es), and envelope ID.
The header lines of the message follow the envelope whose format is mandated by RFC 822. It should be noted that there may be any number of message header lines; the message header formed by this collection of header lines is terminated by a single blank line after which follows the message body. An Internet mail message starts with one or more headers. Each header is composed of a field name followed by a colon then a value which can be generated by, for example, the composer of a message or the mail client. A transfer unit can also add headers to a message. Each transfer unit that accepts a message adds a received header to that message. The last transfer unit to accept the message and to actually deliver the message to the message store adds a return-path header. The received and return-path headers provides information that enables you to trace the routing path taken by the message if a problem occurs.
Submitted messages from the Internet or local clients go to the transfer unit 302 via SMTP (Simple Mail Transport Protocol). If the message address is within the server 302 domain, the transfer unit 302 delivers the message to the message store 304 . If, however, the message is addressed to another domain, the transfer unit 302 relays the message to another transport agent on the Internet or Intranet.
In a preferred embodiment, messages to the local domain are stored in the message store 304 depending on how the system is configured. Once messages are delivered to the appropriate mailbox, they can be retrieved, searched for, and manipulated by IMAP4 or POP3-based mail clients. The transfer unit 302 uses the directory 312 that, in a preferred embodiment, is configured as an LDAP type directory, to retrieve local user and group address information. When the transfer unit 302 receives a message, it uses the directory information to determine where the message should be delivered. The message store uses the directory services to authenticate users logging into their mailboxes. The message store 304 also obtains information about user message quota limits and message store type (IMAP or POP). Outgoing client messages go to the SMTP channel in the LDAP. The transfer unit 302 sends the message to an Internet transfer or, if the address is local, to the message store 304 . It should be noted that the LDAP directory 312 is the master repository of all the information related to hosted domains. That is, the message access server retrieves the necessary information to associate a client with a domain from the LDAP directory 312 . Similarly, the transfer unit 302 retrieves hosted domain information from the LDAP directory 312 to perform proper routing and address rewriting.
Referring now to FIG. 4, showing a flowchart that details a process 500 for defining a virtual domain in accordance with an embodiment of the invention. The process 500 begins at 502 by defining a virtual domain node in the DIT. Once the virtual domain node has been defined, corresponding routing table entries are defined at 504 and at 506 , various virtual domain are stored at the virtual domain node. It should be noted that the various virtual domain include a list of services permitted the domain. Such services include IMAP, MAPS, POP3, POP3S, SMTP which in some cases requires presentation of credentials. Other of the services include identification of a domain administrator who is authorized to manage the particular virtual domain which includes setting particular user-level for particular users in the domain. These services also include designation of a virtual domain postmaster who identifies email message delivery problems, and a state of the domain.
In a preferred embodiment, the state of the domain can be active indicating that all mail can be received, or the state can be inactive, where the particular domain has been temporarily suspended for various and sundry reasons, or, the state of the domain can be deleted indicating that the particular domain no longer exists.
Referring now to FIG. 5 that illustrates a flowchart that details a process 600 that applies a set of precedence rules to the granting of user-level serves in accordance with an embodiment of the invention. The process 600 begins at 602 establishing a set of domain services for the domain. At 604 , a set of user level services is obtained for a user within the domain. At 606 , a determination is made whether or not the set of user level services is a null set. If the set of user level services is not a null set (i.e., certain user lever services have been defined), glen a set of allowed services is defined as an intersection of the set of user level services and the set of domain services at 608 . If, however, the set of user level services is determined to be a null set (i.e., there are no defined user level services), then the allowed set of user level services is defined as the set of domain services. In either case, control is passed to 612 where it is determined if the requested user level service a member of the set of allowed user level services. If it is determined tat the requested service is not a member of the set of allowed user level services, then an error flag is thrown at 614 . Otherwise, the requested user level service is confirmed at 616 .
FIG. 6 illustrates a typical, general-purpose computer system 700 suitable for implementing the present invention. The computer system 700 includes any number of processors 702 (also referred to as central processing units, or CPUs) that are coupled to memory devices including primary storage devices 704 (typically a read only memory, or ROM) and primary storage devices 706 (typically a random access memory, or RAM).
Computer system 700 or, more specifically, CPUs 702 , maybe arranged to support a virtual machine, as will be appreciated by those skilled in the art. As is well known in the art, ROM acts to transfer data and instructions uni-directionally to the CPUs 702 , while RAM is used typically to transfer data and instructions in a bi-directional manner. CPUs 702 may generally include any number of processors. Both primary storage devices 704 , 706 may include any suitable computer-readable media. A secondary storage medium 708 , which is typically a mass memory device, is also coupled bi-directionally to CPUs 702 and provides additional data storage capacity. The mass memory device 708 is a computer-readable medium tat nay be used to store programs including computer code, data, and the like. Typically, mass memory device 708 is a storage medium such as a hard disk or a tape which generally slower than primary storage devices 704 , 706 . Mass memory storage device 708 may take the form of a magnetic or paper tape reader or some other well-known device. It will be appreciated that the information retained within the mass memory device 708 , may, in appropriate cases, be incorporated in standard fashion as part of RAM 706 as virtual memory. A specific primary storage device 704 such as a CD-ROM may also pass data uni-directionally to the CPUs 702 .
CPUs 702 are also coupled to one or more input/output devices 710 that may include, but are not limited to, devices such as video monitors, track balls, mice, keyboards, microphones, touch-sensitive displays, transducer card readers, magnetic or paper tape readers, tablets, styluses, voice or handwriting recognizers, or other wellknown input devices such as, of course, other computers. Finally, CPUs 702 optionally may be coupled to a computer or telecommunications network, e.g., an Internet network or an Internet network, using a network connection as shown generally at 712 . With such a network connection, it is contemplated that the CPUs 702 might receive information from the network, or might output information to the network in the course of performing the above-described method steps. Such information, which is often represented as a sequence of instructions to be executed using CPUs 702 , may be received from and outputted to the network, for example, in the form of a computer data signal embodied in a carrier wave. The above-described devices and materials will be familiar to those of skill in the computer hardware and software arts.
Although only a few embodiments of the present invention have been described, it should be understood that the present invention may be embodied in many other specific forms without departing from the spirit or the scope of the present invention. By way of example, operations involved with accessing a user mailbox can be reordered Operations may also be removed or added without departing from the spirit or the scope of the present invention.
Although the methods defining a set of precedence rules in a virtual domain in a messaging server in accordance with the present invention are particularly suitable for implementation with respect to a Java™ based environment, the methods may generally be applied in any suitable object-based environment. In particular, the methods are suitable for use in platform-independent object-based environments. It should be appreciated that the methods may also be implemented in some distributed object-oriented systems.
While the present invention has been described as being used with a computer system that has an associated virtual machine, it should be appreciated that the present invention may generally be implemented on any suitable object-oriented computer system. Specifically, the methods of defining a virtual domain in accordance with the present invention may generally be implemented in any multi-threaded, object-oriented system without departing from the spirit or the scope of the present invention. Therefore, the present examples are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims along with their full scope of equivalents. | Precedence rules that govern the granting of user level services for a domain in a shared mail server for an email provider are disclosed. Accordingly, when a request for the user level service is made, a determination is made whether or not the requested service is a member of a proper set of allowed domain level services. If the requested user level service is within the proper set of allowed domain level services, then the requested user level service is granted. In so doing, the granted user level service becomes a member of the proper subset of the set of allowed domain level services for the shared mail server. | 7 |
This application is a divisional application of Ser. No. 368,686, filed June 11, 1973.
FIELD OF THE INVENTION
The invention relates to a sewing machine including a dual-purpose complementary-shaped sewing machine case.
In effect, the invention comprises part of the technology concerned with sewing and embroidery equipment and equipment, such as sewing machines and the like, for similar work.
SUMMARY OF THE INVENTION
The sewing machine according to the invention is of the cantilever type designed so as to be compact, of light-weight, exceptionally functional, and of attractive appearance, while at the same time incorporating other significant practical advantages. The inventive sewing machine comprises a closely complementary-shaped fitted case of the "attache case" type, facilitating on the one hand the convenient conveyance of the machine and on the other hand, the removal thereof, when not utilized, with a minimum extent of bulk. During utilization of the machine, the case may be fastened by pivotal motion to a cantilevered free arm of the machine so as to form a large-dimensioned worktable.
The machine may also be equipped with an accessory-containing box adapted to be mounted onto the free arm of the machine, and which may be readily detached therefrom.
A further feature of the invention resides in the utilization of the case so as to comprise a base which is shaped and dimensioned to envelop the pedestal portion and the free arm of the machine, including four flaps protecting the upper edges of the base, and with the flaps being shaped and dimensioned so as to form a closed, protective space when the case is fitted about the machine for transport thereof. The case is further adapted to be detached from the machine and then replaced thereon in a manner whereby the base of the case, which has a recess therein corresponding to the shape and dimensions of the free arm, may be fitted about the free arm and constitute an extension of the free arm and of the pedestal of the machine, thereby creating a large-dimensioned working table.
According to a further feature of the invention, a pivoting handle is provided which is of an extremely simple design and extends substantially over half of the length of the sewing machine, at right angles to the vertical body portions thereof, and in such manner as to permit gripping loads to extend through the axis of the center of gravity of the sewing machine.
According to a further feature of the invention, a reel-holder is retractable into and completely engageable in the rear surface of the vertical portions of the machine, leaving a gripping portion projecting only a few millimeters from the machine frame. Thus, the sewing machine case generally conforms to the contour of the machine and is attached to the latter by means of tongues made from a synthetic material, the latter of which may preferably be a material having a predetermined degree of resilience, which are fastened to the lateral flaps of the case, and the ends of which have a stud adapted to penetrate into orifices formed in the upper portion of the frame of the sewing machine. Thus, due to this arrangement, there is achieved a precise positioning of the bottom of the machine on the bottom of the case, so as to allow for projection of the leg portions of the machine from the case bottom. The said tongues are also employed for maintaining the flaps retracted within the base portion of the case upon the latter being utilized as a work table.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and objects of the invention will become more apparent from the description given hereinbelow in conjunction with the accompanying drawings, in which:
FIG. 1 is a front elevational view of an embodiment of the sewing machine;
FIGS. 2 and 3 are front and rear end views of the machine, taken respectively along lines 2--2 and 3--3 of FIG. 1;
FIG. 4 is a perspective view of the embodiment of the machine of FIG. 1;
FIG. 5 is a perspective view of a box for accessories, adapted to be utilized with the machine illustrated in FIG. 4, and shown in alignment with the free arm onto which it is to be mounted;
FIG. 6 illustrates, in a perspective view, the box for accessories as mounted on the free arm of the machine;
FIG. 7 shows, in an enlarged scale, a cross-section through the box for accessories, with the broken lines indicating the pivoting movements of the flaps thereon for affording access to the interior of the box;
FIG. 8 shows, in a perspective view, the complementary-shaped case adapted to be utilized with the sewing machine of FIGS. 1 to 4;
FIGS. 9 and 10 show in perspective views, respectively, the case mounted on the machine in the machine operative position and the case positioned on the machine in the transport or conveying position thereof;
FIG. 11 is a cross-sectional view through the case taken along the line 11--11 in FIG. 9, showing the case fastened to the machine in the operative position thereof;
FIGS. 12 to 16 illustrate various embodiments of articulating flexible flaps, showing the flaps engaged one within the other and with the case;
FIG. 17 is a perspective elevational rear view of a further embodiment of a sewing machine;
FIG. 18 is an enlarged perspective and partially sectioned view of the rear portion of the sewing machine of FIG. 17 with the flap havng been removed;
FIG. 19 is a fragmentary front view of the rear portion of the sewing machine of FIG. 18 with the folded position of the handle being shown in broken lines;
FIG. 20 is a left-hand view in section of FIG. 19;
FIG. 21 is a partially sectioned view of a reel-holder shown in the position in which it is retracted within the frame of the sewing machine;
FIG. 22 is a front view of the reel-holder of FIG. 21;
FIG. 23 is a partially sectional view of the reel-holder in the extended position in the sewing machine frame;
FIG. 24 is a sectional view of the resilient sheath in which the reel-holder is slidably secured;
FIG. 25 is a plan view of the resilient sheath of FIG. 24;
FIG. 26 is an enlarged perspective view of the resilient sheath;
FIG. 27 is a front view, in section, of the assembled sewing machine and case;
FIG. 28 is a perspective view of the case in the closed position adapted to be utilized as a work table; and
FIG. 29 is a perspective view of the sewing machine positioned within its transport case.
DETAILED DESCRIPTION
The sewing machine comprises a pedestal or base 1, a free (cantilever) arm 2 extending forwardly of the pedestal 1, a vertical support member 3, an upper arm 4, a sewing head 5 and a hand wheel 6. The foregoing machine assembly may be constructed of one or more individual pieces and contains the sewing mechanisms, which need not be described in further detail since the sewing mechanisms, which may be of any known type or of novel type, do not fall within the scope of the invention.
According to the invention, having particular reference to the embodiment of FIGS. 1 to 4, the configurations of the various portions of the machine may be either round or comprise largely rounded and curved segments, in particular as applied (as illustrated) to the longitudinal sides 1a of the pedestal, to the lower portion 2a of the free arm 2, to the upper arm 4, and to the sewing head 5.
The upper surfaces 1b and 2b of the pedestal and of the free arm are aligned and are at least substantially coplanar. The width of the free arm is substantially smaller than the width of the pedestal.
The cross-sectional profile of the pedestal 1 is symmetrical relative to a horizontal median axis x-x with respect to its thickness (FIG. 3). This feature is important, due to the dual fitting or mounting capability of the case, as will be more apparent from the description given hereinbelow.
FIGS. 2 and 3 also show that, if the upper arm 4 and the sewing head 5 are symmetrically arranged relative to a vertical axis y-y, which is median in the cross-section of the pedestal 1, the vertical body 3 is located asymmetrically relative to the axis y-y so as to provide, on one side of the member 3, a larger opening for passage of the machine operators arm, having a wider support surface on the working plane 1b and an operative position which is more comfortable and more convenient for the operator.
The rounded or profiled configuration, such as the largely rounded portions of the upper arm 4, affords excellent manual gripping thereof, facilitating manipulation and transport of the sewing machine.
It is possible to provide the sewing machine, for example, along the arm 4 and the head 5, or only along a portion of the arm 4, with a suitable handle 7 which may be retracted by pivoting, sliding motion etc., in any known manner; or which may be made removable and adapted to be attached to the machine in any manner well known in the art.
Preferably, the lower portion of the pedestal or base is provided with legs 8 which may be made from rubber, felt, plastics or any suitable similar material.
The assembly of machine components 1, 2, 3, 4, 5 may be constituted of one or more pieces, and formed from injected metal, molded plastics or other material; or molded, injected, or possible machined material.
Within the framework of the invention, there is also provided a box 9 for accessories which is adapted to be fitted in a readily detachable manner about the free arm 2 of the machine, so as to form an extension of the working plane, and which provided with the necessary curves. Preferably, as illustrated in FIG. 6, the box 9 conforms in cross-section to the transverse profile of the pedestal 1 so as to form an extension thereof.
The box 9 is preferably made from metal, or molded or injected plastic material, and is shaped to have two utilizable interior spaces or compartments 9a which are of a configuration which is complementary to the cross-section of the free arm with respect to the cross-sectional profile of the pedestal. The compartments 9a are connected by one or more partitions 9b with reinforcing ribs.
The compartments 9a have pivoting flaps 9c articulated, for example, at 9d on hinge-lines of reduced thickness. Within the flaps or in the compartments, there may be formed, by molding or suitably attached, gripper members, supports or other positioning means.
The edge of the flaps 9c opposite the pivoting edge of hinge lines has, for example as illustrated, a tongue 9e for engagement with a lip 9f. The edge of the flaps is prolonged at 9g so as to provide a retaining slideway for supporting the box 9 on the free arm 2 as shown in FIG. 6.
According to the embodiment, if for example, the box is of a construction made from a flexible or resilient material, the box 9 may be fitted about the arm 2 at a predetermined degree of friction with respect to the compartments 9a, thus fixedly maintaining the box in a supported position on the free arm.
In addition from the usefulness thereof for receiving and storing various accessories, the box has the following advantages: -- when it is fitted about the free arm, it extends the working plane or surface constituted by the pedestal and facilitates sliding movement of the fabric over the surface; -- when the machine is utilized without mounting the case thereon as described further on hereinbelow, the box prevents any rocking of the machine upon large pressure or forces being exerted on the free arm during heavy operation of the machine; -- the box provides, as desired, a sewing machine having a pedestal, when the box is in a mounted position, or a free-arm sewing machine, when the box is removed therefrom.
A dual-purpose complementary sewing machine case is shown in FIGS. 8 to 16. The case 10 comprises a base 10a which is shaped and dimensioned so as to envelop the pedestal 1 and the free arm 2, and also the box 9 when the box is mounted on the machine and fitted onto the free arm.
The base 10a is of dished shape and may be molded, or alternatively may be formed from a plate or sheet which is appropriately cut and the edges of which are then turned up.
The edges of the base 10a are extended by four flaps 10b, 10c, 10e, 10e. The flaps are designed and dimensioned so as to have substantially trapezoidal, planar or inwardly curved shapes, whereby contiguous edges are formed or, optionally, overlapping edges, when they are lifted up toward the sewing machine for transport of the latter (FIG. 10). Accordingly, the case forms a closed, protective space. The upper edges 10f of the flaps respectively bear at a tangetial relationship against the upper arm 4, the sewing head 5, and the hand wheel 6.
The articulation of the flaps 10b, 10c, 10d, 10e along the edges 10a is effected,, for example, along hinge-folds 10g, as illustrated in FIG. 13. In this case, the hinge-folds are constituted by thinning lines in the thickness of the material.
Referring to FIG. 12, the articulation of the flaps to the base 10a is effected by means of one or two connecting tongues 10h, having support and stop heels 10i restricting, in one direction, the pivoting of the flap relative to the base. The articulation of the flaps on the base may also be effected by means of a system comprising rings or helixes 10k (FIG. 14) or, alternatively, by hinge arrangements of a known type, as illustrated in FIG. 15. These arrangements are not limitative and are only shown by way of illustrative examples.
Furthermore, the positioning or connection of the flaps to each other or with respect to the case is effected, for example, as illustrated in FIG. 16, which shows a slotted finger having an enlarged end which is engaged under resilient pressure in an associated aperture.
The case is designed in a manner whereby:
the base 10a is dimensioned so that the flaps 10b, 10c, 10d, 10e may be turned down and withdrawn within the base when the case is pivoted so as to be utilized as a work table, as shown in FIG. 9;
the base 10a is cut at the bottom and on one side (at 10m) so as to permit fitting about the free arm 2 when the case is pivoted in order to be utilized as a work table (FIG. 9). In this instance, as seen in FIG. 11, the turned-down flaps 10b, 10c, 10d, 10e are positioned within the base 10a and under the free arm.
The case may be made from any metal, sheet metal, plastic material, or material having similar suitable properties.
The significance and advantage of the present sewing machine case, which facilitates both transporting or storage of the machine under conditions affording good protection (FIG. 10) and also adaptation after pivoting, so as to form a large-surfaced worktable which is practical and convenient, is readily understood.
It is also possible that one or more of the flaps 10b, 10c, 10d, 10e may be extended through articulated, rigid, semi-rigid or flexible portions, for the purpose of completely covering the sewing head, the upper arm and the hand wheel of the sewing machine. In that instance, the extending portion or portions may carry a handle in a direct supporting relationship.
According to the embodiment shown in FIGS. 17, 18, 19 and 20, the gripping or carrying handle 11 is mounted so as to articulate in the frame 12, comprising a rectilinear portion 11a extending longitudinally and parallel to the upper portion 13a of the arm 13 of the sewing machine and over approximately one-half of its length, whereby the user's hand, during transport of the machine, is located to the right of the center of gravity of the sewing machine. The handle 11 has, in extension of the rectilinear portion 11a, a right-angled portion 11b inclined relative to the horizontal axis so that the rectilinear portion 11a is located within the horizontal axis of the machine when the handle is in the extended position and a pivot or crank portion 11c extending from the portion 11b contacts, along one of its generatrices, the horizontal face 12a of an aperture formed in the frame 12, which is slightly offset relative to the axis of the machine, thereby permitting free passage therethrough of the handle 11. The handle 11 includes two portions 11d and 11e which are located in the same plane as the portions 11b, 11c. and adapted to be appropriately pivoted so that the handle 11 is located therebelow and permits free passage for the shaft Va of a handle V. The squared end 11f, located in parallel to the portion 11a, constitutes an articulation pivot for the handle 11 and is disposed within an aperture formed in a boss on the frame 12.
In the folded position illustrated in FIG. 17, only the rectilinear portion 11a of the pivoting grasping handle 11 is visible, whereas in the extended position thereof shown in FIGS. 19 and 20, the portions 11a and 11b project from the arm 13 of the machine.
The retractable reel holder 14 shown in FIGS. 17, 21, 22, 23, 24, 25 and 26 comprises a vertical pivot 14a adapted to receive a reel, and which is secured perpendicular on a slide member 14b sliding and fastened into position within a sheath 15 made from any appropriately suitable plastic material. The side member 14b provides, in the withdrawn position thereof, a gripping portion 14c projecting from the frame 12, and having formed therein a notch affording improved grippability. The sheath 15, which is slightly conical so as to permit force-fitted engagement thereof, is maintained by two shoulders 15a and 15b which lock it against longitudinal translation, and also by relative resilience imparted thereto by appropriate choice of plastic material. A tongue 15c formed at one end of the sheath 15 and projecting into the sheath engages in a notch 14d formed in one end of the slide member 14b, thereby forming a stop for the reel-holder 14 when the latter is in an extended position. When the reel-holder 14 is in a retracted position, the tongue 15c is retracted due to the resilience provided by its plastic material properties, and abuts against the upper face of the slide member 14b. The pivot 14a takes up its position in a recess 12b formed in the frame 12. A recess 15d is also formed in the sheath 15 for permitting passage of the pivot 14a. Thus, when the reel-holder 14 is in the withdrawn position, the gripping portion 14c continues to project.
As shown in FIGS. 27, 28 and 29, the case 16 utilized for transporting the sewing machine is secured by at least two tongues 17 made from any material providing a predetermined suitable degree of resilience.
The tongues 17 are secured to the upper portion of the lateral flap 16a of the case 16 and have studs 17a penetrating into orifices 13b appropriately formed in the upper portion of the arm 13.
Thus, when the tongues 17 are turned down on the arms 13, the studs are engaged in the orifice 13b, and the resilience of the tongues 17 presses the lower portion of the sewing machine against the bottom inner surface of the case, thereby permitting projection of the legs 18 of the machine through the orifice 16b formed in the base of the case 16. The tongues 17 are also utilized for maintaining the flaps 16a in the position in which they are turned-down or folded in within the base of the case 16 when the latter is utilized as a work table. In that instance, the studs 17a of the tongues 17 together with the upper flap 16a engage in the orifice 16c formed in the additional flap.
While there has been shown what is considered to be the preferred embodiment of the invention, it will be obvious that modifications may be made which come within the scope of the disclosure of the specification. | A sewing machine of the cantilever type designed so as to be compact, of light-weight, exceptionally functional and of attractive appearance, while at the same time incorporating other significant practical advantages. The inventive sewing machine comprises a closely complementary-shaped fitted case of the "attache case" type, facilitating on the one hand the convenient conveyance of the machine and on the other hand, the removal thereof, when not utilized, with a minimum extent of bulk. During utilization of the machine, the case may be fastened by pivotal motion to a cantilevered or free arm of the machine so as to form a large-dimensioned worktable. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/015,173, filed Dec. 17, 2004; which is a divisional application of U.S. application Ser. No. 10/299,981, filed Nov. 18, 2002, now U.S. Pat. No. 6,843,435; which applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention generally relates to grinding machines known as horizontal grinders, and more particularly to the apparatus and methods that enable access to the grinding drum and for changing the sizing screens.
[0003] The grinding of a variety of materials can have a desirable effect. For instance grinding of some types of waste results in increased rate of decomposition, which is useful in landfill operations. Ground wood waste results in mulch, which is useful in landscaping applications. Ground asphalt can be reused. Some types of ground shingles can be used in asphalt production. The benefits of and need for such recycling processes continue to grow.
[0004] Several types of machines are useful in the variety of grinding applications. One type is particularly adaptable to a wide variety of applications, known as a horizontal grinder. Horizontal grinders typically include a horizontal feed table onto which the materials to be ground can be placed. The feed table is capable of moving the product to a point where a feed roller begins to cooperate with the feed table, generally pressing down on top of the material and being rotationally powered. The material is then forced, by the cooperation of the feed roller and the feed table, into contact with the side of a grinding drum. The grinding drum is as wide as the feed table and rotationally powered on a generally horizontal axis perpendicular to the direction of travel of the feed table.
[0005] The grinding drum typically includes hammers or cutters that impact the material as it is fed from the feed roller/feed table. These hammers or cutters tend to propel the material around the axis of rotation of the drum, eventually moving the material past a stationary bar, typically known as an anvil, that is in relatively close proximity to the outer swing diameter of the hammers or cutters. The material will be reduced in size to some extent, as necessary to travel past the anvil. However, further size reduction is typically required.
[0006] The additional size reduction is typically accomplished by the interaction of the hammers or cutters with a sizing screen that is also in relatively close proximity to the outer swing diameter of the hammers or cutters. The sizing screen includes holes to allow the material to pass after being reduced to the desired size. It has been found that the shape and size of the holes affects the performance of the machine and the resulting size of the ground material.
[0007] The sizing screens are typically provided on the bottom of the grinding drum, so that as material exits the holes in the sizing screen it will fall to a conveyor. A cover is typically provided over the top of the grinding drum to hold material from being thrown out and to carry material not yet sufficiently ground back around.
[0008] The grinding drum, sizing screens and cover are mounted in a mill box that provides the support needed for the tremendous loads that can be generated, particularly when grinding the more difficult materials. These tremendous loads result in the sizing screens being constructed of thick metal, and are thus heavy and difficult to handle. The normal operation of the grinding machine results in substantial loading and wear of the sizing screens. Thus, they must be removed for repair or replacement. In addition, they are changed out to modify the quality of the resulting ground material when being used for varying applications.
[0009] In some materials there is a possibility that the material will be wrapped around the grinding drum, between the hammers or cutters, and eventually pinched between the drum and the sizing screens. In this condition there may be sufficient drag on the drum to stall it. In this situation it is necessary to gain access to the drum to remove the wrapped material.
SUMMARY OF THE INVENTION
[0010] The present disclosure includes examples of inventive aspects adapted for facilitating providing access to the sizing screen of a grinder. The present disclosure also includes examples of methods for installing and removing sizing screens. Examples of a variety of inventive aspects are set forth in the description that follows. It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the broad inventive aspects disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a materials grinder having features that are examples of inventive aspects in accordance with the present disclosure;
[0012] FIG. 2 is a schematic, partial side elevation view of the grinder shown in FIG. 1 ;
[0013] FIG. 3 is a cross section taken along line 3 - 3 as illustrated in FIG. 1 ;
[0014] FIG. 4 a is the same view as seen in FIG. 3 with the cover in the open position and the sizing screen ¼ removed;
[0015] FIG. 4 b is the same view as seen in FIG. 3 with the cover in the open position and the sizing screen ½ removed;
[0016] FIG. 4 c is the same view as seen in FIG. 3 with the cover in the open position and the sizing screen fully removed;
[0017] FIG. 5 a is a perspective view of a mill box of the horizontal grinder of FIG. 1 , the mill box is shown in the open position with the sizing screen in a partially removed position;
[0018] FIG. 5 b is a perspective view of the mill box of FIG. 5 a in a closed position;
[0019] FIG. 6 is a side view of a sizing screen of the grinder of FIG. 1 shown in the installed orientation and in the removed orientation.
[0020] FIG. 7 is an isometric view showing the sizing screen in the removed position, as suspended by the lifting bar.
DETAILED DESCRIPTION
[0021] Referring to the drawings, and in particular to FIG. 1 , a materials grinder 100 is illustrated that includes features that are examples of inventive aspects in accordance with the present disclosure. This materials grinder is of the type known as a horizontal grinder and includes a feed hopper 110 for supporting a wide variety of materials. The grinder 100 is capable of holding loose materials such as leaves, shingles, small branches and also capable of holding larger objects such as large branches, boards, planks. A feed table 112 , in cooperation with side panels 114 , provides this capability.
[0022] The materials loaded into the feed hopper 110 are propelled towards a mill box 150 by conveyor bars 116 that are attached to conveyor chain 117 . Conveyor chain is routed around conveyor sprockets 119 that are mounted onto conveyor roller shafts 118 . One of the conveyor roller shafts 118 is powered, typically by a hydraulic motor in a manner that allows the conveyor bars to be propelled in either direction.
[0023] As the material is propelled towards the grinding drum, it will contact feed roller 120 . Feed roller 120 is mounted on a feed roller shaft 122 that is supported on mount arms 126 . The feed roller 120 is driven by a hydraulic motor, and typically includes feed bars 124 . The feed bars engage the material to be ground tending to keep it on top of the material and providing additional feed pressure on the material, urging it towards the mill box 150 which will contact the material and grind it to a desired size.
[0024] Ground material will exit mill box 150 and fall onto a discharge conveyor 200 that will transport it to a position beside the materials grinder 100 .
[0025] FIG. 2 illustrates the mill box 150 area in more detail. The mill box 150 includes a grinding drum 160 mounted on drum shaft 162 , a sizing screen 180 and top cover 170 . The sizing screen 180 extends below the drum 160 . The top cover 170 is positioned directly above the grinding drum 160 as further illustrated in FIG. 3 . It serves to hold material that is being ground from being thrown from the machine and provides pivotal support for the feed roller mount arms 126 at pivot points 128 .
[0026] The operating positioning of the components of the mill box is illustrated in FIG. 3 . The feed hopper 110 retains the material to be ground while the conveyor bars 116 propel it towards the mill box 150 . As it nears the mill box 150 feed roller 120 will contact the top portion of the material to be ground and assist in forcing it into contact with the grinding drum 160 which is being rotated about drum shaft 162 . An example of a grinding drum can be seen in U.S. Pat. No. 6,422,495, herein incorporated by reference, including cutters 164 mounted on hammers 166 . Many different styles of grinding drums are available. The cutters 164 will contact the material and drive it down, towards an anvil 182 . The initial impact of the cutters 164 will cause the material to be partially ground. Further impact and shearing forces will be applied as the material passes between the anvil 182 and the grinding drum 160 . The clearance between the outer swing diameter of the cutters 164 and the anvil 182 will affect the size of the ground material, and the anvil is typically located close to this outer swing diameter.
[0027] Once the material passes the anvil it is trapped between an inner surface 182 of the sizing screen 180 and the drum 160 . There it may pass through a hole in the sizing screen 180 and be ejected from the mill box 150 . Bigger pieces may become partially engaged with a hole in the sizing screen 180 and then subsequently impacted again by a cutter 164 causing them to be reduced in size to fit through the holes and be ejected. Other larger particles may be carried around the inside surface 182 of the sizing screen 180 , the inside surface 172 of the top cover 170 , and carried back to the feed hopper 110 .
[0028] The inner surface 182 preferably defines a curvature of constant radius that is centered about the axis of rotation of the drum 160 . The clearance between the inner surface 182 of the sizing screen and the hammers, and the size and configuration of the holes in the sizing screen 180 will affect the performance. Changing these parameters will affect the quality of the ground material as required by the variety of applications. In addition, when grinding some products, they will tend to wrap around the drum 160 rather than being ground, and can wrap sufficiently to prevent free rotation of the grinding drum 160 . In this case it may be necessary to interrupt operation, to relieve the pressure on the wrapped material, and to remove it prior to resuming operation.
[0029] The mill box of the present invention provides enhanced access capabilities as illustrated in FIGS. 4 a , 4 b and 4 c . FIG. 4 a illustrates the top cover 170 pivoted about pivot point 178 into an open position. In this position an operator is able to gain access to the grinding drum 160 to clear any obstacles. It is also possible to attach a lifting device (e.g., a crane or hoist) to a lift member such as a lift bar 186 of the sizing screen 180 in order to lift the sizing screen out of the mill box. As shown in FIG. 7 , the lift bar 186 can include an eyelet 187 or other type of structure for receiving a hook, chain or other component of a lifting device. FIGS. 4 b and 4 c illustrate the sizing screen and lift bar as they are further removed from the mill box, to the position illustrated in FIG. 4 c , where the sizing screen is completely removed.
[0030] The first step of the removal process is to pivot the top cover into the open position of FIG. 4 a . This step is enabled by cylinder 174 , as illustrated in FIG. 5 a with the top cover in its open position. This figure illustrates the top cover 170 in the open position where the cylinder 174 has been extended. The initial extension of cylinder 174 will rotate latch 176 around latch pivot 177 to disengage from latch pin 152 (shown in FIG. 5 b where the cover is closed). Additional extension of cylinder 174 will rotate top cover 170 around pivot 178 to the open position illustrated. In this position any material that had been trapped between the drum 160 and the top cover 170 will be released and an operator can gain access to the grinding drum 160 to remove wrapped material.
[0031] In the normal operating position of the mill box, illustrated in FIG. 5 b , the top cover 170 will be in the closed position where cylinder 174 is retracted and has pulled latch 176 into engagement with latch pin 152 . Latch pin 152 is secured to mill box frame 154 , which is comprised of two sides 155 and cross members 158 , 159 and anvil 182 . The mill box frame also provides support for the top cover pivot 178 , grinding drum bearings 168 and a pair of sizing screen slides 156 (i.e., guides or tracks as shown in FIG. 5 a ). In the closed configuration, with the latch 176 engaged with the latch pin 152 , the forces of the grinding action, occurring between the cutters 164 , the sizing screens, and top cover 150 , are retained within the structural component defined by the mill box frame 154 .
[0032] Referring to FIG. 7 , the sizing screen 180 includes a sizing plate 181 defining a plurality of sizing openings 183 . The plate 181 (i.e., one or more plates) has an upper end 185 and a lower end 187 . Edges 189 , 191 of the plate 181 extend between the upper and lower ends 185 , 187 . Curved reinforcing flanges 193 are secured to the outer side of the plate 181 and extend generally along the edges 189 , 191 . Cross-braces 195 , 197 extend between the flanges 193 . A top plate 184 extends outwards from the upper end 185 of the plate 181 . The top plate 184 is reinforced by enlargements 199 of the flanges 193 , as well as a pair of reinforcing plates 201 that extend between brace 197 and the top plate 184 .
[0033] Referring to FIG. 5 a , the slides 156 are connected (e.g., welded or fastened) to opposite side walls 155 of the mill box. As shown schematically in FIGS. 4 a - 4 c , the slides 156 have a curvature that curves about the axis of rotation of the drum 160 . The slides 156 are oriented such that lower regions 157 of the slides are positioned closer to the axis of rotation of the drum 160 than upper regions 159 . As shown in FIG. 3 , the mill box also includes a stop 205 positioned adjacent the anvil 182 . The stop 205 is adapted to abut against the lower end 187 of the sizing plate 181 .
[0034] Referring still to FIG. 3 , an end plate 207 projects outwardly from the lower end 187 of the sizing plate 181 . The end plate 207 underlaps the stop 205 to prevent the lower end 187 of the sizing plate 181 from flexing inwardly.
[0035] In this normal operating position, as illustrated in FIG. 3 , a flange 171 of the top cover 170 opposes the top plate 184 of the sizing screen 180 , trapping and holding the top plate 184 in position. With the top cover in the open position, there are no retainers holding the sizing screen in position. It is, at that time held in position by slides 156 and cross member 158 of the mill box frame 154 . For example, the top plate 184 seats on cross-member 158 , the edges 189 , 191 of the sizing plate 181 seat on the lower regions 157 of the slides 156 , and the lower end 187 of the sizing plate 181 abuts against the stop 205 of the mill box.
[0036] To remove the sizing screen 180 a lifting device, not shown, is attached to the lifting bar 186 in order to lift it out of the mill box frame 154 , as shown in FIGS. 6 and 7 . As the sizing screen 180 is lifted it will tend to follow the slides 156 , rotating around the centerline of the grinding drum 160 , as the slides 156 are arcuate and extend generally along an exterior of the drum 160 . Lift bar 186 is pivotally attached to the sizing screen 180 at a pivot point 188 that is positioned such that when removed, the sizing screen will be moved by gravity to the orientation illustrated in the upper position of FIG. 6 . In this manner the lift mechanism can operate to provide a nearly straight lift, and the sizing screen will be removed in a manner that makes it easy for an operator to control.
[0037] Likewise for installation, the sizing screen 180 , when lifted by the lift bar 186 , will be in the correct orientation to begin to engage with slides 156 . The installation process will then include first lifting the sizing screen into position so that its lower end 187 engages the slides 156 . The sizing screen is then lowered. As it is lowered it will rotate around pivot point 188 as the screen rides downwardly along the slides 156 . As the sizing screen moves downwardly along the slides 156 , the sizing screen is gradually moved into its final position in close proximity to the drum 160 by the lower regions 157 of the slides 156 . In other words, the transition from the upper regions 159 of the slides to the lower regions 157 of the slides causes the sizing screen 180 to move gradually towards the drum 160 to its final position in close concentric proximity to the drum 160 . After it has been completely lowered, the back surface of the lift bar 186 will be resting against cross member 158 , and the lift bar 186 is positioned between the reinforcing plates 201 of the sizing screen 180 . Once the screen 180 is fully lowered, the lifting device will be detached from the lift bar 186 . The top cover will then be closed, resulting in flange 171 contacting top plate 184 , trapping the sizing screen in place. Sizing screen 180 is then held in place by the lower portions 157 of slides 156 , the cross member 158 and the stop 205 . The cylinder 174 will then fully retract and latch 176 will reengage latch pin 152 .
[0038] In this manner the present invention provides a mill box that allows the operator to quickly and conveniently gain access to the grinding drum to release pressure of wrapped material and clean out wrapped material. It also provides for a quick and convenient method to remove, and exchange or repair the sizing screens.
[0039] The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. While a preferred embodiment of the present invention relates to horizontal grinders, it will be appreciated that the various inventive aspects are also applicable to other types of grinder configurations. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | A grinder having a grinding structure and a sizing screen is disclosed herein. A top cover covers the grinding structure. The sizing screen can be removed from the grinder by opening the cover, and lifting the sizing screen through the opening left by the cover. | 1 |
FIELD OF THE INVENTION
[0001] The invention relates to tools for removing material that has been nailed in place, such as asphalt shingles and roofing materials of all types, and flooring materials such as tile, carpet and wood strips. It is also useful in removing siding, panels, and moldings.
BACKGROUND TO THE INVENTION
[0002] When a building, or part of one, is to be taken apart, if material is to be salvaged, nails must be extracted. Some parts of buildings, notably roofing materials, are intended to be replaced many times in the life of the building. Roofing materials, such as shingles, are nailed in place, so removing the shingles for replacement requires extracting the nails. For efficiency, it is normal to lift the roofing material and the nail together, until the nail is fully extracted and the roofing material is detached from the building. The roofing material and the nail can then be discarded, and the wooden roof that has been exposed will be retained, possibly with some repairs, and covered with new roofing material.
[0003] This description will mainly speak in terms of lifting shingles, for brevity. That is an important use of the tool, but it must be remembered that the tool is useful for removing many types of building materials held by nails.
[0004] Most nails have heads that provide a grip for a pulling tool. Most pulling tools have a slot to grip the nail below the head, and operate as a lever with the fulcrum on the surface in which the nail is embedded, such as the roof. The common claw hammer is an example. Many more elaborate tools have been developed, and patented, but there remains room for improvement in respect of the smoothness of operation in guiding the tool around the nail, and in levering the nail out of the material in which it is embedded.
[0005] U.S. Pat. No. 1,218,145 to Whittier discloses, way back in 1917, a shingle stripper that is a blade having V-shaped slots on the front and back edges, and the bottom surface (and top surface, but that is irrelevant) having two dihedral planes creating a single ridge fulcrum where the two planes meet. The present invention improves on the shape of the slots, and provides a continuous fulcrum as a curved rocker.
[0006] U.S. Pat. No. 4,203,210 to Hadlick discloses a shingle stripper that is essentially a shovel with V-shaped slots at the front edge, and a separate fulcrum affixed at the rear edge. Again, the present invention improves on the shape of the slots, and provides a continuous fulcrum like a curved rocker.
[0007] U.S. Pat. Des. 392,687 to Gracy et al. discloses a multi-purpose wrecking bar that has a flat bottom, so the only fulcrum is the rear edge. Gracy discloses slots with straight sides that taper either continuously, or in two different tapers, and some end the tapering straight side with a round hole.
[0008] U.S. Pat. No. 4,466,188 to Svendsgaard discloses a roofing remover that is wedge shaped and has slots that are straight parallel sides ending in a rounded end. The bottom surface is flat, but the tool as a whole is wedge shaped for forcing up the roofing material after the nail has been extracted. Extracting the nail involves lifting the nail by the slots, and the only fulcrum for lifting is the rear edge.
[0009] U.S. Pat. No. 5,280,676 to Fieni discloses an apparatus with slots having straight sides that taper in two different degrees, so the slot near the mouth of the slot converges rapidly and the remainder of the slot converges slowly or not at all. The bottom surface is almost all flat, but near the rear of the tool there is a bend that provides a ridge fulcrum before the rear edge comes into play as a fulcrum.
[0010] U.S. Pat. No. 6,125,720 to Gohman discloses a tool for removing roofing material that has slots much wider than a nail, and sub-slots within them that could seize a nail. All the slots have straight sides that taper narrower away from the leading edge. The blade is flat on the bottom (and top), but the manner of fastening it to the handle involves a curve that constitutes the rear edge for practical purposes. Most tools of this general type have the handle attached near the middle of the blade, but Gohman bends the blade and attaches the handle at the rear of the working surface of the blade. The bent rear edge of Gohman is not exactly a ridge fulcrum, but it is functionally different from the continuous curved rocker fulcrum of the present invention.
[0011] U.S. Design Pat. D439,126 to Gohman shows a thin blade with V-shaped teeth on the leading edge. The blade as a whole is partly flat and partly convex downward. It is quadrangular. The handle is attached at the rear of the blade, and the blade is not adaptable to have teeth on the rear edge. The prying force is delivered indirectly to the blade from the handle through an offset portion of the rear of the blade. As the blade has no reinforcing ribs or gussets, it is vulnerable to bending both along the main blade and in the offset joining the handle. This tool would require remarkably strong metal to operate with flexing.
[0012] U.S. Pat. No. 5,836,222 to Harpell discloses a shingle removing tool having slots with parallel sides, and an alternative with V-shaped slots. The bottom surface is flat, so the only fulcrum for lifting nails is the rear edge of the tool. The slots are simply parallel sides with rounded leading edges between them.
[0013] U.S. Pat. No. 6,029,545 to Harpell discloses a roofing tool having slots with parallel sides. The largest part of the bottom surface is flat, but blade is thinned near the leading edge so the bottom surface has a small portion near the leading edge that is a flat plane at a small angle to the rest of the bottom surface. Where the two planes meet, there is a ridge across the blade that serves as a fulcrum when the nail is first lifted. After a small advance of the nail, the fulcrum will shift to the rear edge of the blade, so this tool has two fulcrums, rather than the continuous rocker fulcrum of the present invention.
[0014] U.S. Pat. No. 6,098,292 to Harpell discloses a demolition tool having either no slots, or slots with parallel sides. The leading edge is designed for cutting, but cutting is often not desired, and rather grabbing and lifting is desired. It has a flat bottom, although with a groove, so its only fulcrum for leveraging nails upward is the rear edge. It has a quadrangular outline, which does not conform to a partially lifted shingle, and its sharp straight edges tend to cut the shingle, which is undesirable.
[0015] U.S. Pat. No. 6,339,975 to Harpell discloses long teeth on each side with straight sides, directing nails into slots that are rounded at the bottom and at the end of the finger between slots, but essentially have parallel sides. The bottom surface is flat, so the only fulcrum for lifting nails is the rear edge. The long fingers are very aggressive to the shingle, tending to cut, and pushing the long fingers much farther ahead than the slots where the nail will be lifted is inconvenient and hard work.
[0016] Published US application 20070051210 by Harpell discloses a tool blade with slots having two different degrees of taper near the mouth, and parallel sides to complete the slot. The bottom surface is two planes at a small dihedral angle, proving a fulcrum near the middle of the blade. There is also an alternative of a bottom surface that is flat through the middle majority of the surface, with a plane diverging at a small dihedral angle at each end. The present invention will improve on the design of the slots, and will provide a continuous fulcrum as a curved rocker. Harpell also provides an “impact receiving member” which is some distance up the handle above the blade. The present invention provides the equivalent hammer horns at a location that will better deliver the effect of impact to where it is helpful.
SUMMARY OF THE INVENTION
[0017] It is an object of the present invention to overcome the deficiencies noted in the prior art concerning tools for lifting building materials and associated nails. The invention guides itself around nails more smoothly than prior tools. The invention can be inserted under a shingle more smoothly because the envelope of its shape conforms to the shape that the shingle must take. The invention levers the nail more smoothly with a continuous rocking motion, starting with the most powerful prying force and smoothly advancing to the most rapid movement. In this summary, “smoothly” includes the meaning of easily, that is with less work, and it includes the meaning of proceeding without jerks and sudden stops, which is desirable for the comfort of the user.
[0018] All of the prior art uses nail gripping slots that do either little or nothing to guide the tool around the nail, or guide the nail with slanted straight edges that resist the movement of the tool. All of the prior art uses a small number of fulcrums, sometimes just the rear edge, and at other times an additional one, two, or three ridge fulcrums. The disadvantage of the rear edge fulcrum is that it is a long way from the nail to be lifted and the long lever arm gives poor leverage. The disadvantage of several added ridge fulcrums is that the shift from one to another as the extraction progresses causes a jerk in the movement of the handle which is tiresome to the user.
[0019] All of the prior art discloses essentially rectangular tools. The leading edge and the sides are straight, and typically at right angles. If their top is provided with two or more camming gussets to lift the shingles, they are the same height so the envelope of their lifting edges is planar. However, if the material being lifted is at all flexible, such as an asphalt shingle, the tool will be operating in a space under the lifted material that is semi-conical. The shingle is curved in all places where it is not contacting the roof. The lifted portion is like a bubble. When rectangular tools with straight edges are inserted into that bubble, they meet a lot of resistance and they do a lot of damage to the material being lifted. This is analogous to a square peg in a round hole. The lifting head of the present invention has an envelope that is curved, conforming to the curving bubble.
[0020] These and other objects, features, and characteristics of the present invention will be more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The preferred embodiments of the invention will now be described in detail with reference to the following drawings, in which:
[0022] FIG. 1 shows the lifting head from above.
[0023] FIG. 2 shows the design of slots, made of overlapping holes.
[0024] FIG. 3 a shows the forces at work in guiding the lifting head around a nail in the prior art, and FIG. 3 b shows those forces as the operate in the present invention.
[0025] FIG. 4 shows a side view of the lifting head.
[0026] FIG. 5 shows a side view of the whole tool, comprising the handle and the lifting head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring to FIG. 1 , the lifting head has a front portion 1 that is larger than the rear portion 2 . The dividing line between front and rear passes through the handle mounting boss 3 , which is adapted for mounting a handle that is inclined to the rear (downward in the drawing). Each of front portion 1 and rear portion 2 are symmetrical left and right about a line passing through the centre of the handle mounting boss 3 .
[0028] The leading edge of the front portion 1 has slots in it, but if the slots are ignored for a moment, the imaginary envelope 8 of the leading edge is slightly curved so that side tips 6 and 7 are not as far forward as the leading edge between them. The sides 4 and 5 are slightly curved so that it is narrowest near the handle mounting boss 3 , widest about two-thirds of the distance from the boss to the leading edge, and less wide at the leading edge.
[0029] The curved outline has beneficial effects. Until the last nail in a shingle is reached, the shingle under which the leading edge is slipped will be held close to the roof by one or more nails on at least one side of the lifting head. When the lifting head grips a nail and raises the nail and the shingle together, the shingle will bend down on the side where there is another nail, and in the direction ahead of the tool. The shingle will tend to a semi-conical shape, curved with its highest point at the centre line of the lifting head. The curved front and sides of the lifting head are a better fit to the curving bottom surface of the lifted shingle than straight sides would be. If the leading edge were straight, the lifted shingle would have to lift equally across the width of the lifting head and then fall away at the sides. Such a design tends to encourage breaking of the shingle, which is less efficient because a smaller section is lifted and more broken sections of shingles remain to be dealt with individually. Straight sides and a straight leading edge would tend to cut into and break the shingles more than the curved sides and curved leading edge.
[0030] The entire front portion 1 of the lifting head can be imagined surrounded by an envelope which bridges over slots and ridges and is the smooth surface that would neatly encase the lifting head. An aspect of the invention is that such an envelope would have nothing but curved surfaces when viewed from any perspective. There are no straight lines in the envelope, except perhaps the small vertical sidewall that is the thickness of the blade.
[0031] Sides 4 and 5 curve outward as they leave side tips 6 and 7 for the reasons just discussed, but after some distance sides 4 and 5 continue curving so that the lifting head becomes narrower near the handle mounting boss 3 than at the leading edge. That narrowing reduces weight and cost, but it is not an essential feature. The narrowing near the mounting boss 3 also allows the hammer horns to project beyond the lifting head and so be more exposed for the purpose of being struck, without being long. A long hammer horn would have the disadvantage that blows on it tend to rotate the lifting head, which is unhelpful. The hammer horns are preferably located as close to the centreline as possible, because that maximizes the transfer of the force of a blow to the leading edge of the lifting head. In some tools known in the prior art, an element intended to receive blows is placed on the hosel or the handle, but that has the disadvantage that the force of the blow is partly dissipated by the resilience of the handle, and also the force has a vertical component that is wasted, and counterproductive, for the purpose of forcing the tool to lift nails and shingles.
[0032] The leading edge of the front portion 1 has a number of slots, into which nails will slide when the lifting head is pushed forward. All slots are formed from overlapping round holes. In other words, the sides of slots are all arcs of several circles that overlap, so no circle is complete. In principle, the slots could be formed by drilling a number of round holes, but that is not the practical way to produce the slots. In the embodiment shown, the central slot 11 and the two outer slots 12 and 13 are suitably formed from two overlapping holes, with the outer hole about 3 times the diameter of the inner one. The slots 15 , 16 midway between the centre and the sides are each suitably formed with a pair of inner holes, plus a pair of holes overlapping those inner holes and about three times the diameter of the inner holes, and finally a pair of still larger holes, overlapping the last-mentioned holes and overlapping each other. The use of round holes means that the sides of the slots are a series of arcs. Arcs are well suited for guiding the lifting head past the nail shaft until the end of the slot is reached, or until the slot is smaller than the nail shaft diameter. The nail shaft will be cupped by the arcuate side of the slot, and the head of the nail will extend over the top surface of the lifting head so that when the leading edge of the lifting head rises, the nail is pulled and the shingle is lifted.
[0033] FIG. 2 shows the circular nature of the sides of the slots. Circle 60 defines the arcs that are part of the outermost portion of a slot. Circle 61 defines the next portion of a slot, and circle 62 defines the smallest portion and end of a slot. Circles 61 and 62 are shown in separate slots, not overlapping circle 60 , but the shape of slots 15 and 16 is the same as a circle like 62 innermost overlapped by a circle like 61 next outwards, and circle 60 overlapping circle 62 in each of slots 15 and 16 . Circle 63 , defining part of slot 13 , would typically be about the same size as circle 61 , but the exact size of any circle, and so of any slot, is not critical to the invention.
[0034] It is common in the prior art to use converging sides of the slots, and when the nail reaches the slot width equal to the shaft diameter, the tool often goes a little farther and bites into the nail. That is undesirable because the nail clings to the tool, and may be cut right through or is at least easily broken where the bite occurred. Straight sides of a slot bite into the nail because they are tangent to the nail surface, and the point of contact is small so the force is concentrated. In the present invention the sides of the slot are not a straight tangent to the nail but approximately concentric with the nail. The contact is not at a point, but along a short arc, so the force is not concentrated at a point and the edge is less likely to bite into the nail.
[0035] Other known nail extracting tools of the pry-bar type usually have either slots with converging sides, as with the classic claw hammer, or slots with a change of angle along the sides so the leading portion of the slot is wider than the following portion. A common example of the latter type is a series of slots defined by a series of fingers having leading ends that taper to narrowness at the leading edge, which may be a rounded leading edge of each finger. A tool with multiple slots must have the slots spaced sufficiently apart that the fingers between them have enough material to be strong, keeping in mind that the material is necessarily thin since it must slip under the head of the nail. The tool will more readily slide around the shaft of the nail if the slot has a wide opening to find the nail and guide the tool around the shaft.
[0036] FIG. 3 a and FIG. 3 b illustrate the benefit of slots made of overlapping round holes. FIG. 3 a shows the prior art, where the side of the slot 30 is straight but inclined to the direction of motion of the tool, which is vertically upward in the drawing. The force moving the lifting head forward will resolve into a vector 20 moving the tool to the left by pushing on the nail 31 , and vector 21 pushing against the nail. A force equal to vector 21 is felt by the user, as the nail 31 pushes back on the tool 30 . Both vectors 20 and 21 are constant from the moment of first contact of the lifting head with the nail. The forward vector 21 is pushing strongly against the nail 31 , which has the disadvantage of possibly digging into the nail or even cutting through it. Another disadvantage is that the emergence of two vectors happens instantly upon contact with the nail and the user must instantly supply the extra force for vector 21 , which means that the user feels a large shock force upon encountering the nail.
[0037] FIG. 3 b shows an aspect of the present invention, where the sideways vector 22 is very small at the moment of first contact, and so is the forward vector 23 . The side of the lifting head surface 32 is sliding almost tangentially against the nail 33 , with little resistance. The user feels almost no shock force and the forward vector 23 is almost undiminished as the tool continues to advance smoothly. As the nail moves along the curve and takes the position of nail 34 , the sideways vector 24 grows and the sideways movement accelerates. There is little or no shock force felt by the user, because vector 25 increases gradually. Of course, there is a shock when the nail 34 settles at the end of the slot and movement stops, but by that time the various sources of friction, namely the lifting head sliding over the roof and under the shingle and against the nail, have gradually lowered the speed of the tool and the shock of stopping when the nail reaches the end is not large.
[0038] Although the holes have been described as round, which is a shape easily made, the invention would also achieve the intended benefits if the holes were to have some ellipticity.
[0039] The slots in the lifting head will lift nails in a wide range of sizes. The fingers that define the slots will lift staples.
[0040] FIG. 1 shows that the top surface of the lifting head has a number of ridges 17 , 18 . As with all aspects of the lifting head, the ridges are symmetrical about the centre line passing through the handle mounting boss 3 and midway between the side tips 6 , 7 . These ridges not only strengthen the lifting head for its nail-pulling purpose, but lift the shingle from the roof and begin to direct it upwards sliding over the handle, in a camming manner.
[0041] On each side of the lifting head, on a line passing through the handle mounting position, there is a horn 19 that projects to a distance a little greater than the maximum width of the lifting head. This is useful for striking with a hammer, or kicking, to force the lifting head under particularly resistant shingles. The horns 19 curve up away from the surface on which the lifting head is resting, so that the lifting head can be rocked sideways as part of the nail extraction without a horn 19 becoming a fulcrum.
[0042] FIG. 1 shows that the rear portion 2 resembles the front portion 1 , but is smaller. The sides, and the envelope of the leading edge, of the rear portion 2 are curved for the same reason as in the front portion 1 . The construction with ridges is similar. The slots are made of overlapping round holes, with one exception that is optional. The central slot 14 is large enough for a large nail or spike, such as may be encountered sometimes in the course of removing shingles or flooring or siding or any material that was generally attached with smaller nails for which this lifting head as a whole is adapted. Such large nails usually require a claw hammer or pry bar, but if this tool is at hand, slot 14 is convenient for occasional use.
[0043] Another optional feature in FIG. 1 is a hole 9 that has a large end and a small end. The head of a nail will pass through the large end, and the tool can then be pulled so the shaft of the nail is passing through the small end. When the tool is rocked or lifted the small end will press on the head of the nail and extract the nail. This is especially useful for large nails that are occasionally encountered, or particularly stubborn nails that would rather bend than move when pried on by the slots at the leading edge of the lifting head.
[0044] FIG. 4 shows another important aspect of the invention, the convexity of the bottom surface 40 . The bottom surface of the lifting head is a section of a cylinder. It may be an elliptical cylinder. The radius of curvature may be the same for the entire bottom surface of combined front portion 1 and rear portion 2 , as illustrated, or may change at some point, most likely below the handle mounting position, so that there is a smaller radius of curvature in the rear portion 2 . In that case, the bottom surface would be sections of two cylinders. The leading edge 42 and the rear edge 41 must be thin enough to reach under a nail head while slightly compressing a shingle through which the nail passes. The thinness is achieved by the convergence of the semi-cylindrical bottom surface 40 with the top surface, and the top surface may optionally be thinned as it approaches the leading edge 42 and rear edge 41 .
[0045] As the lifting head is rocked to the rear, the bottom surface will be in constant tangential contact with the roof. The point of contact with the roof, the fulcrum, will shift on the roof in the direction towards the rear edge 41 of the lifting head, as the front end 42 rises and brings with it a nail and a shingle. It is advantageous to make such rocking contact, rather than, as in the prior art, having a sharp ridge where two planes of the bottom surface meet at a small dihedral angle. A ridge can dig into the roof surface and cause damage, whereas the convex rocking surface causes no damage. Another advantage is that the rocking motion is smooth through a large angle of the handle, until the point of contact (the fulcrum) reaches the rear edge 41 of the lifting head. In practice, it is often not necessary for the fulcrum to reach the rear edge 41 , as the shingles and nails have been pried from the roof before then. In contrast, the prior art has two types of bottom surfaces—either flat all over, or several flat planes. The fully flat prior tools use the rear edge as the fulcrum for leverage. The multi-plane prior tools use a transverse ridge as a first fulcrum, and then come to another intersecting plane so that the leverage abruptly shifts to the rear edge as the second fulcrum. Some versions have two fulcrum ridges before reaching the rear edge as a fulcrum. The shift of fulcrums subjects the user to an uncomfortable and tiring jerk in every removal. In other words, the prior art for roofing tools has either one fulcrum, that being the rear edge, or two fulcrums, being a ridge near the middle and the rear edge, or rarely three fulcrums of which the last is the rear edge. The convex surface of the present invention has an infinite number of fulcrums. The convex surface is functionally similar to the curved side of a claw hammer, which invariably is a curve not a plane, perhaps with changing curvature but without a ridge where there is a dihedral angle between planes.
[0046] FIG. 4 also shows features discussed in connection with FIG. 1 , a couple of ridges 17 , 18 , and one of the horns 19 projecting out of the page. The ridge 18 , which is closer to the centre line than ridge 17 , is higher than ridge 17 . This is an aspect of the overall roundedness of the lifting head. The shingle that is being lifted will usually be attached to the roof in at least the forward direction and one side direction. When it is lifted, the shingle curves down in all directions from the lift point, which is on the centreline of the lifting head. The shingle could be described as having a bubble formed in it. The lifting head disclosed here conforms approximately to the bubble shape, which has the beneficial effect or reduced resistance to advancing the bubble, and less cutting and breaking of the shingle.
[0047] The top surface of each of the ridges 17 , 18 is preferably concave upwards, to cammingly move the shingles upwards. It is known in the prior art to have one or two camming elements, which may or may not also serve as strengthening gussets, but a larger number, at least 4, of camming elements provides better lifting and dispersal of the shingles. A single gusset tends to slice the shingles without forcing them upwards, so then the leading edge of the shingles strikes the hosel and stalls progress. A triangular gusset would have a greater tendency than a curved ridge to slice the shingles, because the curved arc makes a gradual attack on the shingle, and benefits further from having a rounded top of the ridge all along the ridge.
[0048] FIG. 4 shows a handle 43 attached to the handle mounting boss 3 . The lifting head is most effectively manufactured by hot forging, although the invention is not limited to forged heads. Forging cannot produce a hole suitable for a handle, so a metal handle would typically be attached by a weld 44 to the lifting head. Alternatively a metal hosel could be attached to the handle mounting boss 3 by a weld 44 , and the hosel would stand in the position 43 in the figure. The hosel could be fitted with a handle of wood, fibreglass, or any material suitable for a tool handle.
[0049] Forging is not well suited to producing thin portions of the forged article, as required at the leading edge and typically at the rear edge of the lifting head. To obtain the desired thinness of the leading and rear edges, it is generally desirable to finish the bottom surface with a grinding operation. Grinding is well suited to producing a slightly convex surface, tapering to a thin edge comparable to the edge of a dull knife. The slots, in the pattern of a series of overlapping round holes, and any complete holes, will typically be formed by a hot trimming press while the lifting head is still ductile and softened from the hot forging process.
[0050] FIG. 5 shows the tool with a handle 51 . The handle 51 , if it is metal, will be welded to the handle mounting boss 3 . Alternatively, if the handle mounting boss 3 is fitted with a hosel (not shown) that is a few inches long, a handle can be inserted in the hosel. Such a handle may be made of wood, fibreglass, steel, or any material known to be suitable for tool handles. The preferred shape of the handle has a bend 52 at about two-thirds of the distance towards the end 53 . That ensures that the end 53 of the handle will touch the roof, in an extreme prying operation, before the user's hand which is near the bend 52 would touch the roof, thus protecting the hand.
[0051] Many modifications and variations besides those mentioned herein may be made in the techniques and structures described and depicted herein, resulting in other embodiments of the present invention without departing from the concept of the present invention. The foregoing disclosures should not be construed in any limited sense other than the limits of the claims that follow. Thus the scope of the invention should be determined by the appended claims and their legal equivalents rather than by the examples given. | The invention is a tool for lifting building materials, such as shingles, while extracting nails that fastened those materials. The slots that grip the nails are a concatenation of overlapping holes, for smooth insertion of the tool past the nails, and the envelope of the tool is a surface of curves for smooth insertion of the tool under the building materials. The bottom surface is a rocker that provides a moving fulcrum for prying out the nail, giving maximum force when the nail is first gripped and smoothly moving to maximum speed of extraction as the fulcrum moves back towards the user. | 4 |
[0001] This application is a continuation-in-part of U.S. Ser. No. 09/384,351 filed Aug. 27, 1999.
FIELD OF INVENTION
[0002] The present invention relates to a high viscosity rubber composition which has reduced mixing cycles due to the incorporation of exceptionally large carbon black particles therein.
BACKGROUND OF THE INVENTION
[0003] Heretofore, reinforced rubber compositions, especially for tires, generally utilize conventional sized carbon black, which typically resulted in good reinforcing properties. However, rubber compositions having high viscosity required a large number of remilling operations to reduce the viscosity thereof to an acceptable level.
[0004] U.S. Pat. No. 5, 426,147 relates to rubber compositions having reduced permeability to gases comprising rubber and specified furnace carbon blacks.
[0005] U.S. Pat. No. 5,456,750 relates to furnace carbon blacks that impart advantageous properties to rubber and plastic compositions and may be utilized in place of lampblacks, thermal carbon blacks and blends of carbon blacks. Also disclosed are rubber and plastic compositions incorporating the carbon blacks which exhibit advantageous combinations of compound processing and physical performance properties.
[0006] U.S. Pat. No. 5,688,317 relates to carbon blacks that impart advantageous properties to rubber and plastic compositions and may be utilized in the place of lampblacks, thermal carbon blacks and blends of carbon blacks. Also, disclosed are rubber and plastic compositions incorporating the carbon blacks which exhibit the advantageous combinations of compound processing and physical performance properties.
SUMMARY OF INVENTION
[0007] It is an aspect of the present invention to use large sized carbon black particles to reduce the number of mixing stages of hard or stiff tire compositions without reducing the hardness, stiffness, or other critical physical properties thereof. The reinforced rubber compositions of the present invention thus reduces mix energy usage. The compositions of the present invention generally utilize large carbon particles characterized by low crushed DBP absorption values as well as low iodine numbers.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The rubber compositions of the present invention generally contain one or more rubbers made from a conjugated diene having from 4 to 12 carbon atoms and preferably from 4 to 8 carbon atoms. Examples of such dienes include butadiene (preferred), isoprene (preferred), 2,3-dimethyl-1,3-butadiene; 2-methyl-1,3-pentadiene; 3,4-dimethyl-1,3-hexadiene; 4,5-diethyl-1,3-octadiene; 3-butyl-1,3-octadiene; phenyl-1,3-butadiene; and the like.
[0009] Another class of rubbers which can be utilized in the present invention are copolymers of the above-noted conjugated dienes having from 4 to 12 carbon atoms with one or more vinyl substitute aromatic compounds such as those having from 8 to 12 carbon atoms with specific examples including styrene, alpha-methylstyrene, tertiary-butylstyrene, vinyinaphthalene, and the like, with styrene-butadiene rubber being preferred. Another preferred rubber compound is natural rubber, ie. that is rubber which is derived from trees, which are generally grown in the tropics.
[0010] The present invention is generally not applicable to so-called “soft” rubbers. Such rubbers are generally classified as being rubbers derived from ethylene and propylene, for example, EP rubbers, rubbers which additionally include small amounts of a conjugated diene such as EPDM rubbers, butyl rubber, rubbers made from unconjugated diene monomers such as norbomene, ethyl-norbomene, dicyclopentadiene rubber, other types of soft rubbers such as various urethane rubbers, and the like.
[0011] According to the concepts of the present invention, it has been found that the utilization of large sized carbon black particles added to a so called hard rubber composition reduces the number of mixing stages required and hence results in energy savings. Such carbon blacks can generally be defined as being a low structure carbon black and thus have low DBP absorption numbers such as generally less than about 65, desirably to about 20 to about 55, and preferably from about 30 to about 45. DBP absorption can be determined in accordance with ASTM test number D-2414. The large sized carbon black particles also have low iodine numbers such as generally less than about 40, desirably from about 3 to about 35, and preferably from about 6 to about 25. Such large carbon black particles are commercially available from Cabot Corporation as Regal 85, from Engineered Carbons as N990, from Cancarb Ltd. as Thermax Floform, and from Columbian Sevalco Ltd. as Servacard MT-N-990
[0012] The large sized carbon black particles of the present invention are desirably utilized in hard or stiff rubber compositions, since they have been found to reduce the rubber composition viscosity during mixing, although the end hardness of the rubber composition is generally the same as that when the large carbon black particles are not utilized. Such hard rubber compositions after adding and blending all of the various additives but before curing, generally have a Mooney viscosity ML 1+4 of generally from about 30 to about 80 and desirably from about 40 to about 70. The hard rubber compositions generally contain natural rubber, inasmuch as the same is generally harder than synthetic rubbers, but contain very little oil, that is generally less than 20, often less than 15, and even less than 10 or nil parts by weight per 100 parts by weight of rubber.
[0013] The masterbatching, mixing, remilling, etc., generally relate to a rubber composition containing the large sized carbon black particles, stearic acid, zinc oxide, regular sized carbon black particles, optionally a resin; optionally silica; optionally a silica coupling agent; optionally various fillers such as clay, for example, kaolin clay, and the like; and also optionally a small amount of oil. After the necessary mixing stages have been completed, various rubber additives are added and the rubber composition is mixed a final time.
[0014] The final mixing stage is conducted by optionally further adding one or more of the above-noted additives, as well as by further adding other rubber additives. Additives typically added in the final mixing stage include curing aids such as sulfur or sulfur containing compounds; accelerators such as amines, disulfides, guanidines, thioureas, thiazoles, thiurams, sulfenamides, dithiocarbamates; oils such as aromatic, naphthenic, or paraffinic; antioxidants and antiozonants such as various phenylenediamines; various aliphatic acids such as stearic acid; zinc oxide; various waxes such as micro crystalline waxes; and the like.
[0015] The hard rubber compositions can be utilized in any of a number of applications, such as in a tire where they are often utilized for a tire bead, an abrasion resistant rubber layer which resides on the tire bead, a chafer strip, and the like. Such rubbers are generally referred to in the art as apex rubbers. Depending upon the actual end use, the amount of large carbon black particles can generally range from about 5 to about 70 and preferably from about 10 to about 40 parts by weight per 100 parts by weight of total rubber.
[0016] Moreover, as noted above, the hard rubber formulations can also contain additional regular carbon black, that is carbon black which generally has an iodine number of from about 45 to about 100 and generally from about 70 to about 90 as well as a DBP absorption number of generally from about 70 to about 140 and preferably from about 90 to about 120. The amount of such carbon black will vary depending upon the desired end use but generally is from about 20 to about 120, and desirably from about 75 to about 110 parts by weight per 100 parts by weight of rubber.
[0017] The large sized carbon black particles have been found to reduce the viscosity of the rubber composition during and after all of the mixing stages (e.g., masterbatching, mixing, remixing) but before cure of the rubber and still maintain the final hardness and stiffness of the composition. That is, after all of the additives have been added but before shaping into a tire bead strip, a chafer strip, etc., and before cure, the rubber composition has a viscosity less than a rubber composition containing only normal sized carbon black.
[0018] Moreover, dramatic reductions in mixing cycles or the number of remills required for preparation of a master batch and the final stage of mixing are achieved. For example, in the preparation of a bead filler rubber composition, which heretofore generally required 6 mixing stages, the number of remill stages, generally 3, has been entirely eliminated. That is, instead of a first masterbatch stage, a second masterbatch mixing stage, three remill stages and a final mixing stage wherein various additives were added, the utilization of the large sized carbon black resulted in only a first masterbatch mixing stage, a second masterbatch mixing stage, and a final additive mixing stage. As another example, in the preparation of an abrasion rubber which heretofore required four mixing stages, i.e. first masterbatch mixing stage, a second masterbatch mixing stage, one remill stage, and a final additive mixing stage, all that is required with the present invention is two mixing stages, ie. an initial masterbatch mixing stage and a final additive mixing stage. Elimination of the various mixing stages and the like result in sizable reduction of the energy required and hence mixing costs.
[0019] The present invention will be better understood by reference to the following examples which serve to illustrate, not to limit the present invention.
[0020] With respect to Tables I, II, and III, all formulations were prepared in the following manner:
[0021] Masterbatch (MB) Preparation
[0022] The polymers, fillers, carbon blacks, oil, zinc oxide, stearic acid, and resin were added to a Banbury. The fillers were split between the first and second masterbatch for the conventional mixed stock. The mixing time was from about 1.5 to about 2.5 minutes and the drop temperature was about 330° F. (166° C.) to about 350° F. (177° C.). This stock was then aged for a minimum of 4 hours before the remill stage.
[0023] Remill(s)
[0024] All stock from the masterbatch mix stages were put into a Banbury. The mixing time was from about 1.0 to about 2.0 minutes and the drop temperature was from about 300° F. (149° C.) to about 330° F. (166° C.). The stock was then aged a minimum of 4 hours before the final stage.
[0025] Final Stage Mixing
[0026] All antioxidants, ozonates, accelerators, sulfur, any remaining zinc oxide, stearic acid, or resins, and the rubber from the previous stage (masterbatch or remill), was added to a Banbury. The mixing time was from about 60 about 80 seconds. The batch was then dropped at a temperature of from about 190° F. (88° C.) to about 220° F. (104° C.).
TABLE I (ABRASION) CONTROL EX. 1 PHR PHR 1 st MASTERBATCH BR (Butadiene Rubber) 50.00 50.00 NR (Natural Rubber) 50.00 50.00 Large Sized Carbon Black-Regal — 10.00 85 Regular Carbon Black-Type N330 55.00 74.00 Stearic Acid 2.00 2.00 Oil 15.00 15.00 Zinc Oxide 2.75 2.75 Total: 174.75 203.75 2 Nd MASTERBATCH Normal Sized Carbon Black-Type 23.00 — N330 TOTAL: 197.75 — Remill 1 197.75 — Sulfur 3.50 3.50 Accelerator 1.10 1.10 Wax 0.80 0.80 Antiozonant 0.95 0.95 Antioxidant 1.00 1.00 TOTAL: 205.10 211.10 Number of Mix Stages 4 2 Mooney Viscosity 52.1 54.5 ML1 + 4 Stress/Strain M50% RT (MPa) 1.2 1.2 Tensile RT (MPa) 18.0 18.2 Elongation % 315.0 314.0 Ring Tear 305.1 374.8 Room Temperature Rebound 55.6 55.2 Room Temperature
[0027] [0027] TABLE II (BEAD FILLER) CONTROL EX. 2 PHR PHR 1 st MASTERBATCH NR (Natural Rubber) 100.00 100.00 Regular Carbon Black-Type N330 50.00 37.00 Large Sized Carbon Black-Regal — 25.00 85 Zinc Oxide 5.00 5.00 Cobalt 0.70 0.70 Stearic Acid 1.50 1.50 Resin 2.00 2.00 TOTAL: 159.20 171.20 2 Nd MASTERBATCH Normal Sized Carbon Black-Type 30.00 20.00 N330 TOTAL: 189.50 191.50 Remill 1 189.50 — Remill 2 189.50 — Remill 3 189.50 — FINAL Zinc Oxide 5.00 5.00 Stearic Acid 1.50 1.50 Resin 9.00 9.00 Sulfur-20% oil 12.50 12.50 Accelerator 1.00 1.00 Antioxidant 0.25 0.25 TOTAL: 218.45 220.45 Number of Mix Stages 6 3 Mooney Viscosity 55.8 51.2 ML1 + 4 Stress/Strain M50% RT (MPa) 4.4 4.2 Tensile RT (MPa) 14.7 14.3 Elongation % 128.8 145.9 Ring Tear 96.5 91.4 Room Temperature Rebound 40.2 42.4 Room Temperature
[0028] [0028] TABLE III (BEAD FILLER) CONTROL EX. 3 PHR PHR 1 st MASTERBATCH NR (Natural Rubber) 70.00 70.00 Styrene-Butadiene Rubber 30.00 30.00 Regular Carbon Black-Type N660 70.00 65.00 Large Sized Carbon Black-Regal — 38.00 85 Zinc Oxide 2.00 2.00 Oil 7.00 7.00 Stearic Acid 1.50 1.50 Resin 5.00 5.00 TOTAL: 185.50 218.50 2 Nd MASTERBATCH Normal Sized Carbon Black-Type 33.00 — N660 TOTAL: 218.50 — Remill 1 218.50 — Remill 2 218.50 — FINAL Resin 9.00 9.00 Sulfur 3.00 3.00 Accelerator 1.00 1.00 TOTAL: 231.50 231.50 Number of Mix Stages 5 2 Mooney Viscosity 47.8 48.0 ML1 + 4 Stress/Strain M50% RT (MPa) 4.1 3.7 Tensile RT (MPa) 14.2 15.2 Elongation % 275.0 332.0 Ring Tear 298.0 263.0 Room Temperature Rebound 39.7 40.8 Room Temperature
[0029] As apparent from the tables, rubber compositions utilizing large sized carbon black particles according to the present invention result in an unexpected and drastic reduction in the total number of mixing stages.
[0030] While in accordance with the patent statutes, the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims. | A reinforced high viscosity rubber composition having improved processability such as reduced mixing cycles contains large sized particles of carbon black. The carbon black has low structure and a low DBP absorption number as well as a low iodine number. The rubber composition is useful in various tire rubber compositions such as those requiring a high viscosity, for example an apex rubber. | 2 |
BACKGROUND OF THE INVENTION
The aminoglycoside antibiotics are a valuable therapeutic class of antibiotics which include the kanamycins, gentamicins, streptomycins, sagamicins, and the more recently discovered fortimicins. While the naturally produced parent antibiotics are generally, in themselves, valuable antibiotics, chemical modifications have been found to improve the activity, either intrinsic activity or activity against resistant strains or against one or more strains the parent antibiotic is not effective against. Thus, chemical modification has provided both alternative therapeutic agents as well as those which are held in reserve because of the resistance problem. And, because of the development of aminoglycoside-resistant strains and inactivation of the parent antibiotics by R-mediated factors which can develop, the search for new therapeutic entities continues.
Further, some of the naturally produced, parent antibiotics, such as fortimicin B and fortimicin E, are primarily useful as intermediates in preparing derivatives which have more potent antibacterial properties than their weakly active parent antibiotics. The present invention provides one such fortimicin, fortimicin AN.
The fortimicin of this invention is co-produced in the fermentation of Micromonospora olivoasterospora ATCC No. 21819,31009 or 31010 according to the method of Nara et al. U.S. Pat. Nos. 3,931,400 and 3,976,768 which disclose the production of fortimicin A and fortimicin B.
Fortimicin AN is a minor factor which is co-produced with fortimicin A, fortimicin B and a number of other minor factors which are disclosed and claimed in commonly assigned, copending patent applications Ser. Nos. 025,241; 025,243; 025,247; 025,251; and 025,252. filed on even date herewith and with the minor factors isofortimicin and fortimicin E which are disclosed and claimed in commonly assigned, co-pending application Ser. Nos. 863,015 and 863,016, both filed Dec. 21, 1977.
SUMMARY OF THE INVENTION
The present invention provides an new fortimicin, fortimicin AN. Fortimicin AN can also be named as 1-N-glycyl-3-O-demethylfortimicin B. The compound is useful as an intermediate in preparing 3-O-demethylfortimicin B which is disclosed and claimed in U.S. Pat. No. 4,124,756.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The compound of this invention, fortimicin AN, is represented by the formula: ##STR1##
Fortimicin AN can be prepared by the fermentation of Micromonospora olivoasterospora ATCC No. 21819,31009 or 31010 according to the methods described by Nara et al. in U.S. Pat. Nos. 3,931,400 and 3,976,768 for the fermentation of fortimicin A and fortimicin B and as set forth in detail in Examples 1-4.
Fortimicin AN is useful as an intermediate in the synthesis of 3-O-demethylfortimicin B which is disclosed and claimed in U.S. Pat. No. 4,124,756. Generally speaking, 3-O-demethylfortimicin B can be obtained directly from fortimicin AN by hydrolysis with a suitable base, such as barium hydroxide which removes the 1-N-glycyl group and affords the desired product.
The following examples further illustrate the present invention.
EXAMPLE 1
Preparation of Fermentation Broth
6000 Liters of a fermentation broth having the following composition and pH 7 before sterilization is prepared:
______________________________________Ingredient Weight Percent______________________________________Starch 4.00Soybean meal 2.00Cornsteep liquor 0.05K.sub.2 HPO.sub.4 0.05MgSO.sub.4 . 7H.sub.2 O 0.05KCl 0.03CaCO.sub.3 0.10Water to 100______________________________________
EXAMPLE 2
Preparation of Inoculum
Micromonaspora olivoasterospora ATCC 21819 is used as a seed strain and is intitally cultured in a first see medium containing 2% glucose, 0.5% peptone, 0.5% yeast extract and 0.1% calcium carbonate (pH 7.2 before sterilization) by inoculating one loopful of the seed strain into 10 ml of the seed medium in a 50 ml large test tube. Culturing is carried out at 30° C. for 5 days with shaking. Ten ml of the seed culture broth is then inoculated into 30 ml of a second seed medium in a 250 ml Erlenmeyer flask. The composition of the second seed medium is the same as that of the first seed medium. The second seed culturing is carried out at 30° C. for two days with shaking.
Then 30 ml of the second seed culture broth is inoculated into 300 ml of a third seed medium in a two liter Erlenmeyer flask provided with baffles. The composition of the third seed medium is the same as that of the first seed medium and the third seed culturing is carried out at 30° C. for 2 days with shaking. Thereafter, 1.5 liters of the third seed culture broth (corresponding to the contents of five flasks) is inoculated into 15 liters of a fourth seed medium in a 30 liter glass jar fermenter. The composition of the fourth seed medium is the same as that of the first seed medium. Culturing in the jar fermenter is carried out at 30° C. for two days with aeration (15 liters/min.) and stirring (350 r.p.m).
EXAMPLE 3
Production of Fortimicin AN
Fifteen liters of the fourth seed cultuer broth of Example 2 is inoculated into 150 liters of a main fermentation medium in a 300 liter stainless steel fermenter. The main fermentation medium comprises: 4% starch, 2% soybean meal, 1% corn steep liquor, 0.05% K 2 HPO 4 , 0.05% MgSO 4 ·7 H 2 O), 0.3% KCl and 0.1% CaCO 3 and water (pH 7.0 before sterilization). Culturing in the fermenter is carried out at 30° C. for 4 days with aeration (80 liters/min. and stirring (150 r.p.m).
EXAMPLE 4
Isolation of Fortimicin AN
To 5000 liters of the fermentation broth, prepared as described above, is added 102 liters of a weakly acidic carboxylic(polymethacrylate) type cation exchange resin in the ammonia form, e.g. Amberlite IRC-50 sold by the Rohm and Haas Company. The mixture is agitated for two hours, during which time the mixture is maintained at pH 6.6 by the addition of sulfuric acid. The ion exchange resin is separated from the broth by centrifugation and then added to a column and backwashed with deionized water until free of extraneous solids. The column is washed with water, then eluted downflow with 1 N-ammonium hydroxide. Elutes of pH 9.6 to about 11.3 are collected and concentrated under reduced pressure until excess ammonia is removed. The solution is adjusted to pH 2.0 with hydrochloric acid and treated with 5% (w/v) activated carbon such as Pittsburgh RB carbon sold by Calgon Corporation. The solution is then filtered through a diatomaceous earth mat and the filtrant concentrated under reduced pressure to give a mixture of crude fortimicins. (265 g.).
A portion of the crude fortimicins (265 g.), prepared as described above, is dissolved in 8 liters of water and the solution adjusted to pH 9 with ammonium hydroxide. To facilitate isolation of fortimicin AN, fortimicin A is hydrolyzed to fortimicin B by heating the solution to 70° C. for 20 hours, maintaining a pH 9 by the controlled addition of ammonium hydroxide. After filtration through a mat of diatomaceous earth, the reaction mixture is concentrated under reduced pressure to approximately 3.6 liters. A portion of this material (1.8 liters) is diluted to 15 liters with water and adjusted to pH 6.8 with hydrochloric acid. The solution is charged on a column containing 7 liters of a weakly acidic, carboxylic(polymethacrylate) type, cation exchange resin in the ammonia form, e.g. Amerlite JRC-50. After washing with water, the column is eluted with 20 liters of 0.1 N ammonium hydroxide. One liter fractions are collected and examined by thin layer chromatography using Whatman No. 1 filter paper. Development is carried out at room temperature for 10 to 15 hours using a solvent system consisting of the lower phase of a mixture of methanol-chloroform-concentrated ammonium hydroxide[1:1:1(v/v/v)].
Fractions 1-2: Unidentified minor components
Fractions 3-4: Isofortimicin
Fraction 5: Isofortimicin and fortimicin B
Fractions 6-10: Fortimicin B
Fractions 11-20: Unidentified minor components
A portion of the crude fortimicins is chromatographed on a column of Dowex CG-50 resin eluted with 0.3 M ammonium hydroxide. Initial and final fractions are discarded. The median fractions are combined, adjusted to pH 2.0 with sulfuric acid and treated with carbon. The mixture is filtered and the pH of the filtrate is adjusted to pH 6.0 with Dowex CG-50 WGR resin in the ammonia form and the resin removed. The solution is concentrated and rechromatographed over a column of Dowex CG-50 resin resin eluted with 0.125 N ammonium hydroxide. Initial fractions are combined and adjusted to pH 6 with sulfuric acid. Amberlite IR-124 resin in the ammonia form (3 liters) is added and after 30 minutes filtered off and washed with water. The combined filtrates and washings are treated with 300 g of Pittsburg RB carbon sold by Calgon Corporation. The mixture is filtered. The precipitate is washed with water and the combined filtrate and washings are treated with 4 liters of Dowex WGR resin in the ammonia form and the resin removed. The filtrate (at pH 6) is concentrated to a residue.
A portion of the residue is chromatographed on a column of Bio Rex 70 resin in the ammonia form (2.5 cm diam×40 cm) washed well with water and eluted with a stepwise gradient of 0.3 N, 0.5 N and 1.0 N ammonium hydroxide. Later fractions from the column are combined and concentrated to give 1.4 g of solid material. A portion of this (1 g) is chromatographed on a column of Sephadex G-15 resin in 0.01 N acetic acid. Initial fractions yield fortimicin AN (459 mg). Proton magnetic resonance spectrum measured in deuterium oxide with tetramethylsilane as external reference: δ1.46 (3H) doublet 7'-CH 3 ; δ2.82 (3H) singlet NCH 3 ; δ3.80 (2H) singlet gly-CH 2 ; δ5.76 (1H) doublet C 1' -H.
EXAMPLE 5
3-O-Demethylfortimicin B
A solution of one gram of fortimicin AN in 100 ml of 2 N aqueous barium hydroxide is heated under reflux for 22 hours, allowed to cool and saturated with carbon dioxide. The mixture is filtered through a mat of celite and the filtrate is concentrated to a residue of crude product. This is purified by chromatography on a column of silica gel developed with the lower phase of a mixture of equal volumes of chloroform, methanol and concentrated ammonium hyroxide. Fractions containing the major component are pooled and concentrated to yield 3-O-demthylfortimcin B(700 mg). | Fortimicin AN is coproduced with fortimicin A, fortimicin B and a number of other minor factors in the fermentation of Micromonospora olivoasterospora ATCC Nos. 21819, 31009 or 31010. Structurally, fortimicin AN is 1-N-glycyl-3-O-demethylfortimicin B. The compound is useful as an intermediate for 3-O-demethylfortimicin B which is readily obtained by hydrolysis of fortimicin AN in base. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International Application No. PCT/FR2005/000820 filed Apr. 5, 2005, which was published in the French language on Dec. 22, 2005, under International Publication No. WO 2005/121873 A1 and claims priority to French Patent Application Nos. 0404911, filed May 6, 2004 and 0405711, filed May 27, 2004, the disclosures of which are incorporated herein by reference in their entirety.
The present invention relates to the field of spectacles and hinges for spectacle frame, and relates more particularly to an improvement of an elastic hinge element for spectacle frame of the type described by International Application No. WO 00/68730.
The present invention thus relates to an elastic hinge element for spectacle frame, comprising a housing comprising a hollow longitudinal portion comprising a guiding area and at least one cavity comprising a retaining wall, a slide arranged in the hollow portion according to a longitudinal translation axis, comprising a protruding part extending outside the hollow portion, a guided part cooperating with the guiding area, a central part and a rod, a spring for returning the slide to a rest position, a compression part of the spring, coupled with the rod and forming a rear stop for the spring, and a bushing forming a front stop for the spring, comprising a body mounted around the central part of the slide and at least one elastic tab turned towards the front of the hollow portion according to a determined angle, the end of which presses on the retaining wall.
As a reminder, such a classic hinge element is represented in FIG. 1A . The hinge element comprises a housing 1 in which a hollow portion 2 is made, and a slide 3 arranged in the hollow portion 2 . The hollow portion 2 comprises a guiding area 2 - 1 for guiding the slide 3 according to a longitudinal translation axis T and opens onto the front of the hinge element to form a front orifice. The slide 3 , also represented in FIG. 1B , comprises an end 3 - 1 forming a hinge knuckle, extending outside the hollow portion 2 , a guided part 3 - 2 cooperating with the guiding area 2 - 1 , a central part 3 - 3 and a rod 3 - 4 . A spring 4 is mounted around the rod 3 - 4 , between a bushing 5 and a compression part 3 - 5 that is coupled with the end of the rod 3 - 4 . The bushing 5 comprises a body 5 - 1 slidably mounted around the rod 3 - 4 and two elastic tabs 5 - 2 , 5 - 3 facing forwards according to a determined angle in relation to the translation axis. In the rest position shown in FIG. 1A , the end of each elastic tab 5 - 2 , 5 - 3 enters a cavity 6 , 7 to come and press on a retaining wall 6 - 1 , 7 - 1 substantially perpendicular to the translation axis. As a result, when the slide is pulled forwards, the bushing 5 is translation blocked and the spring is compressed between the mobile compression part 3 - 5 and the fixed body 5 - 1 of the bushing 5 .
Such a hinge element is only a few millimeters in length and is frequently used in the spectacles industry. It is generally fixed by welding or gluing onto a spectacle frame arm 8 schematically represented in FIG. 1A . The knuckle 3 - 1 is generally linked to a hinge element coupled with the frame, such as a tenon, to obtain an arm hinge.
Despite the small dimensions of this hinge element, it is desired to reduce its length so as to produce ultra-compact hinges that are even more aesthetically discreet.
Reducing the length of the hinge element involves reducing the length of the slide. This length depends on the lengths of the four useful parts of the slide, i.e. the part forming the knuckle 3 - 1 , the guided part 3 - 2 , the central part 3 - 3 , and the rod 3 - 4 that bears the spring and the body 5 - 1 of the bushing.
Now, a decrease in the length of the guided part 3 - 2 beyond a determined minimal length would excessively weaken the hinge element, as this part must viably withstand forces and stresses exerted in directions perpendicular to the translation axis. To guarantee a good resistance to the off-axis loads while reducing the length of the guided part, a two-point guiding could be considered, by adding a guiding element at the rear end of the slide, for example using the compression part as additional guiding element. However, using the rear end of the slide would weaken the axis of the slide as the latter would be subject to flexion. Moreover, the compression part is generally an inexpensive element the manufacturing of which is basic, obtained for example by striking the end of the rod 3 - 4 so as to make a blister appear that translation-blocks the spring. Providing a guiding element at the rear of the slide is therefore not desirable.
Secondly, the length of the central part 3 - 3 of the slide is imposed by the length of the bushing 5 , which is approximately equal to the sum of the length of the body 5 - 1 of the bushing and that of the elastic tabs 5 - 2 , 5 - 3 . The central part 3 - 3 indeed enables the retraction of the elastic tabs when the slide equipped with the bushing and the spring is introduced into the hollow portion passing through the front orifice. Now, the length of the tabs of the bushing is also subject to certain technological stresses, and cannot be excessively reduced.
Finally, the length of the rod 3 - 4 cannot itself be reduced below a minimal spring length, corresponding to a targeted minimal backmoving force, to which the length of the body of the bushing is added.
BRIEF SUMMARY OF THE INVENTION
Thus, the present invention aims to reduce the length of the slide of a hinge element of the type described above without reducing the length or the size of the essential elements of the hinge, i.e. the length of the guided part, the length of the bushing, and the length of the spring.
According to the present invention, this object is achieved by providing an elastic hinge element for a spectacle frame, comprising a housing comprising a hollow longitudinal portion comprising a guiding area and at least one cavity comprising a retaining wall, a slide arranged in the hollow portion according to a longitudinal translation axis, comprising a protruding part extending outside the hollow portion, a guided part cooperating with the guiding area, a central part and a rod, a spring for returning the slide to a rest position, a compression part for compressing the spring, coupled with the rod, forming a rear stop for the spring, and a bushing forming a front stop for the spring, comprising a body mounted around the central part of the slide and at least one elastic tab turned towards the front of the hollow portion according to a determined angle, the end of which presses on the retaining wall, in which the cavity comprising the retaining wall is situated in the guiding area and opens into the latter, and the guided part of the slide comprises at least one guiding face that comprises firstly a recess into which a portion of the elastic tab extends when the slide is in rest position, and secondly guiding edges situated along the edge of the recess.
According to one embodiment, the guided part comprises a recess of a size sufficient to ensure the total retraction of the elastic tab when the bushing is introduced into the hollow portion passing through the guiding area.
According to one embodiment, the proximal part of the elastic tab extends entirely in the guiding area and the body of the bushing abuts against the guided part of the slide.
According to one embodiment, the cavity comprising the retaining wall opens onto the outside of the housing.
According to one embodiment, the bushing has two elastic tabs, the guided part of the slide has two first guiding faces and two second guiding faces comprising two recesses receiving the elastic tabs and guiding edges situated along the edge of the recesses.
According to one embodiment, the guided part of the slide has in its region comprising the recess, a section substantially in the form of an “H” with the central cross of the “H”.
According to one embodiment, the guided part of the slide has in its region comprising the recess, a section substantially in the form of an “H” without the central cross of the “H”.
According to one embodiment, the recesses are made in the two narrowest faces of the guided part of the slide.
According to one embodiment, the recesses are made in the two widest faces of the guided part of the slide.
According to one embodiment, the central part of the slide is a prolongation of a rod bearing the spring.
The present invention also relates to a spectacle frame, comprising an elastic hinge element according to the present invention.
The present invention also relates to a spectacle frame arm, comprising an elastic hinge element according to the present invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
FIG. 1A is a cross-section of a classic or prior art elastic hinge element;
FIG. 1B is a side elevational view of a slide present in the prior art hinge element shown in FIG. 1A ;
FIG. 2 is a partial cross-sectional perspective view of a hinge element according to a first preferred embodiment of the present invention;
FIG. 3 is a cross-section of a housing of the hinge element shown in FIG. 2 ;
FIG. 4 is a perspective view of a slide present in the hinge element shown in FIG. 2 ;
FIG. 5 is a perspective view of a bushing present in the hinge element shown in FIG. 2 ; and
FIG. 6 is a perspective view of a slide according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 is an overall view of an elastic hinge element 60 according to the present invention, represented in rest position. The element 60 classically comprises a housing 10 , represented in a cross-section, a slide 20 , a bushing 30 , a coil spring 40 , and a compression part 50 for compressing the spring, forming a rear stop for the spring.
The housing 10 is represented in greater detail in FIG. 3 , the slide 20 is represented in greater detail in FIG. 4 , and the bushing is represented in greater detail in FIG. 5 . Certain references in FIGS. 3 to 5 are not reproduced in FIG. 2 , for the sake of readability of this figure.
The housing 10 comprises a hollow longitudinal portion 11 receiving the slide 20 that opens onto the front of the hinge element to form a front orifice. The shape of the hollow portion is designed to be able to introduce the assembly formed by the slide, the bushing, the spring and the compression part into the hollow portion 11 , passing through the front orifice.
The slide 20 comprises a protruding part 21 forming a knuckle, that extends from the front orifice to the outside of the hollow portion 11 , a guided part 22 , as well as a central part 23 and a rear rod 24 , the central part 23 and the rod 24 having a smaller section than the guided part 22 . Here, the central part 23 and the rod 24 are formed by one and the same rod, of rectangular, round or polygonal section, around which the bushing 30 and the spring 40 are threaded. The protruding part 21 comprises a pierce point intended to receive a pin for connecting with a tenon (not represented). It shall be noted that the compression part, although represented in the Figure as an element distinct from the rod, can be classically formed by a blister of the end of the rod. This part is in this case part of the rod itself.
The hollow portion 11 comprises a guiding area 12 having guiding walls cooperating with the guided part 22 of the slide, and cavities 13 , 14 comprising two retaining walls 15 , 16 substantially perpendicular to the translation axis and turned towards the rear of the hollow portion 11 . The guiding walls do not necessarily cover the entire guiding area 12 , as represented for example in FIG. 3 where it can be seen that the guiding area is obtained by piercing a cylindrical orifice and then by machining flat guiding walls in the cylindrical orifice forming sorts of rails.
Furthermore, the cavities 13 , 14 are for example obtained by transversally piercing the housing 10 , such that the cavity corresponding to the introduction of the piercing tool, here the cavity 14 , opens onto the outside of the housing.
The bushing 30 classically comprises a body 31 , that is threaded around the central part 23 of the slide, and two elastic tabs 32 , 33 facing forwards forming an angle “A” in relation to the translation axis of the slide. Each elastic tab comprises a proximal part 320 , 330 linked to the body 31 , and a distal part 321 , 331 .
When the slide 20 , after being equipped with the bushing 30 , with the spring 40 and with the compression part 50 , is introduced into the hollow portion 11 passing through the front orifice, the elastic tabs 32 , 33 fold up towards the slide when the latter passes through the guiding area 12 . Once the operation performed, the elastic tabs loosen and their ends lodge in the cavities 13 , 14 .
According to the present invention, the cavities 13 , 14 are made in the guiding area 12 itself, and open onto the guiding area 12 instead of opening onto a region of the hollow portion 11 corresponding to the central part 23 of the slide, as is the case in prior art (refer to FIG. 1A ). Again according to the present invention, the guided part 22 of the slide has two recesses 220 , 221 each provided for receiving the proximal part 320 , 330 of one of the elastic tabs 32 , 33 . Thus, the body 31 of the bushing is pushed by the spring 40 against the guided part 22 of the slide, the spring being preferably substantially compressed or bordering on compression when the slide is in rest position.
When the slide 20 is inserted into the hollow portion 11 , and more particularly when the bushing passes through the guiding area 12 , the elastic tabs 32 , 33 of the bushing retract into the recesses 220 , 221 . When the rest position represented in FIG. 2 is reached, they extend in the guiding area 12 and not in the region of the hollow portion 11 corresponding to the central part 23 of the slide, as is the case in prior art. More particularly, the proximal parts 320 , 330 of the elastic tabs extend in the recesses 220 , 221 , the distal parts 321 , 331 of the elastic tabs extend in the cavities 13 , 14 , and the ends of the elastic tabs are opposite the retaining walls 15 , 16 .
When the slide is pulled forwards, the spring 40 , as it compresses, pushes the elastic tabs against the retaining walls 15 , 16 . The latter thus translation-block the bushing 30 , the spring 40 then being compressed between the compression part 50 and the bushing 30 , and ensuring the slide returns to rest position.
In the hinge element structure that has just been described, the longitudinal extension of the elastic tabs 32 , 33 , which is mathematically equal to the length of the tabs multiplied by the cosine of the angle “A”, is not taken into account to determine the length of the central part 23 of the slide and as a result to determine the total length of the slide. The length of the central part 23 of the slide only depends on the length of the body 31 of the bushing. The latter, as represented in FIG. 5 , is here a sort of square section ring formed for example by folding a metal strip cut in the shape of π having two perpendicular tabs that form the elastic tabs.
Furthermore, as it can be seen in FIG. 4 , the guided part 22 of the slide has left 22 - 1 and right 22 - 2 lateral faces that provide the right and left lateral guiding, and upper 22 - 3 and lower 22 - 4 lateral faces that provide the upper and lower lateral guiding. The recesses 220 , 221 are made here on the faces 22 - 3 , 22 - 4 and extend here over approximately half the length of the guided part 22 .
According to the present invention, the elastic tabs 32 , 33 and the recesses 220 , 221 are here narrower than the faces 22 - 3 , 22 - 4 and advantageously on the edge of the recesses 220 , 221 , narrow bands ( FIG. 4 , face 22 - 3 , bands 22 - 5 , 22 - 6 ) remain which form sorts of rails or glides that also provide the upper and lower lateral guiding of the slide, the rear part of the guided part 22 thus having a section substantially in the shape of an H.
Thus, the guided part 22 has a front part that is devoid of any recess and that supports the slide in four complementary directions perpendicular to the translation axis, and a rear part bearing the recesses 220 , 221 , that also advantageously supports the slide in the four directions.
Various alternatives of the present invention can be provided by those skilled in the art. In an alternative embodiment represented in FIG. 6 , the recesses 220 ′ are made in the left 22 - 1 and right 22 - 2 lateral faces of the guided part of the slide, the width of which, corresponding to the height of the slide, is greater than the width of the upper and lower faces of the guided part.
In other alternative embodiments, the guided part of the slide can have a round, oval or polygonal section. The recesses receiving the proximal parts of the elastic tabs can have various shapes, for example they can have an inclined bottom corresponding to an angle of retraction of the elastic tabs when assembling the hinge element. They can also be through-hole and meet, the rear part of the guided part of the slide having in this case the shape of an “H” without the central cross of the H. Furthermore, the bushing may comprise three, or even four elastic tabs, a corresponding number of recesses then being provided in the guided part of the slide. The bushing can also comprise only one elastic tab, although a symmetrical bushing structure is better suited to a good distribution of the spring retaining forces. Secondly, although it is advantageous for the proximal parts of the elastic tabs to extend entirely in the recesses, so that the body of the bushing is in contact with the guided part of the slide and the length of the central part of the slide is minimal, providing an intermediate embodiment between prior art and the embodiment that has just been described falls within the scope of the present invention. In this embodiment, the section of the central part 23 of the slide has an enlargement translation-blocking the body of the bushing before the latter abuts against the guided part (refer for example to FIG. 1B ). The elastic tabs thus comprise a proximal part that extends along the central part of the slide, a central part that extends in the recesses according to the present invention, and a distal part that extends in the cavities comprising the retaining walls. Thus, irrespective of the embodiment of the present invention, the cavities 13 , 14 comprising the retaining walls are arranged in the guiding area 12 and the ends of the elastic tabs 32 , 33 extend up to the guiding area thanks to the recesses according to the present invention. The present invention thus enables the body of the bushing to be moved as close as desired to the guided part of the slide and the total length of the hinge element to be reduced accordingly, while respecting the minimal lengths of the spring and of the guiding part that are imposed by the technological stresses and the solidity requirements of the hinge element.
Finally, although it was stated above that the recesses according to the present invention are formed so as to enable the elastic tabs to fully retract when the slide is introduced into the hollow portion of the housing, this feature is only required if the slide is introduced into the housing in this manner.
Various arrangements of a hinge element according to the present invention may be made. Although it is generally fixed onto spectacle frame arms, such a hinge element can also be mounted onto the rim of the frame, or onto a fixed arm part coupled with the frame rim.
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims. | The invention relates to an elastic hinge element ( 60 ) for a spectacle frame, comprising a body ( 10 ) consisting of a housing ( 11 ) comprising a guiding area ( 12 ) and at least one cavity comprising a retaining partition, a slide ( 20 ) fitted in the housing and comprising a guided part ( 22 ), a center part and a rod, a spring ( 40 ) for returning the slide to a rest position, mounted around the rod, and a bushing ( 30 ) forming a front stop for the spring. According to the invention, the cavity comprising the retaining partition is located in the guiding area ( 12 ) and opens out therein, and the guided part ( 22 ) of the slide comprises a recess into which an elastic tab ( 32 ) of the slide extends. Advantage: creation of a short-length hinge element. | 6 |
FIELD OF THE INVENTION
The present invention relates generally to the field of vehicle emissions measuring systems and, more particularly, to an improved on-board mass emissions measuring system.
BACKGROUND ART
Motor vehicle emissions are the leading source of air pollution in most metropolitan areas, causing health, ecological and economical damage. As a result, considerable effort and resources are currently devoted to various emission reduction strategies, such as emission inspection programs, reformulated or alternative fuels, stricter standards for new vehicles, mass transit, improved engine control and catalyst technologies, and upgrade and repair of existing vehicles. However, in order to evaluate the impact of these reduction strategies, it is necessary to measure and collect accurate real-world emission measurements over the life of a vehicle.
Presently, the vast majority of emission tests are performed in a specialized laboratory, where the vehicle is driven on a dynamo meter according to a prescribed driving cycle, such as I/M 240 or FTP for light and medium duty vehicles and CBD for heavy duty vehicles.
This approach has several significant disadvantages: (1) the driving cycles do not adequately represent real-world driving conditions, which vary and are often unknown; (2) vehicles can be optimized for low emissions during the driving cycle, but do not operate optimally in actual use; (3) the testing equipment is bulky and expensive; (4) there are significant costs associated with testing the vehicle, such as vehicle (and/or mobile laboratory) mileage, vehicle downtime, and the test itself, especially on heavy-duty vehicles; (5) individual vehicles engines have unique characteristics which effect emissions, and (6) only a relatively small number of vehicles can be tested.
The first two disadvantages can be eliminated by using a testing system mounted on the vehicle. However, the use of an on-board system is presently limited to repair grade gas analyzers that provide only a rough estimate of mass emissions for repair purposes and a relatively small number of dedicated instrumented vehicles.
For example, it is known that an on-board testing system mounted on a dedicated instrumented vehicle was disclosed by Sierra Research. This system uses a repair-grade four-gas non-dispersive infra-red (NDIR) analyzer to measure exhaust gas concentrations and several sensors mounted on the engine to determine intake air flow. From these measurements, exhaust mass flow and mass emissions can be computed.
A simpler system, using repair grade NDIR analyzer concentration data only, has been developed at the University of Denver to predict I/M 240 mass emissions. Using this system, the average ratio of pollutant to fuel consumed is calculated from the concentration data. The amount of fuel consumed is then estimated from the length of the trip and fuel economy. While this method is successful in predicting whether a vehicle will pass or fail an I/M 240 test, and has been incorporated into newer repair grade analyzers, it is not sufficiently accurate in measuring actual mass emissions, since it does not properly account for emissions during extreme (high or low) exhaust flow. Also, errors in estimating fuel consumption results in the same relative error in mass emission readings.
Accordingly, a system which allows for the testing of individual vehicles during daily operation is necessary to eliminate many of the shortfalls found in the existing systems. One such system was previously disclosed by the inventor. The system employs a five-gas analyzer drawing undiluted exhaust from the tailpipe and calculates mass exhaust flow from engine operating data obtained via a diagnostic link to the computer controlled engine. However, this system can only be employed on engines which include a computerized engine control unit. This greatly limits the number and type of vehicles from which emission measurements may be taken.
Hence, it would be useful to provide a portable mass emissions measuring system which could measure accurate real-world vehicle emissions on a large variety of vehicles without displacing the vehicle from service.
DISCLOSURE OF THE INVENTION
With parenthetical reference to the corresponding parts, portions or surfaces of the disclosed embodiment, merely for the purposes of illustration and not by way of limitation, the present invention provides an improved mass emissions measuring system ( 15 ) for an internal combustion engine ( 17 ), comprising an exhaust analyzer ( 16 ), at least one sensor ( 18 , 22 or 29 ) which may be temporarily attached to the engine for sensing parameters of the engine, and a processor ( 19 ) programmed to collect and manipulate data from the analyzer and the sensor, whereby the mass emissions of the engine may be calculated.
The system may further comprise a display ( 20 ) for displaying the mass emissions of the engine. The system may also include an engine-control interface ( 21 ). The sensor may be capable of sensing engine RPM, engine oil temperature, or intake manifold pressure. The exhaust analyzer may be capable of measuring concentrations of the engine exhaust constituents, particulates, aerosols, and gases in the engine emissions. The system may be adapted for use on-board a moving vehicle. The present invention also discloses a portable mass emissions measuring system for an internal combustion engine comprising an exhaust analyzer ( 16 ), a trace-gas injector ( 23 ), and a processor ( 19 ) programmed to collect and manipulate data from the analyzer and the injector, whereby the mass emissions of the engine may be calculated.
The present invention also discloses a method for determining the emission flow rate of an internal combustion engine, comprising the steps of providing an internal combustion engine having an exhaust, providing an exhaust analyzer having a sampling point downstream from the engine, operating the engine, injecting a trace-gas upstream from the sampling point of the exhaust analyzer at a controlled flow rate, measuring concentrations of the trace-gas with the exhaust analyzer, and calculating the emissions flow rate of the engine based on the known trace-gas injection flow rates and measured trace-gas concentrations.
Accordingly, the general object of the present invention is to provide an improved mass emissions measuring system which is adapted to be used to determine real-world vehicle emissions.
Another object is to provide an improved system for determining vehicle emissions which is portable.
Another object is to provide an improved system which is adapted for use on a wide variety of vehicles.
Another object is to provide an improved system which may be used on a vehicle without permanent modification to the vehicle
Another object is to provide an improved emission measuring system which can be installed for use in a vehicle in a very short period of time.
Another object is to provide an improved mass emissions measuring system which may be used without displacing a vehicle from service.
Another object is to provide an improved emissions measuring system which allows for use with a large number of vehicles.
Another object is to provide an improved emissions measuring system which may be used on vehicles which do not have an engine electronic control unit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a complete schematic of the emissions measuring system.
FIG. 2 is a partial schematic of the emissions measuring system showing the sensors temporarily mounted to the engine.
FIG. 3 is an exploded view of the manifold pressure sensor.
FIG. 4 is a partial schematic of the emissions measuring system showing the control unit interface.
FIG. 5 is a partial schematic of the emissions measuring system showing the trace gas injector.
FIG. 6 is a schematic showing the trace gas injector.
FIG. 7 is a schematic showing an alternate embodiment of the trace gas injector.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, debris, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof, (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or access of rotation, as appropriate.
Referring now to the drawings, and, more particularly, to FIG. 1 thereof, this invention provides an improved portable mass emissions measuring system, of which the presently preferred embodiment is generally indicated at 15 . The system is shown as broadly including an exhaust analyzer 16 , three engine sensors 18 , 22 , and 29 , a sensor data acquisition interface 27 , an engine control interface 21 , and a processor 19 .
As shown in FIG. 2, in engines which are not computer controlled, engine rpm, intake manifold pressure and intake oil temperature are measured using engine rpm sensor 18 , intake manifold pressure sensor 22 , and intake oil temperature sensor 29 . Sensors 18 , 22 , and 29 are adapted to be temporarily mounted to the engine during testing. Data acquisition interface 27 is a conventional converter which converts analogue readings from the sensors to digital output.
Oil temperature sensor 29 is a conventional dipstick temperature probe which is inserted in place of the oil dip-stick. Engine rpm sensor 18 is a standard rpm pickup probe, which is adapted to clamp onto one of the engine's spark-plug wires. The dipstick temperature probe and rpm inductive clamp manufactured by OTC, a division of SPX Corporation, of Owatonna, Minn. 55060-1171 may be employed in the preferred embodiment. As shown in FIG. 3, manifold pressure sensor 22 is a pressure sensor added to an existing engine vacuum line 25 . In the preferred embodiment, pressure sensor 22 is adapted to take readings from the engine's timing advance line. As shown, a T-adaptor 26 is inserted in vacuum line 25 and connected to a pressure transducer 28 . Pressure transducer 28 includes a link to processor 19 such that the manifold pressure or vacuum may be recorded and stored.
As shown in FIG. 4, on computer controlled engines where engine data can be obtained by an engine diagnostic link, intake air flow or fuel flow is computed from the engine data obtained by engine control interface 21 . Because modern computer-controlled engines provide operating data such as vehicle speed, engine rpm, intake air and coolant temperature, intake air pressure, intake air mass flow, throttle position and engine load through an engine control unit 30 , this information can be fed to processor 19 by engine control interface 21 . The Snap-On MT-2500 engine diagnostic scanner manufactured by Snap-On Diagnostics of Kenosha, Wis. 53141-1410 may be employed in the preferred embodiment.
As explained in greater detail below, processor 19 is programmed to use data from engine control unit 30 to compute exhaust mass flow, which, when multiplied by the measured concentrations of pollutants in the exhaust gas, provides grams per second emissions data. Additional computations provide second-by-second and total grams per gallon and grams per mile emissions, and fuel consumption. Mass emissions in grams per second of a pollutant X for each second are obtained by multiplying concentration of X in the exhaust, measured by exhaust analyzer 16 , by the mass flow of exhaust. By numerical integration of time and distance, grams per mile emissions are then obtained. Processor 19 , exhaust analyzer 16 , data acquisition interface 27 and engine control unit interface 21 are enclosed in a single aluminum housing 37 (not shown), which is vented for heat dispersion and adapted for placement in the seat of a vehicle.
As an alternative to the use of sensors 18 , 22 , and 29 , or engine control interface 21 , a trace-gas injector 23 may be used to determine exhaust flow. As shown in FIGS. 6 and 7, exhaust flow can be measured by injecting a small known continuous flow of a non-reactive trace gas. As shown in FIG. 6, trace-gas injector 23 comprises an inert gas reservoir 31 , a flow regulator 32 , an injector 33 , a downstream sampler 34 and an inert gas analyzer 35 . Injector 33 is placed at an upstream location in the exhaust of a vehicle so as to obtain a homogenous mixture at the sampling point. Helium or neon may be used as the inert gas. The inert gas is fed from inert gas reservoir 31 through a flow-regulator 32 and injected into the exhaust stream. In the preferred embodiment, flow regulator 32 is calibrated so as to inject about 50 to 500 ccm of gas per minute so that the concentration of inert gas is about 1 to 50 ppm. Injector 33 disburses the gas at an upstream point in a fairly uniform manner into the exhaust stream. Sampler 34 is located downstream from injector 33 . Sampler 34 takes a sample of the exhaust stream which is then transferred by an appropriate inert gas analyzer 35 . Alternatively, exhaust analyzer 16 may be used to determine concentrations of the inert gas, rather than a separate sampler 34 and inert gas analyzer 35 . Inert gas analyzer 35 and regulator 32 are also enclosed in housing 37 .
The inert gas concentration Ic determined by gas analyzer 34 will equal the inert gas flow If divided by the sum of the exhaust gas flow Ef and inert gas flow If. The inert gas flow is a known quantity as regulated by flow regulator 32 . Accordingly, the exhaust flow Ef is Ef = If ( ( 1 - Ic ) Ic )
To determine the concentration of pollutant such as hydrocarbons (HC), carbon monoxide (CO), nitrogen oxides (NO x ), carbon dioxide (CO 2 ) and Oxygen (O 2 ) in the exhaust of engine 17 , exhaust gas is drawn from the tailpipe into gas analyzer 16 , located in the vehicle. Raw, undiluted exhaust is collected through a 12″ probe inserted into the tailpipe and secured by a hose clamp. The exhaust gas is then drawn at a rate of approximately 0.1 liters per second through a ¼″ sampling hose, secured by clamps to a set of in-line filters. The in-line filters are located before the analyzer 16 inlet and remove virtually all water and particulate matter from the sample. The filters may include a pre-filter to remove large diesel exhaust particles, a coarse filter, and a fine 0.01 mm coalescing filter that removes heavy aerosols and most of the water vapor.
The gas is then pumped into exhaust analyzer 16 . Exhaust analyzer 16 is a modified repair-grade five-gas non-dispersive infra-red (NDIR) exhaust analyzer, which provides near real-time readings of concentrations of HC, CO, CO 2 , NO x and O 2 . The analyzer is powered from a cigarette lighter adaptor or by a fused cable connected directly to the vehicle battery. The OTC RG-240 digital five-gas analyzer manufactured by OTC may be employed in the preferred embodiment.
On natural gas powered vehicles, and/or where methane and non-methane hydrocarbons (NMHC) are to be measured separately, several options exist. First, a hand-held methane/low-range CO NDIR analyzer is added to the system. From a known concentration of methane and a known (experimentally determined) response of the 5-gas analyzer to methane (ratio of detected to actual methane concentration), both methane and NMHC concentrations can be obtained. A second NDIR unit with different response to methane is added. The methane and NMHC concentrations are then obtained from the two different HC readings by each analyzer. A portable flame ionization detector (FID) is added to measure total hydrocarbons (THC); from the known response of the NDIR analyzer to methane, and HC and THC readings, both methane and NMHC emissions can be determined. All calculations are simple arithmetic.
To obtain mass emissions data, the sample to be analyzed must be drawn from a known flow of gas. Traditionally, dilution tunnels and constant volume samplers were used for this purpose. In the preferred embodiment, the system samples undiluted exhaust and measures the exhaust flow in real-time. To calculate exhaust flow, either intake mass air flow or fuel flow must be known. Also, vehicle speed is necessary for distance and real-time fuel economy (mpg) and emissions (grams/mile, grams/gallon) calculations. Additional data, such as engine temperature, throttle position, or air conditioning operation are useful in correlating emission data to particular driving operations.
As mentioned above, on most modem engines, intake air mass flow and/or fuel flow can be obtained from engine electronic controls using engine control interface 21 which is commercially available. On throttled (such as gasoline powered) engines, the intake air flow (MF i ) is usually determined by the formula: MF i [ mol / s ] = ( ( Adjusted MAP [ kPa ] ) ( Engine displacement [ liters ] ) / ( engine speed [ rpm ] ) 30 ( engine cycle ) 8.314 ( intake air temp . [ deg . C . ] + 273 ) ) VEF
MAP is the manifold absolute pressure and the engine cycle will be either 2 or 4. VEF is the volumetric efficiency of engine 17 at full throttle and Adjusted MAP = Measured MAP - Atmospheric pressure Engine compression ratio
If the intake air temperature is not available, it is approximated by the arithmetic average of engine coolant or oil temperature and ambient air temperature. Some engines report intake air mass flow directly in grams per second.
On naturally aspirated diesel engines, atmospheric pressure is used instead of Measured MAP. On turbo-charged engines, Measured MAP can be substituted by a sum of the atmospheric pressure and turbo boost, where turbo boost is the difference between the intake manifold pressure and atmospheric pressure.
Fuel flow can be obtained either directly as a mass or volume per second (such as on some heavy-duty diesel engines), or calculated from a formula: Fuel Flow = ( Injector displacement ) ( number of cylinders ) ( Engine rpm 30 ( engine cycles ) )
Injector displacement is the amount of fuel injected by one injector during one engine cycle. Injector displacement is directly proportional to the injector pulse width, reported by many non-diesel engines. The proportion constant may be obtained from the vehicle manufacturer or determined experimentally.
As shown in FIG. 1, sensors 18 , 22 and 29 , engine control interface and exhaust analyzer 16 are connected to a processor via a serial (RS-232) port. An Axiom P-1000 panel PC may be used in the preferred embodiment The present system uses software written by the inventor to simultaneously receive both sets of data. Also, the user is allowed, at any time during the measurement, to enter a tag to mark sections of data as desired. The ASCII-text data is parsed, a system time stamp and the most recent tag is added to each complete record, and each record is stored in computer memory.
Processor 19 is programmed to synchronize the data received. Sensors 18 , 22 , 29 and exhaust analyzer 16 produce data with a certain delay (or response time), at a certain rate, and with gaps. Both the delay and the rate can be obtained from the instrument manufacturer and/or obtained experimentally. The gaps are caused by equipment malfunction or by events such as periodic zeroing of exhaust analyzer 16 .
On each set of data, the delay is subtracted from the time stamp. Linear interpolation is then used to generate one record every second (or other set time interval). Small gaps (usually less than 3 seconds) in the data are filled using the linear interpolation; if a large gap exists, the data is marked as “missing”. All data is then combined into one set, which includes vehicle speed and engine operating parameters, such as intake/fuel/exhaust flow, and exhaust concentrations.
A number of parameters are required to calculate the mass exhaust flow, including composition of air (known), fuel (can be obtained) and exhaust gas (measured by exhaust analyzer 16 ), the molecular weight of air, fuel and measured pollutants, and the flow (in moles per second) of air or fuel entering the engine, obtained using the above procedure. Flows in grams per second or other units can be converted using simple arithmetic. It is assumed that hydrocarbons can be represented as propane, C 3 H 8 (any compound can be used, as long as equations are updated accordingly). It is also assumed that fuel can be represented by a hypothetical compound C x H y O z . Engine 17 is a closed system, so that balance equations must be satisfied for carbon, hydrogen and oxygen:
MF f ( x )=( MF e )(3 c e ( HC )+ c e ( CO )+ c e ( CO 2 )) (1)
MF f ( y )=2 MF w +(8 c e ( HC )( Mf e )) (2)
MF f ( z )+(2 MF i (0.210(21.0% oxygen in ambient air))= MF w +MF e (2 c e ( O 2 )+ c e ( CO )+2 c e ( CO 2 )+ c e ( NO x )) (3)
MF is mass flow [moles/second], c is relative concentration [dimensionless]. The indices are: i=intake; e=exhaust without water; f=fuel; w=water contained in exhaust; HC, CO, CO 2 ,O 2 ,NO x =measured pollutants; and C, H, O=atomic carbon, hydrogen, oxygen respectively. This set of three linear equations with three unknowns (MF e , MF f or MF i , MF w ) is then solved for the exhaust mass flow. Calculation from a known fuel flow is similar. Also, if total exhaust flow (dry exhaust plus water) is required, the system can be solved for MF w , and total exhaust flow obtained by adding MF w and MF e . The set of equations can also be solved for fuel flow, allowing for fuel consumption monitoring. Substituting for MF w from (2) to (3):
MF f ( z− 0.5 y )+ MF i (2(0.210))= MF e (2 c e ( O 2 )+ c e ( CO )+2 c e ( CO 2 )+ c e ( NO x )−4 c e ( HC )) (4)
Substituting for MF f from (1) to (4):
MF e [((( x )(2 c e ( O 2 )+ c e ( CO )+2 c e ( CO 2 )+ c e ( NO x )−4 c e ( HC ))−(3 c e ( HC ) + c e ( CO )+ c e ( CO 2 )))( z− 0.5 y )]=( x )(2)(0.210)( MF i ) (5)
Solving for exhaust gas mass flow, yields: MF e = ( 0.420 ) ( x ) ( MF i ) ( x ( 2 c e ( O 2 ) + c e ( CO ) + 2 c e ( CO 2 ) + c e ( NO x ) - 4 c e ( HC ) ) ) - ( ( 3 c e ( HC ) + c e ( CO ) + c e ( CO 2 ) ) ( z - 0.5 y ) )
Mass emissions for a pollutant X are obtained, for each second, using the following formula:
X [grams/second]=(exhaust flow[moles/sec])(concentration( X ))(mol.wt.( X ))
Processor 19 is programmed to use this data for several purposes. First, mass emissions in grams/mile for the trip can be calculated by adding all grams/second data for the trip, and dividing by the total distance. The total distance is obtained by adding vehicle speed data in miles per second for the trip, excluding the sections during which there is “missing data”. (Miles/second=miles/hour÷3600). If the speed data is not available, the distance can be obtained from the vehicle odometer. Second, real-time mass emissions in grams/mile can be calculated by dividing grams/second emissions by instantaneous vehicle speed in miles/second. Third, fuel consumption, both total and real-time, can be obtained by solving the set of equations for fuel flow in moles/second, and multiplying the results by the fuel molecular weight (for grams/second) and, when needed, by fuel density (for gallons/second data). Fourth, real-time mass emissions in grams/gallon can be obtained by dividing grams/second emissions by fuel flow. Fifth, total mass emissions in gramsgallon can be obtained either by integrating the real-time mass emissions data, or by dividing the total emissions for the trip by the total fuel consumption for the trip.
Modifications
The present invention contemplates that many changes and modifications may be made. The particular materials of which the various body parts and component parts are formed are not deemed critical and may be readily varied.
Therefore, while the presently-preferred form of the emissions measuring system has been shown and described, and several modifications discussed, persons skilled in this art will readily appreciate that various additional changes and modifications may be made without departing from the spirit of the invention, as defined and differentiated by the following claims. | The invention is directed to an improved portable on-board mass emissions measuring system for internal combustion engines. In the preferred embodiment, the system is comprised of an exhaust analyzer ( 16 ), at least one sensor ( 18, 22 or 29 ) which may be temporarily attached to the engine for sensing parameters of the engine, and a processor ( 19 ) programmed to collect and manipulate data from the analyzer and the sensor, whereby the mass emissions of the engine may be calculated. The system may further comprise a display ( 20 ) for displaying the mass emissions of the engine and an engine-control interface ( 21 ). The sensor may be capable of sensing engine RPM, engine oil temperature, or intake manifold pressure. The exhaust analyzer may be capable of measuring concentrations of the engine exhaust constituents, particulates, aerosols, and gases in the engine emissions. The present invention also discloses a portable mass emissions measuring system for an internal combustion engine comprising an exhaust analyzer ( 16 ), a trace-gas injector ( 23 ), and a processor ( 19 ) programmed to collect and manipulate data from the analyzer and the injector, whereby the mass emissions of the engine may be calculated. In addition, the present invention is directed to a method for determining the emission flow rate of an internal combustion engine with the trace-gas injector. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a depth stop for a drill, and more particularly to a depth stop device which attaches to a drill used in drilling holes in aircraft parts which insures a precise countersink of these holes.
[0003] 2. Description of the Prior Art
[0004] In most traditional manufacturing processes, manipulation and processing of products are typically accomplished manually by workers. In the case of modern airplane manufacturing, this manual manipulation and processing frequently includes manually drilling a multitude of holes through titanium and the like. The accuracy of these holes can be highly dependent upon the skill of the worker. It is also necessary, in many applications, to prepare these holes with countersunk sections to enable a fastener to lie generally flush with the surface of the material. Especially in the assembly of aircraft parts, such as wings, numerous holes are required to be drilled. These drilled holes must be precisely countersunk. If they are too deep, for example, structural integrity becomes compromised and cost of producing the parts soar. The fasteners must fit flush to the material surface, and when an improperly drilled hole, meaning that the countersink is too deep, for example, occurs, a significant problem is created, which results in penalties for the manufacturer. Simply stated, a drill which included a device to insure a precise countersink to holes drilled in aircraft parts requiring a countersink, that did not depend on any particular skill of the operator of the drill would be most desirable. To this end, the prior art has produced depth stop embodiments which limit the depth within the work piece that the drill bit can travel. For illustration, a typical such device can be seen in U.S. Pat. No. 6,514,018 issued to Martinez et al. This device shows an axially oriented tightening screw which engages a sleeve. The sleeve ultimately guides the drill bit to the desired depth within the work piece, being held in place relative to the moving drill bit by the tightening screw. This particular depth stop embodiment has inherent disadvantages which are magnified when the depth of a countersunk hole, for example, must be extremely precise and repeatable. In the first place, in the manual tools suchs as drills, it is desirable that the tool be as light in weight as possible, and, of course this would also include any device attached to the drill such as a depth stop. The sleeve, therefore, that would sense the work piece and limit drilling depth is preferably has a relatively thin wall. In the common arrangement, as the above mentioned patent is an example, the sleeve would be held in place with a screw. The screw is tightened by the operator of the drill once the proper depth of the hole to be drilled is determined. The problems that can occur include deflection of the sleeve due to the force of the screw on the sleeve especially if the screw is “overtightened” by the operator. Deflection of the sleeve which controls the depth of the drilled hole will ultimately result in a lack of precision in the depth stop device. As the precision requirements increase, the deflection issue further comes to the forefront, with the ideal being no deflection of the sleeve while it is held in place and controlling the depth of the drilled hole. Even a slight misalignment of the sleeve can lead to improper countersunk holes in an aircraft part which can result in defective assembly. Over time, even with the most careful and skilled drill operators, the depth stop device shown in the above mentioned United States patent will result in manufacturing problems due to deflection of the sleeve. These problems will occur sooner rather than later as the necessary degree of precision in countersink holes increases in a particular application.
[0005] The present invention provides a solution to the problems outlined above in the prior art, by presenting a depth stop device which allows the drill to produce repeatable, precise countersunk holes in aircraft parts without relying on an unusual degree of skill by the drill operator.
SUMMARY OF THE INVENTION
[0006] In general terms, the invention disclosed herein presents a novel device, namely, a depth stop for use with a drill. It is contemplated that the disclosed depth stop is especially valuable in situations requiring that the drilled hole be precise with respect to its depth. This type of application occurs, for example, in the aircraft industry in the assembly of aircraft parts. More specifically, many holes having a countersink feature are needed to be drilled during manufacture. These countersunk holes, if not drilled to exacting specifications with respect to depth, will increase the cost of manufacture of the aircraft part dramatically. Further, it is desirable in this application to provide a device which prevents an operator of the drill from inadvertently or accidentally damaging the depth stop during the procedure of fixing the depth stop at a predetermined level. In other words, the depth stop will need to be secured or fixed relative to the drill prior to use of the drill. It is critical that the locking means holding the depth stop in place during drilling is of a nature that will not cause misalignment or damage to the device in any way. The operator, using the present invention, is prevented from tightening the depth sensing part of the device to a point which will cause inaccuracy in later usage of the depth stop.
[0007] The depth stop of the present invention includes a tubular member or inner sensing sleeve, which at one end during use, contacts the work piece to be drilled. The inner sensing sleeve has grooves which partially extend over its outer surface. The purpose of these grooves will be discussed subsequently. The inner sensing sleeve has external fine pitched thread which screw into a second tubular part or outer portion of the sensing sleeve concentric with the inner sensing sleeve. The outer portion of the sensing sleeve has internal threads matching the threads of the inner sensing sleeve. The inner sensing sleeve is adjustable within the outer portion of the sensing sleeve by rotation of the inner sleeve. A lock screw and sensing sleeve anti-rotational member is provided which fix the inner sensing sleeve relative to the outer portion of the sensing sleeve. The sensing sleeve anti-rotational member has a set of teeth extending axially therefrom which engage in the grooves of the inner sensing sleeve to fix the inner sensing sleeve in place during use of the device. The lock screw has external threads which engage an internally threaded aperture of the outer portion of the sensing sleeve. The threaded aperture extends radially from the outer portion of the sensing sleeve. A spring is located between the lock screw and the sensing sleeve anti-rotational member, resting over protrusions of the lock screw and sensing sleeve anti-rotational member. As the lock screw is rotated, the sensing sleeve anti-rotational member moves toward the inner sensing sleeve due to the presence of the spring. Ultimately, when the lock screw is rotated to a locked position, meaning that the inner sensing sleeve is prevented from any axially movement relative to the outer portion of the sensing sleeve, the teeth of the sensing sleeve anti-rotational member engage the grooves of the inner sensing sleeve preventing rotation of the inner sensing sleeve relative to the outer portion of the sensing sleeve. The inner sensing sleeve is locked in position in this configuration as the teeth of the sensing sleeve anti-rotational member can move slightly axially but not enough to cause disengagement from the grooves of the inner sensing sleeve. The travel of the drill bit into the work piece thereby can be limited as one end of the inner sensing sleeve contacts the work piece. The inner sensing sleeve can be unlocked relative to the outer portion of the sensing sleeve by rotation of the lock screw in the opposite direction allowing the teeth of the sensing sleeve anti-rotational member to completely disengage from the grooves of the inner sensing sleeve.
[0008] In the above described configuration, it should be noted that the force applied to the inner sensing sleeve by the lock screw is modulated due to the presence of the spring between the sensing sleeve anti-rotational member and the lock screw. The teeth of the sensing sleeve anti-rotational member fit into the grooves of the inner sensing sleeve and prevent rotation of the inner sensing sleeve, but only minimal pressure is transmitted to the inner sensing sleeve. The inner sensing sleeve, therefore, cannot be inadvertently deflected or in any way damaged during the locking process regardless of how tight the lock screw is made. Further, the lock screw has a shoulder which contacts the threaded aperture when the lock screw is fully tightened preventing further movement of the outer portion of the lock screw within the threaded aperture. When fully tightened, the teeth of the sensing sleeve anti-rotational member cannot put significant pressure on the inner sensing sleeve and potentially damage it, nor can the teeth back out far enough to allow rotation of the inner sensing sleeve. The inner sensing sleeve, and therefore the depth, is set in place with minimal force on the inner sensing sleeve. The inner sensing sleeve is not “loaded up” with force from a lock screw which can produce mechanical misalignment or deflection resulting in the inability of the device to produce accuracy. To adjust the depth of the inner sensing sleeve relative to the drill and work piece, the lock screw is rotated to an open position allowing the inner sensing sleeve to be rotated inwardly or outwardly to the desired depth of the particular application. When the inner sensing sleeve is rotated in this manner, the spring located between the lock screw and the sensing sleeve anti-rotational member causes an audible click as the teeth of the sensing sleeve anti-rotational member slip over the grooves of the inner sensing sleeve thereby signaling a change in depth. In the preferred embodiment of the invention, the device can be set up so that the audible click occurs once for each 7.5 microns of depth change. This audio cue greatly assists the operator in arriving at the desired predetermined depth. The depth stop device can be attached to the end of a drill. Preferably, the drill would have cavities which can receive pins extending from longitudinally from the depth stop device. An adjustable clamping band can radially secure the depth stop device to the end of the drill when the pins are disposed in the aforementioned cavities.
[0009] It is, therefore, an object of the present invention to provide a depth stop device which allows the precise drilling of countersunk holes.
[0010] Another object of the present invention is to provide a depth stop device having a sensing sleeve which cannot be misaligned or damaged by the locking means of the device.
[0011] A further object of the present invention is to provide a depth stop device for use in drilling countersunk holes which can repeatedly produce holes of a precise depth.
[0012] Yet another object of the present invention is to provide a depth stop device having a sensing sleeve fixed in position by a locking screw which cannot be misaligned or deflected by over tightening the locking screw.
[0013] These and other objects and advantages will become more apparent from the following detailed description when taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0014] FIG. 1 a is an elevation view partially in cross section of a depth stop in accordance with the present invention as it would fit on a typical drill with parts of the drill not shown for clarity in identifying the depth stop.
[0015] FIG. 1 b is a cross sectional view through line B-B of FIG. 1 a.
[0016] FIG. 1 c is a detail view of the circled section labeled C of FIG. 1 b.
[0017] FIG. 2 is an elevation view of the depth stop of the present invention.
[0018] FIG. 2 a is a cross sectional view taken through line A-A of FIG. 2 .
[0019] FIG. 2 b is a detailed view of circular section B of FIG. 2 a showing the configuration of the device when the inner sensing sleeve can be adjusted.
[0020] FIG. 3 is an elevation view of the depth stop of the present invention similar to FIG. 2 .
[0021] FIG. 3 a is a sectional view taken through line A-A of FIG. 3 .
[0022] FIG. 3 b is a detailed view of circular section B of FIG. 3 a showing the configuration of the depth stop of the present invention when the inner sensing sleeve is locked in place.
[0023] FIG. 4 a is an elevation view partially in cross section of a depth stop in accordance with the present invention as attached to a drill.
[0024] FIG. 4 b is a cross sectional view taken through line B-B of FIG. 4 a.
[0025] FIG. 4 c is a detailed view of section C of FIG. 4 b.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Referring to the Figures, especially FIGS. 1 a - 1 c, the depth stop in accordance with the present invention can be described. In FIGS. 1 a - c, parts of the drill have been omitted to more clearly distinguish the depth stop itself. FIG. 1 a shows a depth stop assembly, generally designated as 10 , having an inner sensing sleeve 12 and an outer sensing sleeve 14 . Inner sensing sleeve is threaded into outer sensing sleeve 14 with fine pitched thread. The inner sensing sleeve 12 has external threads which match internal threads of outer sensing sleeve 14 . Inner sensing sleeve 12 can be adjusted relative to outer sensing sleeve 14 by rotation of the inner sensing sleeve 12 while keeping the outer sensing sleeve fixed. A lock screw 16 and sensing sleeve anti-rotational member 18 are used to hold the inner sensing sleeve 12 in position relative to the outer sensing sleeve 14 . Lock screw 16 has a projection 17 extending axially from one end, and sensing sleeve anti-rotational member 18 also has a projection 19 extending axially from one end toward the lock screw. More details of this arrangement to hold the inner sensing sleeve 12 relative to the outer sensing sleeve 14 will be disclosed subsequently. A partially threaded aperture 20 is provided and extends in the radial direction within the outer sensing sleeve 14 . The aperture 20 receives the sensing sleeve anti-rotational member 18 in its non threaded portion, designated as numeral 22 , and the lock screw in its thread portion, designated as 24 . A roll pin 25 is provided which secures the sensing sleeve anti-rotational member 18 to the outer sensing sleeve 14 . The sensing sleeve anti-rotational member 18 is received in this manner to prevent inadvertent loss of that part from the depth stop assembly if lock screw 16 is removed completely from the partially threaded aperture 20 .
[0027] Referring now to the FIGS. 2 a - c, and 3 a - c particularly, it can be seen that sensing sleeve anti-rotational member 18 has teeth 26 extending axially from one end opposite the projection 19 . The teeth 26 engage in longitudinal grooves 28 of inner sensing sleeve 12 . Grooves 28 partially extend over the outer surface of inner sensing sleeve 12 . The teeth 26 of sensing sleeve anti-rotational member 18 when engaged in longitudinal grooves 28 of inner sensing sleeve 12 , can hold the inner sensing sleeve 12 in place relative to the outer sensing sleeve 14 . A spring 30 is provided which fits between the end of the lock screw 16 and the end of the sensing sleeve anti-rotational member 18 closest to the lock screw 16 over projection 17 of the lock screw 16 , and over projection 19 of sensing sleeve anti-rotational member 18 . In this configuration, as the lock screw 16 is rotated inwardly, the spring 30 urges sensing sleeve anti-rotational member 18 toward the inner sensing sleeve 12 until the teeth 26 of sensing sleeve anti-rotational member 18 engage the grooves 28 of inner sensing sleeve 12 . When the lock screw is 16 is fully tightened, teeth 26 of sensing sleeve anti-rotational member 18 cannot disengage from grooves 28 of the inner sensing sleeve 12 . The inner sensing sleeve 12 , therefore, cannot rotate and is positively locked into position. The shoulders 32 a, 32 b, of lock screw 16 , when lock screw 16 is fully tightened, rest on the ends of the threaded portion 24 of the partially threaded aperture 20 . Further, when the lock screw 16 is fully tightened, a gap 21 exists between the projection 17 of the lock screw 16 and the projection 19 on the end of the sensing sleeve anti-rotational member 18 . This gap 21 is small enough to prevent the teeth 26 of sensing sleeve anti-rotational member 18 from disengaging from grooves 28 of inner sensing sleeve 12 so that the sensing sleeve anti-rotational member 18 is locked in position. The gap 21 is always present, regardless of the position of the lock screw 16 , effectively preventing lock screw 16 from directly pushing on sensing sleeve anti-rotational member 18 . The force transmitted by sensing sleeve anti-rotational member 18 , therefore, to the inner sensing sleeve 12 is always less than the force necessary to deflect or damage the inner sensing sleeve 12 . The depth stop assembly 10 , has a way to avoid damage to the inner sensing sleeve 12 regardless of the operator's handling of the lock screw 16 . It is impossible to over-tighten the lock screw 16 and thereby damage the inner sensing sleeve 12 . The countersink depth is established with a minimal force on the inner sensing sleeve 12 resulting in countersink depth accuracy over time.
[0028] FIG. 4 a (with more drill parts shown relative to FIG. 1 a ) shows the depth stop assembly 10 attached to a typical drill, generally designated as 33 , used to make countersunk holes in airplane parts. The depth stop assembly 10 is clamped by clamping band 34 to the drill housing 36 . Depth stop pins 38 a, 38 b, extend from the depth stop assembly 10 and fit within suitable cavities within the drill housing 36 . The drill bit 40 will be extended from drill housing 36 to drill a hole until shoulders 42 a, 42 b, within the drill housing 36 contact depth stop pins 38 a, 38 b respectively. The depth of the drilled hole can by regulated by extending inner sensing sleeve 12 relative to outer sensing sleeve 14 . When the lock screw 16 is backed off, and the teeth 26 are not fully engaged in grooves 28 of the inner sensing sleeve 12 , slight contact between the teeth 26 of sensing sleeve anti-rotational member 18 and the grooves 28 of inner sensing sleeve 12 occurs. When the inner sensing sleeve 12 is rotated relative to the outer sensing sleeve 14 , this slight contact of teeth 26 with grooves 28 creates an audible “click” due to the spring 30 . The spacing of grooves 28 of inner sensing sleeve 12 and teeth 26 determine the distance the inner sensing sleeve 12 travels for each click heard. If the teeth 26 and the grooves 28 are spaced relatively widely, a longer travel of inner sensing sleeve 12 relative to outer sensing sleeve 14 will occur and the inner sensing sleeve 12 will extend farther outwardly from the depth stop assembly 10 . In a preferred embodiment of the present invention, the teeth 26 of the sensing sleeve anti-rotational member 18 and the grooves 28 of the inner sensing sleeve 12 will be configured so that an audible click occurs of each 7.5 micron change in countersink depth. This audible cue is helpful to the operator in arriving at the final desired depth of countersink.
[0029] In operation, the depth stop assembly would be fastened to a drill 33 by clamping band 34 as shown in FIG. 4 a. The depth stop assembly would rest on a work piece designated as 44 extending through a template 46 . As shown in FIG. 4 a, the template 46 also rests on the work piece 44 . The operator would proceed by first drilling a hole in the work piece with the countersink drill bit 40 . The drilled hole would then be measure, and the inner sensing sleeve 12 rotated relative to the outer sensing sleeve 14 to precisely determine the depth of the countersunk hole. As mentioned previously, an audible click will occur at every 7.5 microns change in depth to assist the operator in arriving at the exact desired depth of countersink. The inner sensing sleeve 12 can then be fixed in place by tightening the lock screw 16 . Once the lock screw is tightened, the inner sensing sleeve 12 is fixed in place and the hole can be drilled with precision. The drill bit 40 will extend from the drill housing 36 until depth stop pins 38 a, 38 b, contact shoulders 42 a, 42 b, respectively, of drill 33 . The depth of the countersunk hole will be determined by the depth stop assembly 10 . It should be noted that the inner sensing sleeve 12 , outer sensing sleeve 14 , and depth stop pins 38 a, 38 b are all “free floating” and reference only the surface of the work piece 44 for depth of countersink, without being effected by any tooling or work piece 44 deflection during the drilling operation.
[0030] This invention may be embodied in other forms without departing form 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 appended claims rather than the foregoing description, and all change which comes within the meaning and range of equivalency of claims is intended to be embraced therein. | A depth stop attached to a drill for producing precise countersinking in drilled holes. The depth stop produces an accurate and precise countersink in drilled holes by limiting the depth to which a drill bit can drill through a work piece. An audible click occurs for every 7.5 micron change in depth in the preferred embodiment. The depth stop is configured such that attempts to over tighten the lock screw which fixes the depth amount will not damage or deflect the working parts of the device thereby producing accurate and repeatable results. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of nonprovisional patent application Ser. No. 13/714,453 filed 2012 Dec. 14 by the present inventor.
BACKGROUND
Prior Art
The following is a tabulation of some prior art that presently appears relevant:
U.S. patents
patent No.
Issue Date
Patentee
4,344,351
Aug. 17, 1982
McQueen
4,514,923
May 7, 1985
Teel
4,685,379
Aug. 11, 1987
Troncoso
4,787,288
Nov. 29, 1988
Miller
5,074,190
Dec. 24, 1991
Troncoso
6,101,918
Aug. 15, 2000
Akins
6,966,138
Nov. 22, 2005
Deckard
Semi-automatic firearms have a limited firing rate as compared to automatic weapons. Automatic weapons are also known to be prohibitively expensive and harder to acquire than semi-automatic firearms. As a result many devices have been proposed in the past for increasing the firing rate of semi-automatic firearms. See for example, U.S. Pat. No. 4,344,351 to McQueen; U.S. Pat. No. 4,787,288 to Miller; U.S. Pat. Nos. 4,803,910 and 5,074,190 to Troncoso; U.S. Pat. No. 6,101,918 to Akins; and U.S. Pat. No. 6,966,138 to Deckard.
Some of these solutions attempt to make it easier to “bump fire”, or use the firearms recoil to allow user to manipulate trigger faster, but these solutions fail to meet the needs of the industry because of complicated non-intuitive operation or undesirable add on devices. Other solutions attempt to use mechanical means such as crank or slide devices to manipulate trigger quickly, but these solutions are similarly unable to meet the needs of the industry because non-intuitive operation with difficulty maintaining accurate fire. Still other solutions, for example U.S. Pat. No. 6,966,138 to Deckard, seek to convert a standard trigger to fire a shot on both pull and release, but these solutions also fail to meet industry needs because the device needs to be installed and removed to switch between modes of operation, and are not compatible with trigger systems with a forward hammer engagement surface such as AR-15 and AR-10 pattern rifles, one of the most popular rifles in the United States.
Deckard's device also has no means of eliminating the possibility of “hammer follow” in the double-fire mode. In the double fire mode, if the trigger is not manipulated properly, the hammer can follow the bolt assembly forward as it reciprocates resulting in either multiple rounds fired with one function of the trigger or the hammer being in a forward (fired) position with a loaded round in the chamber.
In the double fire mode of Deckard's device, the primary sear surface of the trigger and the disconnector engagement surface are spaced so that if the trigger is improperly manipulated or held in a central position, the hammer will not be held in a rearward position. The hammer will follow the bolt assembly forward, resulting in the aforementioned automatic fire or requiring manually reciprocating the bolt assembly to resume firing. This is a serious shortcoming of the device, as it is capable of firing more than one round with a single function of the trigger thus meeting the definition of a machine gun as described in 26 U.S.C. 5845(b), in which a machine gun is defined as a weapon which is able to fire more than one shot with a single function of the trigger. Thus this device would not gain approval by the Bureau of Alcohol, Tobacco, Firearms and Explosives Firearms Technology Branch for civilian sales.
Thus, the need exists for solutions to the above problems with prior art.
SUMMARY
The present invention is a selectable trigger for semiautomatic firearms, enabling quick and easy transitions between two modes and rates of fire. One mode allows normal semiautomatic operation, in which the firearm fires one round with a pull of the trigger and resets trigger with release of trigger, and another mode which fires a round with a pull of the trigger and fires another round with trigger release, thus doubling rate of fire.
In one embodiment the invention comprises of the following core components: A trigger, a primary disconnector, a secondary disconnector, a hammer, a selector cam, a selector lever, a detent spring and detent ball. These components are connected as follows: The selector cam is positioned under the front of the primary disconnector. The shaft of the selector cam passes through the trigger. The selector lever is fastened to the bottom of the selector cam by a cross pin. A spring and detent ball are located in the selector lever and engage voids in the trigger to keep selector lever in desired position.
When the selector lever is turned, the selector cam engages the primary disconnector, tilting the primary disconnector on its axis, thus varying the amount of engagement of the primary disconnector on the hammer.
With the selector in first position, the firearm will function as most semiautomatic firearms function, a pull of the trigger will fire one round, releasing the trigger will reset the trigger for the next shot. In this mode, the primary disconnector engagement will not release hammer until the engagement surface of trigger or trigger mechanism is in position to retain hammer in a cocked position.
With the selector in the second position, the firearm will fire one round when the trigger is pulled, and fire one round when trigger is released, thus doubling rate of fire. In this mode, the primary disconnector engagement depth is lessened, allowing the hammer to be released before the engagement surface of the trigger or trigger mechanism is in place to retain hammer in a cocked position, thus allowing hammer to fall striking firing pin, firing a round.
The secondary disconnector prevents the hammer from following the bolt assembly forward if the engagement surface of the trigger or the primary disconnector is not in position to retain hammer in a cocked rearward position. If the trigger is either forward or rearward the secondary disconnector will not engage the hammer, but if the trigger is in a central position that would allow the hammer to follow the bolt forward, the secondary disconnector will engage hammer retaining it in a rearward position until the trigger is either pulled or released.
ADVANTAGES
The present invention advantageously fills the aforementioned deficiencies by providing a selectable dual mode trigger for semiautomatic firearms which provides the user the ability to quickly and easily transition between two modes of operation, one mode doubling the rate of fire as opposed to a conventional trigger system. The invention requires no installation or removal of devices to transition between modes of operation, a simple flip of a switch is all that is required to transition between modes of operation.
The inventions secondary disconnector is advantageous in that the possibility of hammer follow is eliminated. The secondary disconnector greatly enhances the reliability of the trigger system, as well as prevents more than one round being fired per trigger function, thus meeting BATFE restrictions.
The invention is advantageous in that it is a mechanical device, and does not depend on the recoil of the weapon to function, as some prior art devices do. It will function equally well on firearms chambered for high or low recoil rounds.
The present invention is advantageous over prior art in that its operation in both modes is intuitive, with no unusual manipulations or motions required to operate. The device operates with a pull and a release of the trigger, in the same manner as practically every other firearm. The selector lever is unobtrusive, and does not hinder normal operation, handling, or function.
The present invention is advantageous in that it is compatible with trigger systems with a forward hammer engagement surface, such as the popular AR-15 and AR-10 pattern rifles or any semi-automatic firearm using or able to be adapted to use such a trigger system.
FIGURES
FIG. 1 shows the individual components of the invention in accordance with the first embodiment in a disassembled state.
FIG. 2 shows various aspects and details of the trigger, selector lever, detent, detent spring and selector cam.
FIG. 3 shows another aspect of the trigger, selector lever, and selector pin, showing the selector lever in the first position, allowing normal semi-automatic operation.
FIG. 4 shows another aspect of the trigger and selector lever with the selector lever in the second position, allowing a dual mode of fire with firearm firing one shot on trigger pull, and firing one shot on trigger release.
FIG. 5 shows various components of the invention in relation to the receiver or trigger housing of a firearm, with the trigger and selector lever protruding exposed allowing manipulation.
FIG. 6 shows another aspect, an underside view, of the trigger showing selector cam bore and recesses for detent engagement.
FIG. 7 shows the dual mode trigger in the forward position with the hammer in the cocked rearward position and the selector lever in the first position for normal semi-automatic operation.
FIG. 8 shows the dual mode trigger in rearward position with the hammer in the forward fired position and the selector lever in the first position for normal semi-automatic operation.
FIG. 9 shows the dual mode trigger in the rearward position with the hammer in rearward position with the hammer being held rearward by the primary disconnector and the selector lever in the first position to allow normal semi-automatic operation.
FIG. 10 shows the dual mode trigger returned to the forward position with the hammer in the cocked rearward position and the selector lever in the first position for normal semi-automatic operation.
FIG. 11 shows the dual mode trigger in the forward position with the hammer in the cocked rearward position and the selector lever in the second position to allow a shot to be fired both with trigger pull and trigger release.
FIG. 12 shows the dual mode trigger in the rearward position with the hammer in the forward fired position and the selector lever in the second position to allow a shot to be fired both with trigger pull and trigger release.
FIG. 13 shows the dual mode trigger in the rearward position with the hammer in the rearward position being held rearward by the primary disconnector and the selector lever in the second position to allow a shot to be fired both with trigger pull and trigger release.
FIG. 14 shows the dual mode trigger in the central position with the hammer in the forward fired position having been released by the primary disconnector and the selector lever in the second position to allow a shot to be fired both with trigger pull and trigger release.
FIG. 15 shows the dual mode trigger returned to the forward position with the hammer in the rearward cocked position and the selector lever in the second position to allow a shot to be fired both with trigger pull and trigger release.
FIG. 16 shows the dual mode trigger in the central position with the hammer in the rearward position being held rearward by the secondary disconnector and the selector lever in the second position to allow a shot to be fired both with trigger pull and release.
REFERENCE NUMERALS
1 trigger
2 hammer
3 primary disconnector
4 secondary disconnector
5 selector cam
6 selector lever
7 selector pin
8 selector detent
9 selector detent spring
10 secondary disconnector pin
11 primary disconnector spring
12 secondary disconnector spring
13 selector cam bore
14 hammer engagement surface of trigger
15 trigger engagement surface of hammer
16 hammer engagement surface of primary disconnector
17 primary disconnector engagement surface of hammer
18 hammer engagement surface of secondary disconnector
19 secondary disconnector engagement surface of hammer
20 raised camming surface of selector cam
21 safety selector (prior art)
22 second position selector detent recess
23 first position selector detent recess
24 hammer pin (prior art)
25 trigger and primary disconnector pin (prior art)
26 selector detent bore
DETAILED DESCRIPTION
FIGS. 1 - 16
Before explaining the disclosed embodiment of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
The core components of the selectable dual mode trigger are illustrated in FIG. 1 . A trigger 1 is manufactured with a selector cam bore 13 in which a selector cam 5 fits, with its shaft protruding from the bottom of the trigger 1 .
Affixed to the lower portion of selector cam 5 by means of a selector pin 7 is a selector lever 6 . A selector detent 8 and a selector detent spring 9 fit inside the selector lever 6 . The trigger 1 has a slot in its top portion to fit a primary disconnector 3 , a primary disconnector spring 11 , a secondary disconnector 4 , and a secondary disconnector spring 12 . A secondary disconnector pin 10 is used to retain the secondary disconnector 4 in the trigger 1 . A hammer 2 is equipped with engagement surfaces 15 , 17 , and 19 for the trigger 1 , primary disconnector 3 , and the secondary disconnector 4 respectively.
Alternative views of the trigger 1 , the selector lever 6 , and the selector cam 5 are shown in FIG. 2 . In this view, the top of the selector cam bore 13 is visible on the upper surface of the trigger 1 . This view shows a selector detent bore 26 in the top surface of the selector lever 6 in which the selector detent spring 9 and selector detent 8 fit. Three different aspect views of the selector cam 5 show in detail a raised camming surface 20 . The raised camming surface 20 interfaces with the primary disconnector 3 when the selector lever 6 is in the second position.
The selector lever 6 is shown in the first position in FIG. 3 . In this position, the firearm will function as a normal semi-automatic, firing one shot with trigger pull, and resetting trigger with trigger release. Also visible in FIG. 3 is the selector pin 7 .
The selector lever 6 is shown in the second position in FIG. 4 . The selector lever 6 rotates 90 degrees to transition between the two modes of fire. In the second position, the firearm will fire one round with trigger pull, and fire one round with trigger release. This mode of operation doubles the rate of fire as compared to normal semi-automatic operation.
In FIG. 5 various components of the selectable dual mode trigger are shown in relation to the firearms receiver or trigger housing. The curved portion of the trigger 1 and the selector lever 6 are exposed allowing manipulation to fire the weapon and to select between two modes of operation. The trigger 1 and the primary disconnector 3 pivot on a trigger and primary disconnector pin 25 . The hammer 2 pivots on a hammer pin 24 . A safety selector 21 serves as a static contact point for the secondary disconnector 4 during the firing cycle of the selectable dual mode trigger.
The underside of the trigger 1 is shown in FIG. 6 . Visible from this perspective are the selector cam bore 13 , a first position selector detent recess 23 , and a second position selector detent recess 22 .
FIG. 7 shows the selectable dual mode trigger cocked ready to fire. The selector lever 6 is placed in the first position to allow normal semi-automatic operation. The trigger 1 is in a forward position. The hammer 2 is retained in a cocked rearward position by the hammer engagement surface of the trigger 14 . The primary disconnector is pushed in a forward position by the primary disconnector spring 11 . The secondary disconnector 4 is pushed in a forward position by the secondary disconnector spring 12 . The secondary disconnector 4 is not contacting the safety selector 21 .
FIG. 8 shows the trigger 1 pulled rearward, disengaging the hammer engagement surface of the trigger 14 from the trigger engagement surface of the hammer 15 . This allows the hammer 2 to pivot forward, firing a round. The selector lever 6 is in the first position. The selector cam 5 is visible above the trigger 1 . The raised camming surface of the selector cam 20 is positioned beside the primary disconnector 3 . The secondary disconnector 4 is in contact with the safety selector 21 and is pivoted rearward.
FIG. 9 shows the trigger 1 in a rearward position being held there by the users finger immediately after a shot is fired. The selector lever 6 is in the first position. The hammer 2 has been returned to a rearward position by the firearms action, and is retained in that position by the primary disconnector 3 . The secondary disconnector 4 is in contact with the safety selector 21 and is in a rearward position.
FIG. 10 shows the trigger 1 released by the operator and returned to a forward position. The hammer 2 has been released by the primary disconnector 3 and is now being held in a cocked rearward position by the hammer engagement surface of the trigger 14 . The selector lever 6 is in the first position. The secondary disconnector 4 is in the forward position, no longer in contact with the safety selector 21 .
FIGS. 7-10 detail one cycle of the selectable dual mode trigger with the selector lever 6 in the first position. The firearm fired one round when the trigger 1 was pulled rearward by the operator, and the hammer 2 reset in a cocked rearward position when the operator released the trigger 1 . This is the normal semi-automatic mode of operation. The hammer 2 is in a cocked position ready to fire another round with the pull of the trigger 1 .
FIG. 11 shows the dual mode trigger with the trigger 1 in the forward position. The hammer 2 is in a cocked rearward position retained in that position by the hammer engagement surface of the trigger 14 . The selector lever 6 has been rotated 90 degrees and is now in the second position. The selector cam 5 has likewise rotated 90 degrees and the raised camming surface of the selector cam 20 is positioned under the front of the primary disconnector 3 . The raised camming surface of the selector cam 20 tilts the primary disconnector 3 rearward about 0.030″.
FIG. 12 shows the trigger 1 pulled rearward by the operator. The hammer 2 has rotated forward, firing a round. The selector lever 6 is in the second position. The primary disconnector 3 is tilted rearward about 0.030″ in relation to the trigger 1 . The secondary disconnector 4 is in contact with the safety selector 21 and is tilted rearward.
FIG. 13 shows the trigger 1 held in a rearward position by the operator immediately after firing a round. The hammer 2 has been returned to a rearward position by the firearms action and is retained in that rearward position by the primary disconnector 3 .
FIG. 14 shows the trigger 1 in a central position having been released by the operator. The selector lever 6 is in the second position and the primary disconnector 3 is tilted rearward about 0.030″ in relation to the trigger 1 . As a result of the primary disconnector 3 being tilted rearward by the raised camming surface of the selector cam 20 , the hammer engagement surface of the primary disconnector 16 is rearward about 0.030″ and releases the hammer 2 before the hammer engagement surface of the trigger 14 is in position to retain it in a rearward position. As a result, instead of the hammer 2 resetting as it does when the selector lever 6 is in the first position, the hammer 2 rotates forward firing a round. Thus, two rounds are fired in one rearward and forward cycle of the trigger 1 accomplishing a rate of fire double that of standard semi-automatic firearms.
FIG. 15 shows the trigger 1 released by the operator in the forward position. The selector lever 6 is in the second position. The hammer 2 has been returned to a rearward position by the action of the firearm. It is retained in the rearward cocked position by the hammer engagement surface of the trigger 14 . One rearward and forward (pull and release) cycle of the trigger 1 has now been completed resulting in the firing of two rounds, one shot on pull, one shot on release.
FIG. 16 illustrates the essential and novel function of the secondary disconnector 4 . When the selector lever 6 is in the second position, the primary disconnector 3 is tilted rearward about 0.030″ in relation to the trigger 1 . In this mode of operation, in which the firearm fires a round both with pull and release of trigger 1 , it is possible that neither the hammer engagement surface of the primary disconnector 16 or the hammer engagement surface of the trigger 14 will be in position to retain the hammer 2 when it is returned rearward by the firearms action. This possibility exists if the trigger 1 is in a central position, neither forward nor rearward completely.
In this scenario, the secondary disconnector 4 will retain the hammer 2 in a rearward position, preventing the hammer 2 from following the action or bolt forward. If the hammer 2 is retained in a rearward position by the secondary disconnector 4 , a complete pull or release of the trigger 1 will release the hammer 2 . If the trigger 1 is pulled to a rearward position, the secondary disconnector 4 will contact the safety selector 21 which tilts the secondary disconnector 4 rearward, causing the hammer engagement surface of the secondary disconnector 18 to disengage with the hammer 2 . The hammer 2 will then move forward slightly before being retained in a rearward position by the primary disconnector 3 as illustrated in FIG. 13 .
If the hammer 2 is retained in a rearward position by the secondary disconnector 4 as illustrated in FIG. 16 and the trigger 1 is released to a forward position by the operator, the secondary disconnector 4 will move rearward in relation to the hammer 2 and the hammer engagement surface of the secondary disconnector 18 will disengage the hammer 2 . The hammer 2 will then rotate forward slightly and be retained in a rearward position by the hammer engagement surface of the trigger 14 as illustrated in FIG. 15 .
In use, the operator chooses which mode of operation he desires to fire the weapon in and rotates the selector lever 6 accordingly. The operator then pulls and releases the trigger 1 . In the first mode the firearm will discharge one round with each complete pull and release of the trigger 1 , in the second mode the firearm will discharge two rounds with each complete pull and release of the trigger 1 .
The trigger 1 , hammer 2 , selector cam 5 , primary disconnector 3 , and secondary disconnector 4 are constructed of hardened firearms grade tool steel. The selector lever 6 can be constructed of various materials including but not limited to aluminum alloys, mild steel, hardened steel, or various composites.
While the invention has been described, disclosed, illustrated, and shown in one embodiment, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially if they fall within the scope of the claims here appended. Other embodiments could use other means of selectively varying the engagement of the primary disconnector such as a sliding or pivoting selector. The secondary disconnector could use a static point of contact other than the safety selector to accomplish disengagement with the hammer. Means other than a detent ball and spring could be implemented to secure the selector lever in the desired position. The invention can include additional features as desired, such as but not limited to a checkered, grooved or resilient surface on the selector lever.
ADVANTAGES
From the description above, a number of advantages of my selectable dual mode trigger for semiautomatic firearms become evident.
(a) The selector lever is unobtrusive and fits close to the receiver or trigger housing of the firearm.
(b) The selector lever allows easy transition between two modes and rates of fire without the addition or deletion of any devices or attachments.
(c) The selectable dual mode trigger can be installed in many firearms, such as AR-15 and AR-10 pattern rifles with no modification to the receiver or other major components of the firearm.
(d) The secondary disconnector retains the hammer in a rearward position if the trigger is in a central position, yet releases the hammer if the trigger is either pulled or released completely, preventing automatic fire or hammer follow malfunctions.
(e) The selectable dual mode trigger is mechanical and functions equally well on high or low recoil firearms, unlike many other devices for increasing rate of fire which are dependent on a firearms recoil to function.
(f) The selectable dual mode trigger is intuitive to use, the operator simply pulls and releases the trigger in both modes of fire, as in virtually every other firearm.
(g) The selectable dual mode trigger functions in both modes while the operator has a firm, natural grasp of the firearm which increases accuracy and control.
(h) Although other devices are add on and external, making them susceptible to damage and contamination with debris, the selectable dual mode trigger's components are contained inside the firearm thus increasing reliability and safety.
(i) The selectable dual mode trigger increases the rate of fire of a semiautomatic firearm without being classified as a machine gun or restricted weapon.
CONCLUSION, RAMIFICATIONS, AND SCOPE
Accordingly, the reader will see that the selectable dual mode trigger can be used to quickly and easily transition between two modes and rates of fire. The selectable dual mode trigger allows rates of fire approaching that of fully automatic firearms without the disadvantages of other proposed devices. Unlike other devices proposed to increase rate of fire, it is unobtrusive and requires no special techniques to operate. The selectable dual mode trigger is compatible with firearms and trigger systems with a forward hammer engagement surface, such as the popular AR-15 type firearms.
Although the description above contains many specificities, these should not be construed as limiting the scope of the embodiments, but providing illustrations of one embodiment. For example, the various components such as the trigger, hammer, disconnectors, selector lever and cam can have different shapes, the trigger can have a separate sear, the secondary disconnector can have alternative means of releasing hammer, etc.
Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given. | One embodiment of a trigger system with an integral selector for semi-automatic firearms. A selector allows the user to choose between two modes and rates of fire. A trigger ( 1 ) is made to allow passage of the lower portion of a selector cam ( 5 ) to the exterior of the firearm. A selector lever ( 6 ) is affixed to the lower end of the selector cam ( 5 ) on the exterior of the firearms action. Turning the selector lever ( 6 ) rotates the selector cam ( 5 ) which tilts a pivotal disconnector ( 3 ) on its axis, varying the amount of disconnector ( 3 ) engagement with a hammer ( 2 ). The variance in the disconnector ( 3 ) engagement causes the firearm to fire in one of two modes, firing one round with a trigger pull and resetting with trigger release, or firing one round with trigger pull, and firing another round with trigger release. Other embodiments are described. | 5 |
This is a continuation of application Ser. No. 681,231 filed Apr. 28, 1976, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a package of the type consisting of an outer supporting covering and a container of pliable material placed therein and intended for liquid, semi-liquid, powdered, semi-solid and solid goods.
BACKGROUND
In U.S. Pat. No. 3,944,127 issued Mar. 16, 1976 packages having a construction in accordance with the above-indicated principle are described. The aforementioned patent discloses a package which is intended for containing goods of one of the above-mentioned types under constant or increasing conditions of pressure.
Previously known packages having an inner flexible container within an outer supporting covering have their containers arranged more or less loosely in the outer containers, so that the emptying of the packages is made difficult. In cases in which the inner container was attached to the outer covering, this attachment was not provided in order to facilitate the emptying of the package. The packages described in the aformentioned patent have, in contradistinction to this, their flexible inner container and outer supporting covering, so developed and secured to each other that the emptying of the packages is facilitated. The concept of facilitated emptying includes, also, the possibility of emptying the stored goods gradually from the package and closing the package again in a simple and effective manner after each removal of the goods.
The reclosing of the packages described in the above-mentioned patent is made possible by the fact that the outer supporting covering of the package is firmly connected to the inner flexible container around the mouth of the opening. A lid of, for instance plastic, which rests tightly against the opening of the outer container, as a result of this design, also closes the inner container.
It is furthermore a characteristic feature of packages in accordance with the above-mentioned patent that the inner containers are filled before they are placed into the outer supporting coverings. In certain cases, it is, to be sure, inadvisable to make use of this method. This may be the case, for instance, when the packages are to be used for storing materials which do not retain their shape, for instance liquids, or when the manufacturer of the material which is to be stored in the packages wishes to utilize for the filling thereof the equipment which he already has and which is designed for filling containers which are already entirely complete.
SUMMARY OF THE INVENTION
The present invention refers to a package which, when filled, has the same properties as the packages described in the patent and the properties of which, upon emptying, are the same as the properties of the containers developed in accordance with the aforementioned applications, the package, however, only being filled after the inner container has been combined with the outer supporting covering.
The package may be of definitely parallelepiped shape and the one wall side may represent the mouth of the package. In this case, the inner container is fastened to the periphery of the mouth in such a manner that one of the sides of the inner container forms a lid disk at the said mouth and can easily be cut with a knife. In this connection, it is desirable for this side of the inner container preferably to have a flat surface without joints, folds, or flaps. The opening of the package is combined with a lid of plastic, for instance, which after the package has been opened seals it tightly. The shape of the mouth may vary. It may, for instance, have completely flat walls or it may be provided with an inwardly directed circumferential flange. In the latter case, it may frequently be advisable to fasten the inner container to such flange. In this way, opening the container is facilitated, particularly when this is effected by cutting the lid disk out with a knife.
It is also characteristic of the invention that the package has such an arrangement that the filling thereof is effected through a part of the package which subsequently represents the bottom of the completed, filled package. In order that the inner container have, within the assembled, closed package, a flat surface in the direction which is subsequently to correspond to the opening portion of the filled package, the inner container is folded together in a special manner. The folding will be explained in detail with reference to the drawings, which form an integral part of the present application. The inner container, after having been folded together, is introduced into the outer supporting cover and fastened to it at the part which corresponds to the mouth portion of the package upon the opening thereof. During the filling, this part, to be sure, represents the bottom of the package. When the inner container has been introduced into the outer supporting cover and fastened therein, the inner container has the shape of an open parallelepiped preferably of flat bottom, with two of its sides provided with a welded joint and flaps extending up from the preferably flat surface on each of the sides provided with joints.
Upon the filling, the package, therefore, consists of an inner container which is surrounded by an outer supporting covering and is fastened to the latter in that part of the package which serves as bottom of the package during the filling. The package is then closed in normal manner by means of a suitable method of folding, employing for instance welding or gluing. The package accordingly does not differ with respect to its method of filling and closing from other known packages and can thus be used with the filling equipment which is normally available. This, of course, is true even in cases in which the package is used for filling with materials which are intended to be kept under vacuum, for instance coffee. It is self-evident that slight adjustments may be necessary when changing to a new format or in the event of a different method of folding. The essential fact in this connection is of course that the basic equipment which is already on hand can always be used.
One advantage of the package is that a relatively cheap material can be used for the outer supporting covering, while a flexible material which is selected with reference to the physical properties required by the goods to be stored is used for the inner container. The use of expensive material is thus limited merely to the inner container.
Another advantage of the package is that the inner container and the outer supporting covering are fastened to each other so that when the package has been emptied the inner container can be easily separated from the outer covering. This facilitates recovery of the material, since different types of material can be easily separated from each other.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be described in further detail with reference to the Figures shown in the drawing, in which:
FIGS. 1 and 2 show various phases during the folding of the inner container, and
FIG. 3 shows an inner container which has been prepared for introduction into an outer supporting covering, and
FIG. 4 shows a complete package with inner container and outer supporting covering, ready to be filled, and
FIG. 5 shows a complete package seen from the bottom--referred to the filling opening--and with the outer covering partially cut away in order to show how the inner container is arranged in the outer covering, and
FIGS. 6 to 8 show an alternative for the enclosing of the inner container in the filling part thereof, and
FIGS. 9 to 11 show another alternative for the closing of the inner container, and
FIG. 12 shows a filled package with its lid being removed from it.
DETAILED DESCRIPTION
In FIG. 1, there can be noted the flexible material 2, which is to be folded together to form an inner container. A punch 1 is partially surrounded by the flexible material. The flexible material can be transparent, for which reason the mandril in the Figure is not concealed by the flexible material. The dimensions and shape of the punch correspond to that of the inner packing which is being produced. The edge portions of the flexible sheet which is to be shaped to form the inner container are designated 3 and 4 and 20 and 21 respectively.
In FIGS. 2 and 3, the numbers 5 and 19 represent longitudinal weld or adhesive seams which connect the edge portions 3 and 4 and 20 and 21 respectively together. The side wall which contains the longitudinal welding seam 5 is marked 11 and the side wall which contains the longitudinal weld seam 19 is marked 23. In the transition between the side walls having the weld seams and the bottom part 8 of the inner container the two weld or adhesive seams 24 and 22 respectively are located. These last two weld seams connect the bottom surface with the two flaps 6 and 7. In FIG. 3 the flaps 6 and 7 have been folded upward against the corresponding side. The inner container in this Figure has the appearance which corresponds to the appearance of the container when it is connected with its outer supporting covering and is ready for the introduction of the goods into it.
In FIGS. 4 and 5 the inner container has been introduced and fastened in the outer packing. In FIG. 4 the assembled package is shown obliquely from above, while in FIG. 5 it is shown obliquely from below. In FIG. 5 the outer packing has furthermore been partially cut away. In the Figures there can be noted the outer supporting covering, which is also referred to as the outer packing 9, with the inwardly directed circumferential flange 10. The inner container is fastened to the inwardly directed circumferential flange of the outer packing adjoining the outer edges of the bottom surface 8. In the package formed in this manner the smooth bottom surface forms a flat lid disk 25 in the manner shown in FIG. 5. The filling opening 12 of the inner container is also shown.
FIGS. 6 to 11 show clearly two different alternative methods of folding, for closing the inner container after the filling. FIGS. 6 to 8 show one alternative, while FIGS. 9 to 11 show the other. In accordance with both alternate method of folding, the closing of the inner container is effected by means of closure welds. In the first alternate method of folding, the weld is designated 17, while in the other alternative it is designated 18. The closure flaps of the outer packing are marked 13, 14, 15 and 16. FIG. 7 contains a detailed view of the folded opening-part of the inner package in accordance with the first method of folding. The folded opening part forms a flange-like upward directed edge 26, which is ready for fastening by welding. The flaps 23 and 28 formed upon the folding are shown in FIGS. 10 and 11.
FIG. 12 shows a filled package and a reclosure lid 19. The lid of the package is shown during its removal.
In order to understand the construction of the inner container, i.e., the manner in which it is folded together, the simplest thing is to effect an imaginary folding together of an inner container. In this connection one proceeds from a sheet of flexible material 2, on which a punch 1 (mandril) is placed. The outer shape of the mandril has the shape of the inner container which is to be produced. Furthermore, the dimensions of the sheet are in accord with the size of the container to be produced. Parts of the sheet are then pulled upward on two sides of the mandril which are opposite each other and vertical in the Figure, in the manner shown in FIG. 1.
In this way a U-like bag is formed from the sheet, the bag being open on top and on both sides, said sides corresponding to the two other opposite sides of the mandril. The vertical parts of the sheet in the Figure, which protrude above the mandril are bent over towards each other so that the edge parts 3 and 4 as well as 20 and 21 meet in such a manner that strips on each side of the edge parts together form a flange which protrudes at right angles from the surface of the mandril and in such a manner that the remaining part of the inner surface of the sheet rests against side surfaces corresponding to this on the mandril. Due to the fact that a flat application is obtained for all the vertical surfaces of the inner container, a fold is obtained on each side along the transition between the vertical surface and the bottom surface of the mandril on the one hand, while, on the other hand, a flap 7 or 6 is formed which protrudes from said fold. The edge parts 3 and 4 as well as 20 and 21 are now welded to each other and the corner welds 22 and 24 are now effected in the fold, i.e., the fold which lies in the transition between the vertical surfaces of the mandril and the bottom surface, in order to stabilize the folds and thus the shape of the container. The two flaps are then swung up on either side and the inner container has the appearance shown in FIG. 3.
An inner container such as shown in FIG. 3 accordingly has a smooth bottom surface 8 which has neither folds nor welds, two vertical sides which are also entirely smooth, as well as two vertical sides on which there are present the longitudinal welds 5 and 19 on the one hand and on the other hand flaps 7 and 6 which have been swung against the sides. The sixth side of the container constitutes its filling opening 12.
In accordance with the invention, an inner container arranged in this manner is introduced into an outer supporting covering 9, in the manner shown in FIGS. 4 and 5. The smooth bottom surface of the inner container is fastened at its edges to the inwardly directed circumferential flange 10 in the outer supporting covering. The smooth bottom surface in this connection forms the flat lid 25.
A composite package developed in this manner has a filling opening for the inner container which does not differ upon its filling from known filling openings of packages. After the filling, the inner package is closed by folding the opening part and then welding. FIGS. 6 to 8 show examples of a method of folding which can be used in this connection. FIGS. 9 to 11 show an alternative method of folding.
In the first method of folding, two of the sides of the opening of the inner container are first of all moved inwards, whereupon the other two sides are also brought against each other, in the manner shown in FIG. 6. The inward-folded sides are preferably the sides which do not have a vertical weld seam. It is assumed that the inner container is filled with material of relative stable shape. By adjusting the required folding apparatus in suitable manner, the result is obtained that the folded filling part of the inner container as a whole forms a flat surface parallel to the surface of the lid disk. From this surface there extends a flange-like strip 26, in the manner shown in FIG. 7. The closing of the inner package is then effected by, for instance, welding or gluing the strip. After the flange has been attached, it is bent over against the flat surface which has been formed over the material in the package, and the inner package has then the appearance shown in FIG. 8. The flaps 13-16 of the outer packing can then be folded over each other, for instance in the manner shown in FIG. 8, and are thereupon fastened to each other. This part of the package is thus complete.
In the other folding method, which is preferable in the case of vacuum packing, two of the sides of the opening part of the inner packing are pulled apart in the manner shown in FIG. 9. In this way the opening part of the inner packing will assume the appearance shown, by way of example, in FIG. 10. The opening part of the inner packing is welded, obtaining the seal designated 18 in FIG. 10. The flaps 27 and 28 are bent over--see FIG. 11--whereupon the flaps 13-16 of the outer packing are folded over each other and fastened to each other and this part of the packing is then complete.
At this point, it should be pointed out that welding of the inner container by the alternative last described simplifies some of the problems inherent in obtaining a tight seal. Normally, in the previously known packings the folding together is effected in such a manner that one obtains a varying number of overlapping layers of wall material in the region of the joint. Upon, for instance, connection by a weld, the welding devices are thereby compelled to take up large differences in thickness in the region of the seal. This is made possible by the fact that the weld jaws yield somewhat, due to ample use of weld material, so that said material flows out everywhere, and/or by profiling the region of the weld. When welding in accordance with the second alternative of the invention, all such variations of thickness in the region of the weld are avoided, since there are no folds or double-folds of the layers of sheet to be connected. In this way demands made on the equipment which is to effect the joining are reduced and, at the same time, the possibilities of obtaining a tight connection are increased.
The opening part of the assembled package which has been closed for instance by one of the alternatives described above, thereupon forms the bottom part of the filled package. The opening part for the filled package consists of the smooth lid disk described above, together with the surrounding parts of the supporting covering. The package will in the future be used normally in the position shown in FIG. 12. A lid 29 is placed on the opening part, protecting it from damage. The lid is held in its seat on the one hand by the fact that it fits by friction in the opening of the outer cover and on the other hand by the fact that, for instance, a sealing strip is fastened over it.
Upon the opening of the package, the sealing strip is torn open, the lid is removed, and the flat lid disk is cut out. If the package is only partially emptied, it can be closed again by means of the lid 16. In this way the package is imparted properties similar to a can. However it is substantially cheaper to manufacture than previously known containers of can type.
As suitable material for use for the inner container as well as the outer covering, there may be used paper board, cardboard, plastic, metal, or the like, as well as combinations of such materials. In those cases in which the material is used for the inner container it must however be flexible, while if used for the outer supporting cover it should be stiff.
The packings described in Swedish patent application Nos. 73 126 83-1 and 73 126 84-9 refer to packings which are developed in a manner corresponding to the development of the packing in accordance with the present description. The inner container of the packings in accordance with said applications are, to be sure, filled with their material before they are placed in the outer supporting covers. Upon the filling they have a tubular shape, after which they are so closed by means of suitable members that the filled inner container has the same geometrical shape as the outer cover. The packing described in the present specification is filled after its inner container has been fastened in the outer cover. Due to the different methods of filling the packings, the packing described in the present application requires a folding together and thus a construction which differs fundamentally from the method of folding, and thus the construction of the aforementioned packings.
In the new packing described here, two of the edge flaps 6 and 7 are folded against two of the side surfaces of the inner packing. This results in a stiffening effect for both the inner packing and the combined packing. In particular the stiffening of the inner packing facilitates the handling of the package when empty. In certain uses, due to the stiffening, a thinner cardboard can be used.
One advantage of the container of the invention is that the re-closure lid does not extend out from the outer walls of the package. In this way, the space available on pallets and in containers is optimally utilized.
In cases in which foil is used for the inner container, the smooth lid disk in the opening part of the package affords the possibility of seeing the content of the package. This may constitute valuable information from the standpoint of the consumer, when considering the purchase of a given article.
The smooth lid disk in the opening part of the container can be provided with figures and writing, giving information, for instance, as to the composition of the goods, how to open the package, etc., or serving merely for decorative purposes. It can also be provided with perforations or other intended tear points, which facilitate the removal of the lid disk.
In the above description it has been stated that the inner container is to have a smooth, joint-free surface for the side walls which the inner container holds directed towards the opening part of the composite package. It is obvious that the inventive concept--namely the combining of an outer supporting cover with a flexible container arranged therein which is filled after the inner container has been fastened in the outer cover--may also comprise other foldings of the inner container. As a result of such other foldings, it may be that the opening part of the inner container no longer has a smooth joint-free surface. Such a folding of the inner container, however, means that the opening part is normally less attractive in appearance and at the same time it is made somewhat difficult to cut open the inner container.
In certain cases of use, it is desirable to facilitate the removal of the lid disk after it has been cut out from the inner container. This can be done by fastening a special grip device to said lid disk. Such a grip device may also be provided together with a perforation of the lid disk, this perforation, facilitating the cutting open of the lid disk or representing a part of an easy-opening device for the lid disk. In certain embodiments, the alternative methods of folding mentioned in the preceding paragraph can be developed in such a manner with a joint lying in the lid disk that the joint can be used as gripping device for the removal of the lid disk after it has been cut out.
In the above description, it has been assumed that the inner container is made of a separate sheet of foil which has been cut to the dimensions of the inner container. It is obvious that this sheet can also be cut to shape upon the initial part of the folding of the container. In this case, the material for the inner container is accordingly removed for instance from a roll of foil material. It is also possible for the inner container to consist of a plurality of sheets or blanks.
It has furthermore been assumed in the description that the folding of the inner container is fixed by means of a number of weld seams. Obviously these attachments can be replaced by fixing with, for instance, glue.
The invention has been described as a combination of an inner container and an outer supporting cover. It is obvious that inner containers which have been folded to shape and fixed as described above, can be used without being combined with an outer supporting cover. This is true if the containers have been made of flexible material and also when they have been made of a stiffer material. | There is disclosed a package or wrapping for powderized material such as ground coffee. The package consists of a substantially rigid outer container and an inner liner or liner made of plastic or other pliable material. The goods to be packaged are placed in the inner liner, the shape of which is so that it substantially fits the container when filled. The container has on one side an opening which can be closed by a cover and the inner liner when placed in the container has on its side facing the container opening a flat closure. The liner may be secured to the container along a flange adjacent to the container opening. | 1 |
BACKGROUND
1. Technical Field
The disclosure relates to a camera module.
2. Description of the Related Art
Current camera modules typically include an image sensor chip, a substrate, a number of gold wires, an encapsulation glass, and a lens module. The image sensor chip is disposed on the substrate and electrically connected to the substrate via the gold wires. The encapsulation glass encapsulates the image sensor chip and the gold wires. The lens module is installed on the substrate via adhesive layer, enclosing the image sensor chip, the gold wires, and the encapsulation glass. The problem is, during installing the lens module to the substrate, the adhesive layer is pressed and it spreads to the immediate area of the lens module on the substrate, contaminating the substrate. In addition, the adhered area of the lens module is limited to the bottom surface thereof, which is typically not adequate to provide reliable long term adherence.
What is desired is a camera module that can overcome the above-described problems.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the present camera module is better understood with reference to the accompanying drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the camera module. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a schematic, cross-sectional view of a camera module, according to a first exemplary embodiment.
FIG. 2 is a schematic, cross-sectional view of a camera module, according to a second exemplary embodiment.
FIG. 3 is a schematic, cross-sectional view of a camera module, according to a third exemplary embodiment.
DETAILED DESCRIPTION
Embodiments of the present camera module will now be described in detail with references to the drawings.
Referring to FIG. 1 , a camera module 100 , according to a first exemplary embodiment, includes an image sensor chip 10 , a substrate 20 , an adhesive layer 30 , a number of conductive wires 35 , a lens module 40 , and a transparent cover 50 .
The image sensor chip 10 can be a charged coupled device (CCD) or a complementary metal-oxide-semiconductor (CMOS). The image sensor chip 10 includes a top surface 11 and a bottom surface 13 facing away from the top surface 11 . The image sensor chip 10 has a photosensitive area 12 formed on the center of the top surface 11 , and a non-photosensitive area 14 surrounding the photosensitive area 12 . The non-photosensitive area 14 has a number of chip pads 101 formed thereon.
The substrate 20 can be made of a material such as: polyimide, ceramic, or glass fiber. The substrate 20 has a supporting surface 22 . The bottom surface 13 of the image sensor chip 10 is adhered to the supporting surface 22 via the adhesive layer 30 . The adhesive layer 30 can be made, for example, from silicone, epoxy, acrylic, or polyamide.
A number of base pads 201 are disposed on the supporting surface 22 of the substrate 20 . Each base pad 201 can be electrically connected to a corresponding chip pad 101 via a conductive wire 35 . The conductive wires 35 can be made of a conductive material, such as gold, silver, aluminum, or an alloy thereof.
Alternatively, the image sensor chip 10 may be mechanically and electrically connected to the substrate 20 by available package processes, such as, chip-scale, wafer-level chip-scale, ceramic leaded, plastic leadless chip, thermal compression bonding, and flip chip packaging processes.
The lens module 40 is aligned with the image sensor chip 10 . The lens module 40 includes a lens barrel 42 , a lens holder 44 , and lens group 46 . The lens holder 44 comprises a top hollow cylinder 441 , a bottom hollow cylinder 442 coaxially aligned with and communicated with the top hollow cylinder 441 , and a connecting plate 443 connecting the top hollow cylinder 441 and the bottom hollow cylinder 442 . The lens group 46 is received in the lens barrel 42 . The combined lens barrel 42 and lens group 46 are received in the top hollow cylinder 441 . The image sensor chip 10 is received in the bottom hollow cylinder 442 . The bottom hollow cylinder 442 comprises a bottom surface 445 contacting with the substrate 20 , and an outer sidewall 446 . The bottom surface 445 defines a sloped surface 4421 extending from the bottom surface 445 to the outer sidewall 446 . The bottom surface 445 and the sloped surface 4421 define an angle therebetween. The angle, in this embodiment, is greater than 30 degrees. A gap 4422 is defined between the substrate 20 and the sloped surface 4421 of the bottom hollow cylinder 442 of the lens holder 44 .
The gap 4422 is filled with the adhesive layer 30 . The lens module 40 is disposed on the supporting surface 22 of the substrate 20 via the adhesive layer 30 .
The lens barrel 42 comprises a lower surface 422 facing the image sensor chip 10 . The transparent cover 50 , such as an infrared filter, is provided between the image sensor chip 10 and the lens group 46 and is configured for protecting the photosensitive area 12 from contamination and filtering light from the lens group 46 . The transparent cover 50 is secured to the lower surface 422 of the lens barrel 42 by the adhesive layer 30 . Alternatively, the transparent cover 50 may be directly fixed to the lens module 40 . Alternatively, the transparent cover 50 can be fixed to the inner surface of the connecting plate 443 . The transparent cover 50 may be an optical glass plate.
In assembly, the adhesive 30 is disposed on the supporting surface 22 of the substrate 20 , when the lens module 40 is assembled on the substrate 20 , the adhesive layer 30 flows into the gap 4422 of the lens holder 44 and contacts with the sloped surface 4421 , which prevents the adhesive layer 30 from overflowing on to the substrate 30 . In addition, the contact area between the adhesive layer 30 and the bottom surface 445 of the lens holder 44 may have complimentary patterns formed therein to increase contact area, thereby, bonding strength between the lens module 40 and the substrate 20 is stronger.
Referring to FIG. 2 , a camera module 200 in accordance with a second exemplary embodiment is disclosed, differing from the camera module 100 only in the lens holder 64 . In this embodiment, the bottom hollow cylinder 642 comprises an inner sidewall 647 facing away the outer sidewall 646 . The bottom surface 645 defines an sloped surface 6441 extending from the bottom surface 645 to the inner sidewall 647 . The bottom surface 645 and the sloped surface 6441 defines an angle therebetween, which in this embodiment, is greater than 30 degree. A gap 6442 is defined between the substrate 70 and the sloped surface 6441 of the bottom hollow cylinder 642 of the lens holder 64 . In this embodiment, the gap 6442 is triangular in shape.
Referring to FIG. 3 , a camera module 300 in accordance with a third exemplary embodiment is disclosed. In this embodiment, the profile of the bottom surface 945 of the lens holder 94 is “V” shaped but is not limited in that configuration. The bottom surface 945 is square shaped, and defines an inner sloped surface 951 extending from the bottom surface 945 to the inner sidewall 941 , and an outer sloped surfaces 952 extending from the bottom surface 945 to the outer sidewall 942 . A first gap 97 is defined between the substrate 96 and the inner sloped surface 951 . A second gap 98 is defined between the substrate 96 and the outer sloped surface 952 . It should note that, the bottom surface 945 of the lens holder 94 can also define a trapeziform gap for accommodating the adhesive layer 95 . Because the profile of the bottom surface 945 is “V” shaped, when the adhesive layer 95 disposes between the bottom surface 945 and the substrate 96 , which not only prevents the adhesive layer 95 from overflowing on to the substrate 96 , but also increases the amount of surface contact between the substrate 96 and the bottom surface 945 via the adhesive 95 .
It will be understood that the above particular embodiments and methods are shown and described by way of illustration only. The principles and the features of the disclosure may be employed in various and numerous embodiment thereof without departing from the scope of the invention as claimed. The above-described embodiments illustrate the scope of the invention but do not restrict the scope of the invention. | An camera module includes a substrate, an image sensor chip, and a lens module. The image sensor chip is disposed on and electrically connected to the substrate. The lens module is mounted on the base via an adhesive layer. The lens module includes a bottom surface contacting with the substrate. The bottom surface defines at least one sloped surfaces thereon. At least one gap is defined between the substrate and the at least one sloped surface. The adhesive layer is disposed between the bottom surface and the substrate, the gap is capable of accepting adhesive when the lens module and substrate are pressed together. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a 35 U.S.C. §371 National Phase conversion of PCT/FR2011/051140, filed May 19, 2011, which claims benefit of French Application No. 1053856, filed May 19, 2010, the disclosures of which are incorporated herein by reference. The PCT International Application was published in the French language.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to novel organic compounds, to their processes of preparation and to their uses, on the one hand in the field of electronics, in particular in the fields of “plastic electronics” and “molecular electronics” and, on the other hand, in the field of coatings, in particular in the fields of adhesive primers and intelligent coatings.
The invention also relates to a material comprising a novel compound according to the invention.
In the description below, the references between square brackets [ ] refer to the list of references which is presented at the end of the text.
2. Related Art
For several years, research targeted at developing novel organic compounds, in the form of a crystal or of a polymer, for example, which show similar properties to inorganic compounds has continued to expand. These properties are conduction by electrons and holes, and the presence of a forbidden band. Furthermore, research targeted at developing novel functional coatings is also very active. By virtue of their elasticity, their lightness, their strength and their plasticity, organic molecules are of great interest due in particular to the extent of their fields of application in electronics or also as functional coatings.
Unlike materials based on inorganic compounds (inorganic materials), such as silicon, for example, materials based on organic molecules (organic materials) exhibit the advantage of being able to be deposited and/or grafted, in the form of thin films or layers, by relatively inexpensive techniques, on flexible and light substrates which are conducting or insulating.
Furthermore, like inorganic materials, organic materials can be doped, that is to say the density of the electrons (N doping) or of the holes (P doping) can be increased therein.
The immobilization of organic compounds, for example in the form of a polymer, on insulating, metal, semiconducting or carbon-based substrates makes it possible to develop novel interfaces for applications which can range from the manufacture of molecular or plastic electronic devices, biosensor systems, corrosion-resistant coatings, to intelligent coatings.
The formation of thin films or layers resulting from the grafting or deposition of organic molecules or polymers at the surface of the substrates makes it possible both to maintain the properties of the substrates and to confer, at the surface of the material, novel and distinct properties. One of the particular advantageous properties is in particular the ability to switch between different electrical conduction states. The nature of the organic compounds can determine the electric potential at which the layer switches.
At the current time, the existing organic compounds capable of forming deposited or grafted layers at the surface of the substrates are not entirely satisfactory for at least one of the following reasons:
they are not suitable for all types of substrates in the sense that they cannot form thin films or layers by grafting or deposition on all types of substrate; the layer(s) formed are not always homogeneous (in particular in thickness), which can affect the quality and the properties of the layer and of the substrate on which it is deposited or grafted and of the interface between the substrate and the layer or layers and thus the quality of the material or devices using these layers; the number of layer(s) deposited or grafted cannot be adjusted, which can result in films which are either too thin or too thick, and can thus affect the quality and the properties of this layer, of the substrate on which said layer is deposited or grafted and of the interface and consequently the quality of the material or devices using these layers; the nature of the interface between the substrate and the layer is not always controlled, which can result in layers which do not adhere strongly and/or in an interface exhibiting hole- or electron-injection barriers which are insufficient for the uses targeted, and can affect the quality of the devices using these layers; the layer or layers formed often exhibit defects of micronic or subnanometric size which are harmful to the quality of the layer, of the substrate on which it is deposited or grafted and of the interface and consequently the quality of the material or devices using these layers; although grafted to the substrate, the layer or layers formed are not always electroactive, which can result in properties which cannot be adjusted via an electrochemical or electrical stimulus (electron- or hole-injection, for example) and can thus affect the quality of the devices using these layers; although grafted to the substrate, the electroactive layer or layers formed do not always switch between two states having different conduction properties; the electroactive layer or layers formed do not always switch between two states having different conduction properties at the electric or electrochemical potential desired, which can affect the quality of the devices using these layers; the use of the organic compounds and/or the formation of organic polymers can present technical problems, in particular in terms of reproducibility and/or operating on the industrial scale.
The need to have available novel organic compounds capable of forming one or more electroactive layers which can switch between an insulating state and a conducting state at the surface of various types of substrates, overcoming the failings, disadvantages and obstacles of the state of the art, remains topical.
There thus exists a real need to have available novel organic compounds which are compatible with any type of substrate and which are capable of forming one or more layer(s) at their surface.
There also exists a real need to provide novel organic compounds, the use of which and/or the formation of polymers of which is easy and reproducible, can be carried out industrially and is economically advantageous.
DESCRIPTION OF EMBODIMENTS
It is a specific aim of the present invention to meet these needs by providing compounds of formula (I):
in which:
R 1 represents a hydrogen atom, a halogen atom, a hydroxyl group, a C 1 -C 4 alkoxy group, a —COOR 3 group, a —COR 3 group, an —SR 3 group, an —SeR 3 group, an —Si(OR) 3 group, an —NR 3 R 4 group, a —C≡N group, an —N 3 group, a —C≡C—H group, a heterocycle chosen from the group consisting of pyrrole, furan, phosphole, thiophene, tetrathiafulvalene, selenophene, imidazole, oxazole, thiazole, triazole, pyrazole, pyridine, bipyridine, terpyridine, phenanthroline, pyrazine, pyridazine and pyrimidine, ferrocene, cobaltocene, a polyethylene group of formula —(—O—CH 2 —CH 2 —) p— , a C 1 -C 10 alkyl group and a phenyl group, said polyethylene, alkyl, phenyl and heterocycle groups being optionally substituted by one or more groups chosen from the group consisting of: a —COOR 3 group, a —COR 3 group, a hydroxyl group, a C 1 -C 4 alkoxy group and a —CONR 3 R 4 group; R 2 represents an amino (—NH 2 ) group, a diazo (N 2 + ) group, an aniline group, a phenyl group substituted by a diazo (N 2 + ) group, an —NO 2 group or a phenyl group substituted by an —NO 2 group; optionally substituted by one or more groups chosen from a C 1 -C 4 alkyl group, a —COOR 3 group, a —COR 3 group, a hydroxyl group, a C 1 -C 4 alkoxy group, a —CONR 3 R 4 group, an —NO 2 group or an —NR 3 R 4 group; Z represents thiophene, optionally substituted by one or more groups chosen from the group consisting of:
a C 1 -C 10 alkyl group, a carboxyl group, a —COOR 3 group, a hydroxyl group or a C 1 -C 4 alkoxy group;
R 3 and R 4 represent, independently of one another, a hydrogen atom, a C 1 -C 6 alkyl group or a phenyl group; n=1, 2, 3, 4 or 5; m=0, 1, 2 or 3; p=0, 1, 2, 3, 4 or 5;
it being understood that, when R 1 represents a hydrogen atom and m=0, then n is other than 1.
The compounds of formula (I) have the advantage of being compatible with any type of substrate and can form one or more layer(s) at their surface. The formation of said layer(s) at the surface of the substrate can be carried out by deposition of or by grafting the compounds of formula (I). Within the meaning of the invention, the term deposition is understood to mean the formation of one or more layers at the surface of a substrate by oxidation of the compounds of formula (I). The term grafting is understood to mean the formation of one or more layers at the surface of a substrate by reduction of said compounds of formula (I), namely: attachment of the compounds to the substrate in an essentially covalent way.
Thus, the compounds of formula (I) can adhere to the substrates by grafting. Grafting can be carried out by means of any type of bond which makes possible good adhesion of said compounds to the substrate, for example by means of strong bonds.
The term “alkyl” is understood to mean, within the meaning of the present invention, a saturated and linear, branched or cyclic carbon-based group which is optionally substituted and which comprises from 1 to 10 carbon atoms, for example from 1 to 6 carbon atoms, for example from 1 to 4 carbon atoms. Mention may be made, by way of indication, of the methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, cyclobutyl, pentyl (or amyl), sec-pentyl, isopentyl, neopentyl, hexyl, isohexyl, tert-hexyl, neohexyl, heptyl, octyl, nonyl or decyl groups and their branched and/or cyclic isomers.
The term “heterocycle” is understood to mean, within the meaning of the present invention, a system comprising at least one aromatic ring or one saturated or unsaturated ring comprising at least one heteroatom chosen from the group consisting of sulfur, oxygen, nitrogen and phosphorus. In the context of the invention, the heterocycles can comprise from 3 to 20 carbon atoms. The heterocycles can be substituted. Mention may be made, as examples of heterocycles, of pyrrolidine, pyrazoline, pyrazolidine, imidazole, imidazolidine, piperidine, piperazine, oxazolidine, isoxazolidine, morpholine, thiazole, thiazolidine, isothiazolidine, tetrahydrofuran, pyridine, bipyridine, terpyridine, pyridazine, pyrazine, pyrimidine, pyrrole, pyrazole, triazole, imidazoline, thiazoline, oxazole, oxazoline, isooxazoline, thiadiazoline, oxadiazoline, thiophene, furan, quinoline, isoquinoline, benzopyrrole, benzofuran, benzothiophene, phosphole, tetrathiafulvalene, selenophene, phenanthroline and similar groups.
The term “alkoxy” is understood to mean, within the meaning of the present invention, a saturated and linear, branched or cyclic alkyl group which is optionally substituted and which is bonded to an oxygen atom. For example, an alkoxy radical can be a methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, tert-butoxy, neopentoxy or n-hexoxy radical or a similar radical.
The term “aryl” group is understood to mean an aromatic hydrocarbon which is optionally substituted. For example, an aryl group can be a phenyl group, a benzyl group, a tolyl group, a xylyl group or vinylbenzene.
Within the meaning of the invention, the halogen atom can be chosen from the group consisting of fluorine, chlorine, bromine and iodine.
The term “substituted” denotes, for example, the replacement of a hydrogen atom in a given structure by a group as defined above. When more than one position can be substituted, the substituents can be the same or different at each position.
In the context of the present invention, the term “to switch” is understood to mean the alternation between the nonconducting (or insulating) reduced state and the conducting oxidized state of the organic compounds according to the invention.
Within the meaning of the invention, the term “polymer” means a sequence of at least two identical or different and natural or synthetic compounds. This sequence can be linear or branched. The term “polymer” encompasses oligomers and homopolymers as well as copolymers.
Within the meaning of the invention, the term “electroactive or electroactivity” denotes a state where an exchange of electrons takes place. More particularly, an electroactive layer denotes a layer capable of alternating between two different conduction states, in particular between the nonconducting (or insulating) reduced state and the conducting oxidized state.
According to a first embodiment of the invention, the compounds of the invention can be of formula (I) in which: R 1 represents a hydrogen atom or thiophene; R 2 represents the amino (—NH 2 ) group or the aniline group; Z represents thiophene; n=1, 2 or 3; m=0 or 1; it being understood that, when R 1 represents a hydrogen atom and m=0, then n is other than 1. The compounds according to the first embodiment are particularly advantageous since they are capable of forming layers or films on substrates by grafting. This makes it possible to obtain a layer exhibiting both the switching nature between an insulating state and a conducting state, and very good adhesiveness on the substrate.
According to a second embodiment, the compounds of the invention can be of formula (I) in which: R 1 represents a hydrogen atom or thiophene; R 2 represents the aniline group, the phenyl group substituted by the diazo (N 2 + ) group or the phenyl group substituted by the —NO 2 group; Z represents thiophene; n=1, 2 or 3; and m=0 or 1; it being understood that, when R 1 represents a hydrogen atom and m=0, then n is other than 1. The compounds according to the second embodiment make it possible to form, either by grafting or by deposition on any type of substrate, thin films or layers having the ability to switch.
According to the invention, it is preferable, when m=0, for n to be other than 1.
According to an advantageous alternative form of the invention, R 1 represents a hydrogen atom; R 2 represents the aniline group; n=2; and m=0. It thus concerns 2-(4-aminophenyl)-3,4,3′,4′-bis(ethylenedioxy)-5,2′-bithiophene (2EB).
According to another advantageous alternative form of the invention, R 1 represents thiophene; R 2 represents the aniline group; n=1; and m=0. It thus concerns 2-(4-aminophenyl)-3,4-ethylenedioxy-5,2′-bithiophene (TEB).
According to an advantageous alternative form of the invention, R 1 represents a hydrogen atom; R 2 represents the aniline group; Z represents thiophene; n=1; and m=1. It thus concerns 2-(4-aminophenyl)-3′,4′-ethylenedioxy-5,2′-bithiophene (ETB).
According to an advantageous alternative form of the invention, R 1 represents a hydrogen atom; R 2 represents the aniline group; n=3; and m=0. It thus concerns 2-(4-aminophenyl)-3,4,3′,4′,3″,4″-ter(ethylenedioxy)-5,2′,5′,2″-terthiophene (3EB).
Surprisingly, when the thin films or layers are formed from the compounds 2EB, TEB, ETB or 3EB, it is possible to obtain better adhesion to the substrate while retaining the ability to switch between an insulating state and a conducting state.
The compounds according to the invention offer several advantages in comparison with the organic compounds conventionally used. As already indicated, the compounds according to the invention can form one or more layers or films which can be grafted to or deposited on any type of substrate, whether insulating or conducting and rigid or flexible. The thickness of these layers or films can be adjusted according to the nature of the organic compounds and/or according to whether they are deposited or grafted. Thus, the thickness of these layers or films can be, for example, between 1 and 100 nm, for example between 1 and 20 nm, for example between 1 and 5 nm, when it concerns grafting by a reduction reaction of the organic compounds of the invention (reductive route), but can also be between 10 nm and 1000 nm, for example between 1 nm and 10 000 nm, for example between 1 and 1000 nm, for example between 1 and 100 nm, when it concerns deposition by an oxidation reaction of said compounds (oxidative route).
These layers, which advantageously have a homogeneous thickness, have the property of being electroactive and of switching between an insulating state and a conducting state. As indicated, the formation of these layers can take place by the reductive route or by the oxidative route. The bond between the surface of the substrates and the compounds of the invention can be strong in nature (grafting by reduction) or weaker in nature (deposition by oxidation). Whether grafted or deposited, said layers have good adhesion to the surface of the substrate. However, when the formation of the layers takes place by grafting, the adhesion of said layers to the substrates is better. The compounds according to the invention thus make it possible to control the interface between the substrate and the layer or film. In the case of grafting by reduction, the grafted molecules result in films exhibiting an ability to switch between an insulating state and a conducting state which is comparable to that which is observed with known conventional organic compounds obtained by oxidative deposition. However, unlike the organic compounds of the state of the art, the compounds of the invention make it possible to significantly adjust the electric potential window which makes possible this switching while making possible strong grafting to the substrate. The switching potential of these layers can lie, for example, between −0.5 volt and +1 volt, for example between −0.3 volt and +1 volt, for example between 0 volt and +1 volt and between 0 volt and +0.5 volt, versus a calomel electrode.
According to a third embodiment of the invention, the compounds of the invention can be of formula (I) in which: R 2 represents the —NO 2 group or the phenyl group substituted by the —NO 2 group. These compounds can operate not only as plastic electronic compound but also as intermediate compound for 2EB, TEB, ETB and 3EB.
According to a characteristic of the invention, R 1 represents a hydrogen atom; R 2 represents the —NO 2 group or the phenyl group substituted by the —NO 2 group; n=2; and m=0.
According to a characteristic of the invention, R 1 represents thiophene; R 2 represents the —NO 2 group or the phenyl group substituted by the —NO 2 group; n=1; and m=0.
According to a characteristic of the invention, R 1 represents a hydrogen atom; R 2 represents the —NO 2 group or the phenyl group substituted by the —NO 2 group; Z represents thiophene; n=1; and m=1.
According to a characteristic of the invention, R 1 represents a hydrogen atom; R 2 represents the —NO 2 group or the phenyl group substituted by the —NO 2 group; n=3; and m=0.
The invention also relates to the processes for the preparation of the compounds according to the invention.
According to a first alternative form, the invention relates to a process for the preparation of a compound of formula (I) in which a halogenated compound of formula (II) is reacted with a compound of formula (III) in the presence of at least one palladium catalyst in order to obtain the compound of formula (I):
With Z, R 1r n and m as defined above;
Hal represents a halogen atom; T represents a hydrogen atom or a —B(OR′)(OR″) group, in which:
R′ and R″ represent, independently of one another, a hydrogen atom, a C 1 -C 6 alkyl group or an aryl group chosen from the group consisting of benzyl, phenyl, tolyl and xylyl, or R′ and R″ together form a 5- or 6-membered ring optionally substituted by one or more C 1 -C 4 alkyl groups;
X represents an —NO 2 group or a phenyl group substituted by an —NO 2 group.
According to a second alternative form, the invention relates to a process in which a halogenated compound of formula (II) is reacted with a compound of formula (III) in the presence of at least one palladium catalyst in order to obtain the compound of formula (IV), which compound (IV) provides the compound (I) after reduction:
with Z, R 1 , n and m as defined above;
Hal represents a halogen atom; T represents a hydrogen atom or a —B(OR′)(OR″) group, in which:
R′ and R″ represent, independently of one another, a hydrogen atom, a C l -C 6 alkyl group or an aryl group chosen from the group consisting of benzyl, phenyl, tolyl and xylyl, or R′ and R″ together form a 5- or 6-membered ring optionally substituted by one or more C 1 -C 4 alkyl groups;
X represents an —NO 2 group or a phenyl group substituted by an —NO 2 group,
it being understood that, when X is the —NO 2 group, R 2 represents an amino (—NH 2 ) group and, when X is the phenyl group substituted by an —NO 2 group, R 2 represents an aniline group.
In both alternative forms, the reaction of the halogenated compound (II) with the compound of formula (III) can be carried out in the presence of a palladium (Pd) catalyst.
The palladium catalyst can be chosen from the group consisting, for example, of tetrakis(triphenyl-phosphine)palladium(0), 1,2-bis(diphenylphosphino)ethane]palladium(0), palladium(II) acetate, palladium(II) propionate, palladium(II) chloride, palladium(II) bromide, palladium(II) acetylacetonate, di(benzylidene acetate)palladium(0), palladium-on-charcoal and palladium-on-alumina.
Said reaction can be carried out in a polar solvent or a mixture of polar solvents chosen from the group consisting, for example, of N,N-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), acetonitrile, ethyl acetate, triethylamine, pyridine, diethyl ether, THF, diglyme, triglyme, dichloromethane, chloroform, acetone and butanone.
In both alternative forms, the reaction of the halogenated compound (II) with the compound of formula (III) can also be carried out in an ionic liquid chosen from ionic liquids comprising an imidazolium, such as, for example, 1-n-butyl-3-methylimidazolium tetrafluoroborate.
Said reaction can be carried out in the presence of a base chosen from the group consisting, for example, of sodium carbonate, potassium carbonate, cesium carbonate, sodium hydrogencarbonate, potassium hydrogencarbonate, triethylamine, potassium phosphate, silver oxide, sodium tert-butoxide, potassium tert-butoxide, sodium hydroxide, potassium hydroxide, barium hydroxide, cesium fluoride and sodium ethoxide.
The compound (II) reacts with the compound (III) at a temperature of at least 20° C., for example between 40° C. and 140° C., for example between 60° C. and 120° C.
The duration of said reaction varies according to the compounds of formulae (II) and (III), to the palladium catalyst and to the solvent used. It can range from a few minutes to several days. It can range, for example, from 30 minutes to 5 days, for example from 1 hour to 3 days.
In the first alternative form, the compound (I) is obtained on conclusion of the reaction of the compound (II) with the compound (III) and can be used as is or after purification by known methods.
In the second alternative form, the compound of formula (IV) is obtained on conclusion of the reaction between the compounds of formulae (II) and (III). The compound (I) can then be obtained after reduction of said compound of formula (IV).
The reduction of the compound of formula (IV) can be a hydrogenation reaction. The hydrogenation catalyst is advantageously chosen from palladium, rhodium or nickel catalysts, such as, for example, the Lindlar catalyst, palladium-on-charcoal, palladium-on-calcium carbonate, palladium-on-alumina, palladium hydroxide-on-charcoal, palladium(II) acetate, palladium(II) propionate, palladium(II) chloride, palladium bromide, the Wilkinson catalyst and Raney nickel.
The reduction can also be carried out using a hydride. The hydride can be a hydride chosen from the group consisting of AlH 3 /AlCl 3 , sodium dihydro(trithio)borate (NaBH 2 S 3 ) and NaBH 4 catalyzed by NiCl 2 (PPh 3 ) 2 or CoCl 2 .
The reduction can also be carried out by the action of a metal in an acidic medium. The metal can be zinc, tin or iron. The acid can, for example, be sulfuric acid, hydrochloric acid or nitric acid.
The reduction of the compound of formula (IV) can also be carried out by the action of hydrazine in the presence of a catalyst. The catalyst can advantageously be chosen from catalysts comprising palladium, nickel, iron, zinc or carbon.
Still in the second alternative form, the compound (I) can be obtained after reduction of said compound of formula (IV), for example, by the action of the triirondodecacarbonyl complex [Fe 3 (CO) 12 ] in an alcoholic medium. The alcoholic medium can be an alcohol or a mixture of alcohols chosen, for example, from methanol, ethanol or isopropanol.
The reduction of said compound of formula (IV) can also be carried out by the action of sulfides. The sulfide can be chosen from sodium hydrosulfide, ammonium sulfide or polydisulfide.
The reduction can in addition be carried out electrochemically in an acidic medium or in a micellar medium; among the surfactants used can be anionic, cationic or neutral in nature.
The reduction reaction of the compound of formula (IV) to result in the compound (I) can be carried out in a suitable solvent or a mixture of suitable solvents chosen from the group consisting, for example, of water, hydrazine, methanol, ethanol, isopropanol, methanoic acid, acetic acid, THF, dichloromethane, chloroform, carbon tetrachloride, N,N-dimethylformamide (DMF), ethyl acetate, benzene, toluene and dioxane.
The reduction reaction is advantageously carried out at the reflux temperature of the solvent or mixture of solvents.
The duration of the reduction reaction can vary and can range, for example, from 30 minutes to 6 hours.
The compound of formula (I) obtained on conclusion of the reduction can be used as is or can be purified by known purification processes.
The halogenated compounds of formula (II) can be prepared by any suitable halogenation process which makes possible the halogenation of a compound of formula (V):
in which Z, m and X are as defined above.
The halogenation reaction can be carried out by the action of a halogenating agent chosen from the group consisting, for example, of N-chlorosuccinimide, N-bromosuccinimide, N-iodosuccinimide, chlorine, bromine, iodine, sulfuryl chloride, hypochlorous acid, hydrobromic acid, magnesium bromide and magnesium iodide.
The halogenation reaction can be carried out in the presence of a metal chosen from the group consisting, for example, of zinc, mercury oxide and mercury acetate.
The boronic esters of formula (VIII) correspond to the compounds of formula (III) in which T represents a —B(OR′)(OR″) group. When said boronic esters of formula (VIII) are not commercially available, they can be prepared, for example, by a process in which a compound of formula (VI) is reacted with a borate of formula (VII):
in which R 1 and n are as defined above;
R′″ represents a hydrogen atom, a C 1 -C 6 alkyl group or an aryl group chosen from the group consisting of benzyl, phenyl, tolyl and xylyl; R′ and R″ represent, independently of one another, a hydrogen atom, a C l -C 6 alkyl group or an aryl group chosen from the group consisting of benzyl, phenyl, tolyl and xylyl, or R′ and R″ together form a 5- or 6-membered ring optionally substituted by one or more C 1 -C 4 alkyl groups.
The reaction between the compounds of formulae (VI) and (VII) can be carried out at a temperature which can range from −85° C. to 25° C.
The duration of this reaction can be between 30 minutes and 5 hours.
The reaction between a compound of formula (VI) and a borate of formula (VII) can be carried out in a polar solvent or a mixture of polar solvents chosen from water, N,N-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), N-methylpyrrolidinone, ethanol, propanol, isopropanol, acetonitrile, ethyl acetate, diethyl ether, THF, dioxane, anisole, ethylene glycol dimethyl ether, diglyme, triglyme, dichloromethane, chloroform, acetone or butanone.
Once prepared, the organic compounds of formula (I) are capable of forming deposited or grafted layers at the surface of the substrates by reduction or oxidation. The reduction or the oxidation can be carried out electrochemically or by chemical reactions. In the latter case, any oxidizing agent or any reducing agent having a standard redox potential respectively greater than or less than the standard redox potential of the compound of formula (I) can be used.
The depositing or grafting can be carried out in a polar solvent or in a mixture of solvents chosen from the group consisting, for example, of water, N,N-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), N-methylpyrrolidinone, ethanol, propanol, isopropanol, acetonitrile, ethyl acetate, diethyl ether, THF, dioxane, anisole, ethylene glycol, dimethyl ether, diglyme, triglyme, dichloromethane, chloroform, acetone and butanone.
The depositing or grafting of the organic compounds of formula (I) at the surface of the substrates can also be carried out in an ionic liquid chosen from ionic liquids comprising imidazolium, such as, for example, 1-n-butyl-3-methylimidazolium tetrafluoroborate.
The reduction or oxidation reactions which make possible the grafting or the deposition of the layers, whether chemical or electrochemical in nature, can be carried out in a micellar medium using surfactants which are anionic, cationic or neutral in nature.
The depositing or the grafting of the layers by oxidation or grafting reactions, whether carried out chemically or electrochemically, can also be carried out in an aqueous medium in the presence of cyclodextrins of variable size added in order to dissolve the organic compounds of formula (I).
The processes for the preparation of the organic compounds of formula (I) and the depositing or grafting of said compounds at the surface of the substrates in the form of one or more layers exhibit the advantage of being easy to carry out, of being reproducible, of being able to be carried out industrially and of being economically advantageous.
A subject matter of the invention is the use of a compound of formula (I) as defined above, as plastic electronics, in molecular electronics. The invention relates in particular to the use of said compound of formula (I) to produce a layer on insulating, semi-conducting and conducting surfaces. In this case, it is preferable for said layer to be formed on a substrate by grafting.
More particularly, the compounds of the invention can be used to produce organic light-emitting diodes, transparent electrodes, organic photovoltaic cells, organic transistors, single-electron transistors, or sensors and biosensors.
The invention also relates to the use of a compound of formula (I) as defined above to produce corrosion-resistant coatings, surfaces having switchable wetting properties, self-lubricating surfaces, electrochromic coatings, intelligent coatings, that is to say coatings having certain properties which can be reversibly switched using the external stimulus, or adhesion primers, that is to say layers which make possible the attachment and the adhesion of a second layer having a variable chemical nature but which would not have been adherent if this second layer had been deposited directly on the substrate.
The invention also applies to the use of a compound of formula (I) as defined above in the field of the storage of energy as electrode materials for batteries, or supercapacitors, which are electrical storage systems which can deliver large amounts of energy in a short period of time, in particular as layers deposited on carbon nanotubes.
Another subject matter of the present invention is a material comprising a compound of formula (I) as defined above.
The materials according to the invention can be prepared by known processes.
The present invention, according to another of its aspects, also relates to an article comprising a compound of formula (I) according to the invention as defined above.
EXAMPLES
Solvents and Reactants
The toluene is distilled, under an argon atmosphere, over sodium; the tetrahydrofuran (THF) is distilled, under an argon atmosphere, over sodium and benzophenone. The other solvents used originate from the supplier VWR.
Nuclear Magnetic Resonance (NMR)
The 1 H and 13 C spectra are recorded with a Bruker Avance III 300 MHz and 400 MHz apparatus.
The chemical shifts (δ) of the 1 H NMR and 13 C NMR spectra are calibrated with regard to the reference value of the solvent, as described in the paper by Gottlieb et al., J. Org. Chem., 1997, 62, 7512.
The measurements are carried out at 25° C. in tubes with a diameter of 5 mm. The spectra are recorded in deuterated solvents originating from the supplier Eurisotop. The coupling constants are given in hertz.
Chromatography
Thin layer chromatography (TLC) is carried out on “TLC Silica gel 60F 254 ” aluminum plates from Merck. The compounds are visualized under a UV lamp at 254 or 326 nm.
The chromatography columns are produced with a silica gel (Silica gel 60 (40-63 μm) from Merck).
Mass Spectrometry
The mass spectra were recorded on a Finnigan 5890 spectrometer coupled to a DSQ 1 in electron impact mode, in solvents of “Analytical” grade.
Synthesis of Precursors
The 1-(thien-2-yl)-4-nitrobenzene and the 1-(3,4-ethylenedioxythien-2-yl)-4-nitrobenzene were prepared according to the protocols described in the references [1] and [2].
For its part, the biEDOT was synthesized according to the procedure described in the reference [3].
Example 1
General Procedure for the Iodination of the Thiophene Derivatives
Mercury oxide (1.04 equivalents, 8.32 mmol) and iodine (1.02 equivalents, 8.16 mmol) are added to a suspension of a thiophene derivative (8 mmol) in acetic acid (150 ml). The mixture is degassed in an ultrasonic bath for 20 minutes and then stirred overnight. The precipitate is filtered off and then dissolved in dichloromethane. The organic phase is washed successively with a potassium iodide solution, a sodium bicarbonate (NaHCO 3 ) solution and water. After drying over magnesium sulfate, the solvent is evaporated under vacuum. The product is used without additional purification.
1-(5-Iodothien-2-yl)-4-nitrobenzene
The iodinated thiophene derivative was prepared according to the general procedure for iodination indicated above, with 7 mmol of thiophene derivative.
Yield: 2.10 g; 90%. A yellow powder is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 7.13 (d, 1H, J=3.6 Hz); 7.30 (d, 1H, J=3.6 Hz); 7.66 (d, 1H, J=8.4 Hz, CH c ); 8.23 (d, 1H, J=8.4 Hz, CH b ).
13 C NMR (75 MHz, CDCl 3 ) δ 76.1 (C h ); 124.5 (C c ); 125.9 (C b ); 127.0 (C f ); 138.5 (C g ); 139.4 (C a ); 146.9 (C d ); 147.5 (C e ).
MS: M calculated 331; found: [M] + 331.
1-(5-Iodo-3,4-ethylenedioxythien-2-yl)-4-nitrobenzene
The iodinated EDOT derivative was prepared according to the general procedure for iodination indicated above, starting from 6.57 mmol of 3,4-ethylenedioxythiophene derivative (EDOT).
Yield: 2.52 g; 98%. A yellow powder is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 4.37 (m, 4H); 7.78 (d, 1H, J=9.2 Hz); 8.21 (d, 1H, J=9.2 Hz).
13 C NMR (75 MHz, CDCl 3 ) δ 52.1 (C h ); 64.9 and 64.9 (C f′ and C g′ ); 120.4 (C e ); 124.2 (C b ); 125.7 (C c ); 139.0 (C a ); 139.6 (C f or C g ); 145.0 (C f or C g ); 145.7 (C d ).
MS: M calculated 389; found: [M] + 389.
Example 2
General Procedure for the Synthesis of the Boronic Ester [4]
A solution of the thiophene compound (30 mmol) in distilled THF (100 ml) is cooled to −78° C. with stirring under an argon atmosphere. A 2.5M butyllithium solution (12 ml, 1 equivalent) is added dropwise and the solution obtained is stirred at −78° C. for one hour. Triisopropyl borate (21 ml, 3 equivalents) is added and the reaction mixture is allowed to return to ambient temperature (20° C.). After 2 h 30 min, a solution of pinacol (10.6 g) in THF (30 ml) is added. The reaction mixture is stirred for 30 minutes and the solvent is subsequently evaporated under vacuum. The residue is dissolved in diethyl ether and the solution is washed twice with water and dried over MgSO 4 . The solvent is evaporated under vacuum. The product is used without additional purification.
4,4,5,5-Tetramethyl-2-(thiophen-2-yl)-1,3,2-dioxaborolane
This compound was prepared according to the general procedure above for the synthesis of the boronic ester, starting from 30 mmol of thiophene.
Yield: 5.3 g; 85%. A white powder is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 1.36 (s, 12H, CH 3 ); 7.20 (dd, 1H, J=3.6 and 4.8 Hz, H 4 ); 7.64 (d, 1H, J=4.8 Hz, H 5 ); 7.66 (d, 1H, J=3.6 Hz, H 3 ).
13 C NMR (75 MHz, CDCl 3 ) δ 24.8 (CH 3 ); 84.1 (C—OB); 128.2 (C 3 ); 132.4 (C 4 ); 137.2 (C 5 ).
MS: M calculated 210; found: [M] + 210.
2-(2,3-Dihydrothieno[3,4-b][1,4]dioxin-5-yl)-4,4,5,5-tetramethyl-1,3,2-dioxaborolane
This compound was prepared according to the general procedure above for the synthesis of the boronic ester, with 50 mmol of EDOT.
Yield: 11.13 g; 85%. A white powder is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 1.34 (s, 12H, CH 3 ); 4.17-4.20 (m, 2H, OCH 2 ); 4.29-4.31 (m, 2H, OCH 2 ); 6.63 (s, 1H, CH edot ).
13 C NMR (75 MHz, CDCl 3 ) δ 24.7 (CH 3 ); 64.3 (CH 2 —O); 65.1 (CH 2 —O); 83.8 (C—OB); 107.5 (CH edot ); 142.3 and 149.0 (C 3 —O and C 4 —O).
MS: M calculated 268; found: [M] + 268.
4,4,5,5-Tetramethyl-2-(2,2′,3,3′-tetrahydro-5,5′-bithieno[3,4-b][1,4]dioxin-5-yl)-1,3,2-dioxaborolane
This compound was prepared according to the general procedure above for the synthesis of the boronic ester, starting from 10 mmol of bi-EDOT.
Yield: 3.94 g; 93%. A green solid is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 1.28 (s, 12H, CH 3 ); 4.23-4.25 (m, 2H, OCH 2 ); 4.32-4.34 (m, 6H, OCH 2 ); 6.31 (s, 1H).
13 C NMR (75 MHz, CDCl 3 ) δ 24.5 (CH 3 ); 64.6 (CH 2 —O); 65.0 (CH 2 —O); 83.2 (C—OB); 97.5 (CH edot ); 109.9 (C—S); 137.0 and 141.2 (C—O).
MS: M calculated 408; found: 408.
Example 3
General Procedure for the Suzuki Coupling Reaction [4]
The boronic derivative (2 mmol), the halogenated derivative (2 mmol), sodium carbonate (3 equivalents, 6 mmol) and tetrakis(triphenylphosphine)palladium (Pd 0 ) (5%) are successively introduced into a Schlenk flask containing 25 ml of N,N-dimethylformamide (DMF). The reaction mixture is heated at 110° C. for from 2 to 3 days. After cooling to ambient temperature (20° C.), the solvent is evaporated under vacuum.
The brown residue is dissolved in dichloromethane and the solution is washed twice with water, dried over MgSO 4 and concentrated. The crude product is purified by silica gel chromatography.
2-(4-Nitrophenyl)-3, 4-ethylenedioxythiophene
The nitrophenyl-EDOT compound was prepared by the procedure indicated above, with 15 mmol of boronic derivative (chromatography eluent: petroleum ether/dichloromethane 3/7).
Yield: 2.79 g; 70%. A yellow powder is obtained.
1 H NMR (400 MHz, CDCl 3 ) δ 4.28-4.40 (m, 2H, H g′ ); 4.37-4.40 (m, 2H, H f′ ); 6.48 (s, 1H, H h ); 7.86 (d, J=9.0 Hz, 2H, H c ); 8.17 (d, J=9. 0 Hz, 2H, H b ).
13 C NMR (100 MHz, CDCl 3 ) δ 64.3 (OC g′ H 2 ); 65.1 (OC f′ H 2 ); 101.0 (C h ); 124.1 (C b ); 125.7 (C c ); 139.8 (C a ); 140.9 (C g ); 142.9 (C f ); 145.8 (C d ).
MS: M calculated 263; found: 263.
Elemental analysis: calculated: C 54.75, H 3.45, N 5.32, S 12.18; found: C 55.04, H 3.50, N 6.05, S 10.88.
2-(4-Nitrophenyl)-3,4,3′,4′-bis(ethylenedioxy)-5,2′-bithiophene
The compound nitrophenyl-bi-EDOT was prepared by the general procedure described above, with 2 mmol of boronic derivative. The product was purified by silica gel chromatography using a 3/7 petroleum ether/dichloromethane mixture as eluent.
Yield: 316.3 mg; 36%. A dark powder is obtained.
1 H NMR (400 MHz, CDCl 3 ) δ 4.23-4.27 (m, 2H, OCH 2 ); 4.36-4.40 (m, 6H, 3×OCH 2 ); 6.36 (s, 1H, H 1 ); 7.84 (d, J=9.2 Hz, 2H, H c ); 8.17 (d, J=9.2 Hz, 2H, H b ).
13 C NMR (100 MHz, CDCl 3 ) δ 63.9, 64.0, 64.4 and 64.7 (4×OCH 2 ); 98.6 (C l ); 108.8, 111.5, 111.7 (C e , C h and C i ); 123.4 (C b ); 124.7 (C c ); 136.7, 137.4, 139.8, 140.7 (C f , C g , C j , C k ); 139.3 (C a ); 144.4 (C b ); 145.0 (C d ).
MS C 18 H 13 NO 6 NaS 2 [M+Na + ]: calculated: 426.0082, found: 426.0093.
Elemental analysis: calculated: C 53.59, H 3.25, N 3.47, S 15.89; found: C 54.74, H 3.54, N 3.60, S 14.02.
2-(4-Nitrophenyl)-3′,4′-ethylenedioxy-5,2′-bithiophene
2-(4-Nitrophenyl)-3′,4′-ethylenedioxy-5,2′-bithiophene was prepared according to the general procedure described above, starting from 4 mmol of boronic derivative (chromatography eluent: 25/75 petroleum ether/dichloromethane mixture).
Yield: 1.38 g; 78%. An orange powder is obtained.
1 H NMR (400 MHz, CDCl 3 ) δ 4.28-4.31 (m, 2H, OCH 2 ); 4.40-4.42 (m, 2H, OCH 2 ); 6.23 (s, 1H, H l ); 7.25 (d, J=4.0 Hz, 2H, H f or H g ); 7.41 (d, J=4.0 Hz, 2H, H f or H g ); 7.73 (d, J=8.8 Hz, 2H, H c ); 8.24 (d, J=8.8 Hz, 2H, H b ).
13 C NMR (100 MHz, CDCl 3 ) δ 64.6 and 65.2 (2×OCH 2 ); 98.1 (C l ); 111.7 and 138.4 (C j and C k ); 123.9 and 126.0 (C f and C g ); 124.5 (C b ); 125.4 (C c ); 137.6 and 139.0 (C h and C i ); 140.6 (C a ); 142.0 (C e ); 146.3 (C d ).
MS C 16 H 11 NO 4 S 2 [M+H + ]: calculated: 345.0130, found: 345.0145.
Elemental analysis C 16 H 11 NO 4 S 2 : calculated: C 55.64, H 3.21, N 4.06, S 18.56; found: C 55.04, H 3.13, N 4.22, S 17.97.
2-(4-Nitrophenyl)-3,4-ethylenedioxy-5,2′-bithiophene
2-(4-Nitrophenyl)-3,4-ethylenedioxy-5,2′-bithiophene was prepared according to the general procedure described above for the Suzuki coupling reaction, with 2 mmol of boronic derivative (chromatography eluent: 25/75 petroleum ether/dichloromethane mixture).
Yield: 690 mg; 63%. An orange powder is obtained.
1 H NMR (400 MHz, CDCl 3 ) δ 4.43 (s, 4H, 2×OCH 2 ); 7.08 (dd, 1H, J=3.2 and 5.2 Hz, CH k ); 7.30 (d, 1H, J=5.2 Hz, CH l ); 7.34 (d, 1H, J=3.2 Hz, CH j ); 7.86 (d, 1H, J=8.8 Hz, CH c ); 8.18 (d, 1H, J=8.8 Hz, CH b ).
13 C NMR (100 MHz, CDCl 3 ) δ 64.7 and 65.0 (2×OCH 2 ); 112.1 (C e ); 113.8 (C i ); 124.0 (C j ); 124.1 (C b ); 125.0 (C l ); 125.6 (C c ); 127.4 (C k ); 133.9 (C h ); 137.9 and 140.9 (C f and C g ); 139.4 (C a ); 145.3 (C d ).
MS C 16 H 11 NO 4 S 2 [M + ]: calculated: 345.0130, found: 345.0139.
Elemental analysis C 16 H 11 NO 4 S 2 : calculated: C 55.64, H 3.21, N 4.06, S 18.56; found: C 55.27, H 3.21, N 4.09, S 17.70.
2-(4-Nitrophenyl)-3,4,3′,4′,3″,4″-ter(ethylenedioxy)-5,2′,5′,2″-terthiophene
The nitrophenyl-terEDOT compound was prepared according to the general procedure described above for the Suzuki coupling reaction with 2 mmol of boronic derivative. The product was purified by alumina chromatography using dichloromethane as eluent.
Yield: 465 mg; 71%. A dark powder is obtained.
1 H NMR (400 MHz, CDCl 3 ) δ 4.26 (m, 2H, OCH 2 ); 4.30-4.50 (m, 10H, 5×OCH 2 ); 6.33 (s, 1H, CH p ); 7.86 (d, 2H, J=8.8 Hz, CR c ) 8.19 (d, 2H, J=8.8 Hz, CH b ).
MS C 24 H 17 NO 8 S 3 [M+H + ]: calculated: 543.0116; found: 543.0126.
Example 4
General Procedure for the Reduction of the Nitro (NO 2 ) Functional Group to Give an Amine (NH 2 ) [5]
10% palladium-on-charcoal (0.086 mmol, 10%) and hydrazine (1 ml) are added to a solution of the nitro derivative (0.86 mmol) in THF (20 ml). The reaction mixture is brought to reflux for 4 hours. After cooling to ambient temperature (20° C.), the suspension is filtered through celite and then the solvent is evaporated under vacuum. The residue dissolves in dichloromethane, is washed with water and then the solution is dried over magnesium sulfate. The product is used without additional purification.
2-(4-Aminophenyl)-3,4,3′,4′-bis(ethylenedioxy)-5,2′-bithiophene
The amine derivative was prepared from 1 mmol of nitro derivative, according to the general procedure for reduction of the nitro functional group to give an amine indicated above.
Yield: 124 mg; 76%. A red powder is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 3.70-3.73 (broad s, 2H); 4.24-4.27 (m, 2H); 4.33-4.37 (m, 6H); 6.27 (s, 1H); 6.69 (d, 2H, J=8.4 Hz); 7.55 (d, 2H, J=8.4 Hz).
13 C NMR (75 MHz, CDCl 3 ) δ 64.6, 64.6, 64.9 and 65.0 (4×CH 2 O); 97.3 (C 1 H); 106.2 (C i or C h ); 110.2 (C i or C h ); 115.2 (C b H); 115.8 (C e ); 123.7 (C a ); 127.3 (C c H); 136.3, 136.7, 137.5 and 141.3 (C f , C g , C j and C k ); 145.0 (C d ).
MS C 18 H 15 NO 4 NaS 2 [M+H + ]: calculated: 374.0521; found: 374.0515.
Elemental analysis C 12 H 11 NO 2 S: calculated: C 57.89, H 4.05, N 3.75, S 17.17; found: C 58.50, H 4.33, N 3.93, S 15.95.
2-(4-Aminophenyl)-3′,4′-ethylenedioxy-5,2′-bithiophene
The amine derivative was prepared starting from 0.6 mmol of nitro derivative, according to the general procedure for the reduction of nitro functional group to give an amine indicated above.
Yield: 189 mg; 83%. A yellow powder is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 4.76 (s, 2H); 4.25-4.27 (m, 2H, H j′ ); 4.34-4.37 (m, 2H, H k′ ); 6.20 (s, 1H, H 1 ); 6.68 (d, 2H, J=8.8 Hz, H b ); 7.06 (d, 1H, J=4.0 Hz, H f ); 7.14 (d, 1H, J=4.0 Hz, H g ); 7.41 (d, 2H, J=8.8 Hz, H c ).
13 C NMR (75 MHz, CDCl 3 ) δ 64.6 (OC j′ H 2 ); 65.0 (C k′ H 2 ); 96.5 (C l ); 112.6 (C i ); 115.3 (C b ); 121.3 (C f ); 123.8 (C g ); 125.0 (C a ); 126.8 (C c ); 132.4 (C h ); 137.2 (C k ); 141.9 (C j ); 143.2 (C e ); 145.9 (C d ).
MS C 16 H 9 NO 2 S 2 [M+H + ]: calculated: 316.0466; found: 316.0461.
Elemental analysis C 16 H 9 NO 2 S 2 : calculated: C 60.93, H 4.15, N 4.44, S 20.33; found: C 60.82, H 4.80, N 4.01, S 17.46.
2-(4-Aminophenyl)-3,4-ethylenedioxy-5,2′-bithiophene
The amine derivative was prepared starting from 0.86 mmol of nitro derivative, according to the general procedure for the reduction of the nitro functional group to give an amine indicated above.
Yield: 270 mg; 95%. A yellow powder is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 4.32-4.35 (m, 2H); 4.37-4.39 (m, 2H); 6.70 (d, 2H, J=8.8 Hz, H b ); 7.02 (dd, 1H, J=3.6 and 5.0 Hz, H k ); 7.20 (d, 1H, J=5.0 Hz, H l ); 7.22 (d, 1H, J=3.6 Hz, H j ); 7.53 (d, 2H, J=8.8 Hz, H c ).
13 C NMR (75 MHz, CDCl 3 ) δ 64.6 and 64.9 (2×OCH 2 ); 108.3 (C e or C h ); 115.2 (C b ); 115.5 (C a ); 122.3 (C j ); 123.3 (C l ); 127.1 (C k ); 127.3 (C c ); 135.0 (C i ); 136.7 (C f or C g ); 137.9 (C f or C g ); 145.3 (C d ).
MS C 16 H 9 NO 2 S 2 [M+H + ]: calculated: 316.0466; found: 316.0466.
Elemental analysis C 16 H 9 NO 2 S 2 : calculated: C 60.93, H 4.15, N 4.44, S 20.33; found: C 61.11, H 4.61, N 4.62, S 17.95.
2-(4-Aminophenyl)-3,4,3′,4′,3″,4″-ter(ethylenedioxy)-5,2′,5′,2″-terthiophene
The amine derivative was prepared starting from 0.11 mmol of nitro derivative, according to the general procedure for the reduction of the nitro functional group to give an amine indicated above.
Yield: 56 mg; quantitative. A red powder is obtained.
1 H NMR (300 MHz, CDCl 3 ) δ 4.21-4.40 (m, 12H); 6.27 (s, 1H, CH p ); 6.68 (d, 2H, J=7.6 Hz, CH b ); 7.55 (d, 2H, J=7.6 Hz, CH c ).
MS: C 24 H 19 NO 6 S 3 [M+H + ]: calculated: 513.0374; found: 513.0371.
Example 5
Process for the Preparation of 2-(4-nitrophenyl)-3,4,3′,4′-bis(ethylenedioxy)-5,2′-bithiophene [6]
BiEDOT (2.2 g, 7.8 mmol, 1.3 eq.), 4-bromonitrobenzene (1.21 g, 6 mmol) and potassium acetate (1.76 g, 18 mmol, 3 eq.) are successively introduced into a Schlenk flask containing 20 ml of DMF. After complete dissolution of the reactants, palladium acetate (134 mg, 0.6 mmol, 0.1 eq.) is added and then the reaction medium is heated at 80° C. for one hour. After returning to ambient temperature (20° C.), the red precipitate is filtered off and washed with ethanol. The nitrated compound is subsequently used without additional purification.
Yield: 72%.
LIST OF REFERENCES
[1] U.S. Pat. No. 6,130,339
[2] U.S. Pat. No. 6,197,921 B1
[3] G. A. Sotzing, J. R. Reynolds, P. J. Steel, Adv. Mater., 1997, 9, 10, 795-798.
[4] M. Frigoli, C. Mostrou, A. Samat, R. Guglielmetti, Eur. J. Org. Chem., 2003, 2799-2812.
[5] L. Flamigni, B. Venture, E. Baranooff, J-P. Collin, J-P. Sauvage, Eur. J. of Inorg. Chem., 2007, 33, 5189-5198.
[6] A. Borghese, G. Geldhof, L. Antoine, i Tetrahedron, 2006, 47, 9249-9252. | The present disclosure relates to novel organic compounds, to the processes for preparing same and to the uses thereof, firstly in the electronics field, in particular in the fields referred to as plastic electronics and molecular electronics, and, secondly, in the coatings field, in particular in the fields of adhesion primers and intelligent coatings. The disclosure also relates to a material comprising a novel compound according to the invention. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of school and office supplies and more particularly to the field of clipboards used to provide rigid support for someone writing on a sheet of paper or a tablet. The present invention also relates to the field of clipboards of the type which include an easel support built into the back thereof.
2. Description of the Prior Art
Clipboards have been known for many years, probably the most common example of which is a clipboard including a generally rectangular, press board or plastic back and a spring clip mounted adjacent one end of the short side of the rectangle and adapted to receive sheets of paper, for example a tablet or a legal pad. Clipboards are known for use in a variety of sizes, including ones designed for use with standard 81/2×11 inch paper, and longer versions used for legal size paper. Smaller clipboards are also known for use with notepaper and the like.
It is also known in the art that easel-type supports may be used with clipboards, so that the clipboard may be placed on a level surface and be used to display information contained on the paper held by the clip. One well-known type of support is that used for supporting picture frames, in which a portion of the back is hingedly mounted to be rotated to a position where it is at an angle to the back of the object. In such position, and with appropriate design of the bottom of the support, the object will stand on the end opposite the clip.
One frequently encountered problem with clipboards is the tendency of the paper or tablet held by the clip to move, especially if the clipboard is used without placing it on a firm support surface. For example, someone standing and using a clipboard for taking notes may exert pressures as he or she is writing which will cause the paper to twist from its normal position. The problem is especially pronounced if the sheets of paper or the pad or tablet is thin, in which case the spring-imposed pressure of the clip is less than if more sheets or a larger pad or tablet was employed.
A clipboard of the standard type or one which could be adapted to include an easel-type support, and which prevents paper or a pad or tablet from twisting on the surface of the board would represent a significant advance in the art.
SUMMARY OF THE INVENTION
The present invention features a clipboard which is capable of preventing twisting of individual sheets of paper or a tablet when used. The present invention further features a design for achieving that result, whether the clipboard be of the standard variety with a plain back, or the type which includes an easel-type support. The invention further features a clipboard which is adaptable to a wide variety of sizes and shapes of paper and which itself may be constructed from a variety of materials to accomplish utilitarian as well as aesthetic purposes.
How the features of the invention are accomplished will be described in the following detailed description of the preferred embodiment of the invention, taken in conjunction with the drawings. Generally, however, the features are accomplished by a clipboard which includes a planar surface for supporting paper or a pad or tablet of a particular size and which includes a clip mounted on that surface under which an edge of the paper, pad or tablet can be inserted. The clipboard further includes a pair of raised, spaced apart and parallel ridges extending along the sides of the clipboard, the spacing between the inner edges of the ridges being coincident with the width of the paper with which the clipboard is to be used. The edges prevent movement of the paper during use, as well as a unique decorative appearance. Other ways in which the features of the invention are accomplished will become apparent to those skilled in the art after the present specification has been read and understood. Such other ways are deemed to fall within the scope of the invention if they fall within the scope of the claims which follow.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prior art clipboard having rounded corners and a spring clip at one end;
FIG. 2 is a top plan view of a clipboard according to one preferred embodiment of the present invention; and
FIG. 3 is a rear perspective view of an alternate embodiment of the present invention and illustrating an easel-type support for the clipboard.
Like components are illustrated by like reference numerals in the various figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Before proceeding to the detailed description of the figures and the preferred embodiments represented by FIGS. 2 and 3, several general comments should be made about the scope and applicability of the present invention.
While the present invention is illustrated in connection with a clipboard designed for use with a pad of 81/2×11 inch paper (not including the section which is retained by the clip), the principles of the present invention can be expanded to a wide variety of different paper sizes. Furthermore, a number of design elements can be incorporated without departing from the invention's intended scope. For example, the prior art clipboard is shown to have rounded corners, but square corners are also known. The particular type of clip which can be employed is also not, in and of itself, relevant to the scope of the present invention. Two styles of clips are illustrated, one in connection with the prior art clipboard shown in FIG. 1 and the other in FIG. 2. The length of the clip extending across the clipboard may be varied up to the width of the paper, and the particular characteristics of the spring mechanism used to permit insertion and withdrawal of the sheets, pad or tablet can vary widely. Any type of clip known to the art could be substituted for those illustrated.
With regard to materials of construction, these can also vary widely. Press board, plastic and the like are presently used, and similar materials which exhibit the desired rigidity and toughness for clipboard applications can be substituted.
Lastly, one particular type of easel arrangement is shown in FIG. 3, but numerous other types of easel supports are known in the display and picture frame arts which could be substituted therefor.
Proceeding now to FIG. 1, a clipboard 10 according to the prior art is illustrated to include a generally rectangular plate 12 having narrower sides 13-14 and longer sides 15-16. Located near side 13 is a clip 18 including a first portion 19 attached to plate 12 and a second portion 20 hingedly mounted to portion 19 in such a manner that an elongate edge 22 of element 20 is urged toward plate 12. An opposite end 24 of element 20 is pivotable toward element 19 to raise and lower portion 23 to permit the insertion and removal of a sheet or sheets of paper, a pad or a tablet.
Proceeding next to FIG. 2, a preferred embodiment of the present invention is illustrated to include a clipboard 30 having a generally rectangular backing 32, a portion of which is shown below the cutaway portion of the legal pad 33. Clipboard 30 includes shorter upper and lower ends 34 and 35, respectively, and side edges 36 and 37, respectively. The particular clipboard 30 is designed to hold a legal pad having detachable 81/2×11 inch sheets of paper. The overall dimensions of such a legal pad might exceed 11 inches in the long direction by 3/4 -inch or more.
Unlike the prior art clipboard 10 where the width of plate 12 is approximately equal to the width of the paper to be used, clipboard 30 is wider, plate 32 having a width of approximately 91/2 inches. Extending along either side 36 and 37 are a pair of parallel and spaced apart ridges 40 and 41 which, in the most preferred form, extend the entire length of sides 36 and 37. More specifically, in the preferred form of the invention, ridges 40 and 41 are integrally molded with plate 32. Ridges 40 and 41 have inner edges 43 and 44 which preferably are just slightly larger than 81/2 inches between each other.
Located at end 34 of clipboard 30 is an elongate, spring loaded clip 45 extending between ridges 40 and 41. In the preferred embodiment, the clip extends the entire distance but, as previously mentioned, could extend only part of the way between the two ridges. The spring mechanism is not shown but, in and of itself, is similar to those used in prior art clipboards and does not form part of the present invention.
Unlike the clipboards of the prior art, paper, whether to be in sheet, pad or tablet form, is inserted by pressing on the upper portion 47 of clip 45, thereby raising the lower edge 48 of the clip 45. The paper is placed between the ridges 40 and 41 and held by the clip 45 when it is lowered. The paper itself is captured between the ridges 40 and 41 and the clipboard may be used without concern about the paper twisting from its proper position.
The clipboard 30 is of the type which may be held by the user or placed horizontally on a support surface. An alternate embodiment of the present invention is shown in FIG. 3, where an easel-type support 50 is hingedly mounted to the back of plate 32. A recess 52 is provided to receive the support 50 so that it can be folded out of the way for storage. The oblong opening 54 in the middle of the support is primarily for material reduction and aesthetics and does not alter the utility or play any role in the construction of the clipboard. The attachment of the upper end 57 of support 50 may be by any conventional technique of attaching a plate to another plate, i.e., by pin and socket or by the use of attached hinge elements, or the like.
While the present invention has been described in connection with two preferred embodiments, the invention can be varied as mentioned above by those skilled in the art after the present specification has been read and understood. It is not necessary that the ridges be formed integrally with the plate and they can be made separately and attached, such as through the use of adhesives. Accordingly, the invention is not to be limited by the foregoing description but is to be limited solely by the scope of the claims which follow. | A clipboard, which may include an easel support, includes a pair of spaced apart and parallel raised side ridges adapted to confine paper so that it does not move during use of the product. In one embodiment, in which an easel support is built into the back of the clipboard, the product may be used to display information provided on sheets of paper or a pad or a tablet thereof. | 1 |
FIELD OF THE INVENTION
The invention relates to spinning machines of the type known as free fiber machines or open end machines which comprise spinning rotors having high rotational speeds and constituted by a rotatable bowl having an inlet at which the free fibers are introduced and an outlet at which formed and twisted fiber is removed, the outlet being at the opposite side across the axis of the rotor.
BACKGROUND
Rotors of the above type must turn at very high speeds of 25,000 to 60,000 RPM, which poses very serious problems for the construction of the support bearings. There are generally utilized ball bearings of small size whose interior ring or race is mounted on a fixed hollow axle for the rotor and whose exterior ring is mounted in a bore of the rotor, such that the rows of balls and their cages rotate at a very high speed and are subjected to a substantial centrifugal force which produces deformations and abnormal wear. Furthermore, the chamber containing the rotor is subjected to a suction, necessary to the process, but which has the disadvantage of aspirating, through the ball bearing, external dust which fouls and causes wear of the ball bearing. In order to avoid this entry of dust, these rollers are generally lubricated by means of an oil mist under pressure, but then a substantial part of the oil is found on the fiber filaments while the remainder is evacuated into the suction source. By maintaining the bearing chamber under pressure a great consumption of air is effected. Finally the rotor is driven by a belt whose tension produces a constant force on the same side of the interior ring of the bearings which constitutes a condition of use which is unfavorable and rapidly leads to wear of the bearing.
SUMMARY OF THE INVENTION
An object of the invention is to eliminate the above-noted disadvantages by the provision of a rotor whose hollow axle is fixed but whose bearings have interior races which are moveable and fixed exterior races while additionally the bearings are protected from entry of dust from the exterior of the bearing without the need for a particular type of lubrication system nor under any particular pressure.
The invention contemplates fixedly mounting the the rotor on a hollow axle containing a fixed sleeve and supporting the axle in a bearing having oblique contact surfaces, the two exterior races or rings of the bearing being axially spaced after mounting and maintained at the spacing by a cross-piece of U-shape and an elastic washer. These exterior rings as well as the cross-piece are mounted in the bore of a fixed support member and axially and rotatably maintained solely by immobilization of the cross-piece.
The hollow rotatable axle is additionally traversed coaxially by the fixed sleeve, this sleeve having being subjected to no force whatsoever. The sleeve in turn is secured with the base of the support member which in turn is mounted in a clamp having branches with facing ends in spaced relation, said branches being provided with bores providing both elasticity therefore and air passageways so that the two end faces of the clamp are subjected to atmospheric pressure.
Baffles are provided on the upper face of the bearing at the base of the rotor and the lower face of the bearing at the top of the drive pulley fixed to the lower extremity of the hollow shaft and the space thus defined between the support member and the bearing assembly can be lubricated by any means whatsoever via a tube passing between the branches of the clamp and through the support member.
To avoid all pressure leakage, the base of the rotor is additionally encircled by sealing washer mounted frictionally on the lower cover of the suction chamber.
Other features of the invention will appear from the following description of an embodiment given by way of example and illustrated in the attached drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a vertical section taken along line I--I in FIG. 2, and
FIG. 2 is a horizontal section taken along line II--II in FIG. 1.
DETAILED DESCRIPTION
There is shown in FIG. 1 a fixed housing 1 of a chamber 2 subjected to suction through a conduit (not shown) and closed by a lower removable cover 3. In the chamber 2 there is mounted a spinning rotor 4 of conventional form, in which fibers arrive at the upper part through an inlet 5 and these fibers are divided towards the inner periphery of the rotor under the effect of a current of air traveling from bottom to top through the central hole 6 under the effect of the suction and meet a descending current of air traveling through the orifice 5. The filament formed by the progressive collection and the twisting of these fibers is continuously removed at the base through the orifice 6.
Contrary to the conventional arrangement, the orifice 6 is not mounted in a fixed axle of the rotor, but, in contrast, in a sleeve 7 which is fixed at its base in a disc 8 and which is substantially without contact with the rotatable part. The sleeve can therefore have a relatively thin wall since there is no mechanical force to resist. The rotatable part comprises in addition to the rotor 4, a tubular axle 9 in which are directly formed two grooves constituting the interior races of ball-bearing rollers. These rollers are of the annular disposition type having oblique contact which requires that when mounting exterior rings 10 and 11, these initially are between the rows of balls and are pushed outwardly to enclose the rows of balls. After mounting the two external rings 10 and 11 at their specified spacing, there can be interposed between them a cross-piece 12 shown in particular in FIG. 2, and having a U-shape form which encircles the hollow axle 9. The cross-piece 12 serves as a bracing member and directly bears against the lower surface of the upper ring 10 and indirectly on the upper surface of the lower ring 11 through the intermediary of an elastic washer 13 and a plate washer 13a preliminarily placed into position. The washer 13a prevents one of the undulations of the spring washer 13 from coinciding with the opening between the branches of the U-shape cross-piece 12.
This particular type of mounting permits the utilization of rows of balls 14 mounted in cylindrical roller cages 15 which are formed in one piece and possess excellent resistance to centrifugal force. At the same time, the elastic washer 13 constantly takes up all play of the roller assembly.
The assembly of the two rows of balls and the cross-piece 12 is then introduced with a minimum of play in the central bore of a support element 16 completing the bearing and having a small transverse bore 17 in which there is introduced a screw 18 which is threaded in a tapped hole in the cross-piece 12. This axially locks the cross-piece 12 without deforming it, cross-piece 12 being a member of great precision. As a consequence of axial locking of cross-piece 12, the two exterior rings 10,11 of the rollers are also axially immobilized. The screw 18 is introduced with play in the bore 17 in order to avoid bending of the cross-piece 12. This space is then taken up by filling it with a thermofusible material such as sealing wax. After the mounting of the hollow shaft 9 in the bearing there is then mounted on a lower projecting extremity of shaft 9 a drive pulley 19, for example, by fixing the pulley on said extremity.
The screw 18 also presents the advantage of immobilizing the cross-piece 12 in rotation such that the cavity 20 formed in the bore of the bearing at the lateral opening between the branches of the cross-piece can be fed with lubricant by means of a tube 21 opening through the wall of the support element 16 into cavity 20. The tube 21 permits the lubrication of the roller bearings by any suitable means such as an oil spray of low pressure from an oil container, or grease. The lubricant is retained by means of baffles at the top and bottom of the bearing respectively formed by circular skirts 22 integral with the rotor 4 and the pulley 19, the skirts penetrating into corresponding circular recesses in the support 16.
The support 16 is formed at the bottom with a tubular prolongation 23 provided with a large slot 24 for the passage of the belt 25 and prolongation 23 is terminated by a threaded portion on which a screw 26 is threaded to lock the disc 8 supporting the sleeve 7.
The bearing assembly is mounted through the intermediary of an elastic ring 27, for example of rubber, in a clamp 28, shown particularly in FIG. 2 and having branches whose facing ends are spaced apart to form a slot 29. This allows the engagement of the bearing assembly and its lockage therein by means of a screw 30. The slot also permits the passage of the tube 21. The clamp further has a bore 31 which allows passage of the nut 26 and then the reception of the elastic ring 27. The clamp also has bores 32 providing elasticity for the branches of the clamp. The assembly of the rotor and its bearing can then be mounted and dismounted very rapidly in the clamp 28 for maintenance, control, replacement, or repair, this clamp being fixed, by means of threaded holes 33, in a pivotal support of conventional type including the return drive pulley for the belt 25.
The opening or slot 29 of the clamp, and the bores 32 are additionally furnished to provide a large communication passage between the lower face of the clamp and the annular space 34 situated at the base of the rotor above the support 16 and at the interior of the lower cover 3, so that this space will constantly be at atmospheric pressure in order to avoid all passage through the bearing assembly of a current of air under the effect of the suction. This space 34 is sealed from the interior of the cavity 2 by means of a sealing ring 35. The ring 35 is adjustably mounted at the periphery of the base 36 of the rotor and is formed with grooves defining baffles, ring 35 being frictionally mounted by means of elastic washers 37 applying it onto the cover 3 while permitting automatic lateral adjustment due to the existence of large play between the head 38 of mounting bolts 39 and corresponding holes formed in the ring 35. The elastic washers 37 can themselves be fixed to the heads 38 by means of circlips 40. Finally the bolts 39 which also serve to secure the cover 3 on the clamp 28 pass through holes in cover 3 with a minimum of play then traverse the clamp through the much larger bores 41 therein to permit the deformation movements of the clamp at the time of its engagement with the bearing. The nuts 42 are then threaded onto the lower end of the bolts to lock the same.
Due to this arrangement there is a low loss of suction which is particularly advantageous and additionally it permits, due to the large exposure to the atmosphere, the two extremities of the support 16 to have no flow of air through the roller bearing assembly. To increase the precaution there can also be provided bores 43 establishing communication between the two circular recesses in the support 16 receiving the two skirts 22 in order to insure a still better equilibrium of the pressure on the two faces. Due to this disposition there can be therefore utilized as has been previously indicated, any lubrication means whatsoever to establish a pressurization at the interior of the bearing.
Finally, thanks to the more efficient mounting with the fixed external rings and the rotatable internal ring, the load corresponding to the tension of the belt 25, does not run the risk of always being applied on one side of the shaft 9 since this shaft rotates and the exterior rings 10,11 better resist the contact pressure and the wear due to their concavity and their more substantial surface area. The annular disposition of the oblique contact with elastic take-up of the play also provides clear improvement of performance and a better stability of the rotor. Finally the drive speed in rotation of the rings, ball-bearings and the cages will be reduced with respect to the conventional disposition. Thanks to all of the improvements, the rotor according to the invention is extremely simple in fabrication, maintenence, and demounting and presents the advantage of a much reduced wear even at speeds of rotation up to 60,000 RPM. | A spinning rotor for free fibers having axial extraction and a rotatable depending hollow shaft secured thereto and provided with two grooves receiving two rows of balls mounted in cylindrical cages and disposed in fixed exterior rings having oblique contact surfaces. These exterior rings are mounted in the bore of a bearing support and are maintained in spaced relation by a cross-piece of U-shape and an elastic washer, the cross-piece being axially and rotatably immobilized in the bearing support by a clamp or similar element. | 3 |
BACKGROUND
In the downhole industry, control of flow is critical to a compliant operation. Many different valves and safeties have been and are employed to ensure well control. One such device is a Surface Controlled Subsurface Safety Valve (SCSSV). These are often installed during completion of the well and function to provide rapid valve closing under various preselected conditions or upon command from a command center, which may be at surface. Over time, the SCSSV may experience deterioration due to a number of factors and it may then become desirable to replace its function with a replacement valve such as a wireline insert SCSSV. In such case, the control line that had operated the original SCSSV would be accessed to provide controllable hydraulic fluid pressure to the insert SCSSV. Normally this is affected by using a puncture communication tool. It is to be understood that an SCSSV is only an example of the type of tool that might use a puncture communication tool. Any other tool where communication to a hydraulic fluid chamber is also contemplated. Such a tool is illustrated in prior art FIGS. 1 and 2 , in a run-in and an actuated position, respectively. This device is well known to the art and commercially available from Baker Hughes Incorporated, Houston Tex. It is therefore not necessary to consider the Figures in detail but rather suffices to note that a ramp 10 is visible in both Figures but in a different position. The positional change in the ramp causes a penetrator assembly 12 to move radially thereby causing a penetrator 14 to puncture a hydraulic fluid chamber 16 .
While the Puncture communication tool of the prior art serves its purpose well, it requires that the penetrator 14 be retracted to ensure that the hydraulic fluid chamber has been successfully breached. This is verified by a pressure change registered remotely such as at the surface. Because the penetrator itself may effectively plug the opening the penetrator creates, there may be insufficient pressure change (drop or rise if tubing pressure is higher than hydraulic cylinder pressure at that time) to be measured at surface hence the requirement for retracting the penetrator to verify its action. In the event successful penetration was not achieved, the Puncture Communication Tool would have to be re-actuated and placement might not be exactly the same or the tool might be tripped out for redress simply to avoid damage. Moreover, it is possible that the penetrator will be broken during the retraction which will require a trip to surface to replace the penetrator at least.
As one of skill in the art is painfully aware, any additional actions required for any well function come at an exquisitely high price in terms of equipment to perform the action, loss of production, etc. Accordingly, the art is always receptive to improvements in processes and tools to improve efficiency
BRIEF DESCRIPTION
A penetrator for a Puncture Communication Tool includes a base; a body extending from the base and terminating at a tip; and a fluid bypass disposed in the body.
A method for communicating a hydraulic chamber includes urging a penetrator through a wall of a hydraulic chamber to penetrate into the hydraulic chamber; registering a pressure change in the hydraulic chamber without retracting the penetrator.
BRIEF DESCRIPTION OF THE DRAWINGS
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
FIG. 1 is a cross sectional view of a portion of a prior art Puncture Communication Tool in a run in position;
FIG. 2 is a cross sectional view of the portion of a prior art Puncture Communication Tool of FIG. 1 in an actuated position;
FIG. 3 is a perspective view of a penetrator as described herein;
FIG. 4 is a perspective view of a penetrator as described herein;
FIG. 5 is a perspective view of a penetrator as described herein;
FIG. 6 is a perspective view of a penetrator as described herein; and
FIG. 7 is a perspective view of a penetrator as described herein.
DETAILED DESCRIPTION
Referring to FIGS. 3-7 simultaneously, one of skill in the art will understand the overarching functional requirement of facilitating immediate fluid communication through the various penetrator 14 configurations upon breach of the hydraulic chamber 16 . In each case, a fluid bypass is created even if the penetrator 14 itself remains in the breach that it created in the hydraulic chamber 16 .
Referring to FIG. 3 , a first embodiment of the penetrator 14 is illustrated in a perspective view. The Penetrator 14 includes a base 20 and a tip 22 . The base 20 is of a greater area than the tip 22 more for convenience than for function as the base will interact with the prior art Puncture Communication Tool in the same way that the prior art penetrator did. The tip 22 is configured (shaped and dimensioned) to create the hole into the hydraulic chamber.
Importantly to the embodiment is the configuration of the section between the base and the tip, given the moniker herein of “body” 24 . The body 24 is roughly hourglass shaped, with the thinnest portion denoted neck 26 . Precisely how radically the hourglass shape is shaped relates to both fluid passage desired and strength of the penetrator 14 . The two considerations are juxtaposed to one another. More particularly, the more extreme the hourglass shape (narrower the neck), the more fluid flow is achievable but the weaker the penetrator simply because the amount of material that makes up the smallest diameter along the hourglass shape will be the weak link. Fluid flow will be greater because an annulus formed between the puncture size in the hydraulic chamber (dictated by the tip dimensions) and the neck 26 of the hourglass will have a larger annular dimension as the neck diameter decreases.
In two other illustrated embodiments, referring to FIGS. 4 and 5 , the penetrator 14 comprises base 20 and tip 22 as in FIG. 3 but body 24 is distinct. Body 24 comprises a flared frustoconical structure beginning at the base 20 and ending at the tip 22 . This shape is very similar to the prior art penetrator but in the invention, the body 24 is also provided with one or more recesses 30 therein (one illustrated) positioned through a side of the body 24 . Such a recess is producible by any number of machining tools that are known to the art. Referring to FIG. 5 , it will be appreciated that the recess 30 extends into the surface of tip 22 while that of FIG. 4 does not extend to the surface of tip 22 . In either case, the recess 30 provides a fluid pathway through which fluid in the hydraulic chamber 16 may escape thereby facilitating a pressure change thereby confirming penetration of the penetrator in to the hydraulic chamber 16 . Communication with the control line is hence assured.
In another embodiment hereof, referring to FIG. 6 , the penetrator 14 includes one or more passageways 32 through tip 22 and into body 24 . While the one or more passageways 32 is illustrated to originate at tip 22 and extend coaxially with penetrator 14 , it need not be so positioned. The opening could be off center and the one or more passageways would be off center and parallel with the axis of penetrator 14 or could be nonparallel with the axis of penetrator 14 . The depth of the one or more passageways 32 into body 24 is variable. The one or more passageways 32 is intersected with one or more cross passageways 34 that vent the passageway 32 to a surface of body 24 . Although the cross passageways 34 in FIG. 6 are positioned orthogonally to passageway 32 , they can be positioned at any angle that allows the fluid in passageway 32 to vent to a surface of body 24 . Also, although a single cross passageway is drilled diametrically across body 24 , it is noted that the cross passageway 34 could be radially positioned to extend from the passageway 32 to one side of the body 24 instead of both sides. There can also be more cross passageways and they may be at any angle.
Finally, referring to FIG. 7 , another alternate embodiment presents one or more through bore 36 from tip 22 to base 20 . The one or more through bores may be of varied diameter and can be positioned coaxially or non-coaxially with the penetrator 14 . In the case of one or more through bores being non-coaxial, they or it may be in parallel to the axis or may be nonparallel with the axis. In each embodiment fluid will pass the penetrator upon puncturing the hydraulic chamber thereby allowing a pressure change to be perceivable remotely to confirm puncture.
While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. | A penetrator for a Puncture Communication Tool includes a base; a body extending from the base and terminating at a tip; and a fluid bypass disposed in the body. Communicating a hydraulic chamber. | 4 |
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/398,161, filed Apr. 4, 2006, and claims the benefit of provisional patent application Nos. 60/708,206, filed Aug. 15, 2005, and 60/668,022, filed Apr. 4, 2005, the entire contents of each of which is incorporated herein by reference.
GOVERNMENT RIGHTS
[0002] This invention was made with Government support under Grant No. N00014-04-1-0654, awarded by the Office of Naval Research. The Government has certain rights in this invention.
[0003] Throughout this application various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this invention pertains.
TECHNICAL FIELD OF THE INVENTION
[0004] The invention disclosed herein relates to compositions and methods for modulating the blood coagulation cascade, accelerating bone generation, and assisting in wound healing and body repair. Both the materials selected for the hemostatic composition and the method for regulating hemostasis provide novel means for predictable control over blood coagulation, allowing for both accelerating and slowing or stopping blood flow.
BACKGROUND OF THE INVENTION
[0005] U.S. Pat. No. 4,822,349 issued to Hursey, et. al. describes reduction of blood flow by application of a dehydrated zeolite material to the site of blood flow. In this method, a particular calcium rich zeolite formulation of the class Linde Type 5A has been utilized as an external application to a traumatically wounded individual to induce hemostasis through dehydration of the wounded area and induction of a blood clot formation (Breck, D W et al., J. Am. Chem. Soc. 78, 23 (1950) 5963.). A major disadvantage to this product has been the excessive heat generated locally at the injured site as a consequence of the large enthalpy of hydration associated with the material currently marketed under the trade name, QuikClot™ and distributed by Z-medica corporation of Newington, Conn. USA. There remains a need for modifications and improvements that optimize the enthalpy of hydration upon rehydration of the dehydrated zeolite.
[0006] Bioactive glasses (BGs) with SiO 2 —CaO-P 2 O 5 -MO (M=Na, Mg, etc.) compositions were invented by Hench in 1971 (L. L. Hench et al., J. Biomed. Mater. Res. 1971, 2:117) and have been widely studied and used in clinical applications for bone and dental repair due to their chemical bonding with both soft and hard tissue through an apatite-like layer. The apatite-like layer promotes the adhesion of bioactive glass to tissues and avoids the formation of an intervening fibrous layer. This has been shown to decreases the failure possibilities of prostheses and influence the deposition rate of secondary bone and tissue growth. In vivo implantation studies demonstrate that these compositions produce no local or systemic toxicity, are biocompatible, and do not result in an inflammatory response. The SiO 2 —CaO-P 2 O 5 -MO BG system has been synthesized by the melting-quenching method (Hench et al., 1971, supra) or by the sol-gel method (P. Sepulveda et al., J. Biomed. Mater. Rev. 2002, 59:340; P. Saravanapavan and L. L. Hench, J. Biomed. Mater. Res. 2001, 54:608). Compared with the traditional melting-quenching method, sol-gel techniques were developed in the past decade to produce the same material at a lower working temperature. Sol-gel techniques also allow a greater degree of functionalization to be incorporated into the bioactive glass material to increase the rate of apatite-like layer growth as well as afford a wider range of bioactivity.
SUMMARY OF THE INVENTION
[0007] The invention provides a homogeneous composition comprising a hemostatically effective amount of a charged oxide, wherein the composition has an isoelectric point, as measured in a calcium chloride solution, below 7.3 or above 7.4. Typically, the charged oxide is selected from the group consisting of silaceous oxides, titanium oxides, aluminum oxides, calcium oxides, zinc oxides, nickel oxides and iron oxides. In some embodiments, the composition further comprises a second oxide selected from the group consisting of calcium oxide, sodium oxide, magnesium oxide, zinc oxide, phosphorus oxide and alumina. In a typical embodiment of the invention, the charged oxide is silaceous oxide, the second oxide comprises calcium oxide and the ratio, by molar ratio, of silaceous oxide to calcium oxide is 0.25 to 15. Optionally, the composition further comprises phosphorous oxide. Unlike conventional silaceous oxide compositions, the composition of the invention can be free of sodium oxide.
[0008] The charged oxide can be porous or nonporous. In some embodiments, the charged oxide comprises glass beads that are from about 10 nm to about 100 microns in diameter, typically from about 3 to about 10 microns in diameter. In some embodiments, the oxide is a layered clay such as the aluminosilcate Kaolin. In some embodiments, the charged oxide is porous, having pores of 2-100 nm diameter, typically 100-0200 μm diameter. The greater the porosity, the greater the surface area. The internal surface area can be between 1 and 1500 square meters per gram as determined by BET N 2 adsorption. While non-porous bioactive glass typically has a surface area around 20-30 square meters per grain, mesoporous bioactive glass is distinct because its surface area is greater than 200 square meters per gram. In a typical embodiment, the surface area is between 300 and 1000 square meters per gram.
[0009] Additional components that can be included in a composition of the invention include a zeolite and/or an inorganic salt. Examples of an inorganic salt include, but are not limited to, a divalent ion selected from the group consisting of zinc, copper, magnesium, calcium and nickel, as well as the following. CaO, CaCl 2 , AgNO 3 , Ca(NO 3 ) 2 , Mg(NO 3 ) 2 , Zn(NO 3 ) 2 , NH 4 NO 3 , AgCl, Ag 2 O, zinc acetate, magnesium acetate, calcium citrate, zinc citrate, magnesium citrate, magnesium chloride, magnesium bromide, zinc chloride, zinc bromide, calcium bromide, calcium acetate and calcium phosphate.
[0010] In some embodiments, the charged oxide is hydrated to between 0.1% and 25%, typically between 0.5% and 5% w/w. The composition of the invention can be prepared as a sol-gel. In some embodiments, the composition further comprises an ammonium phosphate buffer.
[0011] The invention additionally provides a method of modulating hemostasis comprising contacting blood with a composition described herein. The modulating can comprise decreasing blood coagulation time, for which purpose the composition has an isoelectric point below 7.3. Examples of materials with an isoelectric point below 7.3 include, but are not limited to, silaceous oxides, titanium oxides, and aluminosilicates. Alternatively, the modulating comprises increasing blood coagulation time and the composition has an isoelectric point above 7.4. Examples of materials with an isoelectric point above 7.4 include, but are not limited to, Al 2 O 3 and related aluminum oxides, calcium oxides, zinc oxides, nickel oxides, and magnetite and related iron oxides.
[0012] Also provided is a method of preparing a hemostatic composition. The method comprises: co-assembling a bioactive glass sol with a structure-directing amount of a triblock copolymer of poly(ethylene oxide)-poly(propylene oxide)-poly(ethylene oxide) to form a gel; and calcining the gel so produced at a temperature sufficiently high to remove the block copolymer and form mesopores; wherein the bioactive glass has all isoelectric point below the pH of blood. Similarly, the invention provides a method of preparing a passivated surface composition for minimizing coagulation upon contact of blood with the surface. The method comprises co-assembling a bioactive glass sol with a structure-directing amount of a triblock copolymer of poly(ethylene oxide)-polypropylene oxide)-poly(ethylene oxide) to form a gel; and calcining the gel produced in step (a) at a temperature sufficiently high (typically 300-700° C.) to remove the block copolymer, form mesopores and create a highly hydroxylated surface; wherein the bioactive glass has an isoelectric point above the pH of blood.
[0013] In addition, the invention provides a method of preparing a hemostatic composition. This method comprises passing a carrier gas through a solution comprising a bioactive glass sol to produce droplets; and spraying the droplets down a furnace. Examples of a carrier gas include, but are not limited to, air, nitrogen, oxygen, or natural gas. In some embodiments, such as for preparation of mesoporous materials, the solution further comprises a block copolymer.
[0014] In another embodiment, the invention provides a method of preparing a hemostatic composition of micropores. The method comprises cooling a solution comprising silicic acid and calcium salts to below 0° C. to form a gel; and freeze-drying the gel to form micropores. Typically, the cooling step comprises cooling the solution to −70° C. to −200° C. In some embodiments, the solution further comprises a phosphorous oxide, typically in the form of a phosphate group. In another embodiment, the solution further comprises chitosan. The method can further comprise calcining the gel at 300 to 900° C. In a typical embodiment, the cooling comprises direction freezing. In some embodiments, the micropores produced by the method are 1 to 200 microns in diameter.
[0015] The invention further provides a method of modulating hemostasis comprising contacting blood with a composition prepared by one of the methods described herein. In addition, the invention provides a medical device that has been coated with a composition of the invention, such as a composition having an isoelectric point above the pH of blood.
[0016] Also provided is a method of promoting the formation of tissue comprising contacting the composition of the invention with a hydroxyapatite precursor solution. The tissue can comprise, for example, artificial bone, artificial skin, or a component thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a plot of both clot detection time, R, (filled shapes) and rate of coagulation, α, (un-filled shapes) vs. BG Si:Ca. Data represents the mean of four trials. ▪ Porous BG; ● Non-porous BG; ▾ Spherical BG; +No HA.
[0018] FIG. 2 is a Thrombelastograph®plot of bioactive hemostatic agents. Inner Thromboelastograph plot on both plots is sheep blood without a HA added.
[0019] FIG. 3 is a Thrombelastograph® plot of bioactive glass, QuikClot™, and sheep's blood alone.
[0020] FIG. 4 is a thermogravimetric analysis and differential scanning calorimetry of the dehydration of porous and non-porous bioactive glass. 90 J/g (Non-porous Bioactive glass) and 450 J/g (Porous Bioactive glass).
[0021] FIG. 5 is a Thrombelastograph® plot of mesoporous bioactive glass with varying SiO2:CaO ratios. BG 80 has a molar ratio of SiO2:CaO of 80:16. BG 60 has a molar ratio of SiO2:CaO of 60:16.
[0022] FIG. 6 is a Thrombelastograph® plot of non-porous bioactive glass with varying SiO2:CaO ratios. BG NP 80 has a molar ratio of SiO2:CaO of 80:16. BG NP 70 has a molar ratio of SiO2:CaO of 70:16. BG NP 60 has a molar ratio of SiO2:CaO of 60:16.
[0023] FIG. 7 is a thermogravimetric analysis and differential scanning calorimetry of the dehydration process for a hydrated mesoporous bioactive glass and a non-porous bioactive glass.
[0024] FIG. 8 is a compilation of the heat of hydration and hydration capacity of bioactive glass. BG80 has a molar ratio of SiO2:CaO of 80:16. BG60 has a molar ratio of SiO2:CaO of 60:16.
[0025] FIG. 9A shows a Thromboelastograph® plot of the hemostatic activity MBGM-80 induced coagulation vs. blood w/o MBGM-80.
[0026] FIG. 9B shows a plot of both clot detection time, R, (filled shapes) and rate of coagulation, α, (un-filled shapes) vs. amount of mesoporous bioactive microspheres. Data represents the mean of four trials. ▪ MBGM-60, ● MBGM-80, ▴ MBGM-60 Non-porous, ▾ MBGM-80 Non-porous, +Sheep Blood w/o MBGM.
[0027] FIG. 10 shows BET adsorption-desorption isotherm of bioactive glass.
[0028] FIG. 11 shows pore size distribution of mesoporous bioactive glass.
[0029] FIG. 12 shows BET surface area and pore diameter calculations.
[0030] FIG. 13 shows wide angle x-ray diffraction of bioactive glass substrates pre- and post-immersion in simulated body fluids for 1 hour.
[0031] FIG. 14 is a Thrombelastograph® plot of oxides with an isoelectric point below the pH of blood.
[0032] FIG. 15 is a Thrombelastograph® plot of oxides with a isoelectric point above the pH of blood.
[0033] FIG. 16 shows R (min), onset of clot detection, versus the metal oxide's isoelectric point for low-surface area metal oxides.
[0034] FIG. 17 shows α (°), rate of coagulation, versus the metal oxide's isoelectric point, for low-surface area metal oxides.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The invention is based on the discovery that oxide materials can be prepared to modulate hemostasis on the basis of surface charge. This modulation enables the synthesis of materials that are pro-coagulants; or, alternatively other materials that are anticoagulants. The latter are of importance with respect to die oxide coatings that form on metal medical implant devices. The methods of preparing oxide compositions of the invention avoid problems associated with longer setting times and also produce materials having better performance characteristics. The methods of the invention produce materials that offer superior compositional and structural homogeneity and higher surface area, which provide more effective materials. For example, one embodiment of the invention provides a rapid-setting, mesoporous, bioactive glass cement that exhibits excellent plasticity, superior bioactivity and is mechanically robust. In addition to modulation of hemostasis, the oxide compositions of the invention can be used for growth and repair of bone and other tissues as well as in drug delivery.
[0036] In one embodiment of the invention, high surface area mesoporous bioactive glass has been prepared by a sol-gel template directed assembly. This material has the ability to conform and adhere to wounded tissue to promote blood clot formation. This specific material has a distinct morphological advantage over previous bioactive glass materials in that it can conform and adhere to any wound cavity geometry. When mixed with an ammonium phosphate buffer solution, a bioactive glass cement can be formulated that has a predictable set time and accelerates the deposition of new apatite, layers when in contact with biological fluids. Mesoporous bioactive glass (MBG) cements are malleable before setting and retain their shape and mechanical strength without crumbling after setting. Furthermore, mesoporous bioactive glass has demonstrated a high osteoconductive property. This material can be formulated in a variety of compositions for applications as a rapid acting hemostatic agent, template for the growth of artificial bone, and the generation of tissue. Bioactive glass can be formulated for a variety of distinct wound healing scenarios and can elicit a predictable wound healing response, for both controlling the flow of blood as well as controlling the rate of apatite deposition, as a function of agents chemical composition and Si to Ca ratio.
[0037] In addition to the synthesis of mesoporous bioactive glass, this invention provides a method by which materials can be selected based on their isoelectric point to induce a predictable hemostatic response. Under physiological conditions, the isoelectric point of an oxide will determine both the sign and magnitude of the initial surface charge density upon exposure to biological fluids. Oxides have been identified that will induce coagulation upon exposure to blood. Oxides have also been identified that will prevent or slow down the coagulation response of blood in contact with the surface of the oxide. A strategy to produce both rapid acting hemostatic agents and passivated medical device surfaces is described based on the selection criteria.
DEFINITIONS
[0038] All scientific and technical terms used in this application have meanings commonly used in the art unless otherwise specified. As used in this application, the following words or phrases have the meanings specified.
[0039] As used herein, a “hemostatically effective amount” means an amount sufficient to initiate detectable blood clotting (R) within 2 minutes, and/or achieve a rate of clotting (α) of 50° or greater, and/or achieve a clot strength (MA) of ≧50, as determined by Thromboelastograph® measurements. Assays for determining hemostatic effectiveness are known in the art, and described in die Examples below.
[0040] As used herein, a “Thromboelastograph” assay refers to measurements typically taken using about 5-30 mg of material mixed with 340 microliters of citrate stabilized blood. Calcium ions are re-supplied to the citrate stabilized blood prior to measurements to replace the calcium ions chelated by citrate.
[0041] As used herein, “isoelectric point” refers to the pH at which the zeta-potential equals zero in an aqueous electrolyte such as 2 mM CaCl 2 . The zeta potential is the surface charge density of a metal oxide in aqueous suspension, measured as a function of pH by the electrophoretic method using the Smoluchowski equation (Cocera, M. et al., Langmuir 1999, 15, 2230-2233). Unless specifically indicated otherwise, the zeta potential of the metal oxide is measured in a CaCl 2 electrolyte that mimics the Ca 2+ concentration in blood.
[0042] As used herein, “homogeneous” means an absence of phase separation (e.g., separation of a silicate phase and a phosphate phase); the materials are not phase segregated when examined by energy-dispersive x-ray analysis (EDX) using scanning electron microscopy (SEM) with a resolution limit of 0.5 microns. A composition is homogeneous if it consists of a uniform distribution or dispersion of components.
[0043] As used herein, a “bioactive glass sol” means a colloidal suspension containing silica precursors and calcium salts that can be gelled to form bioactive glass solid, wherein the solvent can be water, ethanol or other substance that can dissolve silica precursors and calcium species.
[0044] As used herein, “a” or “an” means at least one, unless clearly indicated otherwise.
[0000] Bioactive Glass (BG)
[0045] For the sol-gel-derived BGs to exhibit in vitro bioactive behavior, it has been shown that both the chemical composition and textural properties (pore size and volume) are important. Melt-derived glasses show a direct dependence on composition with bioactivity. Increasing the specific surface area and pore volume of BGs will greatly accelerate the kinetic deposition process of hydroapatite and therefore enhance the bone-forming bioactivity of BGs. Several strategies have been developed to obtain high specific surface area materials and engineer pore stricture of the BGs, including using soluble inorganic salt, colloidal spheres or block copolymers as pore-forming agents. The high surface area mesoporous bioactive glass described herein has a unique morphology with advantages over these methods including higher surface area and ease of functionalization of the final material. This functionalization includes, but is not limited to, the surface immobilization and the controlled release of biologically relevant molecules. Molecules such as phospholipids, fibrin, collagen, clotting zymogens, heat shock proteins, antibacterial peptides, and silver, magnesium, calcium, sodium, zinc, chloride, and phosphate ions can be controllably released to effect an optimal bio-response.
[0046] The porous bioactive glass material can be described by the general formula SiO 2 —CaO—P 2 O 5 -MO (M=Na, Mg, etc.). BET analysis has shown that the bioactive glass of the invention has a surface area far greater than the 5 square meters per gram (m 2 /g) observed in prior art materials, and typically in the range of more than 100 m 2 /g, often more than 200 m 2 /g. In one embodiment, the bioactive glass of the invention has a surface area of at least about 300 m 2 /g. Surface areas of 500-1000 m 2 /g can be attained. The surface area is influenced by the polymer used in synthesis of the bioactive glass. A surface area of about 300 m 2 /g has been attained with bioactive glass prepared from P123, while low molecular weight polymers, such as L43, can produce much higher surface area (in the range of 900 m 2 /g). The high surface area provides for optimal pore volume.
[0000] Hemostatic Activity of Bioactive Glass
[0047] Disclosed herein is a new and specific application of bioactive glass related to rapid acting hemostatic agents for the treatment of traumatic injuries. The traumatic wound healing scenario is distinct from prior medical applications for bioactive glass-like materials. The term “bioactive glass” has been loosely applied to many composites of calcium oxide, silicon dioxide, phosphorous oxide and other metal oxides, the combination of which is able to promote the growth of bone and tissue.
[0048] The invention described in U.S. provisional patent application No. 60/668,022, filed Apr. 4, 2005, provides a calcium loaded zeolite linde type A that is ion exchanged with aqueous solutions of alkali, alkaline earth, and transition metal cations to specific ion formulations. This ion exchanged zeolite can be mixed with neutral inorganic salts like calcium chloride, aluminum sulfite, and silver nitrate and dehydrated to remove water. The dehydrated inorganic materials are sealed in mylar foil bags to prevent rehydration until required during medical application. At the time of medical application, the mylar bag can be opened and the inorganic contents poured into the traumatically injured site.
[0049] The present invention provides the bioactive glass in a gel) liquid, cement, paste or powder form, which allows for greater ease of use and better conformation to a desired area to be treated. By providing the material in gel (or cement) form, for example, it can be applied to a greater variety of surfaces, increasing its availability for use in numerous contexts, including application to medical devices and drug delivery.
[0050] Porous bioactive glass materials have been designed to treat traumatically injured tissue by inducing hemostasis through contact activation and release of coagulation co-factors. In addition, the compositions of the present invention provide a uniform pore size that further optimizes its use for regulation of hemostasis.
[0051] The hemostatic activity of bioactive glass is dependent on the material's chemical composition. For the range of chemically distinct bioactive glass agents studied (Si:Ca:P atomic — ratio 60:36:4 to 90:6:4), the onset time for contact-activated coagulation, rate of coagulation of post-initiation, and ultimate clot strength was found to be dependent on the material's Si:Ca ratio, porosity, and heat of hydration. The onset time for contact-activated coagulation was found to decrease in an increasing Si:Ca ratio.
[0052] The rate of coagulation post-initiation was found to increase with an increasing Si:Ca ratio. Porous bioactive glass was found to have a greater procoagulant tendency than non-porous bioactive glass.
[0000] Bone-Generating Activity of Bioactive Glass
[0053] The bone-generating activity of bioactive glass is dependent on the material's chemical composition. For the range of chemically distinct bioactive glass agents studied, (Si:Ca:P atomic — ratio 60:36:4 to 90:6:4) the deposition rate of hydroxyapatite deposition in biological fluids is related to the material's Si:Ca ratio and particle size and shape. The rate of deposition of hydroxyapatite was observed to be faster for bioactive glass samples with a lower Si:Ca ratio (e.g. BG60:36:4 faster than BG80:16:4).
[0054] The high osteoconductive properties of this unique formulation of bioactive glass is a result of the presence of a large number of surface hydroxyl groups (Si—OH) that provide nucleation sites for apatite-like layer growth. The sol-gel technique developed in our laboratory allows us to optimize these nucleation sites for a tailored bio-response, and ultimately an improved generation of hydroxyapatite.
[0000] The Isoelectric Point Material Property as a Predictor of Hemostatic Activity
[0055] The isoelectric point of a material is a critical material parameter that can be utilized to select oxides that can either promote or prevent the induction of hemostasis. Rapid acting hemostatic agents and passivated medical devices are applications intended for this material. The present inventors have discovered that the oxide's initial surface charge, driven by the isoelectric point of the material relative to the pH of the immersing biological medium, is the key factor in controlling hemostatic efficacy of the composition.
[0056] The onset time for contact-activated coagulation, rate of coagulation post-initiation, and ultimate clot strength are found to be dependent on the initial surface charge density of the metal oxide when exposed to blood, which is related to the oxide's acid-base nature and is quantitatively described by its isoelectric point. Wee found, that for polar metal-oxide substrates, the time to initiate contact-activated coagulation increases with the increase in the metal oxide's isoelectric point.
[0057] Blood is usually the first fluid an implanted foreign body encounters, and thus the thrombotic complications which arise from metallic implants (chronic inflamatory response), and inorganic-based extracorporeal circulating devices parts, arterial stents, and catheters is related to the chemistry that occurs during the initial exposure of blood to a foreign oxide surface. Although the activating inorganic surface will become contaminated with biological products over time (e.g. massive attack complex, fibrin 12 ), the initial surface charge density of a metal oxide surface will affect the selective adhesion of oppositely charged molecules and biological media (e.g. cells and larger proteins) immediately upon contact with blood. We observed that both the sign and magnitude of the metal oxide's surface-charge density affects blood coagulation metrics, including the onset time, rate of clot formation, and viscoelastic strength of contact-activated blood clots, and that an oxide's isoelectric point can be used to predict its in vitro hemostatic activity.
[0058] Negatively-charged surfaces are known to initiate the intrinsic pathway of the blood coagulation cascade, a network of feedback-dependent reactions that when activated results in a blood clot. The activation of this process by a foreign body is referred to as contact-activation of coagulation. The same network of coagulation reactions also can be activated via the extrinsic pathway, which occurs when a breach in the endothelium allows the exposure of platelets to tissue factor bearing cells.
[0059] Because of the electronegativity difference between oxygen atoms and the metallic atoms they are covalently bonded to, metal oxides are inherently polar surfaces. Their surface chemistry is all the more complicated due to the presence of “dangling” terminal hydroxyl groups on unsaturated metal sites and related defect sites. The surface charge of metal oxides is known to be pH dependent and is thought to result from either the amphoteric dissociation of surface MOH groups or the adsorption of metal hydroxo complexes derived from the hydrolysis product of material dissolved from the metal oxide. There exists a unique pH for each oxide above which the material is negatively charged and below which the material is positively charged. The pH at which the sum total of negative and positive surface charges equals zero, Σ(z−n)M z+ (OH) n z−n =0, is called the isoelectric point.
[0060] We have observed a variable contact-activated coagulation response from metal oxides with distinct isoelectric points, all of which are inherently polar substrates, and which requires that we refine our understanding of the traditional definition of hemocompatibility based on surface energetics. We have found that acidic oxides are prothrombotic while basic oxide are antithrombotic. The relative difference between the metal-oxide's isoelectric point and the pH of blood determines the initial surface-charge density of the substrate when exposed to blood. This material parameter has been shown to affect the onset time for coagulation, rate of coagulation post-initiation, and ultimate clot strength.
[0000] Thromboelastograph Assay
[0061] Thromboelastograph®. The in vitro hemostatic activity of metal-oxide hemostatic agents was evaluated as previously described using a Thromboelastograph®, a clinical instrument that monitors the change in viscoelasticity of blood as a function of time. Briefly, 340 μL of 4% v/v citrate-stabilized sheep blood (Quad Five of Ryegate, Mont.) was introduced into the sample cup of a Thromboelastograph®, Haemoscope model 5000, along with 20 μL of 0.2M CaCl 2 (aq) and 5-20 mg of a tested metal-oxide in a powder morphology. The 20 μL of 0.2 M CaCl 2 (aq) was added to the stabilized blood to replenish the Ca 2+ ions chelated by citrate, which was added to prevent coagulation of stored blood. Blood was stored at 8° C. prior to use.
[0062] The Thromboelastograph® sample cup is rotated ±5° about a vertical torsion wire suspended in the middle of the cup. As the hardening blood clot tugs on the torsion wire, the change in viscoelastic clot strength is monitored as a function of time. The time until the bimodal symmetric viscoelasticity curve's amplitude is 2 mm is referred to as R (minutes), and represents the initial detection of clot formation. The angle between the tangent to the curve and the horizontal is referred to as α (°), and is related to the rate of coagulation. The maximum amplitude of the curves is referred to as MA (mm) and represents the maximum clot strengths. Thromboelastograph® clotting parameters reported represent the mean of four reproducible trials. A summary of the hemostatic properties of metal-oxides with variable isoelectric points is described in Table 1.
TABLE 1 Summary of Metal-Oxide Contact-Activated Coagulation Low-surface-area metal High-surface-area metal Clotting Metric oxides oxides Onset of coagulation; R Coagulation onset time Coagulation onset time for (min) increased or of equal value positively charged surface Initially Positively compared to blood alone similar to blood alone Charged Metal Oxide for positively charged surface, and slowest for the most positive surface Initially Negatively Coagulation onset time Coagulation onset time Charged Metal Oxide reduced for negatively reduced for negatively charged surfaces, and charged surfaces fastest for most negative substrate Rate of coagulation post- Positively-charged surfaces Positively-charged surfaces initiation; α (°) decelerate the rate of decelerate the rate of Initially Positively coagulation coagulation Charged Metal Oxide Initially Negatively Negatively-charged Negatively-charged Charged Metal Oxide surfaces accelerate the rate surfaces accelerate the rate of coagulation of coagulation in the presence of sufficient Ca2+ ions Isoelectric Point Below Isoelectric Point Above Clotting Metric the pH of Blood the pH of Blood Onset of coagulation; R Coagulation onset time Coagulation onset time (min) reduced for negatively increased or of equal value charged surfaces, and compared to blood alone fastest for most negative for positively charged substrate surface, and slowest for the most positive surface Rate of coagulation post- Negatively-charged Positively-charged surfaces initiation; α (°) surfaces accelerate the rate decelerate the rate of of coagulation coagulation Ultimate clot strength Most negative oxide Induced blood clots are (MA) resulted in steongest blood less than or equal in clots and least negative strength to naturally oxide resulted in weakest formed blood clots blood clot
Methods
[0063] The invention provides a method of producing a composition for modulating hemostasis, and also a method of modulating hemostasis comprising contacting blood with a composition of the invention. Compositions that modulate homeostasis can be prepared by the methods described in the Examples below, including aerosol synthesis and use of sol-gel chemistry. Sol-gel chemistry can be used to produce bioactive glass. By spraying the sol-gel solution down a hot furnace (e.g., 400° C.), spherical bioactive glass particles are produced. These bioactive glass particles can be as small as 10-50 nm in diameter, or smaller, or as large as about 100 μm or larger. In one embodiment, the particles are 50-200 nm in diameter.
[0064] Typically, the method of producing a composition of the invention involves starting from a bioglass sol, wherein the solvent is ethanol (or another solvent that can dissolve precursors and has a low boiling point). A block copolymer can be used as all additive to provide a pore-forming gent.
[0065] In some embodiments, such as the freezing method, the ideal solvent is water rather than ethanol because the melting point of ethanol is very low. The difference in solvent typically calls for some difference in the method. For example, most PEO—PPO-PEO block copolymers cannot dissolve in water. Second, chitosan can be incorporated into the system because it doesn't dissolve in the ethanol, and chitosan plays an important role in modulating blood coagulation. In addition, the silica and phosphous precursors are different from those in an ethanol-based method and phosphorous oxide is not required in the starting sol, as would be the typical case when starting with a bioglass sol.
[0066] In some embodiments, the method of modulating hemostasis comprises decreasing blood coagulation time. In one embodiment, the time to initiate detectable coagulation (R), as measured by Thromboelastograph®, is less than 2 minutes, and can be less than 1.8 minutes. In another embodiment, the rate of coagulation (α), as measured by Thromboelastograph®, is more than 50°. Coagulation rates of more than 55°, and of more than 65° have been achieved. In a further embodiment, the coagulation results in a maximum clot strength (MA), as measured by Thromboelastograph®, of 55 to 100 mm, and can be less than 75 nm. Alternatively, the modulating comprises increasing blood coagulation time. Increased coagulation time is desirable, for example, when clotting poses a health risk to the subject.
APPLICATIONS OF THE INVENTION
[0067] Oxides with an isoelectric point below the pH of blood can be formulated for action to induce blood clot formation faster than blood would naturally do in the absence of an oxide-contact activator. The materials can be applied both externally and internally as agents to induce hemostasis and reduce the flow of blood in a particular area of the body.
[0068] Oxides with an isoelectric point above the pH of blood can be formulated to induce blood clot formation slower than blood would naturally do in the absence of an oxide-contact activator, and therefore would be suitable as passivated surfaces for medical devices. Thus, the invention provides a medical device and methods of coating a medical device with a composition of the invention. Coatings can be prepared from a composition in powder form or using sol-gel chemistry, using conventional methods known in the art. In one embodiment, the coating reduces coagulation of blood in contact with the device. The medical devices include, but are not limited to, arterial and venal stents, catheters, shunts, and any medical machinery that will contact blood during invasive medical procedures.
[0069] Oxides with an isoelectric point above the pH of blood can be formulated for devices that require a positively charged surface to interface with biological tissue and fluids.
[0070] Oxides with an isoelectric point below the pH of blood can be formulated for devices that require a negatively charged surface to interface with biological tissue and fluids.
[0071] When mixed with an ammonium phosphate buffer solution, a bioactive glass cement can be prepared with a controllable set time. Bioactive glass, and particularly, bioactive glass cement, can be prepared with a flexible morphology that allows for conformation and adhesion to any wound geometry. The bioactive glass cement can be molded in a variety of shapes that retain their mechanical integrity post-setting. The bioactive glass cements can accelerate the deposition of an apatite layer compared to the bioactive glass agent alone.
[0072] Mesoporous bioactive glass can be formulated as a rapid acting hemostatic agent. This material can predictably warm injured tissue to promote wound healing.
[0073] Mesoporous bioactive glass can be formulated to promote the formation of artificial bone. This same material can be used to generate tissue including, but not limited to, artificial skin and structural elements such as fibrin and collagen.
[0074] The internal porous architecture can be loaded with biologically relevant molecules and cofactors for controlled released during wound healing and body repair. These biologically relevant molecules and cofactors include, but are not limited to, phospholipids, blood coagulation factors, fibrin, collagen, blood clotting zymogens, silver ions, magnesium ions, and calcium ions.
[0075] The internal porous architecture can be loaded with antibacterial peptides and silver ions for a controlled release of antibacterial agents.
[0076] Non-porous bioactive glass can be formulated as a rapid acting hemostatic agent. This material can predictably warm injured tissue to promote wound healing.
[0077] Non-porous bioactive glass can be formulated to promote the formation of artificial bone. This same material can be used to generate tissue including, but not limited to, artificial skin and structural elements such as fibrin and collagen.
[0078] The hemostatic activity of bioactive glass can be controlled and optimized for a variety of wound healing scenarios by manipulating the ratio of Si to Ca in the chemical composition of both porous and non-porous bioactive glass.
[0079] The bone-generating activity of bioactive glass can be controlled and optimized for a variety of wound healing scenarios by manipulating the ratio of Si to Ca in the chemical composition of both porous and non-porous bioactive glass.
EXAMPLES
[0080] The following examples are presented to illustrate the present invention and to assist one of ordinary skill in making and using the same. The examples are not intended in any way to otherwise limit the scope of the invention.
Example 1
Hemostatic Activity of Bioactive Glass
[0081] The time until clot detection, R, decreases for increasing Si:Ca ratios in BG ( FIGS. 1, 2 ). R is reduced by a factor of 2 when the Si:Ca ratio is doubled over the range studied.
[0082] BG can perform the dual role of providing surface area for thrombosis and supplying Ca 2+ ions; hence there will be an optimum ratio of SiO 2 to Ca 2+ ions, which are co-factors throughout the clotting cascade, for the fastest hemostatic response. The BG-induced coagulation rate, α, increases with increasing Si:Ca ratios and maximizes for the same Si:Ca ratio as for the minimum R time (Si:Ca(R min α max ) ˜2.5). All blood clots induced by BGs resulted in stronger than natural clots (MA BG ≧62 and MA Natural =58 dyn/cm 2 .
Example 2
Formulation of Mesoporous Bioactive Glass
[0083] The unique formulation of high surface area mesoporous bioactive glass that we have prepared has the ability to rapidly induce a blood clot when exposed to blood. In fact, the formulation we have prepared has a faster clotting time and results in a stronger clot than QuikClot™, the leading inorganic hemostatic agent currently available (see FIG. 3 ). Both the porous and non-porous formulations of bioactive glass possess this ability to rapidly promote blood coagulation. Because the porous and non-porous formulations of bioactive glass can be hydrated to different degrees, and consequently will deliver different amounts of heat upon hydration during medical application to a wound site, we can further tailor the rate of blood coagulation. Combinations of porous and non-porous bioactive glass can be formulated to the desired specifications of hydration and delivery of heat (see FIG. 4 ).
Example 3
Mesoporous Bioactive Glass with Varying Ratios of SiO2:CaO
[0084] This example shows that one make the bioactive glass with varying ratios of SiO2:CaO. At higher SiO2:CaO ratios (more silica), the material tends to clot blood faster. This is illustrated in both FIGS. 5 and 6 . As the amount of SiO2 relative to the amount of CaO is reduced, the kinetics of clot formation are much slower. The difference in clotting kinetics between two bioactive glass samples with different SiO2:CaO is more pronounced with the non-porous samples. The mesoporous bioactive glass is a faster clotting agent than the non-porous samples, but the difference between samples is greater within the non-porous samples.
[0085] This example also shows that one can use combinations of porous and non-porous bioactive glass, as well as composites with multiple bioactive glasses of different SiO2:CaO ratios, to achieve any desired hydration capacity and heating response when in contact with blood (see FIGS. 7 and 8 ).
Example 4
Spherical Bioactive Glass
[0086] Spherical Bioactive glass is produced by an aerosol assisted method and with the same sol-gel precursor solution employed for bioactive glass previously described. Spherical bioactive glass accelerates the formation of a contact-activated clot. The activity of bioactive glass is dependent on the relative amount of contact activating agent to the surrounding blood volume ( FIG. 9 ).
Example 5
Host-Guest Composites
[0087] The porous architecture of mesoporous bioactive glass is ideal for the controlled release of biomolecules. These molecules can be immobilized on the oxide surface of bioactive glass or solvated with surfactants inside the pores, or loaded alone in die pores. Each of these formulations will have a unique release profile with regard to concentration and rate of release. The combination of porous bioactive glass and biomolecules is referred to as a host-guest composite.
[0088] Host-guest composites can also be prepared to release ions including, but not limited to, silver, magnesium and calcium ions. Silver ions have been shown to be antibacterial at parts per billion concentration in biological fluids. Magnesium and calcium ions are essential cofactors during the coagulation of blood. Certain formulations of porous bioactive glass can also sequester magnesium and calcium from blood to delay the coagulation response.
[0000] Synthesis
[0089] Mesoporous bioactive glasses (MBGs) were synthesized by co-assembly of a BG sol with a triblock copolymer poly(ethylene oxide)-poly(propylene oxide)-poly(ethylene oxide) as the structure-directing agent through an evaporation-induced self-assembly (EISA) process. The dried gel was calcined at high temperature to remove the block copolymer and form mesopores. The final MBGs were ground into powders. The as-calcined MBGs have more accessible mesopore surface area and ordered pore structure. In vitro study showed a greater bone-forming bioactivity than conventional sol-gel derived BGs by fast formation of an amorphous bioactive HA layer.
Example 6
Bioactive Glass Cements
[0090] Bioactive glass cements were prepared by mixing bioactive glass powders with an ammonium phosphate buffer solution. The liquid component of MBGCs, an ammonium phosphate buffer solution, was prepared by dissolving 60.1 g (NH 4 ) 2 HPO 4 and 5.0 g NH 4 H 2 PO 4 in 100 mL water. The pH of the resulting solution was ˜7.3. MBGC cements were made by mixing the solid and liquid components at the ratio of 1 g to 1 mL. The cements were kept in the ambient environment to set. Before setting fully, they were soft enough to be kneaded or molded. Structural characterizations were typically carried out at ˜1 h after the mixing of the solid and liquid components of MBG, and no structural changes were observed after 1 h after mixing.
[0091] The assessment of the in vitro bioactivity of bioactive glass powders and cements was carried out in SBF at 37° C. SBF contained 142.0 mM Na + , 5.0 mM K + , 1.5 mM Mg + , 2.5 mM Ca 2+ , 147.8 mM Cl − , 4.2 mM HCO 3 − , 1.0 mM HPO 4 2− , and 0.5 mM SO 4 2− . Its chemical composition is similar to that of human plasma. The solution had a pH of 7.3-7.4 and was kept at 37° C. before use.
Example 7
Surface Area Measurements of Mesoporous Bioactive Glass
[0092] This example presents data on the surface area measurements that have been made of the mesoporous bioactive glass of the invention. In FIG. 10 , the adsorption-desorption isotherm is presented. The lack of hysteresis suggests a channel-like structure without internal cages. This adsorption-desorption isotherm can be used to calculate the pore size distribution of the mesoporous bioactive glass based on the BJH model. A plot of the pore size distribution is illustrated in FIG. 11 .
[0093] The calculated surface area of mesoporous bioactive glass is displayed in FIG. 12 . Bioactive glass can be formulated with a surface area ranging from 300 m 2 /g to 1000 m 2 /g. The sample that was used for the measurements described in this example had a surface area of 960 nm/g. The internal pore diameter was calculated to be 3.1 nm based oil the BJH model and 2.5 nm based on the BET model.
Example 8
Bone-Generating Activity of Bioactive Glass
[0094] The assessment of the in vitro bioactivity of bioactive glass powders and cements was carried out in simulated body fluids (SBF) at 37° C. SBF contained 142.0 mM Na + , 5.0 mM K + , 1.5 mM Mg 2+ , 2.5 mM Ca 2+ , 147.8 mM Cl − , 4.2 mM HCO 3 − , 1.0 mM HPO 4 2− , and 0.5 mM SO 4 2− . Its chemical composition is similar to that of human plasma. The solution had a pH of 7.3-7.4 and was kept at 37° C. before use.
[0095] The in vitro assessment of in vivo bone-generating bioactivity is typically conducted by monitoring the formation of hydroxyapatite on die surface of bioactive glass after immersion in SBF. After mixing the bioactive glass powder with the ammonium phosphate buffer solution, weak x-ray diffraction peaks at 2θ=26° (002) and 32° (211) corresponding to hydroxyapatite are observed. The broad peak at 2θ=23° is due to the amorphous nature of the bioactive glass walls ( FIG. 13 ). The average hydroxyapatite crystal size nucleated after immersing BG60:36:4 in simulated body fluids for one day is 37 nm. The average hydroxyapatite crystal size nucleated after immersing BG80:16:4 in simulated body fluids for one day is 32 nm. Faster rates of hydroxyapatite were observed with BG60:36:4 compared to BG80:16:4.
Example 9
Isoelectric Point Fast Acting Clotting Agents, and Passivated Medical Device Surfaces
[0096] As described in U.S. provisional patent application No. 60/668,022, filed Apr. 4, 2005, we have identified four critical materials parameters that can be used to predict the hemostatic response for exposing a given oxide to blood. We have shown that blood coagulation can be induced rapidly through the dehydration of blood, application of an appropriate amount of heat, and by delivering ions, like calcium, that are cofactors in the blood coagulation network. Oxides with a surface charge will also induce a coagulation response. More specifically, the isoelectric point is the underlying principle effecting the surface charge induced contact activation coagulation response.
[0097] Every oxide material will possess an initial surface charge that is a function of both the isoelectric point of the material and the pH conditions of the immersing solution (see FIG. 14 ). By observing the rate of coagulation of blood upon exposure to a variety of inorganic oxides, we have observed that those materials with an isoelectric point below the pH of blood accelerate the coagulation response (see FIG. 14 ). Those materials with an isoelectric point above the pH of blood are observed to decelerate the coagulation response (see FIG. 15 ).
[0098] Designing rapid acting hemostatic agents requires an optimization of the four material parameters already identified: isoelectric point, hydration capacity, thermal application (heat), and control of the local electrolyte conditions. Similarly, designing passivated medical device surfaces for contact with blood requires a related, albeit opposite, optimization of these material parameters compared to a fast acting clotting agent. By selecting oxides of varying isoelectric points, it is possible to modulate the blood coagulation response from spontaneous coagulation to inhibition of coagulation. This control over the blood response is unique to inorganic oxides and offers major advantages over current organic based hemostatic technology. This relationship between isoelectric point and coagulation provides for the design of new bioactive glass compositions tailored to desired objectives in the regulation of hemostasis.
Example 10
Isoelectric Point and Low-Surface-Area Metal Oxides
[0099] It is well accepted that negatively charged surfaces activate the intrinsic pathway of the blood clotting cascade. The SiO 2 glass beads, which have the lowest isoelectric point (IEP=2.1) of all the low-surface-area oxides analyzed, initiated the formation of a detectable blood clot on average 2.9 min after exposure to sheep blood. Because this material has the lowest isoelectric point, under physiological conditions (pH=7.3-7.4), SiO 2 substrates will initially posses the greatest negative surface-charge density compared to the other oxides tested. The time until clot detection increases with the increasing isoelectric point of the low-surface-area materials studied ( FIG. 16 ). NiO has the isoelectric point that is closest to the pH of blood, and the average clot time induced by NiO is nearly indistinguishable from that of blood in its absence (R NiO =11 min and R BloodAlone =10.9 min). ZnO has the highest isoelectric point of the materials studied (IEP=9.5) and was observed to actually delay the time until blood clot detection by about 1.5 min compared to sheep blood alone.
[0100] The fastest rate of coagulation, α (°), for the low-surface-area metal oxides, was observed with the SiO 2 glass beads (α=75.2°, IEP=2.1), which initially posses the most negative surface in blood compared to the other low-surface-area metal oxides studied. ( FIG. 17 ). The slowest rate of coagulation was observed when ZnO was introduced to sheep blood (α Blood =50.2°; α ZnO =30.4°). ZnO possesses the maximum positive surface charge when immersed in blood. All of the oxides with an isoelectric point above the pH of blood were observed to decelerate the rate of coagulation compared to blood alone, and in particular, NiO, which has the closest isoelectric point to the pH of blood but will be positively charged after immediately contacting blood, was observed to reduce the rate of coagulation.
[0101] From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. | The invention provides a homogeneous composition comprising a hemostatically effective amount of a charged oxide, wherein the composition has an isoelectric point, as measured in calcium chloride, below 7.3 or above 7.4. Typically, the charged oxide is selected from the group consisting of silaceous oxides, titanium oxides, aluminum oxides, calcium oxides, zinc oxides, nickel oxides and iron oxides. In some embodiments, the composition further comprises a second oxide selected from the group consisting of calcium oxide, sodium oxide, magnesium oxide, zinc oxide, phosphorus oxide and alumina. In a typical embodiment of the invention, the charged oxide is silaceous oxide, the second oxide comprises calcium oxide and the ratio, by molar ratio, of silaceous oxide to calcium oxide is 0.25 to 15. Optionally, the composition further comprises phosphorous oxide. Also described are methods of making and using such compositions. | 0 |
[0001] This is a Divisional Application of U.S. patent application Ser. No. 10/844,171, filed on May 12, 2004, which is herein incorporated by reference in its entirety, and assigned to a common assignee.
RELATED PATENT APPLICATION
[0002] This application is related to Docket No. HT 02-019, Ser. No. 10/371841, filing date Feb. 20, 2003, to Docket No. HT 02-032, Ser. No., 10/768917, filing date Jan. 30, 2004 and to Docket No. HT 03-025/031, Ser. No. 10/849310, filing date May 19, 2004, assigned to the same assignee as the current invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to magnetic tunneling junction (MTJ) MRAMs and more particularly to the use of a simple fabrication process that leads to a smooth bottom electrode and superior performance properties.
[0005] 2. Description of the Related Art
[0006] The magnetic tunneling junction device (MTJ device) is essentially a variable resistor in which the relative orientation of magnetic fields in an upper and lower magnetized electrode controls the flow of spin-polarized tunneling electrons through a very thin dielectric layer (the tunneling barrier layer) formed between those electrodes. As electrons pass through the lower electrode they are spin polarized by its magnetization direction. The probability of an electron tunneling through the intervening tunneling barrier layer then depends on the magnetization direction of the upper electrode. Because the tunneling probability is spin dependent, the current depends upon the relative orientation of the magnetizations of magnetic layers above and below the barrier layer. Most advantageously, one of the two magnetic layers (the pinned layer) in the MTJ has its magnetization fixed in direction, while the other layer (the free layer) has its magnetization free to move in response to an external stimulus. If the magnetization of the free layer is allowed to move continuously, as when it is acted on by a continuously varying external magnetic field, the device acts as a variable resistor and it can be used as a read-head. If the magnetization of the free layer is restricted to only two orientations relative to the fixed layer (parallel and anti-parallel), the first of which produces a low resistance (high tunneling probability) and the second of which produces a high resistance (low tunneling probability), then the device behaves as a switch, and it can be used for data storage and retrieval (a MRAM).
[0007] Magnetic tunneling junction devices are now being utilized as information storage elements in magnetic random access memories (MRAMs). Typically, when used as an information storage or memory device, a writing current orients the magnetization of the free layer so that it is either parallel (low resistance) or anti-parallel (high resistance) to the pinned layer. The low resistance state can be associated with a binary 0 and the high resistance state with a binary 1. At a later time a sensing current passed through the MTJ indicates if it is in a high or low resistance state, which is an indication of whether its magnetizations are, respectively, antiparallel or parallel and whether it is in a 0 or 1 state. Typically, switching the magnetization direction of the free layer from parallel to antiparallel and vice-versa is accomplished by supply currents to orthogonal conductor lines, one which is above the MRAM cell and one which is below it. The line below the cell is referred to as the word line and it is electrically isolated from the cell. The line above the cell, called the bit line, is in direct electrical contact with the cell and is used for both writing on the cell, ie changing the direction of the free layer magnetization and reading the cell, ie detecting the free layer magnetization direction. The two lines pass each other orthogonally, in separated vertical planes, with the cell lying between them. Thus their combined field peaks just above the switching threshold of the cell, the field required to cause a transition from parallel to antiparallel orientations of the free layer and pinned layer magnetizations.
[0008] For fast operation, the cell must have a high magnetoresistance ratio (DR/R), where DR represents the resistance variation when the free layer switches its magnetization direction and R represents the total minimum resistance of the cell. For stable operation, the cell's junction resistance, RA, where A is cell cross-sectional area, must be well controlled. When the MRAM device is used as the basic element of a memory, it is replicated to form an array of many such devices and integrated with associated CMOS circuitry which accesses particular elements for data storage and retrieval.
[0009] When fabricating an MRAM element or an array of such elements, the necessity of creating a high value of DR/R and maintaining a high degree of control over the junction resistance requires the formation of thin, smooth layers of high quality.
[0010] Slaughter et al. (U.S. Pat. No. 6,544,801 B1) teaches a method of fabricating such a magnetic tunneling device wherein the problem of interdiffusion between layers of different metals during high temperature annealing processes is significantly reduced. Such interdiffusion would adversely affect the properties of the various layers because of the tendency of the various metals to alloy with each other.
[0011] Dill et al. (U.S. Pat. No. 6,114,719) teaches a method of effectively biasing an MTJ device using biasing layers disposed within the device stack, so that its magnetic states are stable, yet there is not required the addition of adjacent magnetic structures which would adversely affect the high device density required for an MRAM array.
[0012] In a “standard process” MRAM array structure the MTJ stack (lower electrode/AlOx tunneling barrier/upper electrode) is deposited on top of the bottom conductor, which is typically a tri-layer such as Ta/Cu/Ta or NiCr/Ru/Ta. In the latter tri-layer, the Ta that caps the Ru is grown with an α-phase structure, in the former tri-layer, the Ta that caps the Cu is grown with a β-phase structure. Prior to depositing the MTJ stack it is necessary to sputter-etch the TaO which grows on the Ta capping layer. This sputter-etch not only removes the surface TaO, but the energetic Ar sputtering ions also alter the Ta surface structure. The resulting sputter-etched Ta surface appears to be “amorphous-like”, similar to that of amorphous Al 2 O 3 . In our experiments we have found that an altered Ta surface is necessary for forming a flat, smooth bottom electrode on which to most advantageously form an oxidized Al tunneling barrier layer of high integrity. It was also noted by us that refilling the sputter-etched Ta surface by a Ta sputter-deposition actually results in a rougher surface structure of the bottom electrode. The integrity of the oxidized Al barrier layer is an essential element in fabricating a high quality MTJ device.
[0013] Formation of a high-speed MRAM array is quite complicated. Normally its word line structure is surrounded by a dielectric layer, so the line essentially lies within a cavity. This cavity has a back (or bottom) surface and two parallel side surfaces that are spaced apart. The back and/or side surfaces of the cavity are covered with an NiFe magnetic layer which acts as a field keeper (it contains the magnetic flux). The conducting portion of the line, surrounded by the magnetic keeper structure, is formed within the cavity. A polishing process is then used to remove any portion of the keeper or conducting portion of the line that extends above the level of the dielectric surface and to generally render that surface planar.
[0014] A novel MRAM array structure, not using the conducting lead structure of the standard process, has been developed in which the word line is constructed on top of the MTJ. The MRAM configuration of this novel array structure is:
NiCr50/NiFe100/NiCr30/Cu50/MnPt100/CoFe18/Ru7.5/CoFe15/Al(8-10)/ROX/free/cap
The NiCr50/NiFe100/NiCr30/Cu50 portion is the bottom conducting lead (the numerals representing thicknesses in angstroms), which includes a NiCr 50 seed layer, a 100 angstrom NiFe soft adjacent keeper layer, a second NiCr 30 seed layer and a Cu 50 conducting layer; the MnPt100/CoFe18/Ru7.5/CoFe15 portion is the bottom electrode (a synthetic pinned structure), the Al(8-10)/ROX is a tunneling barrier layer formed by radical oxidation of an 8-10 angstrom thick Al layer and then there is the upper electrode, which includes a free layer and a capping layer formed thereon but not described here in detail. The entire stack is advantageously formed by magnetron sputtering in a single pump-down of the sputtering chamber.
[0015] In initial testing of this single pump-down fabrication, RA (junction resistance), DR/R and V b (breakdown voltage of the barrier layer) were found to be much lower than values obtained from the standard (prior art) process in which the patterned conductor lead and the MRAM stack are formed separately. Further, high resolution TEM analysis of the single pump-down layers showed that the bottom electrode layers had a columnar grain structure, which tended to create rough surfaces. In contrast, the surfaces of layers formed in the standard process were relatively smooth and flat. The essential difference in the two processes is that the standard process configuration includes a Ta capping layer that is sputter-etched.
[0016] The object of this invention is to modify the single pump-down process so that a smooth, flat layered structure (as in the standard process) is obtained while still maintaining the advantages of the single pump-down of the novel process.
SUMMARY OF THE INVENTION
[0017] A first object of this invention is to provide a method of forming an MTJ MRAM element and an array of such elements, that are characterized by smooth, flat layers in the bottom electrode and an ultra thin, smooth tunneling barrier layer with high breakdown voltage.
[0018] A second object of this invention is to provide such an MRAM element and MRAM element array that can be fabricated in a single pump-down process.
[0019] The objects of the present invention will be achieved by the fabrication of an MRAM element having the following novel configuration:
NiCr50NiFe100/NiCr30/Cu50/Ta80/Ru30/[SE Ru30Ta(20-30)]/NiCr40/MnPt100/CoFe18/Ru7.5/CoFe 15/Al(8-10)/ROX/free/cap
Here, an initially deposited Ta80/Ru30 bilayer plays the role of a capping layer (the Ru protecting the Ta from oxidation) for the conducting lead layer of Cu50, and then it is sputter-etched (SE) to remove the Ru 30 and between approximately 20 and 30 angstroms of the Ta 80, leaving only 50 to 60 angstroms of the Ta prior to deposition of the NiCr40/MnPt100/CoFe18/Ru7.5/CoFe15 pinned bottom electrode layer.
[0020] MRAM devices manufactured as above have excellent characteristics. Prior to the above configuration, the single pump-down without the sputter-etched Ta capping layer produced values of RA, DR/R and V b that were respectively 0.4-0.8 kΩ-μm 2 , 10-15% and 1.0 volt. Using the new process, the values obtained are 3.0-4.0 kΩ-μm 2 , 38% and 1.6 volts. These values are comparable to those obtained in the prior multiple step process. In addition to these improved characteristic values, the MRAM device of the present invention also has excellent switching characteristics, with MR v. field curves showing simple rectangular shapes with no jumps or kinks in hysteresis loops. For a cell of 0.2×0.4 μm cross-sectional area the switching current required is about 2 ma, compared to a switching current of about 5 ma for the conventional process elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 a - FIG. 1 e are schematic cross-sectional views of the formation of an MTJ MRAM device on a conducting lead layer using the method and configuration of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The present invention is a method of forming an MTJ MRAM with a tunnel barrier layer of high integrity, in a single pump-down process, by the introduction of a sputter-etched Ta capping layer formed on the lower bit line. The sputter-etched Ta layer promotes the subsequent formation of smooth, flat layers within the bottom electrode and thereby allows the formation of a thin, smooth and flat tunnel barrier layer made by subjecting a thin Al layer to a process of radical oxidation (ROX).
[0023] Referring first to FIG. 1 a, there is seen in a schematic cross section an initial stage of a preferred embodiment of the invention, the formation of a single MRAM element, which can be a part of an array of such elements. It is to be understood that in the embodiments to be disclosed in what follows, all layer depositions take place in a high vacuum system suitable for depositing thin layers by sputtering. In these embodiments the system was a commercially available Anelva 7100 system which includes ultra-high vacuum sputtering-deposition chambers and oxidation chambers, but other comparable systems are also suitable. It is also noted that in all the embodiments to be discussed, when the tunneling barrier layer was to be oxidized, the fabrication already formed (having the un-oxidized, as-deposited Al layer on it) was removed from the high vacuum system and placed in a separate oxidation chamber for the oxidation process to occur. Subsequent to the oxidation, the fabrication is replaced into the high vacuum sputtering chamber for the remaining layer depositions.
[0024] There is shown first a substrate ( 10 ), which in this embodiment is a dielectric layer formed on a silicon substrate. A lower conducting lead (the bit line), on which the MRAM element will be formed, is deposited on the substrate. This invention includes the formation of the bit line, which contains a soft magnetic keeper structure, on the substrate and the subsequent formation of the MRAM stack on the bit line. It is further understood that the single MRAM element to be described can be one of an array of such elements and that such element or array may be further connected to associated circuitry used in storing and retrieving information.
[0025] On the substrate ( 10 ), there is deposited a first seed layer ( 20 ), which in this embodiment is a layer of NiCr(35%-45%) formed to a thickness between approximately 50 and 100 angstroms, with approximately 50 angstroms being preferred. The percentages refer to percent of atoms of Cr in the NiCr alloy. On the seed layer is then formed a keeper layer ( 25 ) of soft magnetic material, which in this embodiment is a layer of NiFe formed to a thickness between approximately 50 and 200 angstroms with 100 angstroms being preferred. On the keeper layer there is formed a conducting lead layer ( 35 ) which can have two different structures. In one structure it includes a (third) seed layer ( 30 ), which is a layer of NiCr (40%) formed to a thickness between approximately 20 and 50 angstroms and which will serve as a seed layer for the subsequently deposited conductor layer. On the seed layer ( 30 ) there is then formed a layer of conducting material ( 40 ), which in this form is a layer of Cu of thickness between approximately 50 and 100 angstroms with 50 angstroms being preferred. In a second structure, there is first deposited a layer of Ta ( 30 ) of thickness between approximately 50 and 100 angstroms with 50 angstroms being preferred. On the Ta layer ( 30 ) there is then formed a layer of conducting material ( 40 ), which in this embodiment is a layer of Cu of thickness between approximately 50 and 100 angstroms with 50 angstroms being preferred.
[0026] On either structure of the conducting layer there is then formed a capping layer ( 50 ) of Ta, of thickness between approximately 50 and 100 angstroms with 80 angstroms being preferred. A layer of Ru ( 55 ), of thickness between approximately 20 and 40 angstroms with 30 angstroms being preferred is then formed on the Ta capping layer to protect it from oxidation.
[0027] Referring next to FIG. 1 b, there is shown this Ta/Ru bilayer as then being sputter-etched to remove the Ru entirely and to remove between approximately 20 and 30 angstroms of the as-deposited Ta layer, now denoted ( 53 ). This sputter-etching interrupts the columnar grain growth of the Ta which, if not interrupted, would produce a rough surface and poor quality subsequent layer structure. Instead, the sputter-etched Ta has a smooth surface which is characteristic of amorphous material layers.
[0028] Referring now to FIG. 1 c, there is shown the initial steps in the formation of the bottom electrode (the pinned layer) on the sputter-etched Ta capping layer. It is the feature of this invention that the layers of this electrode will be flat and smooth as a result of being formed on the sputter-etched Ta capping layer. First, a second seed layer ( 70 ), which in this embodiment is a layer of NiCr(40%) formed to a thickness between approximately 40 and 50 angstroms is formed on the sputter-etched Ta layer ( 53 ). A pinned/pinning layer ( 80 ) is then formed on the NiCr layer. The layer includes an antiferromagnetic pinning layer ( 82 ), which in this embodiment is a layer of MnPt formed to a thickness between approximately 100 and 200 angstroms, with approximately 150 angstroms being preferred. It is noted that a thinner layer of IrMn can be substituted for the MnPt if a thinner structure is required in order to produce a smaller spacing (and larger corresponding magnetic field) between the keeper layer and the free layer. On the pinning layer there is then formed a synthetic antiferromagnetic pinned (SyAP) layer ( 84 ), which in this embodiment is a first ferromagnetic layer ( 92 ) of CoFe of thickness between approximately 15 and 25 angstroms with 18 angstroms being preferred. On this layer is formed a thin coupling layer ( 94 ) of Ru, which is formed to a thickness between approximately 7 and 8 angstroms with 7.5 angstroms being preferred. On the coupling layer is formed a second ferromagnetic layer ( 96 ) of CoFe (25%) with a thickness between approximately 10 and 20 angstroms with 15 angstroms being preferred. The 25% by number of atoms of Fe in this layer of CoFe is found to produce a particularly good value of DR/R.
[0029] Still referring to FIG. 1 c, there is shown the first step in the formation of a thin, flat and smooth tunneling barrier layer on the pinned layer in which an Al layer ( 100 ) between approximately 7 and 12 angstroms thickness with 10 angstroms being preferred is formed on the CoFe(25%) layer ( 96 ).
[0030] Referring now to FIG. 1 d, there is shown the fabrication of FIG. 1 c, with the as-deposited Al layer ( 100 ) thus far formed, removed from the high vacuum sputtering-deposition chamber and placed in an oxidation chamber where it is oxidized (shown schematically as arrows) by a process of radical oxidation (ROX) in-situ. The oxidized layer is now denoted as ( 110 ) and other layers and their numeric designation have been suppressed for clarity. The details of the oxidation chamber are not shown. Briefly, the ROX process as applied to achieve the objects of the present invention is a plasma oxidation process carried out within a plasma oxidation chamber wherein a grid-like cap is placed between an upper ionizing electrode and the wafer surface being oxidized. Oxygen gas is then fed to the upper electrode and power is supplied to the electrode to at least partially ionize the gas. Passage of the partially ionized gas through the cap produces a shower of oxygen atoms, molecules, radicals and ions and renders the various species produced by the electrode less energetic when they arrive at the wafer surface. Within the plasma chamber used herein, an upper electrode within the chamber is fed with 0.5 liters of oxygen gas to produce a shower of oxygen radicals. Power is supplied to the electrode at a rate of 500 to 800 watts. The tunneling barrier layer is thereby formed to exceptional smoothness and uniformity and has a high breakdown voltage, all being a result of its formation over the sputter-etched Ta and NiCr layers.
[0031] Referring next to FIG. 1 e, there is shown the formation of free layer ( 120 ) on the bottom electrode. The free layer is preferably a layer of NiFe (18%) formed to a thickness between approximately 20 and 60 angstroms with 50 angstroms being preferred. It is found that NiFe with approximately 18% Fe by atom number used as the free layer gives particularly good switching characteristics. A capping layer ( 130 ) is formed on the free layer.
[0032] As is understood by a person skilled in the art, the preferred embodiments of the present invention are illustrative of the present invention rather than limiting of the present invention. Revisions and modifications may be made to methods, materials, structures and dimensions employed in forming and providing an MTJ MRAM device in which the lower electrode has a smooth and flat layer structure and the naturally oxidized tunneling barrier layer is thin, smooth and flat and has a high breakdown voltage as a result of all layers being formed on a sputter-etched Ta layer, while still forming and providing such a device and its method of formation in accord with the spirit and scope of the present invention as defined by the appended claims. | An MTJ (magnetic tunneling junction) MRAM (magnetic random access memory) cell is formed on a conducting lead and magnetic keeper layer that is capped by a sputter-etched Ta layer. The Ta capping layer has a smooth surface as a result of the sputter-etching and that smooth surface promotes the subsequent formation of a lower electrode (pinning/pinned layer) with smooth, flat layers and a radical oxidized (ROX) Al tunneling barrier layer which is ultra-thin, smooth, and to has a high breakdown voltage. A seed layer of NiCr is formed on the sputter-etched capping layer of Ta. The resulting device has generally improved performance characteristics in terms of its switching characteristics, GMR ratio and junction resistance. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a screen cylinder intended for use in screening wood pulp and other fibrous fluid suspensions for removing foreign particles from a pulp slurry, and a method for manufacturing the apparatus. More particularly, the apparatus and method relate to rebuildable screen cylinders for screening thick stock or thick pulp slurry within the pulp and paper industry. Still more particularly, the apparatus and method relate to improved screen cylinders that are less expensive to manufacture and provide increased wear life and durability as compared to similar screen baskets known heretofore.
2. Description of the Prior Art
Screens are used to separate acceptable papermaking fiber from unacceptable constituents of a slurry of pulp fiber in preparing the wood fiber for the papermaking process. In typical wood pulp screens, a slurry of pulp flows through a perforate cylindrical screen plate or basket which may be smooth, or which may have a contoured surface facing toward the stock flowing through the screen cylinder. The screen plate openings are formed in different hole or hole and slot combinations for optimizing screening performance. To aid in passage of the acceptable pulp through the screen plate, and to avoid plugging, pulsations are generated in the slurry such as by passing a hydrofoil-shaped member or rotor past the screen plate. Screen cylinders used in pulp and paper mills are subjected to heavy pressure loads. To provide sufficient strength to a screen cylinder or a screen plate, which generally is a basket-shaped member surrounding a rotor, so that it can withstand the pressures experienced in a pressurized screen cylinder, it has been the accepted practice to provide thick-walled screen plates or baskets which are machined to present the desired screening surface, or thin-walled formed screen plates or baskets with reinforcing rods.
A thick-walled screen cylinder is described in U.S. Pat. No. 3,664,502. Screen cylinders of the type described in this patent are formed of a metal plate rolled and welded in tubular form and provided with a multiplicity of screening openings. To withstand the pressures involved, relatively heavy gauge metal is used, such as 1/8" to 5/16" stainless steel. When the screen plate of the type described in this patent is rolled into tubular form, a weld seam is used to connect the ends of the metal plate. In order to perform the welding operation, a welding fixture must be utilized to hold the rolled screen plate in proper position to perform the weld. The weld seam leaves a rough, abrasive surface on the inside diameter of the rolled screen plate. Left as is, the weld seam would drastically affect the screening surface of the screen plate and reduce the effectiveness and efficiency of the screening operations. As a result, screens of this type that are rolled and welded into tubular form must undergo grinding operations to smooth out the interior surface of the screen plate. After the grinding operations, the screen cylinder is machined in the round or rolled condition to provide a finished interior surface.
In addition to the expensive costs of production and manufacturing, in large part due to the lengthy welding and grinding procedures, the type of one-piece screen described above has been expensive to use and maintain in that, even if only a small area of screen is damaged, the entire screen plate, which includes the screening surface, mounting bodies and support members must be replaced, thereby presenting a costly operating experience.
An improvement to the solid, one-piece, thick-walled screen is described in U.S. Pat. No. 4,264,438. The screen cylinder or drum according to this patent is assembled into cylindrical form by using a plurality of adjacent cylindrical screen members spaced apart, between which a stiffening ring is disposed. The cylindrical screen members and the stiffening ring are attached to each other by a weld joint connecting a projecting part of the stiffening ring and the ends of the cylindrical screen members and filling the gap between them. As with the prior art screen described in U.S. Pat. No. 3,664,502, because of the welding operations needed to connect the ends of the screen members and the screen members to the rings, welding fixtures are necessary to hold the screen assembly in proper position. The numerous weld seams must be ground smooth on the interior surface of the screen so as not to disturb the screening operations, and finish machining is also required. The lengthy welding and grinding operations to this prior art screen cause slot and hole distortion in the heat affected zones of the screening media. Because of the welding stresses that occur in the welds connecting the cylindrical screen members and the stiffening rings, the teaching of the patent for this prior art screen provides that the ends of the cylindrical screen members should be expanded before welding by the same amount as they are contracted by the welding stresses. As a result, manufacturing a screen drum according to the method described in U.S. Pat. No. 4,264,438, is extremely costly and time consuming.
The prior art screens described above require that the screen cylinder ends be seam welded when rolled into cylindrical form. This manufacturing method of construction leads to screen failure at the welded seam when the screen is used under normal operating conditions. The welded seam joint constrains the cylinder screen in the round condition under mechanical stress, and the welding process induces thermal stresses in the screen at locations near the weld seam. The weld seam creates a heat-affected zone at and near the seam which becomes very brittle. Thus, under normal operating conditions, the screen is subject to failure at or near the weld seam. To help overcome these problems, stress relieving is performed in one of two ways to prevent or reduce the stresses introduced into these prior art screens. The first method involves vibratory stress conditioning of the screen, and the second method involves thermal stress relieving the screen by heat treatment. However, internal stresses of the nature created in manufacturing these prior art screens are not always successfully stress relieved by the above methods, and, as a result, the potential for failure is not eliminated; and it has been observed in prior art screen cylinders that fractures tend to occur along the welded seam and heat-affected zones even under normal operating conditions.
U.S. Pat. No. 4,954,249 describes an improved screen over the screens described above as used in the pulp and paper industry. Beloit Corporation sells and markets screen cylinders according to this patent under the trademark BelWave™. The modular screen plate structure of Beloit's BelWave™ screen simplifies screen plate changing and eliminates the need to change an entire screen plate when only a portion of the plate is damaged or worn. One of the features of Beloit's BelWave™ screen plate is utilizing corrugated, thin-walled screen material in order to avoid the attendant difficulties of machining thick-walled screen plates and to reduce the cost associated with manufacturing thick-walled screen plates. The modular, cylindrically-shaped screens also reduce the number of welding operations needed to create cylindrical screens by positioning and connecting modular screen sections into grooves located in support rings. The modular screen sections are formed into a corrugated pattern and then rolled into cylindrical form. One end of the corrugated screen plate section overlaps the other end of the corrugated section and a weld seam is not required to hold the ends together because the corrugated thin-walled section is pressed into the grooves located in adjacent support rings.
Although Beloit's BelWave™ screen cylinder has been and continues to be an improved screen plate for the pulp and paper industry, in certain thick stock or slurry screening operations, the thin, corrugated screening media is subject to impact failure.
What is needed is a screen cylinder that utilizes the benefits of Beloit's Modular BelWave™ screen cylinder construction and yet is capable of withstanding the high pressure and wear due to contaminants encountered in thick slurry environments and, at the same time, eliminate the disadvantages and problems associated with manufacturing screens of the types described above.
SUMMARY OF THE INVENTION
A novel, modular, thick-walled, smooth or contoured screen cylinder and a method of manufacturing this screen cylinder is described below. The thick-walled, smooth or contoured surface screen cylinder is capable of withstanding the destructive elements found in thick slurry pulp and paper screening environments. The problems associated with using a weld seam for a screen cylinder or section where rolled ends of the screen cylinder or section meet has been obviated by the present invention. A lap joint according to the present invention is used to connect the ends of a screen cylinder or section when the screen is rolled into cylindrical shape. The lap joint is machined into the ends of the screen cylinder or section before it is rolled into final form. The lap joint connection eliminates any need to weld the ends of the screen cylinder or section together; which, consequently, eliminates any grinding or machining operation on the inside surface of the screen after it has been rolled into cylindrical shape. Additionally, because the lap joint allows for an overlapping floating design, tight manufacturing tolerances needed for prior art screens are eliminated.
Accordingly, it is a feature of the present invention to eliminate the weld joint or seam used to connect ends of a rolled screen cylinder or section. The nonwelded construction of the screen will prevent any slot and hole distortion encountered in the heat zones of the currently used welded screens. The nonwelded construction of the screen also improves operational strength and eliminates failures that are associated with welded screen cylinders.
A further feature of the invention is that the lap joint does not constrain the screen cylinder or section after rolling, which in turn reduces the mechanical stresses induced into prior art screen cylinders from the current rolling and welding operations. Furthermore, the lap joint of the current invention is beneficial in that it eliminates the heat-affected zone created by the prior art welding operations and all of the thermal stresses associated with prior art welding operations.
A still further feature of the invention is to eliminate expensive weld fixtures currently necessary in order to assemble screens as described herein.
An additional feature is to eliminate costly grinding operations utilized in manufacturing screen cylinders because of current welding processes. Eliminating welding operations conducted on or near the interior surface of a screen eliminates grinding and finish machining operations on the interior surface of the screen.
Another feature is to reduce high-tolerance machining operations in connection with manufacturing screen cylinders.
Yet another important feature of the novel screen cylinder described herein is that it is capable of withstanding the destructive environments found in thick slurry or pulp screening applications in the pulp and paper industry.
A still further feature of the screen cylinder according to the present invention is that when used as a replacement for earlier modular designs, the novel screen cylinder provides greater capacity in the same screen apparatus.
These, and other features and advantages of the present invention will become readily apparent to those skilled in the art upon reading the description of the preferred embodiments, in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, with portions broken away, illustrating a screening apparatus having a prior art modular cylindrical screen cylinder sold by Beloit Corporation under the trademark BelWave™.
FIG. 2 is an enlarged fragmentary, sectional view taken substantially along line II--II of FIG. 1.
FIG. 3 is a side view, partly in section, of another prior art screen cylinder.
FIG. 4 is an enlarged, fragmentary view of the region designated "4" in FIG. 3.
FIG. 5 shows a screen cylinder according to the present invention.
FIG. 6 shows a partially assembled screen cylinder of the present invention.
FIG. 7 is a cross-sectional detail of a screen section lap joint according to the present invention.
FIG. 8 is a top cross-sectional view of a rolled screen section depicting the lap joint according to the invention.
FIG. 9 is a perspective view of the screen cylinder of FIG. 5, with portions broken away, illustrating details of the assembly of one embodiment according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 5 shows a screen cylinder according to the present invention. FIG. 8 shows a lap joint 42, described more fully below, as used in the screen cylinder of the present invention. Screen cylinders of the type described according to the present invention that utilize the lap joint 42, shown in FIG. 8, are intended to replace the prior art screens described in FIGS. 1-4.
FIG. 1 illustrates a prior art screening apparatus 1 wherein previously treated pulp is screened to remove foreign elements such as sheaves, bark, knots, particles of wood, dirt, glass, plastic and the like.
A screen plate assembly is shown at 10, defining in the apparatus 1 an interior chamber 2 where the pulp to be screened flows in and an exterior chamber 3 where the screened pulp flows out after passing through the screen plate assembly. The assembly is enclosed in a housing 4 which has an inlet (not shown) for the entrance of pulp to be screened into the chamber 2, and an outlet (not shown) leading from the chamber 2 for the foreign material such as the sheaves, bark and dirt. The accepted pulp flows out through an outlet 5.
The screen plate assembly 1 is stationary within the housing 4, and for aid in passing the liquid stock with pulp through the screen plate, and to help inhibit plugging, hydrofoils 6 are mounted for rotation within the cylindrical screen plate assembly. The hydrofoils 6 are supported on arms of a rotary driven shaft 7, and rotate in a clockwise direction, as viewed in FIG. 1. The hydrofoils shown are merely illustrative of a suitable type, and it should be understood that the present invention can be used for screen plates of various types for various pulse, turbulence and combination pulse and turbulence generating rotors.
The prior art screen plate assembly 1 includes cylindrical, thin-walled, corrugated screen sections 8 and 9 which, without support, are essentially flexible and require rigidifying or strengthening for use in the pressurized environment of screen apparatus 1. The necessary support and strengthening is provided by end rings 11 and 12 and an intermediate support ring 13. Each of the rings has grooves such as illustrated by the grooves 14 and 15 in the ring 13 shown in FIG. 2. The grooves 14 and 15 are circular to hold the screen sections in a substantially cylindrical shape. The grooves 14 and 15 have a radial dimension substantially equal to the radial thickness of the shaped screen plates.
The screen plates according to this prior art device are formed from relatively thin material formed in various shapes or contours. During assembly, each of the shaped screen plates is positioned into the grooves in the end rings 11 or 12 and the intermediate ring 13, and the rings are pulled together to force the screen plates into the grooves 14 and 15. For this purpose, axially extending rods 16 are provided, spaced circumferentially from each other, and the rods are provided at their ends with threads and nuts 17 so that the nuts can be tightened to pull the end rings toward each other and force the ends of the screen plates into the respective grooves. The grooves 14 and 15 are tapered so that the slot becomes narrower in an inward direction toward the bottom of the grooves, as indicated by the illustration shown in FIG. 2. When the rods are tightened, the screen plates are pushed tightly into the tapered grooves so that the screen plates are held firmly in a fixed, circumferential position. With screen assemblies of different lengths, the screens can be longer or shorter, and additional reinforcing intermediate rings such as 13 may be employed between the ends of each of the adjacent screens.
Screening openings such as 18 and 19 extend through the thin-walled, corrugated prior art screen material, as shown in the screen sections 8 and 9 in FIG. 2. Depending upon the types of stock to be screened and the specific problems of screening, different combinations of slots or holes may be employed, and the thin material used in this prior art screen plate assembly can be provided with holes or slots of different sizes and shapes through various manufacturing techniques.
If wear or damage to any of the prior art cylindrical screen sections 8 or 9 occurs, the damaged section can be replaced by loosening the axial tie rods and replacing or exchanging the damaged section. This also enables replacement with substitute sections of different hole or slot arrangements so that, with a given piece of screening machinery, different screening operations can be achieved through easy replacement of screen sections. As will be seen from the drawing of FIG. 1, access to the interior of the housing 4 is readily afforded by removal of the end plate 4a through removal of the bolts 4b. This permits withdrawal of the screen assembly for ready exchange or replacement of the screen sections.
Before assembling the prior art cylindrical screen plate assembly 10 of FIG. 1, the screen sections 8 and 9 are formed into a variety of undulated patterns by simple bending and forming techniques, as described in U.S. Pat. No. 5,023,986.
FIGS. 3 and 4 show another prior art screen cylinder or drum 20 that comprises a plurality of adjacent cylindrical screen members 21 between which there is a gap 22. In the screen drum, there are a plurality of stiffening rings 23 spaced apart, which have been fitted with a flange-like projecting part 24 that extends between end surfaces 26 of the cylindrical screen members. Cylindrical surfaces 25 of the stiffening ring 23 are of the same size or slightly larger in diameter than the outer surface 27 of the cylindrical screen member so that, when assembling a screen drum, they can function as guiding surfaces for the ends 28 of the cylindrical screen member. The cylindrical screen members and the stiffening ring are attached by a weld joint 29, connecting the projecting part of the stiffening ring and the ends of the cylindrical screen member and filling the gap between the cylindrical screen members.
FIG. 5 illustrates a modular, thick-walled screen cylinder 30 according to the present invention that is an improvement to the screen cylinders shown in FIGS. 1-4. Additionally, the screen cylinder of the present invention can be used as a replacement for prior art screen cylinders in most common pulp and paper screen apparatuses. The screen cylinder 30 fits into a screening apparatus housing having similar inlets and outlets as those described for the screening apparatus 1 shown in FIG. 1. Also, a hydrofoil and drive shaft similar to that used in the screen of FIG. 1 is used for the screen cylinder of the present invention.
The modular screen cylinder of the present invention includes cylindrical screen sections 31 which are made from smooth or contoured, relatively thick, polished 316 stainless steel or other suitable alloy. Occasionally, if the environment requires it, the screen sections or media 31 are chrome plated to provide further wear and corrosion resistance. The screen sections 31 can have a variety of hole or slot sizes and/or various contours.
The modular screen cylinder 30 includes end rings 33 and 34 and intermediate support rings 35. To provide enhanced durability, the screen cylinder support rings 35 are made of 17-4ph stainless steel, and treated to C-40 material specification, but can also be made from other suitable alloys. As shown in FIG. 9, each of the support rings 35 has grooves 36 and 37. End rings 33 and 34 each have a groove which is similar to the grooves 36 and 37 of support ring 35. The grooves 36 and 37 are circular to hold the screen sections in substantially cylindrical shape.
During assembly, each of the shaped screen sections 31 is positioned into the grooves 36 and 37 of the respective rings. In one embodiment, the modular screen cylinder assembly 30 is pulled together to position the screen sections into the grooves. For this purpose, axially extending stainless steel tie rods 38 are provided, spaced circumferentially from each other, and the rods are provided at their ends with threads and nuts 39 so that the nuts can be tightened to pull the end rings toward each other and force the ends of the screen sections into the respective grooves. In another embodiment (not separately shown), tie rods are not used; rather, screen sections 31 are held firmly in place via grooves 36 and 37 by welding the outside surface 46 of the screen sections 31 to the support rings 35 or end rings 33 or 34. Importantly, the minimal amount of welding necessary on the outside surface of the screen in order to firmly hold the screen cylinder together, does not affect the inside screening surface and does not induce any significant amount of thermal stresses into the screen section. Eliminating the weld used on the inside of a cylinder to hold it together eliminates the need to grind and finish machine the inside surface of the screen as is currently done in prior art screen cylinders.
FIG. 6 shows a partially assembled screen cylinder according to the present invention. Screen sections 31 fit into the grooves 36 and 37 and are stacked one on top of the other until a complete cylindrical screen is formed. Tie rods 38 hold the screen cylinder 30 together. As previously mentioned, in another embodiment, the tie rods 38 are not used; rather, the sections 31 are welded directly to the rings.
FIG. 7 shows a cross-section of a screen section 31 before it is rolled into cylindrical shape. Ends 40 and 41 of the section 31 contain a machined joint that, when fitted together in a rolled shape, form a lap joint 42, as shown in FIG. 8, according to the present invention. The lap joint 42 is of a floating design, meaning that when the screen section 31 is rolled into cylindrical form, it will align itself circumferentially with the rings. The rings are formed into cylinder shape. Screen sections 31 will conform to the cylindrical shape of the rings when fitted into the grooves of the rings because of the floating design of the lap joint 42.
FIG. 9 shows a partially broken away section of screen section 31 and further depicts how the screen sections fit with the grooves of the rings. The screen section 31 has top and bottom portions 43 and 44. The top and bottom parts have ring groove ears 45. The groove ears 45 fit into the grooves 36 and 37 of the rings 35, or rings 33 or 34, when assembled together. Although the groove ears and grooves are shown with particular shapes, e.g., tongue and groove connection, the groove ears and grooves can be of many different shapes and sizes.
The prior art screen shown in FIG. 1 is assembled in the following manner. First, the screen sections are machine drilled or slotted while in a flat configuration or formed through mechanical bending and shaping. Once the sections are drilled, slotted or formed, the individual screen sections are rolled into cylindrical shape. After the sections are rolled, if necessary, the ends of the sections are machined so they will fit into the grooves of the rings. After the screen sections are formed, the screen cylinder is assembled by placing the sections into the grooves of the rings stacking one section on top of another. Because the grooves are of a tapered design, in order to snuggly fit the ends of the sections into the grooves and bottom out the ends of the sections in the grooves, a 100-ton press is used to force the screen media into the grooves. Tie rods are used to firmly hold the screen cylinder assembly together.
The prior art screen shown in FIG. 3 is assembled in the following manner. First, the holes or slots are drilled or machined into the section while the section is in a flat configuration. The section is then rolled into cylindrical form. Once rolled, a welding fixture is utilized in order to hold the section together while the ends of the section are seam welded together. The screen sections are assembled one on top of the other by connecting each section to each other via the use of a stiffening ring and a weld. Once all the welding operations are finished, the inside surface of the screen cylinder must be ground and finish machined.
The welding and grinding operations of prior art screens create heat affected zones and the holes or slots are affected by the heat generated, thereby preventing efficient screening media and reducing the overall area of the screening surface. Additionally, the heat-affected zones represent possible failure sites of these prior art screens. Furthermore, the BelWave™ screen shown in FIG. 1 is not particularly suited for screening thick, heavily contaminated pulp because the sections are subject to impact failure due to the fact that this screen uses thin-walled, corrugated screen sections.
The modular screen cylinder of the present invention utilizes thick, smooth or contoured screen sections and eliminates welding the ends of screen sections together. Eliminating the weld seam eliminates the need for welding fixtures, inside diameter grinding operations and finish machining procedures of prior art screens. Because welding the seams is eliminated, the drilled or slotted holes are not affected, which provides for an improved screening surface. All of which greatly reduces the overall cost associated with manufacturing screen cylinders. Even more importantly, eliminating the weld seam improves the operational strength of the screen cylinder and eliminates the possibility of screen cylinder failures at or near a weld seam.
According to the invention, all machining to a screen cylinder section 31 is performed while the screen media is in a flat configuration. This includes slotting, drilling, surface contouring, but most importantly, the lap joint shown in FIGS. 7 and 8 and the groove ears 45 shown in FIG. 9 are machined into the section while the material is flat. Because the weld seam is eliminated, the modular screen assembly according to the present invention eliminates the need for special weld fixtures which are required to hold individual screen media and rings together during the welding process for the present prior art conventional screen cylinders. The screen media has groove ears 45 machined onto the screen sections 31, and the rings are machined with mating grooves 36 and 37, as shown in FIG. 9. After the screen media are rolled, the screen media groove ears are then placed into the mating ring grooves as shown in FIGS. 6, 7 and 9. This is repeated until the entire screen assembly has been stacked to its finished size, see FIGS. 5 and 6. The ring grooves 36 and 37 work as integral devices which lock and hold the screen media in place to the exact inside screen cylinder diameter specifications. The modular screen has no inside diameter welding at the groove ears and groove interface, and all parts are machined to their finished dimensions prior to assembly. Therefore, all finish grinding and finish machining on the inside diameter of the screen cylinder are eliminated.
Lap joint ends 40 and 41, according to the present invention, are machined in the flat as shown in FIG. 7 on opposing sides of a screen section. The lap joint creates an overlapped mechanical joint when the screen section is rolled into a cylinder shape as shown in FIG. 8. This overlapping mechanical lap joint allows for ease of assembly because of the tolerances associated with generating the lap. All welding is eliminated at the inside diameter of the screen media seam. Thus, this eliminates any need to grind the inside diameter to ensure proper finished dimensions and surface finish. Because the lap joint is a floating design joint, this allows for less costly machine tolerances. The lap joint is designed with enough tolerance for slippage or movement so that rolled screen media will expand or contract as needed to properly locate itself, cylindrically, with the grooves of the respective rings. The inside diameter of the ring groove is the controlling factor for the finished screen cylinder's inside dimensions. The lap joint will remain fixed once the screen media sections are placed into the captive ring grooves. After the cylinder is completely assembled, the tie rods hold the assembly together. Because of the shape of the grooves and groove ears, assembly can be accomplished without the use of a large press machine, as is needed with Beloit's BelWave™ design. In those applications where tie rods are not necessary, the outside surface of the screen sections can be lightly welded to the support rings. These light welds are unlike the large weld seam of the prior art screens. The small amount of welding necessary to connect the outside surface of the screen section to the support ring will not induce any significant amount of thermal stresses into the screen, unlike the large weld seam of the prior art screens which induces a significant amount of thermal stresses into the screens. These welds will not affect the inside screening surface of the cylinder. As a result, these welds will not require the cylinder to be further finish ground or machined.
The system of interchangeable cylindrical screen members is essential to modular screen technology. The screening media section is a replaceable hoop that fits securely into a groove in a support ring. High strength stainless steel tie rods hold the cylinder together in one embodiment of the invention. Damaged hoops can be replaced one at a time for a fraction of the cost of replacing the entire cylinder. The screen cylinder frame of rings and tie rods can be reused again and again. The modular screen section allows the use of varying screen media within a single cylinder. For example, because the concentration of large debris increases as flow moves further down the cylinder, greater spacing between the screening holes toward the cylinder's outlet end allows for avoiding plugging and keeping the screen apparatus operating smoothly. Additionally, because of the nonwelded construction, the slotted cylinders have approximately 5 percent more open area than conventional cylinders, resulting in increased screening capacity. The precise tongue and groove connection between the screening media hoop and the support rings ensures a solid seal between components.
While an apparatus and method for a modular screen section has been shown and described in detail, herein, various changes may be made without departing from the scope of the present invention. | An apparatus and method for screening wood pulp and other fibrous fluid suspensions. The apparatus and method relate to rebuildable, modular screen cylinders for screening thick pulp slurry in pulp and paper applications. The screen sections of the modular screen cylinder of the present invention are of a nonwelded construction. A lap joint according to the present invention is provided in each screen section connecting the ends of the individual sections when the screen sections are rolled into cylindrical shape. As a result, the lap joint of the current invention provides for a nonwelded, modular screen cylinder which is less expensive to manufacture and provides for increased wear life and durability as compared to similar screen baskets previously known. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The apparatus disclosed herein relates to mechanical broom sweepers and more particularly to such sweepers which have the capability of sweeping over irregularities on the swept surface while maintaining sweeping contact with the surface.
2. Description of the Prior Art
A power driven sweeping machine is disclosed in U.S. Pat. No. 2,448,328, issued to A. Russell, in which a machine body portion contains a forwardly located debris receiving bin. The body portion has a forwardly located towing arm attached thereto and a set of rear supporting wheels so that it may be towed behind a suitable tractor. Under the body portion a brush housing is supported on a forwardly located pivot and a number of rearwardly located depending support arms. The support arms include coil springs which absorb the shocks imparted to the brush housing. A series of sprocket chains are coupled between the rear supporting wheels and a pair of sweeping brushes which are mounted on shafts supported between the side walls of the brush housing. When the body portion is towed in a forward direction, the rotation of the rear support wheels causes the sweeping brushes to rotate and to thereby sweep an underlying surface. One of the brushes clears debris off of the underlying surface and elevates the debris to the second brush which in turn sweeps the debris toward the debris receiving bin within the body portion.
A street sweeper is disclosed in U.S. Pat. No. 982,570, issued to C. C. Brooks, which sweeper includes a casing supported on members depending from a framework. The depending members include coil springs which allow the casing to move in a vertical direction relative to the framework. A number of brushes are driven by a chain drive which is coupled to the drive wheels on the framework of the sweeper. The brushes are mounted within the casing on shafts which extend between journals disposed in the side walls of the casing. The casing and brush assembly may move vertically against the yielding coil springs to compensate for uneven characteristics in the underlying surface being swept.
U.S. Pat. No. 1,286,481, issued to N. C. Woodin, discloses a broom support for a street sweeper wherein a broom having an overlying hood is driven through a chain drive. The broom is mounted on a shaft extending between two broom support arms. The broom is movable in a vertical direction as the support arms are pivoted about a transverse pivot shaft connecting the broom's support arms together behind the broom. A spring is provided which is positioned above the broom and the hood and is coupled to the ends of the broom shaft for the purpose of absorbing shock imposed upon the system due to sudden downward broom movement.
A sweeping machine is disclosed in the O. F. Presbrey U.S. Pat. No. 1,904,881, in which a rotary broom is mounted forward of a mobile vehicle and is supported by a cable system attached to the vehicle. Raising and lowering of the broom is accomplished by manipulation of the cable system and the broom is said to be in a freely floating condition in front of the vehicle as the supporting cable for the broom is maintained in a taut condition at all times during operation by a pair of coiled tension springs. The entire broom assembly in the Presbrey patent may move vertically, or one end may move vertically independent of the other end so that the broom follows the topography of the underlying surface being swept.
Another sweeping machine is disclosed in the J. R. Royer U.S. Pat. No. 2,156,065. A sweeping machine arranged to be towed by another vehicle is configured so that two rotary brooms are mounted underneath the machine, each of which is capable of independent vertical motion relative to the framework of the machine. A motor is provided for driving the two brooms through appropriate chain and sprocket linkage. Dirt deflectors are mounted adjacent to the upper periphery of the brooms and move vertically therewith. A coiled tension spring is coupled between the framework and the structure supporting the brooms so that the brooms are suspended resiliently beneath the frame and may therefore ride upwardly and over projections on the surface being swept.
Another surface sweeper is disclosed in U.S. Pat. No. 4,007,026, issued to A. F. Groh. An industrial sweeper contains a hopper supported on the sweeper framework. A dust filter configured as a number of rows of cartridges having pleated paper filter elements is located within the hopper between a dust laden air portion of the hopper and a filtered air portion. The filters are cyclically cleaned by the application of reverse air jet pulses. The cleaning is performed in only a portion of the filters at any one time. A broom chamber is rigidly affixed to the framework containing a rotating broom which is disposed to engage an underlying surface to be swept. The broom is movable vertically within the broom chamber over a limited distance and serves to sweep debris and dust from the underlying surface toward an elevator paddle which urges the dust and debris through aligned apertures in the broom chamber and the hopper so that the dust and debris is collected within the hopper. A blower exhausts air from the filtered air portion of the hopper, thereby drawing an airflow along a path from the underlying surface into the broom chamber, into the dust laden air portion of the hopper, to the filter and the filtered air portion of the hopper and to the atmosphere. While the Groh device will accommodate small irregularities in the surface being swept, it will not sweep continuously and afford good dust control when encountering large irregularities in the underlying surface, such as parking lot speed bumps.
SUMMARY OF THE INVENTION
In accordance with the present invention a framework is provided in a mobile sweeper which supports a hopper configured to receive dust and debris. A floating broom chamber is provided together with means for mounting the floating broom chamber on the framework so that it is movable vertically relative to the chamber. A broom is mounted within the floating broom chamber for contacting the underlying surface, and means is provided for mounting the broom within the broom chamber in a manner to provide limited vertical movement between the broom and the chamber. Dust and debris which is swept off of the surface by the broom in the floating broom chamber is thereafter directed from the floating broom chamber into the hopper. Thus, by providing both a movable broom chamber (with respect to the frame) and a movable broom (with respect to the chamber) the sweeper can traverse relatively large obstacles, such as speed bumps, while the broom remains in continuous sweeping contact with the underlying surface.
In a preferred form of the invention a resilient tubular seal is disposed between the hopper and the floating broom chamber. The tubular seal is collapsible across the diameter thereof so that the floating broom chamber may be moved upward from the down position while maintaining the seal between the broom chamber and the hopper so that all dust which is swept up by the broom will be delivered to the hopper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an industrial sweeper embodying the floating broom chamber of the present invention.
FIG. 2 is an enlarged partial side elevational view of the industrial sweeper of FIG. 1 with portions thereof being broken away.
FIG. 3 is an enlarged partial longitudinal section taken along a plane parallel to the fore and aft axis of the industrial sweeper of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An industrial type sweeper 11 is shown in FIG. 1 which is of the general type described in detail in U.S. Pat. No. 4,007,026 to A. F. Groh. As described therein, the sweeper is of the driven front wheel type wherein one centrally located front wheel 12 is mounted for pivotal movement within a framework 13. The front wheel is controlled through appropriate linkage and gearing by a steering wheel 14 as described in the Groh specification. An operator's seat 16 is located behind the steering wheel together with appropriate controls for operating the various components of the sweeper. One of the controls is seen in FIG. 1 as a broom elevation control handle 17 which pivots about a pivot point 18 in the framework when raised or lowered by a sweeper operator. A curb or side brush 19 is also provided which may be raised or lowered by the operator as discussed in the Groh patent, such mechanism being unrelated to the invention described herein.
A hopper 21, configured to receive dust and debris, is mounted on the framework 13 toward the rear thereof. The hopper has a dust laden air chamber 22 therein separated by an internal wall 23 from a filtered air chamber 24. An array of filters 26 is disposed between the chambers 22 and 24 mounted in the wall 23 as described in the Groh patent. The hopper is mounted on the framework 13 for pivotal motion relative thereto about a pivot point 27 at the rear end of the framework. The hopper is pivoted about the pivot point 27 through the actuation of a hydraulic piston and cylinder combination 28, one such assembly being located on each side of the hopper 21. A rear door (not shown) is provided in the rear wall of the hopper so that dust and debris may be dumped therefrom when the hopper is pivoted rearwardly about the pivot point by the hydraulic piston and cylinder assemblies.
A pair of rear supporting wheels 29 is located at the rear of the sweeper 11 supporting the framework 13 above an underlying surface 31 which is to be swept. A floating broom chamber shown generally at 32 is supported beneath the hopper 21 in a position immediately overlying the surface 31. A crusher plate 33 is located immediately forward of the floating broom chamber, being pivoted at the forward end thereof at a pivot point 34 in a member 36 depending from the framework 13. The crusher plate has a slotted ear 30 attached to each side thereof. A guide pin 35 extends from each side of the broom chamber passing through the slot in the ear 30. The guide pins and slotted ears serve to support the rear end of the crusher plate above the surface 31 and provide limited independent upward pivotal motion of the crusher plate relative to the broom chamber.
The broom chamber 32 may be seen to admit air, shown by the dashed arrows in FIG. 1, underneath depending flaps 77 attached thereto into the interior of the floating broom chamber. The air follows a flow passage through the broom chamber, into the dust laden air chamber 22 of the hopper 21, through the filter array 26 and into the filtered air chamber 24. The air is caused to flow along the flow passage by the operation of a blower 37 which exhausts the air from the filtered air chamber 24 to the atmosphere. A vacuum of 0.3 to 0.4 inches of mercury is induced in the hopper by the blower which has been found to be sufficient for operation of industrial sweepers of the type described herein.
Turning now to FIG. 3, the manner in which the floating broom chamber 32 is mounted in the frame-work 13 is there shown. The hopper 21 has a generally vertical front wall portion 38 on the lower end of which is mounted a baffle channel 39 which overlies a portion of an aperture 41 through an inclined bottom wall portion 42. The baffle channel 39 protects the filter array 26 from direct impingement by debris being flung into the dust laden air chamber 22 of the hopper. The bottom wall of the hopper also has a V-shaped depending channel 43 attached thereto that deflects dust and debris that might otherwise be flung back into the rear portion of the floating broom chamber 32.
The floating broom chamber includes a broom housing 44 having two side walls 46, a rear wall 47, a front wall 48 and an opening 49 in a top wall 51. The opening in the top wall of the broom housing 44 may be seen to be aligned, or in registration with, the aperture 41 in the bottom wall portion 42 of the hopper 21. An elevator arch 52 is shown attached to the front wall of the broom housing 44.
A broom 53 having a drive shaft 54 running therethrough is shown disposed within the broom housing 44 (FIG. 3) with the drive shaft running transversely across the broom housing. The broom drive shaft is driven by means such as a hydraulic motor 55 (FIG. 3) mounted directly on the end of the drive shaft and movable therewith. The broom 53 is driven in the counterclockwise direction as seen in FIG. 3, thereby functioning as an "underthrow" type of a sweeping broom. An elevator paddle assembly 56 is shown mounted on an elevator drive shaft 57 forward of the broom 53. The elevator paddle assembly is driven by the elevator drive shaft also in a counterclockwise direction by an appropriate motor such as a hydraulic motor 60 mounted directly to the side wall of the broom chamber and movable therewith. The periphery of the elevator paddle assembly 56 passes close to the inner surface of the elevator arch 52, thereby urging dust and debris to be swept upwardly within the broom housing 44 through the exit opening 49 in the broom housing and through the inlet opening 41 in the hopper.
A pair of angles 58 (FIG. 2) are attached to the framework 13 at opposite sides of the broom chamber 32. Each angle 58 includes a bar 59 pivotally attached thereto and extending rearwardly. A bracket 61 is fixed to each side wall 46 on the broom housing 44 near the rear end thereof. The bracket 61 is configured to accept the rear end of the associated bar 59 for pivotal motion therein. Each bar 59 therefore forms a link operating to pull or tow the broom housing 44 along with the framework 13. A pair of rear stop brackets 62 are affixed to a vertical wall 63 on the framework 13 disposed behind the broom housing 44. An adjustable rear stop bolt 64 passes through an opening in each rear stop bracket and is locked in place by means of a nut 66. Each rear stop bolt 64 contacts the underside of the bracket 61 on the adjacent side of the broom housing, thereby supporting the rearward end of the broom housing 44 in a down position.
The front wall 48 of the broom housing 44 (FIG. 3) has a hole therein through which is passed a front stop bolt 67. A flange 68 on a channel member 98 of the framework 13 has a through hole which accepts the shank of the front stop bolt 67. The end of the front stop bolt has threads which receive a pair of stop lock nuts 69 which rest against the upper surface of the flange 68, thereby adjustably supporting the front end of the broom housing 44 in a down position. The crusher plate 33 has an upwardly extending land 71 thereon. An angle 72 extending from the outer surface of the elevator arch 52 has a threaded hole therein which accepts a lift point bolt 73. The lift point bolt is locked in place by a pair of lock nuts 74.
It may be seen in FIG. 3 that the underside of the broom housing 44 is spaced above the underlying surface 31. A flexible front flap 76 is attached to the broom housing at the lower end of the elevator arch 52 and extends to the underlying surface. The flexible side flaps 77 depend from the side walls 46 of the broom housing to a position proximate to the underlying surface. A flexible rear flap 78 is mounted to depend from the rear wall 47 of the broom housing toward the underlying surface. Also mounted at the bottom of the rear wall of the broom housing is a brush strip 79 which forms a rear broom arch extension and serves to dislodge debris from the brush 53 so that it may be re-engaged and swept forwardly into the broom chamber formed by the broom housing. As the periphery of the broom 53 wears away due to contact with surfaces being swept, the rear broom arch extension 79 requires adjustment toward the periphery of the rotating broom. This adjustment is obtained by means of an adjustment bolt 81 having a set of lock nuts 82 threaded thereon. The adjustment bolt is capable of being selectively positioned fore and aft as it passes through a threaded hole in an adjustment flange 83. Positioning of the adjustment bolt forwardly pushes the rear broom arch extension brush strip forward to a position where it properly engages the periphery of the broom 53 for the purpose hereinabove described.
A resilient tubular seal 84 is secured by a plurality of spaced bolts to the top wall 51 of the broom housing 44 surrounding the opening 49 therein. The resilient tubular seal therefore also surrounds the inlet aperture 41 in the bottom wall 42 of the hopper 21. As seen in FIG. 3, the upper edge of the tubular seal 84 engages the bottom wall 42 of the hopper when the hopper is in its normal, operative position and when the broom chamber is in its lowermost position so as to provide a seal between the hopper and the broom chamber, it being recognized that the hopper is supported in its lowermost FIG. 3 position by portions of the framework 13 (not shown). As a consequence, air which is drawn in underneath the flexible flaps 76, 77 and 78 entrains the dust and debris swept into the interior of the broom housing 44 and, together with the inertia imparted by the rotating broom 53, carries the dust and debris into the path of the elevator paddles 56. The elevator paddles working in conjunction with the elevator arch 52 further elevate the dust and debris within the broom housing 44 flinging it through the exit opening 49 and the inlet opening 41 into the dust laden air chamber 22 in the hopper 21. Heavier debris may be seen to fall toward the rear of the hopper while the lighter dust particles are still entrained in the airflow travelling toward the filter array 26. The airflow through the flow passage is sustained by the blower 37, as hereinbefore described. Therefore, good dust control is obtained at the underlying surface 31 being swept and substantially no debris or dust particles are allowed to pass the resilient collapsible tubular seal 84 as the bottom wall 42 of the hopper engages the upper surface of the seal and the top wall 51 of the broom housing is in secured engagement with the bottom surface of the seal. The crusher plate 33 serves to crush cans and break bottles into fragments before they pass under the front flexible flap 76 to be swept forwardly and upwardly into the broom housing. The crusher plate also serves as the means for elevating the broom housing when the sweeper passes over a large obstacle, as shown in FIG. 2 and as will be explained in greater detail hereinafter. The broom 53, being free to undergo limited relative vertical movement in the broom housing 44, maintains contact with the underlying surface being swept as it moves vertically relative to the broom housing and the framework to accommodate small undulations in the underlying surface.
Returning momentarily to FIG. 1 a broom lift rod 86 is shown engaged by a link 87 actuated by the broom elevation handle 17. As seen in FIG. 2, the broom lift rod 86 at one side of the housing 44 engages an upper broom lifting link 88 in a slot 89 formed therein. The upper broom lifting link is fixed to a lower broom lifting link 92 upon which is mounted a journal 93 accepting the projecting end of the broom drive shaft 54. Both the upper and lower links 88, 92 are secured to a rod 91 which extends laterally through the broom chamber and which is journalled in the side walls 46 thereby (by means not shown). The motor 55, which drives the broom, is secured to a link (not shown) which is similar to the link 92 and which is secured to the rod 91 at the opposite side of the broom housing. The broom is therefore allowed to traverse through limited vertical movement relative to the broom housing 44 without movement of the broom elevation handle 17 as the slotted link 88 is free to move relative to the broom lift rod 86. At the same time the drive shaft 54 is allowed to traverse slots 94 in each of the side walls 46 for the broom housing, as seen in FIG. 2. Also mounted in the side wall 46 seen in FIG. 2 is a journal 96 which accepts one end of the elevator paddle assembly drive shaft 57.
An angle 97 is shown (FIGS. 2 and 3) attached to each side of the broom housing 44. A section of channel 98 on which the flange 68 is formed is attached to the framework 13 overlying the angle 97. A locating pin 99 is mounted on each of the angles 97 and a coiled compression spring 101 is positioned to surround each locating pin and to be captured between the angle 97 and the channel 98. The locating pin 99 may best be seen in FIG. 3 where the floating broom chamber 32 is in its normal, lowered position subjecting the spring to lesser compression.
In FIG. 2 a projection, such as a speed bump 102, is seen extending upwardly from the underlying surface 31 to engage the underside of the crusher plate 33. The land 71 on the crusher plate is shown in engagement with the lift point bolt 73 thereby urging the broom housing 44 away from its downward position. The front stop bolt 67 is shown having traveled upwardly to displace the stop lock nuts 69 from contact with the flange 68. The upward movement of the broom housing 44 causes the tubular seal 84 to collapse transversely as seen in FIG. 2. The broom housing is shown with both the front and rear ends elevated by contact between the speed bump and the pressure plate in FIG. 2 for purposes of illustration only. The broom housing front end is capable of independent vertical movement relative to the rearward end. When the sweeper 11 has advanced to a point where the speed bump 102 underlies the rear portion of the side plates 46, as seen in phantom lines in FIG. 2, the broom housing is elevated to lift the lower surface of each bracket 61 from contact with the associated rear stop bolt 64, as shown. At this time the front end of the broom housing may have begun to return to the down position with the stop lock nuts 69 in contact once again with the flange 68. It should be noted that with the broom housing in the elevated position as seen in FIG. 2, the broom 53 has been lowered relative to the broom housing (with respect to the FIG. 1 position) by motion of the drive shaft 54 in the slot 94 so that the broom is maintained in sweeping contact with the underlying surface. The forward edge of the flexible side flaps 77 are bevelled and carry a metal guard 103 thereon to protect the side flaps from accelerated wear and damage as the edges thereof advance into surface projections such as the speed bump 102.
An industrial sweeper has been disclosed herein having attached thereto a floating broom chamber with a resilient collapsible tubular seal disposed between the broom chamber and a hopper for receiving dust and debris. The broom chamber is normally supported in a down position by down stops between the frame and the broom chamber but is capable of being elevated by large protrusions on the underlying surface being swept. The resilient tubular seal may be rubber or a resilient plastic material and may be of solid or porous construction while maintaining the dust control seal for either the elevated or the down positions or any position therebetween. Dust control is maintained and sweeping contact between the rotating sweeping broom and the underlying surface being swept is also maintained for both the elevated and the down positions of the floating broom chamber.
Although the best mode contemplated for carrying out the present invention has been herein shown and described, it will be apparent that modification and variation may be made without departing from what is regarded to be the subject matter of the invention. | A maneuverable surface sweeper has a framework supporting a hopper configured to receive dust and debris swept from an underlying surface. A broom chamber is mounted within the framework overlying the surface to be swept and in communication with the hopper. The broom chamber may move vertically relative to the framework. A rotary driven broom is mounted in the broom chamber and has limited vertical movement capability relative to the chamber. A resilient tubular seal is disposed between the broom chamber and the hopper so that dust control is obtained therebetween while the broom chamber undergoes vertical movement. A bump encountered on the underlying surface elevates the broom chamber permitting the sweeper to pass thereover while allowing the broom to descend and continue in sweeping contact with the surface. | 4 |
BACKGROUND OF THE INVENTION
This invention was made with United States Government support and the United States Government has certain rights therein.
This invention relates to bearings, and more particularly, to an apparatus for lubricating the bearing.
In an effort to extend the life of a bearing, previous systems have been developed for adding lubricating materials (usually some type of oil) to the bearing while in operation. (note that the term "oil" used herein is intended as a generic lubricating material and is intended to include oil, synthetic oil, graphite, grease, . . . ) These previous systems have many problems associated therewith. An oil mist system does not permit the required control for the oil placement; also too large a quantity of oil must be injected at predetermined times. A cone injection system lacks precise delivery of the oil to the contact area of the bearing, and also requires a relatively large amount of space outboard of the bearing. An outer race injection system includes a hole through the stationary ring of a ball bearing. The hole intersects the race just outside of the ball-race contact zone. Oil which is fed through the hole hits the passing balls and is thereby distributed. A problem with the distribution system is that the ball, moving at a relatively high speed and simultaneously spinning about its own axis, tends to sling the oil causing part of the oil to be distributed to non-useful parts of the bearing. The second problem with this distribution system is the proximity of the injection hole to the running track.
Thus there is a need to provide a system which can deliver oil to the running track of the bearing and eliminates the problems of the previous systems identified above. The present invention provides an active lubrication system which injects predetermined quantities of oil to the contact area of the bearing thereby eliminating the problems of the previous systems.
SUMMARY OF THE INVENTION
Therefore, there is supplied by the present invention, a system for inserting oil into the critical areas of a bearing, which has rolling elements. The system comprises a delivery element for delivering lubricating oil to a predetermined point relative to the bearing. The bearing, which is rotating about a spin axis, causes the lubricating oil to be slung outward of the spin axis of the bearing. A cage element, having a lip which extends outboard of the outboard bearing face, captures the lubricating oil to direct the lubricating oil to the outer race of the bearing and to the rolling elements of the bearing, which track the oil to the inner race.
Accordingly, it is an object of the present invention to provide an apparatus for adding oil into a bearing.
It is another object of the present invention to provide an apparatus for adding predetermined amounts of oil into a bearing.
It is still another object of the present invention to provide an apparatus for adding predetermined amounts of oil into a critical area of a bearing.
It is a further object of the present invention to provide an apparatus for adding predetermined amounts of oil into a critical area of a bearing without interfering with normal operation of the bearing.
These and other objects of the present invention will become more apparent when taken in conjunction with the following description and attached drawings, wherein like characters indicate like parts, and which drawings form a part of the present application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partial sectional view of a bearing mounted on a rotatable shaft and incorporating the lubrication system of the present invention;
FIG. 2 shows an expanded partial view of the bearing, including a showing of the path of the oil flow;
FIG. 3 shows a diagram of the placement of the delivery tube relative to the bearing;
FIG. 4 shows a diagram of a cage of the preferred embodiment of the present invention; and
FIG. 5 shows a partional sectional view of an alternative embodiment of the lubrication system of the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown a partial sectional view of a bearing mounted on a rotatable shaft and incorporating the lubrication injection system of the present invention. A bearing 1 is shown contained in a cartridge 2, and driven by a shaft 3 around a spin axis 9. The bearing 1, includes an inner race 5, an outer race 6, a cage 7, and the balls 8 (or rolling elements) of the bearing. Lubricating fluid/material is delivered to the bearing 1 via a delivery tube (or more simply referred to herein as tube) 4. (Note that the term "oil" will be used hereinafter to refer to lubricating fluid/material and is intended to be generic to include oil, grease, synthetic oil, graphite, . . . )
The operation of the lubrication insertion system will now be described. Referring to FIG. 2, there is shown an expanded partial sectional view of the bearing 1, and includes a showing of the path of the oil from the delivery tube 4 to the running track 10 of the ball. When lubrication of the bearing 1 is desired, oil is pumped to the delivery tube 4 in predetermined quantities. In the preferred embodiment of the present invention, the face of the delivery tube 4' is parallel to the outboard face of the inner race 5', and placed a distance D 2 therefrom. As the oil is pumped to/through the delivery tube 4, a hemisphere of oil begins to form at the face of the delivery tube 4. (The distance D 2 is selected such that a droplet of oil 11 being formed at the face of the delivery tube 4 contacts the inner race 5 before the hemisphere of oil completes its formation and drops off.) When the droplet of oil 11 is large enough, it contacts the inner race 5 of bearing 1, which is rotating with the shaft 3 about the spin axis 9. Viscous coupling between the oil and inner race 5 imparts momentum to the oil droplet 11 propelling it tangentially to the inner race 5 and outward from the spin axis 9 to the cage 7. The outboard portion of cage 7 extends a distance D 1 from the outboard face of the inner race 5, the distance D 1 being greater than the distance D 2 . Oil droplets 11 propelled outward by the spinning inner race 5 are caught by the extended portion of cage 7 and directed into the bearing.
At least part of each oil droplet 11 adheres to the cage 7 while some of the oil droplet 11 deflects off the cage 7 surface. Any oil that is deflected off the cage 7 is directed toward the balls 8 due to the impingement angle of the cage 7 relative to the spin axis 9. All the surfaces of the inner and outer diameters of the cage 7 are angled so that the centrifugal forces acting on any oil on the surfaces of the cage 7 will direct that oil (dashed arrow line) to the ball pockets or to the point on the cage with the greatest outside diameter (Point B). The axial location of Point B, the point of greatest outside diameter is selected to coincide with the nominal operating contact angle (or running track) 10 of the bearing. Any oil not picked up by the ball 8 is slung outward such that the oil contacts the outer race 6 in the normal running track 10. Outside corner 12 of cage 7 is rounded such that any oil that might contact the outside face of the cage 7 creeps along the cage to Point B rather than being slung off the edge outside the bearing (secondary oil path shown by the dotted line).
Referring to FIG. 3, there is shown a diagram of the placement of the delivery tube 4. The placement and material of the delivery tube 4 is important to insure that the oil does not leak from it unintentionally. The material should be non-wettable to the oil used. In the preferred embodiment of the present invention a teflon material is used which forms the nozzle (ie., the delivery tube) 4. The end of the nozzle should be smooth and parallel to the outboard face of the inner race 5. The axis of the nozzle 14 should be perpendicular to the outboard face of the inner race 5, of the bearing 1. The nozzle face should also have a smooth surface finish and be kept as clean as possible in order to further minimize wettability. The dotted line C shows the hemisphere which would form as a result of microliter quantities of oil being pumped into the delivery tube 4 if the inner bearing race 5 were not present. Although only partially shown, it will be understood by those skilled in the art that the delivery tube 4 can be attached to and/or form part of the cartridge/cartridge clamp ring 2.
Referring to FIG. 4 there is shown a diagram of the cage (or bearing cage) 7. The cage of the preferred embodiment is a biased cage, well known to those skilled in the art, although it is not necessary in order to implement the lubrication system of the present invention. Section X--X shows the angles inside the cage 7 relative to the spin axis 9, and shows Points A and B referenced above. The outboard face of cage 7 includes the rounded corner to allow the oil flow, which contacts the outside face of cage 7, to creep ,to Point B as described above. Although surface "D", "E", "F", and "G" are, in the preferred embodiment, flat surfaces, it will be understood by those skilled in the art that these surfaces may be rounded. It is only necessary that the diameter of circles about the spin axis 9 along the surfaces D, E, and F, going inward toward the circle J, be increasing, the circle J having the largest diameter. This is to insure that oil on the surfaces D, E, and F will creep inward toward the circle J by the centrifugal forces acting on the oil. Note that Section X--X has all but one of the openings for the rolling elements (i.e., opening 15) omitted.
Referring to FIG. 5, there is shown a partial sectional view of a bearing mounted on a rotatable shaft and incorporating an alternative embodiment of the lubrication system of the present invention. The delivery tube 4 delivers a drop (droplet) of oil 11 to a predetermined point relative to the bearing 1. The outboard portion of the cage 7 extends outward from the bearing 1 such that when the drop of oil 11 drops from the delivery tube (in this case a force such as gravity causes the droplet to be directed to the extended portion of the lip of cage 7), the oil droplet is caught or captured by the extended portion of cage 7, and due to the spinning of the bearing 1 about spin axis 9, the oil droplet is directed into the bearing 1 as described above. In this embodiment, the face of the delivery tube 4 need not be brought sufficiently close to the face of the inner race 5 to impede the growth of the oil droplet 11. In this instance it is desired that the oil droplet 11 "fall off" to the extended portion of cage 7 and take advantage of the available forces.
The insertion technique described above is especially effective in vacuum or partial vacuum conditions where fluid dynamic effects of gasses in the bearing cartridge will not interfere with the formation of the oil drop and the transfer of momentum from the inner race to the drop, although it will be understood by those skilled in the art that the system of the present invention will operate in any environment which does not have any external forces which prevents the formation of the oil drop, or substantially interferes with the oil flow as described herein. It will further be understood by those skilled in the art that modifications to the cage, and deliver tube can be made to overcome external forces within the scope of the present invention. Although the preferred embodiment describes the insertion system for a ball bearing, it will also be understood by those skilled in the art that the system is equally adaptable for other type bearings, including roller bearings, . . .
While there has been shown what is considered the preferred embodiment of the present invention, it will be manifest that many changes and modifications can be made therein without departing from the essential spirit and scope of the invention. It is intended, therefore, in the annexed claims to cover all such changes in modifications which fall within the true scope of the invention. | The lubrication insertions system of the present invention inserts lubricating oil into the critical areas of a bearing. The system comprises a delivery element for delivering lubricating oil to a predetermined point relative to the bearing. The bearing, which is rotating, causes the lubricating oil to be slung outward of the spin axis of the bearing. A cage element, having a lip that extends beyond the edge of the bearing, captures the lubricating oil and directs the lubricating oil into the bearing to the outer race of the bearing and to the rolling elements of the bearing, which track the oil to the inner race of the bearing. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of international application number PCT/EP2008/003895 filed on May 15, 2008.
[0002] The present disclosure relates to the subject matter disclosed in international application number PCT/EP2008/003895 of May 15, 2008 and German application number 10 2007 024 239.7 of May 16, 2007, which are incorporated herein by reference in their entirety and for all purposes.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to an angiogenesis-promoting substrate.
[0004] In living mammals, endothelial cells which line existing blood vessels form new capillaries wherever these are required. The endothelial cells have the remarkable capability of adapting their number and arrangement to the local requirements. Tissues are dependent upon the blood supply which is provided by the blood vessel system. The vessel system, in turn, is dependent upon the endothelial cells. The endothelial cells create an adaptable life-ensuring system which branches into almost all regions of the body.
[0005] While the largest blood vessels, the arteries and veins, have a thick, strong wall of connective tissue and partly smooth muscles and are lined on the inside with only an extremely thin, single layer of endothelial cells, in the finest branches of the vessel system, the capillaries, walls are found which consist solely of endothelial cells and a so-called basal lamina. Endothelial cells thus line the entire blood vessel system running from the heart into the smallest capillary, and they control the passage of factors and cells into and out of the blood stream.
[0006] In the event of a deficiency of oxygen, tissue cells release angiogenic factors which activate the growth of new capillaries. Local (mechanical) irritations and infections also cause proliferation of new capillaries, most of which recede and disappear once the inflammation subsides.
[0007] The newly forming blood vessels first always develop as capillaries which sprout on existing small vessels. This process is called angiogenesis.
[0008] The sprouting of the capillaries propagates until the respective sprout encounters another capillary and can unite with it, so that blood can circulate therein (cf., for example, B. Alberts et al., Molekularbiologie der Zelle, VCH Weinheim, 3rd edition 1995, pages 1360-1364).
[0009] Factors which stimulate angiogenesis are widely known and include, for example, the factors HGF, FGF, VEGF and others.
[0010] In the literature (cf., for example, EP 1 415 633 A1 and EP 1 555 030 A1), administration of such angiogenesis-stimulating factors in a sustained release matrix was proposed, and a gelatin hydrogel comprising gelatin with an average molecular weight of 100,000 to 200,000 daltons (Da) was recommended as sustained release matrix.
[0011] The suitability of various types of collagen as scaffold in the formation of new vessels as well as their anti-angiogenetic effects are described. Reference is made to S. M. Sweeney et al., The Journal of Biological Chemistry, volume 278, No. 33, pages 30516 to 30524 (2003) and to R. Xu et al. in Biochemical and Biophysical Research Communications 289, pages 264 to 268 (2001) as examples of this literature.
[0012] The object underlying the present invention is to provide an angiogenesis-promoting substrate which can be manufactured easily and cost-effectively.
SUMMARY OF THE INVENTION
[0013] This object is accomplished by an angiogenesis-promoting substrate comprising a non-porous shaped body formed from a gelatin-containing material which is insoluble and resorbable under physiological conditions.
[0014] Owing to their good biocompatibility, gelatin-based materials have been in use for quite some time for medical applications, for example, as matrix material for the release of pharmaceutically active substances or as carrier material for colonization with cells. In contrast, for example, to collagen, gelatin can be produced in reproducible quality and with a high degree of purity. Furthermore, it is essentially completely resorbable in the body.
[0015] Within the scope of the present invention, it has now, surprisingly, been found that the gelatin-containing material as such has an angiogenesis-promoting effect, i.e., stimulates the formation of new blood vessels in its immediate vicinity, without any further angiogenesis-promoting factors such as, for example, the aforementioned signalling molecules VEGF, FGF or HGV being required.
[0016] It is particularly remarkable that the angiogenesis-promoting effect in accordance with the invention is observed in a non-porous shaped body, which is formed from the gelatin-containing material. In earlier examinations conducted by the inventors, an angiogenesis-promoting effect was first found in porous shaped bodies made of gelatin-containing material, with the angiogenesis primarily taking place within the shaped bodies, i.e., an ingrowth of blood vessels into the pores, cavities or interspaces of the shaped body was observed. The pro-angiogenetic effect was, therefore, primarily attributed to the porous structure of the shaped body (see the German patent application with file number 10 2005 054 937). Examples of such structures are sponges, woven fabrics or fleeces.
[0017] In contrast to this, it has now been found that in accordance with the present invention a non-porous shaped body can also be used as angiogenesis-promoting substrate, with the blood vessel formation not taking place in the shaped body, but in its spatial environment. Without wishing to be bound to this theory, it is assumed that this effect is caused by a release of soluble components of the gelatin and, therefore, is substantially independent of the structure of the shaped body.
[0018] As a rule, non-porous shaped bodies made of a gelatin-containing material are easier to produce than those with a porous structure. On the other hand, use of a shaped body made of an insoluble material, which is only resorbed or broken down after a certain time, has in comparison with use of soluble or dissolved gelatin the advantage that the angiogenesis can be stimulated in a targeted manner at a certain location, namely in the vicinity of the shaped body used.
[0019] The gelatin-containing material is preferably a gelatin-based material and consists predominantly of gelatin. This means that the gelatin constitutes the largest proportion where further components are used in the material.
[0020] Further preferred is use of a gelatin-based material consisting essentially entirely of gelatin.
[0021] Particularly suitable gelatin types are pigskin gelatin, which is preferably high-molecular and has a Bloom value of approximately 160 to approximately 320 g.
[0022] To a considerably lesser extent, an angiogenesis-stimulating effect is also observed with low-molecular, water-soluble gelatin having an average molecular weight of less than 6 kDa, but such an effect is comparatively unspecific when compared with other agents that likewise stimulate to a lesser extent.
[0023] Therefore, the gelatin used preferably has an average molecular weight greater than approximately 6 kDa.
[0024] To ensure optimum biocompatibility of the substrate according to the invention in medical use, a gelatin having a particularly low content of endotoxins is preferably used as starting material. Endotoxins are products of metabolism or fractions of microorganisms which occur in the raw animal material. The endotoxin content of gelatin is indicated in international units per gram (I.U./g) and determined in accordance with the LAL test, the performance of which is described in the fourth edition of the European Pharmacopoeia (Ph. Eur. 4).
[0025] To keep the content of endotoxins as low as possible, it is advantageous to kill the microorganisms as early as possible in the course of the gelatin production. Furthermore, appropriate hygiene standards should be maintained during the manufacturing process.
[0026] The endotoxin content of gelatin can thus be drastically reduced by certain measures during the manufacturing process. These measures primarily include the use of fresh raw materials (for example, pigskin) with avoidance of storage times, thorough cleaning of the entire production plant immediately before start of the gelatin production and possibly exchange of ion exchangers and filter systems in the production plant.
[0027] The gelatin used within the scope of the present invention preferably has an endotoxin content of approximately 1,200 I.U./g or less, even more preferred approximately 200 I.U./g or less. Optimally, the endotoxin content lies at approximately 50 I.U./g or less, determined, in each case, in accordance with the LAL test. In comparison with this, many commercially available gelatins have endotoxin contents of over 20,000 I.U./g.
[0028] As indicated hereinabove, the non-porous shaped body of the angiogenesis-promoting substrate is formed in accordance with the invention from a material which is insoluble under physiological conditions, so that it maintains its structural integrity over a certain period of time, and the angiogenesis can be localized to the desired target area. However, since gelatin is dissolved quickly under physiological conditions, the gelatin-containing material is preferably cross-linked.
[0029] In accordance with a further embodiment of the present invention, a quick dissolution can be counteracted by using the gelatin together with other components which dissolve more slowly (examples of such resorbable biopolymers are chitosan and hyaluronic acid). Such components may be used for the purpose of temporary immobilization of the gelatin proportions.
[0030] If cross-linking is chosen for stabilization of the material, in particular, the gelatin proportion of the gelatin-containing material can be cross-linked, and chemical cross-linking or also enzymatic cross-linking can then be resorted to.
[0031] Preferred chemical cross-linking agents are aldehydes, dialdehydes, isocyanates, carbodiimides and alkyl dihalides. Formaldehyde, which simultaneously effects a sterilization of the shaped body, is particularly preferred.
[0032] The enzyme transglutaminase, which effects a linking of glutamine and lysine side chains of proteins, in particular, also of gelatin, is preferred as enzymatic cross-linking agent.
[0033] The stability with respect to resorption under the physiological conditions referred to hereinabove, to which the material is exposed during its use, can be simulated under corresponding standard physiological conditions in vitro. Here a PBS buffer (pH 7.2) is used at 37° C., and under these conditions the substrates can be tested and compared as to their time-dependent stability behavior.
[0034] The gelatin-containing material preferably has a prescribed degree of cross-linking. In particular, the resorption stability of the shaped body, i.e. the time during which it maintains its structural integrity under physiological conditions can be set by prescribing the degree of cross-linking. It is thus possible, for example, to use as angiogenesis-promoting substrates non-porous shaped bodies which in dependence upon the degree of cross-linking of the gelatin-containing material are stable for, for example, one, three, six or twelve weeks under physiological standard conditions, depending on for whatever period of time an angiogenetic effect is desired by the attending physician.
[0035] Surprisingly, it has also been found that the higher the degree of cross-linking of the gelatin-containing material, the higher is the angiogenesis-promoting effect of the shaped body, in particular, in the case of chemical cross-linking of the gelatin. This opens up further possibilities for also stimulating the angiogenesis in a quantitatively targeted manner.
[0036] The structure of the non-porous shaped body is preferably stabilized by a two-stage cross-linking, wherein at a first stage the gelatin-containing material in solution is subjected to a first cross-linking reaction, and a shaped body produced from this material is then further cross-linked at a second cross-linking stage.
[0037] Whereas at the first cross-linking stage, the cross-linking takes place in solution, in particular, a cross-linking in the gaseous phase, for example, using formaldehyde, is possible for the second cross-linking stage.
[0038] The production of shaped bodies from a gelatin-containing material by means of a two-stage cross-linking process is described in detail in the publication DE 10 2004 024 635 A1.
[0039] The two-stage cross-linking has, in particular, the advantage that overall a higher degree of cross-linking is obtainable, which, in addition, is then achievable substantially uniformly over the entire cross section of the shaped body. As a consequence of this, the degradation characteristics of the shaped body during the resorption are homogenous, so that it substantially maintains its structural integrity for the intended period of time in dependence upon the degree of cross-linking and is then completely resorbed in a relatively short time, whereby the structural integrity is lost.
[0040] Owing to the prescribed degree of cross-linking and the above-described homogenous degradation behavior, the angiogenesis-promoting effect of the substrate according to the invention can, therefore, be employed in a precisely targeted manner with respect to both time and space.
[0041] For many applications, the degree of cross-linking should be so selected that under the standard physiological conditions mentioned hereinabove approximately 20 wt % or less of the gelatin-containing material is broken down over 7 days.
[0042] The non-porous shaped body can be made with very different structures, which have not yet been discussed.
[0043] In accordance with a preferred embodiment of the invention, the shaped body is a sheet material. Sheet materials can be used in a variety of ways as medical substrates in or on the body.
[0044] It is particularly preferred for the shaped body to be a film. Such films can be produced in a simple way by casting a solution of a gelatin-containing material, and this process can be combined with the two-stage cross-linking process described hereinabove.
[0045] Films made from a gelatin-containing material are easy to handle and can be cut to the respectively required size by the attending physician. In order to increase the flexibility of the film, the gelatin-containing material can additionally contain one or more softeners. Preferred softeners are selected from glycerin, oligoglycerins, oligoglycols, sorbite and mannite.
[0046] The film preferably has a thickness ranging from approximately 20 to approximately 500 μm, further preferred from approximately 50 to approximately 100 μm.
[0047] In accordance with a further embodiment of the invention, the non-porous shaped body is in the form of particles. The particles can be, for example, globules, granulate or powder made from a gelatin-containing material.
[0048] Preferred particles have an average diameter of from approximately 0.1 mm to approximately 5 mm.
[0049] In accordance with an advantageous embodiment of the invention, the non-porous shaped body comprises one or more pharmaceutically active substances not based on gelatin. These can be, for example, anti-inflammatory and antibiotic agents.
[0050] In an embodiment of the invention, the non-porous shaped body is colonized with cells. In this case, the substrate according to the invention can be used for cell transplantations in which an angiogenesis is desired in the area of the implanted cells.
[0051] The present invention also relates to the use of a non-porous shaped body formed from a gelatin-containing material which is insoluble and resorbable under physiological conditions, for producing an angiogenesis-promoting substrate, which is intended for use in or on the body of a human being or an animal. Advantages and preferred embodiments of this use will be apparent, in particular, from the above description of the angiogenesis-promoting substrate according to the invention.
[0052] In a preferred use, the substrate is used as wound dressing or covering. By applying the substrate to injuries or burns, in particular, on the skin, the angiogenetic effect can contribute towards quicker wound healing.
[0053] In accordance with a further preferred embodiment, the angiogenesis-promoting substrate is intended for implantation in the body. Here the substrate can be intracorporally inserted at many different locations of the body, wherever a targeted promotion of the angiogenesis is required or desired.
[0054] Preferred areas of application of the angiogenesis-promoting substrate according to the invention are, for example, transplantations, the treatment of diabetes or of infarctions.
[0055] When performing therapeutic procedures using the angiogenesis-promoting substrate according to the invention, a non-porous shaped body is made available in the respectively required shape and size or is cut to size by the attending physician, in order to then be inserted into or placed on the corresponding area on the human or animal body.
[0056] These and further advantages of the invention are explained in detail hereinbelow with reference to the drawings and the examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIG. 1 : shows a photographic representation of the blood vessel formation without an angiogenesis-promoting substrate;
[0058] FIGS. 2 a to 2 c : show photographic representations of the blood vessel formation with various angiogenesis-promoting substrates according to the invention; and
[0059] FIG. 3 : shows a photographic representation of the blood vessel formation after resorption of the angiogenesis-promoting substrate.
DETAILED DESCRIPTION OF THE INVENTION
Production of Films from a Gelatin-Containing Material
[0060] Gelatin films with three different degrees of cross-linking (films A, B and C) were produced by a two-stage cross-linking process as examples of non-porous shaped bodies.
[0061] For each of the three batches, 25 g of pigskin gelatin (300 g Bloom), 9 g of an 85 wt % glycerin solution and 66 g of distilled water were mixed, and the gelatin was dissolved at a temperature of 60° C. After degassing of the solutions by ultrasound, in order to perform the first cross-linking step, an aqueous formaldehyde solution (2.0 wt %, room temperature) was added, more specifically, 3.75 g of this solution for batch A, and 6.25 g of the solution for each of the batches B and C.
[0062] The mixtures were homogenized and spread with a doctor blade at approximately 60° C. in a thickness of approximately 250 μm onto a polyethylene base.
[0063] After drying at 30° C. and a relative atmospheric humidity of 30% for approximately one day, the films were detached from the PE base and redried for approximately 12 h under the same conditions. For performance of the second cross-linking step, the dried films (thickness approximately 50 μm) were exposed in a desiccator to the equilibrium vapor pressure of a 17 wt % aqueous formaldehyde solution at room temperature. In the case of films A and B, the duration of exposure to the formaldehyde vapor was 2 h, in the case of film C 17 h.
[0064] Of the shaped bodies produced in this way, film A has overall the lowest and film C overall the highest degree of cross-linking, film B lies between these. This is reflected in the different degradation behavior of the films, the resorption times of the described films under physiological conditions in tests on animals (see below) being between approximately 14 days (film A) and approximately 21 days (film C).
[0065] Owing to the use of glycerin as softener, the films exhibit adequate flexibility, in particular, in the hydrated state, to ensure easy handling during medical application, without having to fear that the films will break or tear.
Proof of the Angiogenesis-Promoting Effect in Tests on Animals
[0066] The efficacy of the gelatin films A, B and C as angiogenesis-promoting substrates in vivo was examined in tests on animals. Ten-week-old mice of the Balb/C strain from the Charles River company (Sulzfeld) with a body weight of 20 g were used as test animals.
[0067] Pieces of the above-described gelatin films, each measuring 5×5 mm 2 were used as substrates. Two pieces of film having a certain degree of cross-linking were implanted subcutaneously in the neck area of each of the mice. To do so, the animals were anaesthetized and their coat was shaved off in the neck area. A piece of the neck skin was lifted with tweezers and an incision of approximately 1 cm in length was made. Through this incision, a subcutaneous pocket was created with blunt scissors, and, in each case, two pieces of film were placed in it with tweezers. The wound was closed with two single button knots.
[0068] After 12 days the animals were killed, and the angiogenetic effect of the implanted substrates was optically evaluated.
[0069] FIG. 1 shows as negative control the corresponding area of the subcutaneous tissue of a mouse in which no implantation of the angiogenesis-promoting substrate was performed. Only a very slight permeation with blood vessels is to be observed, as is normal for the subcutaneous tissue of the mouse.
[0070] FIGS. 2 a to 2 c show photographs of the subcutaneous tissue in the area of the implanted pieces of film A, B and C, respectively, after the corresponding mice were killed 12 days after the implantation. The position of the pieces of film is marked by black squares (references A, B and C, respectively, for the corresponding film), as the films themselves are difficult to discern in the photograph. Experimentally, the films were partly dyed with Coomassie Brilliant Blue, as is apparent in FIG. 2 a.
[0071] In all three representations, a significantly increased blood vessel formation is recognizable in the vicinity of the implanted pieces of film. Both the number and the size of the blood vessels are significantly higher in each case than in the negative control in FIG. 1 . This result proves that the angiogenesis can be stimulated locally by non-porous shaped bodies formed from a gelatin-containing material which is insoluble and resorbable under physiological conditions.
[0072] In order to examine the time frame of the angiogenesis-promoting effect, two pieces of film of film B (middle degree of cross-linking) were implanted (as described above) in a further mouse. This mouse was killed after 21 days, and the subcutaneous tissue was optically evaluated again in the area of the implants.
[0073] FIG. 3 shows the result. The relatively thin gelatin films B are already substantially resorbed and have lost their structural integrity after 21 days. At the same time, the photograph shows that the newly formed blood vessels, which were observed in the corresponding films after 12 days (see FIG. 2 b ), have receded again.
[0074] This result shows that the angiogenetic effect of the non-porous shaped body is temporary. As resorption of the angiogenesis-promoting substrate progresses, the blood vessels also recede again. However, the resorption speed and, therefore, also the time frame of the angiogenesis can be influenced by the choice of the prescribed degree of cross-linking.
[0075] All in all, these tests confirm that in terms of both space and time, the angiogenesis can be stimulated in the human or animal body with the aid of the substrate according to the invention. | To provide an angiogenesis-promoting substrate which can be easily and cost-effectively produced, it is proposed that the substrate comprise a non-porous shaped body formed from a gelatin-containing material which is insoluble and resorbable under physiological conditions. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to floating systems, rigs and vessels used in wellbore operations; to floating systems, rigs, drill ships and vessels with a height-adjustable derrick; to methods for selectively adjusting a floating system's center of gravity; and to methods for adjusting derrick height by changing the position of part of a derrick, e.g. a crown block assembly and associated structure.
2. Description of Related Art
Well drilling has been conducted in areas where a substantial body of water overlies an oil field. In many cases a variety of fixed drill platforms mounted on legs resting on or driven into a sea floor or lake floor are used. These, however, are typically used only in relatively shallow depths of water, often not greater than about 300 feet, which is a realistic depth limit for many practical commercial operations.
Often deep water drilling is accomplished using specifically designed and constructed rigs, vessels and drill ships. Deep water and exploratory drilling has been accomplished using surface floating rigs, drilling ships or vessels which are either towed or self-propelled to a drilling site and are self-contained in that the drilling rig, auxiliary equipment, and crew's quarters form an integral part of the vessel or ship. These floating drilling systems (rigs, vessels, drill ships) are positioned over a drilling site. Certain typical rigs, vessels and drill ships have, in addition to all of the equipment normally found on a large ocean ship, a drilling platform and derrick located on the deck. In addition, such rigs, vessels and drill ships contain a hole (or “moonpool”), extending through the ship down through the hull, which allows for a drill string to extend through the ship, down into the water.
Drill ships are often used for deepwater drilling in remote locations with moderate weather environments because of their mobility and large load carrying capability. Drill ships can move from one location to the next rapidly and under their own power. On the open seas, size and height are generally not a consideration for drill ship movement; but, in certain specific circumstances, size and height limit a drill ship's mobility and can significantly increase the expense of movement from one site to another. For example, moving a drill ship through the Panama Canal can require the partial disassembly of a ship's derrick (and then its reassembly after passing through the canal) at a cost of several million dollars.
Various prior art drill ships are relatively large. For example Transocean's Discoverer Enterprise, an ultra-deepwater drill ship, is 835 feet in length and 125 feet wide and can drill a well more than 6.5 miles beneath its drill floor. Drill ships can be, in total, 20 to 30 stories high with an upright derrick over 400 feet high. The JOIDES Resolution drill ship is 470 feet long with a 202 foot high derrick.
In the past a variety of drill ship tragedies have involved the capsizing of a drill ship, particularly in stormy seas. One factor contributing to the instability of a drill ship is the height of the ship's center of gravity which is related to the height and the weight of a derrick projecting up from a ship's deck. The weight of pipe and equipment in and on the derrick can also affect the location of the ship's center of gravity. In typical drill ships, although pipe can be moved from a vertical to a horizontal position, the derrick itself is a permanent upright structure whose height is not adjustable in adverse conditions.
There are a variety of known rigs, vessels, and drill ships used in drilling and various wellbore operations; for example, and not by way of limitation, those disclosed in U.S. Pat. Nos. 2,929,610; 3,011,318; 4,064,822; 4,269,543; 4,657,438; 4,885,698; 5,139,366; 5,450,695; 5,622,452; 5,833,396; 5,906,457; 5,975,805; 5,975,806; 6,056,071; 6,047,781; 6,076,996; 6,085,851; 6,068,069; 6,443,240; 6,539,888; 6,682,265; 7,011,471; 7,163,355; 7,186,061; and U.S. Application Pub. No. 2008/0000685, and in the references cited in these patents—all these patents incorporated fully herein for all purposes.
There are a variety of known systems with a portable and/or erectable derrick or mast; for example U.S. Pat. Nos. 7,308,953; 6,860,337; 6,523,319; 5,450,695; 5,423,158; 5,342,020; 5,216,867; 4,932,175; 4,837,992; 4,757,592; 4,590,720; 4,269,395; 4,134,237; 3,996,754; 3,403,485; 3,340,938; and 2,804,949,
BRIEF SUMMARY OF THE INVENTION
The present invention, in certain aspects, provides a floating system, e.g. a vessel, a drill ship, a rig, (e.g., but not limited to, jack-up rigs and semi-submersible rigs) with a height-adjustable derrick; and, in one particular aspect, a rig, vessel or a drill ship with a derrick having a crown assembly (and, in some aspects, associated structure, e.g. but not limited to support structure and/or motion compensator apparatus) whose position is selectively adjustable. In certain aspects, adjusting the position of the crown assembly provides adjustment of the ships's center of gravity which can be beneficial during various operations and during adverse sea and weather conditions. In one aspect, the crown assembly includes a motion compensation system.
The present invention, in certain aspects, provides systems and methods for effectively reducing the overall height of a derrick on a floating well operations system by lowering a crown assembly (and, in some aspects, associated items). This is advantageous when moving the system through certain waterways (e.g., under bridges or through a strait or a canal, e.g. the Panama Canal) which present various height-restricted passages. In one aspect, such a system has a hull; a deck on the hull; a derrick on the deck, the derrick having a top and a top portion; a crown assembly (optionally with a motion compensator) on the derrick; and the crown assembly movably mounted to the derrick for movement with respect to the top portion of the derrick to reduce overall height of the derrick.
The present invention discloses, in certain aspects, a floating well operations system with a derrick having one or more apparatuses for pivotably connecting derrick equipment to the derrick so that the equipment is selectively movable away from the path of a crown assembly being lowered in the derrick. In one particular aspect, a top drive system is included with a guide rail structure on which a top drive moves up and down in the derrick. According to the present invention, part of the guide rail of the derrick is pivotably connected to the derrick so that it can be moved aside to permit the crown assembly to be moved down into the derrick.
Accordingly, the present invention includes features and advantages which are believed to enable it to advance floating well operations systems technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, other objects and purposes will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide the embodiments and aspects listed above and:
New, useful, unique, efficient, nonobvious floating systems for well operations, including drilling operations, including rigs, vessels and drill ships and new, useful, unique, efficient, nonobvious floating systems with a height-adjustable derrick;
Such systems with a derrick and with a crown assembly movably mounted on the derrick for selective height adjustment; and
Such systems with an adjustable center of gravity.
The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, various purposes and advantages will be appreciated from the following description of certain preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form, changes, or additions of further improvements.
The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.
It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.
Certain aspects, certain embodiments, and certain preferable features of the invention are set out herein. Any combination of aspects or features shown in any aspect or embodiment can be used except where such aspects or features are mutually exclusive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or equivalent embodiments.
FIG. 1 is a side view of a prior art drill ship.
FIG. 2 is a schematic side view of a drill ship according to the present invention.
FIG. 3A is a front view of part of the ship of FIG. 2 , including, among other things, a crown block assembly.
FIG. 3B is a front view of the part of the ship of FIG. 3A showing the crown block assembly lowered.
FIG. 4A is a front view of a derrick (shown partially) with a crown assembly according to the present invention.
FIG. 4B is a front view of the crown assembly of the derrick of FIG. 4A .
FIG. 5A is a front view of a derrick according to the present invention and a crown assembly according to the present invention.
FIG. 5B shows a line of the derrick of FIG. 5A .
FIG. 5C is a front view of the derrick and crown assembly of FIG. 5A with the crown assembly lowered.
FIG. 5D shows the line of FIG. 5B in the position shown in FIG. 5C .
FIG. 6A is a front view of a derrick according to the present invention.
FIG. 6B is a front view of the derrick of FIG. 6A with a top part tilted.
FIG. 6C is a front view of the derrick of FIG. 6A with a top part tilted.
FIG. 7 is a front view of a derrick according to the present invention.
FIG. 7A is a front view of the crown assembly of the derrick of FIG. 7 .
FIG. 7B is an illustration of a lowered position of the crown assembly of the derrick of FIG. 7 .
FIG. 8A is a rear view of a derrick according to the present invention on a drill ship according to the present invention approaching a bridge.
FIG. 8B is a side view showing the beginning of lowering of a crown assembly of the derrick of the drill ship of FIG. 8A .
FIG. 8C is a side view further showing the beginning of lowering of a crown assembly of the derrick of the drill ship of FIG. 8A .
FIG. 8D shows the drill ship of FIG. 8A passing under the bridge and the beginning of raising of the crown assembly.
FIG. 8E shows further raising of the crown assembly.
FIG. 8F shows the crown assembly raised.
FIG. 9A is a front view of a derrick according to the present invention.
FIG. 9B is a front view of a crown assembly of the derrick of FIG. 9A .
FIG. 9C is a front view of the derrick of FIG. 9A with the crown assembly lowered.
FIG. 10A is a front view of a drill ship according to the present invention with a derrick according to the present invention.
FIG. 10B is a side view of the derrick of FIG. 10A .
FIG. 10C is a partial view of the derrick of FIG. 10B showing the crown assemblies lowered.
Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a typical prior art drill ship S with a deck K on a hull H. One or more cranes C are on the deck K. An upright derrick D is mounted on the deck K.
FIG. 2 shows a floating system 10 , e.g., in one aspect, a drill ship, according to the present invention with a deck 12 on a hull 14 . A derrick 20 according to the present invention is mounted on the deck 12 . The derrick 20 has a crown assembly 40 and an associated (optional) motion compensator 40 a releasably and movably connected to a top part 22 of the derrick 20 . Movement apparatus 11 (shown schematically) selectively moves the crown assembly 40 and the motion compensator 40 a down to reduce the overall weight of the derrick 20 . The movement apparatus 11 may be any apparatus disclosed herein.
As shown in FIG. 3A , in an embodiment 10 a according to the present invention the derrick 20 has a plurality of crossmembers and braces 23 . A pipe handling system 60 connected to the derrick moves pipe, e.g. drill pipe. A guide rail structure 66 connected to the derrick 20 guides a top drive system TDS (shown schematically, FIG. 3B ) within the derrick. A support 9 is pivotably secured to the derrick 20 with pivoting arms 9 a so that the top drive TDS is movably downwardly out of the way of the crown assembly 40 .
A crown assembly 40 has crown sheave 40 s and a base 42 which is movable by movement apparatus 11 a (shown schematically) within the derrick 20 .
Initially, e.g. as shown in FIG. 3A , the crown block assembly 40 with the compensator 40 a projects beyond the top part 22 of the derrick 20 . As shown in FIG. 3B , the crown block assembly 40 and compensator 40 a have been lowered to a lower position within the derrick 20 .
In one particular aspect, the derrick 20 (including the crown block assembly and compensator) is 201 feet 8 and 11/16 inches in height as shown in FIG. 3A ; and, in the crown-block-assembly-lowered position of FIG. 3B , the overall height is 171 feet 8 and 11/16 inches—a difference of 30 feet. In one such aspect, the crown block assembly 40 etc. weighs about 150,000 pounds so that lowering the crown block assembly 40 etc. as shown results in a significant lowering of the center of gravity of the drill ship 10 .
FIG. 4A shows a system 10 b according to the present invention (like the system 10 ) in which a crown assembly 40 b with a base 40 c (see FIG. 4B ) is movably mounted at the top of a derrick 20 b of a drill ship with a motion compensator 40 d . The crown assembly 40 b with the compensator is lowered in the derrick 20 b by a powered apparatus 30 with line 32 connected to the crown assembly 40 b and passing over sheaves 33 , 34 . The apparatus 30 reels in and pays out the line 32 to raise and lower the crown assembly 40 b and the compensator. Optionally, two apparatuses 30 and lines 32 are used.
FIGS. 5A and 5C show a system 10 c according to the present invention (like the system 10 ) with a crown assembly 40 e and motion compensator 40 f movable with respect to a top 22 c of a derrick of a drill ship. Apparatuses 30 c raise and lower the crown assembly 40 e.
As shown in FIG. 5A , the crown assembly 40 e is at its highest position with respect to the top 22 c of the derrick. Pistons 30 p of the apparatuses 30 c are retracted and lines 30 l extend around piston sheaves 30 s and derrick sheaves 30 d and are secured to the crown assembly at points 40 p.
As shown in FIG. 5C , the pistons 30 p have been extended resulting in lowering of the crown assembly 40 e and the compensator with respect to the top 22 c of the derrick.
FIGS. 6A-6C illustrate a system 60 according to the present invention which includes a derrick 62 on a drill ship (not shown). A top part 61 of the derrick 62 is pivotably mounted with pivot apparatus 64 to a lower part 65 of the derrick 62 . The top part 65 includes a crown assembly/compensator combination 68 .
As shown in FIG. 6B , a connection 66 has been released and the top part 61 has begun to tilt toward a support 67 . As shown in FIG. 6C the top part 61 (with the combination 68 ) has been tilted approximately ninety degrees and rests on the support 67 . This effectively reduces the overall height of the derrick 62 and, therefore, of the drill ship on which the derrick 62 is mounted; and also lowers the center of gravity of the drill ship.
FIG. 7 shows a system 100 according to the present invention which has a crown assembly 140 at the top 112 of a derrick 110 . The derrick 110 is on a drill floor 114 on a main deck 116 of a drill ship 120 (shown partially). A racker 101 handles pipe in the derrick 110 and a top drive 102 on a carriage 103 is movable within the derrick 110 . A drawworks 106 has a fastline 105 which passes over crown sheaves 142 . A deadline 107 is on the other side of the derrick 110 .
Jacking systems 130 operate on toothed pillars 144 (see also FIG. 7A ) to lower and raise the crown assembly 140 . There are four pillars 144 and four jacking systems 130 (two shown, FIG. 7 ). The jacking system 130 are supported by a platform 134 .
FIG. 7A illustrates the reduced overall height of the derrick 110 when the crown assembly 140 is lowered. The raised position (as in FIG. 7 ) of the crown assembly 140 is shown in dotted lines in FIG. 7B . The crown assembly 140 has been lowered a distance a. In one particular aspect, this distance is about 23 feet 7 inches (or about 6.9 meters). With the top drive 103 lowered, the crown assembly 140 can be lowered within the derrick 110 without having to remove or relocate any other major pieces of equipment.
FIGS. 8A-8F illustrate steps in the operation of a system 100 when the drill ship 120 approaches an obstacle (e.g. a bridge 150 ) under which it must pass. As shown in FIG. 8B , the jacking systems 130 , working on teeth 144 t of the pillars 144 , has begun to lower a crown assembly 141 (like the crown assembly 140 ) down within the derrick 110 , as the drill ship 120 continues to move toward the bridge 150 .
FIG. 8C illustrates the crown assembly 141 sufficiently lowered for the drill ship 120 to pass under the bridge 150 .
As shown in FIG. 8D , part of the drill ship 120 is still passing under the bridge 150 and the derrick 110 has already passed under the bridge 150 . The jacking systems 130 have begun to again raise the crown assembly 141 back to its position as in FIG. 8A before it was lowered. Continued raising of the crown assembly 141 is shown in FIG. 8E as the drill ship 120 continues to move.
As shown in FIG. 8F , the crown assembly 141 has been raised to its full upright position as in FIG. 8A .
FIG. 9A illustrates a dual activity rig 200 on a drill floor 202 of floating well operations system 201 which may be a floating rig, vessel or ship and which, as shown in one embodiment in FIG. 9A is a drill ship. The rig 200 is used with respect to two (or more) adjacent wellbore locations W 1 , W 2 over which the drill ship 201 is positioned.
The rig 200 has a derrick 210 with two crown assemblies 221 , 222 both of which are on a base 230 . Movement apparatus 240 (which is shown schematically; may be any crown assembly movement apparatus disclosed herein) moves the base 230 and the crown assemblies 221 , 222 down within the derrick 210 .
FIG. 9C illustrates a lowered position of the base 230 and crown assemblies 221 , 222 within the derrick 210 .
FIGS. 10A-10C illustrate the application of the present invention to dual activity rigs, e.g. as disclosed in U.S. Pat. Nos. 6,068,069; 6,047,781; 6,085,851; 6,056,071; and 6,443,240—all incorporated fully herein for all purposes.
A system 300 includes a drill ship 301 , a hull 309 and with a multi-activity derrick 340 which is located above a moonpool 334 . The multi-activity derrick 340 drawworks 341 (two present; one shown in FIG. 10B ) with appropriate cable 344 and sheaves 346 , 350 traveling blocks 352 , 354 etc. The derrick 340 is on a drill floor 314 .
First and second mini-derricks 332 and 334 on a base 336 are movable down within the derrick 340 by movement apparatus 360 (shown schematically; may be any movement apparatus disclosed herein for moving a crown assembly). FIG. 10C shows the position—in dotted line—of the mini-derricks once lowered within the derrick 340 .
Other apparatus, equipment, and structure in the rig 340 which is not labeled or named is as in, e.g., U.S. Pat. No. 6,068,069.
It is within the scope of the present invention to provide a derrick of any suitable height for a vessel or a drill ship, to provide a crown block assembly of any suitable height, and to provide structure and apparatuses for moving the crown block assembly or a crown block assembly and some support structure up and down to achieve a derrick height and/or a desired relocation of a vessel's or a ship's center of gravity.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a vessel or a drill ship with a selectively adjustable height and/or an adjustable center of gravity and a crown block assembly movably mounted in a derrick of the ship.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a system for well operations, the system comprising a floating system, the system having: a hull; a deck on the hull; a derrick on the deck, the derrick having a top and a top portion; a crown assembly on the derrick; the crown assembly movably mounted to the derrick for movement with respect to the top portion of the derrick to reduce overall height of the derrick. Such a system may one or some, in any possible combination, of the following: the system is one of a vessel, drill ship, semi-submersible rig, floating jack-up rig, and floating rig; wherein the system has a center of gravity and the crown assembly is movable to lower the center of gravity; well operation equipment connected to the derrick, the well operation equipment movable to facilitate lowering of the crown assembly past the well operation equipment; wherein the crown assembly is lowered between twenty feet and fifty feet below the top of the derrick; wherein the crown assembly is lowerable within the derrick; motion compensation apparatus connected to the crown assembly and lowerable therewith; movement apparatus connected to the crown assembly for lowering the crown assembly with respect to the derrick; wherein the movement apparatus is one of powered apparatus with reeled lines connected to the crown assembly; powered piston-cylinder apparatus; and a toothed-pillar jacking system; wherein the crown assembly is a first crown assembly, the system further having the derrick being a dual activity derrick structure, the first crown assembly connected to a lowerable with respect to the dual activity derrick structure, a second crown assembly connected to and lowerable with respect to the dual activity derrick structure, and movement apparatus for moving the crown assemblies with respect to the dual activity derrick structure; and/or the crown assembly includes a base, the base receivable within the derrick.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a system for well operations, the system comprising a floating system, the system having: a hull; a deck on the hull; a derrick on the deck, the derrick having a top and a top portion; a crown assembly on the derrick; the crown assembly movably mounted to the derrick for movement with respect to the top portion of the derrick to reduce overall height of the derrick; the system one of a vessel, drill ship, semi-submersible rig, floating jack-up rig, and floating rig; wherein the system has a center of gravity and the crown assembly is movable to lower the center of gravity; wherein the crown assembly is lowered between twenty feet and fifty feet below the top of the derrick; wherein the crown assembly is lowerable within the derrick; movement apparatus connected to the crown assembly for lowering the crown assembly with respect to the derrick; and wherein the movement apparatus is one of powered apparatus with reeled lines connected to the crown assembly; powered piston-cylinder apparatus; and a toothed-pillar jacking system. Such a system may one or some, in any possible combination, of the following: the crown assembly may be a first crown assembly, and the derrick may be a dual activity derrick structure with the first crown assembly connected to and lowerable with respect to the dual activity derrick structure and a second crown assembly connected to and lowerable with respect to the dual activity derrick structure, and movement apparatus for moving the crown assemblies with respect to the dual activity derrick structure.
The present invention, therefore, provides in some, but not in necessarily all, embodiments methods for reducing derrick height of a derrick of a system for well operations, the system being a floating system, the method including: activating a movement apparatus of a system, the system as any disclosed herein; and moving a crown assembly of the system on a derrick with the movement apparatus to reduce derrick height. In such methods there may be motion compensation apparatus connected to the crown assembly, the method further including lowering the motion compensation apparatus with the crown assembly; and/or the crown assembly may include a base, the method including lowering with the movement apparatus the crown assembly and the base within the derrick.
In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. §102 and satisfies the conditions for patentability in §102. The invention claimed herein is not obvious in accordance with 35 U.S.C. §103 and satisfies the conditions for patentability in §103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. §112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements. | Floating systems for well operations are disclosed with a height-adjustable crown assembly movably connected to a derrick; in one aspect, movable within the derrick by movement apparatus; and, in one aspect, movable with a motion compensator. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b). | 4 |
BACKGROUND OF THE INVENTION
This invention relates to pollution control systems and more particularly to particulate and gas collection systems for electric arc furnaces.
Electric arc furnaces are commonly employed in a variety of metallurgical operations, such as the melting of scrap metal and in the refining of iron and steel. Such electric arc furnaces generally include a furnace body and a removable roof through which the electrodes extend. Periodically during a furnace operation, the roof and electrodes are elevated and swung away from the furnace body to permit charging with scrap, hot metal, pig iron or other furnace charge. In addition, when the treatment of each batch of metal in the furnace is completed, the furnace is tapped and the molten metal collected in a ladle located along one side of the furnace. During the charging and tapping operations, large amounts of polluting gases and particulate matter are released into the surrounding environment. Additional pollutants are also released from the furnace through various openings during the furnace metallurgical operations.
One type of prior art systems for collecting gaseous and particulate pollutants from electric arc furnaces includes a furnace enclosure having collection ducts located at critical positions therein. Examples of such prior art furnace enclosures are disclosed in U.S. Pat. Nos. 4,088,824 and 4,477,910. Each of these patents discloses a first gas and particulate collector adjacent the upper end of the enclosure and a second collector adjacent the tapping ladle position.
Another example of a prior art pollution control system for electric arc furnaces is disclosed in U.S. Pat. No. 4,410,166 which shows an arc furnace enclosure having a gas collector which is movable to permit furnace charging.
A further expedient employed in the prior art for collecting pollutants and arc furnace enclosures involves blowers for directing gases and particulate material toward prepositioned collectors.
Such prior art gas collecting systems have generally been a compromise with respect to various furnace sizes, operating sequences and pollution sources.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a new and improved pollution control system for electric arc furnaces.
A further object of the invention is to provide a pollution control system for electric arc furnaces which is not dependent on furnace size or the particular furnace operation being performed.
Yet another object of the invention is to provide a pollution control system which can effectively capture pollutants from various locations around the furnace.
These and other objects and advantages of the present invention will become more apparent from the detailed description thereof taken with the accompanying drawings.
In general terms the invention comprises a system for collecting pollutants from an electric arc furnace having a removable cover and a teeming spout wherein molten products may be discharged into a container disposed adjacent one side of the furnace. An overhead crane is movable above the furnace for positioning a charging bucket or a container of molten metal avove the furnace. Pollution collection means are disposed above and to one side of the furnace with the crane being movable bidirectionally relative to the collector. Nozzle means is mounted on the crane and is operative for blowing an air stream toward the collector. The crane is operable to position the nozzle means on the side of the furnace opposite the collector and in alignment with the furnace during a charging operation when the furnace roof is in an open position. The crane is also operable to move the nozzle in a direction parallel to the collector inlet and to a second position whereby the pollutants rising from the container during a teeming operation are between the nozzle and the collector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the gas collecting system in accordance with the preferred embodiment of the invention;
FIG. 2 is an end view of the gas collecting system shown in FIG. 1;
FIG. 3 a fragmentary view showing a side view of the blower assembly of the gas collecting system of FIG. 1.
FIG. 4 is a top plan view of the blower assembly shown in FIG. 3;
FIG. 5 is a view taken along lines 5--5 of FIG. 4;
FIG. 6 is a top view of a fragmentary portion of the blower assembly of FIG. 3; and
FIG. 7 is a front view of a fragmentary portion of the blower assembly of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show a gas collecting system in accordance with the preferred embodiment of the invention as applied to a conventional electric arc furnace 12. In general terms, the system includes gas collectors 14 disposed generally above and to one side of the furnace 12 and a blower assembly 16 mounted on an overhead crane 17 movable generally above and to the oppposite sides of the furnace 12.
Because the furnace 12 is conventional, it will not be described in detail for the sake of brevity. It will be sufficient for purposes of understanding the invention to state that the furnace 12 includes a furnace body 18 which is mounted on a platform 19. Also mounted on the platform 19 and adjacent the body 18 is a vertically extending column 20 which supports the furnace roof 22 and the furnace electrodes 24. Means not shown, but which are well known in the art, are mounted on the column 20 for elevating the furnace roof 22 relative to the furnace body 18 and the electrodes 24 relative to the roof 22 as well as the body 18. The column 20 also includes rotating means (not shown) so that the elevated roof 22 and electrodes 24 may be swung to one side of the furnace body 18 to permit the contents of a container 26, to be discharged into the furnace body 18. This material may comprise, for example, scrap, pig iron or hot metal which is to be melted, refined or otherwise treated within the electric arc furnace 10. While the container 26 is shown to be a charging bucket, it may also be a ladle if hot metal is to be charged into the furnace 12.
After the contents of the container 26 is discharged into the furnace body 18, the column 20 is again rotated to position the furnace roof 22 over the furnace body 18. The roof 22 and the electrodes 24 are then lowered into their operative positions. Electrodes 24 may then be energized for melting or otherwise treating the contents of the furnace 12.
The overhead crane 17 is conventional, and is provided for moving the container 26 or a ladle into a position above the furnace body 18 to permit charging. The crane may include a generally rectangular frame 28 and spaced apart wheels 30 which are disposed along each of its opposite sides and adjacent each end. The wheels 30 are mounted on rails 32 which in turn are supported on beams 34 forming part of the framework 35 for a furnace enclosure or shop building. The rails 32 and the beams 34 which support them are shown to be disposed in a generally horizontal, parallel, spaced apart relation above and on the opposite sides of the furnace 12. As those skilled in the art will appreciate, the crane 28 includes an electrical or hydraulic drive mechanism for moving the frame 28 along the rails 32 and above the furnace 12. Mounted atop the frame 28 are a second pair of rails 36 for receiving a trolley 38 from which the bucket 26 is supported by means of cables 39. It will be appreciated by those skilled in the art that the trolley 38 also includes conventional means (not shown) for moving the same over the rails 36 and for elevating and lowering the bucket 26 through the agency of the cables 39.
The furnace 12 is also provided with a pouring spout 40 so that the molten metal within the furnace may be periodically discharged into a teeming ladle 42. To this end, the platform 19 is mounted on a pair of parallel, spaced apart toothed rockers 44 each of which engages a complimentary rack 46. Hydraulic means (not shown) are provided for tilting the furnace 12 from its position shown by broken lines in FIG. 1 to its position shown by full lines wherein the contents of the furnace 12 may be discharged into the teeming ladle 42 after the treatment or melting of the metal within the furnace 12 has been completed. Thereafter, the furnace body 18 is returned to its operative position and the roof 22 and the electrodes 24 are again elevated and pivoted to permit the furnace 12 to be recharged.
The gas collector 14 includes a duct 50 which is connected to a gas cleaning system (not shown) which includes a suction fan. The duct 50 is supported on the framework 35 and includes a pair of inlet openings 52 and 53 as seen in FIG. 2. First inlet opening 52 is shown to be in alignment with the furnace 12 when the same is in its upright operating position. The second inlet opening 53 is in general alignment with the area above the teeming ladle 42. Each of the inlet openings 52 and 53 is provided with an individually operable damper 55 so that the openings 52 and 53 may be selectively opened and closed.
The blower assembly 16 preferrably includes a pair of separate nozzle assemblies 57 and 58 which are mounted in spaced apart relation on one side of the crane 28 and parallel with the inlet openings 52 and 53. Nozzle assemblies 57 and 58 are identical and accordingly, only nozzle assembly 57 will be discussed in detail for the sake of brevity. With reference to FIGS. 3 and 4, the nozzle assembly 57 is shown to include a blower 60 and a pair of horizontally spaced apart nozzles 62 and 63. The blower 60 includes a motor 64 and a fan 66 supported by a frame 68 below the frame 28 of crane 17. The nozzles 62 and 63 are also supported beneath frame 28 by short I-beam sections 70 and are connected to the fan 66 by a Y-shaped duct 72 and flexible conduit sections 73.
Each nozzle includes a rectangular chamber 74 coupled at one side to one of the flexible duct sections 73 and having a rectangular window 76 formed in its opposite side. Flanges 78 and define the upper and lower margins of window 76 and its sides are defined by dished end caps 80 suitably affixed to the vertical edges of window 76. A pair of opposed flow deflectors 82 and 83 are disposed within window 78 and each includes a cap plate 84 which defines a cylindrical section. A rectangular flow plate 86 is fixed to the inner edge of each cap plate 84 and its opposite ends are closed by semi-circular end plates 88. The flow deflectors 82 and 83 are mounted for pivital movement on the end caps 80 by means of bolts 90 which extend through aligned openings in the end caps 80 and generally triangular adjusting vanes 92 and 93 fixed to the opposite ends of flow deflectors 82 and 83, respectively.
It will be appreciated that the spaced apart flow plates 86 define a flow path from chamber 74. By adjusting the horizontal and angular position of flow deflectors 82 and 83 the vertical discharge angle of the air discharging from chamber 74 may be adjusted within limits defined by the flanges 78. It will also be appreciated that the angle between the flow plates 86 can be adjusted to a limited extent. Felt strips 94 may be disposed between the flanges 78 and the cap plates 84 for sealing the gap therebetween.
Each of the nozzles 62 and 63 are supported from the I-beam sections 70 by a pair of inverted, L-shaped brackets 95 which are affixed at their lower edges in spaced apart relation to the upper surface of the chamber 74. Each of the brackets 95 has an arcuate slot 96 formed its upper flange 97. The slots 96 have a common center of curviture 98 which lies midway between the brackets 95. Bolts 99 extend through slots 96 and holes 100 formed in I-beam sections 70. It will be appreciated that by loosing the bolts 99 the nozzles 62 and 63 may be pivoted through a horizontal angle whose limits are defined by the length of the slots 96. To permit such horizontal adjustment, the conduit section 73 are preferrably formed of a material that permits limited flexibility such as interlocked metal hose having a smooth internal bore.
When the furnace roof 22 is in its open position shown in FIG. 2, polluting gases and particulate matter, symbolized by arrows 70, will discharge from the open upper end of the furnace body 18. As the pollutants 70 rise, they move between the inlets 52 and 53 of the gas collector 14 and the blower assembly 16. The first nozzle 62 of each nozzle assemblies 57 and 58 will be positioned for blowing air directly toward the gas collector 14 as symbolized by arrows 72 and the second nozzle 63 of each is positioned to blow air downwardly and inwardly toward the column of rising pollutants as symbolized by the arrows 74. In addition, the crane 17 is positioned so that the container 26 will be directly over the furnace 12. This positions the nozzle groups 57 and 58 so that they are spaced apart a distance approximately equal to the width of the furnace 12 and with one nozzle group disposed along each side of the furnace 12. As a result, the nozzles will be positioned so that their individual air streams blow inwardly and downwardly toward the rising column of pollutants 70 and for directing the same into the inlet 52 whose damper is in an open position while the damper 55 of inlet opening 53 is closed.
When the furnace 12 is tilted for teeming as shown in FIG. 2, a column of pollutants, symbolized by the arrows 75, rises from the teaming ladle 42 and from the stream of metal discharging from the spout 40. It can be seen that these pollutants are generally to one side of the furnace 12. During a teeming operation, therefore, the crane 28 is moved to its position wherein the nozzle groups 57 and 58 lie along the opposite sides of the rising column of pollutants 75 and along the margins of the inlet 53. During the teeming operation, therefore, the damper 55 of inlet 53 is open and the damper of inlet 52 is closed. As a result, the air streams from the nozzle assemblies 57 and 58 are directed downwardly from the opposite sides of the rising column of pollutants and inwardly toward the inlet 53.
While only a single embodiment of the invention is illustrated and described, it is not intended to be limited thereby but only by the scope of the appended claims. | A pollution control system for electric arc furnaces includes fume collectors disposed at one side and above the furnace and pairs of blower nozzles mounted on an overhead crane used to deliver feed materials to the furnace. One nozzle of each pair is adjustable in a vertical plane and the other nozzle of each pair is adjustable in vertical and horizontal planes so that the nozzles may be positioned for blowing furnace fumes into the fume collectors when the furnace roof is elevated for charging, during furnace operation and when the furnace is tilted for tapping. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS —
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT —
BACKGROUND OF THE INVENTION
[0001] The present invention relates to electrical switches and in particular to an electrical switch having a key lock and suitable for certain override applications.
[0002] In certain applications, for example, those which provide manual override of machine guard features, it is desirable to have an override switch that may be locked against use by all but a single individual using a key or the like.
[0003] With any key switch, there is a risk that the key will be left in the lock eliminating its security.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention provides an electrical key switch that may sense the presence of a key within the switch. A key ejector, incorporated into the switch, prevents defeating of the key sensor; that is, “parking” the key or partially inserting the key into the key slot enough to hold the key in place but not to activate the sensing switch is avoided.
[0005] Specifically, in one embodiment, the invention provides an electrical key switch having a housing attachable to a support, and a key mechanism receiving a key within a key slot to allow rotation of the key mechanism with respect to the housing. At least one electrical switch element communicates with the key mechanism to switch state with rotation with the key mechanism and an ejector ejects the key from the key slot absent a countervailing pressure on the key holding the key within the key slot.
[0006] Thus it is one object of at least one embodiment of the invention to provide an electrical switch which reduces the possibility of the key being forgotten or “parked” in the lock.
[0007] The electrical key switch may provide a second electrical switch element communicating with the key mechanism to change state when a key is inserted in the key slot.
[0008] It is thus another object of at least one embodiment of the invention to provide a method of electrically sensing the key in the key slot so as to respond appropriately when the key is left in the key slot for too great a length of time.
[0009] The ejector may be a shaft passing along the key slot to be displaced by a key inserted into the key slot to activate the second electrical element.
[0010] It is thus another object of at least one embodiment of the invention to provide a simple mechanism that serves both as a sensor and ejector of the key.
[0011] The shaft may be hardened steel.
[0012] It is thus another object of at least one embodiment of the invention to use a simple shape that may be easily fabricated out of hardened steel or other similar material providing stiffness and strength.
[0013] The shaft may be positioned along an axis of rotation of a key mechanism to maintain constant axial alignment with respect to the housing during rotation of the key mechanism.
[0014] It is thus another object of at least one embodiment of the invention to provide an ejector that may remain substantially aligned with a non-rotating electrical switch element to activate the electrical switch element at a variety of different rotary positions.
[0015] The shaft may extend rearwardly from the key slot with respect to an opening of the key slot through which the key is inserted to activate the electrical switch element.
[0016] It is thus another object of at least one embodiment of the invention to provide a mechanism in which the key-sensing switch element may be aligned with the key slot to provide a narrow profile switch element fitting in a standard panel area.
[0017] The second electrical switch element may be a set of contacts with a travel less than a length of the key slot and further include a spacer block spacing the contacts away from the key slot by an amount at least equal to a difference of the length of the key slot and the travel of the contacts.
[0018] Thus it is another object of at least one embodiment of the invention to provide a simple mechanical interface between the ejector shaft which must travel the full length of the key slot to fully eject the key, and the switch which may have a relatively short operator throw.
[0019] The housing may include releasable fittings allowing assembly of different combinations of modular contact blocks to the key mechanism including at least one contact block aligned with an axis of rotation of the key mechanism and the spacer may be received by the releasable fitting.
[0020] Thus it is one object of at least one embodiment of the invention to provide a mechanism that may be easily integrated with standard multi-application key switches that are assembled out of standard modular blocks.
[0021] The ejector shaft may have a coaxial helical extension spring biasing the shaft into the key slot.
[0022] It is thus another object of at least one embodiment of the invention to provide an extremely compact mechanism for ejecting the key.
[0023] The ejector may provide an average ejecting force on a key inserted into the key of a key slot of at least one half pound.
[0024] Thus it is another object of at least one embodiment of the invention to provide a large ejection force to reduce the chance of a key remaining inadvertently in the key slot.
[0025] The key mechanism may include a blocking structure allowing insertion of the key into or removal of the key from the slot only when the key mechanism is in a first rotative position and the key mechanism may rotate to a second position when the key is in the key slot.
[0026] Thus it is an object of at least one embodiment of the invention to provide an option for the key to be retained in the key slot when in use to prevent the user from having to hold the key when the switch is being activated.
[0027] The key mechanism may be spring biased to return to the first rotative position. Alternatively, the key mechanism may not be spring biased so that it remains stably in either the first or second rotative position.
[0028] Thus it is another object of at least one embodiment of the invention to provide a variety of different modes of operation of the key switch.
[0029] The key mechanism may be a pin tumbler/cylinder lock.
[0030] Thus it is another object of at least one embodiment of the invention to provide a simple mechanism that works with standard and readily available lock assemblies.
[0031] These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a perspective view of a modular electric key switch providing one embodiment of the present invention showing the rotative positions of the cylinder and rear-attached modular contact assemblies;
[0033] FIG. 2 is a cross-sectional view along 2 - 2 of FIG. 1 showing an internal ejector shaft within the cylinder of the key switch as may move rearward to close contacts indicating a key has been inserted in the key switch;
[0034] FIG. 3 is cross-sectional view along lines 3 - 3 of FIG. 1 showing an internal cam mechanism for activating modular contact assemblies with rotation of the key;
[0035] FIG. 4 is a partial, fragmentary perspective view of a rearward portion of the lock cylinder showing its engagement with a helical extension spring used with the ejector shaft; and
[0036] FIG. 5 is a cross sectional view along line 5 - 5 of FIG. 1 showing the retention of the key by tumblers when the key switch is activated and showing an optional return spring.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] Referring now to FIG. 1 , an electrical key switch 10 of the present invention provides a front housing 12 having an escutcheon 14 surrounding a lock cylinder 16 extending along a cylinder axis 20 from a front face of the front housing 12 . The front housing 12 may be attached to a panel or the like (not shown), for example, captured between a front face of the housing 12 and the escutcheon 14 as is generally understood in the art.
[0038] The lock cylinder 16 includes a key slot 18 extending along the cylinder axis 20 . A blade 22 of a key 24 may be inserted into the key slot 18 when the cylinder 16 is in an insertion orientation as shown in FIG. 1 . Once the key 24 is inserted, the key 24 may be rotated to the right or to the left about the cylinder axis 20 to activation positions. As will be described further below, turning the key 24 in the key slot 18 activates contact blocks 26 and 28 positioned at left and right edges of a rear face of the housing 12 . The contact blocks 26 and 28 contain contacts (not shown in FIG. 1 ) which change state (i.e., open or close) depending on the rotative position on the key 24 .
[0039] A spacer block 32 positioned between the contact blocks 26 and 28 , centered on rear face of the housing 12 , supports a third contact block 30 .
[0040] Referring also now to FIG. 2 , the lock cylinder 16 may rotate within a hull 34 about the cylinder axis 20 . A series of radial bores 37 pass through the cylinder 16 and hull 34 to align when the cylinder 16 is in the insertion position allowing movement within the bores 37 of lower key pins 36 and upper drive pins 38 under the influence of compression springs 40 held in the hull 34 . The structure is that of a standard pin-tumbler cylinder lock well known in the art.
[0041] As will be understood to one of ordinary skill in the art when a blade 22 of the key 24 is inserted in the key slot 18 , notches 42 in the upper edge of the blade 22 cause the lower key pins 36 and upper drive pins 38 to move up and down so as to align their interfaces along a shear surface 44 between the cylinder 16 and the hull 34 . This alignment allows the cylinder 16 to rotate under the influence of the key 24 with respect to the hull 34 to the activation positions.
[0042] In the present invention, the key slot 18 receives an ejector shaft 48 extending along axis 20 through a rear of the cylinder 16 opposite the front of the cylinder 16 through which the blade 22 is inserted in the key slot 18 . The shaft 48 is preferably hardened steel to ensure that the shaft 48 will resist deformation by the softer brass blade 22 of the key 24 . By using a simple cylindrical shaft 48 , complex machining operations on hardened steel are not required.
[0043] The shaft 48 , prior to insertion of the blade 22 of the key 24 occupies the full length of the key slot 18 along axis 20 . In this state, the shaft 48 continues through the rear of the cylinder 16 into the housing 12 terminating at a rear button 50 approximately even with the rear surface of the housing 12 .
[0044] Referring now to FIGS. 2 and 4 , the shaft 48 is free to move along axis 20 through a journal 56 formed by the rear face of the cylinder 16 , but is biased into the key slot 18 by a helical extension spring 52 . The cylinder 16 and journal 56 may be of brass or other easily machinable material that provides for a natural bearing surface for the hardened and polished steel shaft 48 . The outer circumference of the journal 56 has threads 58 of a pitch and diameter suitable to receive the wire end of the helical extension spring 52 threaded thereon. Likewise the rear button 50 of the shaft 48 has threads 60 similarly receiving the opposite end of the helical extension spring 52 . In this manner, the helical extension spring 52 is retained coaxially about the shaft 48 to occupy very little additional space. It will be recognized, however, that other methods of biasing the shaft 48 , including leaf springs and or the springs associated with electrical contacts of the third contact block 30 , described below, may also be used.
[0045] Referring again to FIG. 2 , each of the contact blocks 26 and 28 and the spacer block 32 have opposed snap hooks 62 extending forward along axis 20 from upper and lower edges of their front faces. These snap hooks 62 may be received by corresponding hook holds 64 formed in the abutting rear face of the housing 12 . Thus, contact blocks 26 and 28 may be snapped to the rear face of the front housing 12 . Spacer block 32 includes corresponding hook holds 66 in its rear face that may receive the snap hooks 62 of the contact block 30 . In this way, contact block 30 may be snapped to spacer block 32 which may be snapped to the rear of housing 12 so that contact block 30 is spaced away from the housing 12 by the width of the spacer block 32 .
[0046] The snap hooks 62 are preferably molded as part of the housing of the contact blocks 26 , 28 , and 30 and spacer block 32 to flex outward and then to engage the holds 66 to firmly retain the assembled parts together. Modular switches of this design providing contact blocks 26 , 28 , and 30 , but not spacer block 32 are commercially available from the Rockwell Automation Company.
[0047] Contact block 30 like contact blocks 26 and 28 includes an axially extending operator 68 activated by pressing of the operator 68 inward along axis 20 by a operator activation distance 70 . The operator 68 connects to a movable contact set 72 which, with motion of the operators 68 by activation distance 70 , causes the movable contact set 72 to bridge a stationary contact set 74 against the returning bias of compressing spring 78 . The stationary contact set 74 may be connected through terminals or the like to external wiring 75 as shown in FIG. 1 . As shown, the contact set 72 and contact set 74 are normally open, however, it will be understood to those of ordinary skill in the art that normally closed contacts may also be used. In an alternative embodiment, the contact sets 72 and 74 may be replaced with other equivalent switch elements including proximity detectors, Hall effect switches, and the like.
[0048] Referring to FIG. 3 , when the key 24 is fully inserted with its blade 22 extending a full length 19 of the key slot 18 , the tip of the blade 22 presses the shaft 48 rearward through the journal 56 to pass through a hollow bore within the spacer block 32 so that the rear button 50 of the shaft 48 compresses the operator 68 of the contact block 30 by the activation distance 70 . While the full length 19 of the key slot 18 is greater than the activation distance 70 , the spacer block 32 absorbs the extra distance of the movement of the shaft 48 providing compatibility between the desires of moving the operator 68 and activation distance 70 without significant over travel and having the key 24 stay in contact with the shaft 48 as it travels the full length 19 of the key slot 18 .
[0049] The helical extension spring 52 provides, when the shaft 48 is fully rearward in the key slot 18 , a spring force of as much as one pound. Thus an average ejection force of about a half-pound is provided to the key 24 as it is inserted
[0050] This force is sufficient to move the key 24 against the friction of the key slot 18 and the lower key pins 36 and fully eject the key 24 out of the key slot 18 when the key 24 is released.
[0051] Referring still to FIG. 3 , when the cylinder 16 is rotated to either activation position from the insertion position, the shaft 48 , as aligned with axis 20 , remains aligned with the operator 68 of the stationary contact block 30 .
[0052] The rotation of the cylinder 16 from the insertion position to either activation position moves a cam disk 46 and cam surfaces 80 which may selectively compress the operator 68 of contact block 26 or contact block 28 depending on the direction of rotation of the key. Optional follower blocks (not shown) riding on the cam disk 46 may be interposed between the operators 68 and the cam surfaces 80 . Switches of this type having cam disks 46 are well known in the art. The contact block 26 or 28 provide signals indicating key rotation, independent from a signal produced by contact blocks 30 , the latter which indicates the presence of the key 24 in the electrical key switch 10 regardless of position of the cylinder 16 .
[0053] Referring now to FIG. 5 when the blade 22 of the key 24 is fully inserted in the key slot 18 of the cylinder 16 and rotated to a first activation position, the lower key pins 36 are trapped beneath the shear surface 44 thus pinning the blade 22 within the key slot 18 preventing its ejection under the influence of the shaft 48 . In this manner, after rotation of the cylinder 16 , ejection of the key 24 is prevented and activation of the electrical key switch 10 does not require continued holding of the key 24 .
[0054] Optionally and alternatively, the cylinder 16 may be subject to rotational bias by a spring 86 to cause it to naturally rotate back to the insertion position 89 from one or either activation position 88 in either a counter clockwise or clockwise direction. When such a spring 86 is provided, the operator must retain a grasp on the key 24 or it is ejected as the cylinder 16 returns to the insertion position 89 ?
[0055] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. | An electrical key switch provides a sensing of inserted keys and an ejector mechanism preventing parking of the key in a partially inserted position within the key switch. | 4 |
FIELD OF INVENTION
[0001] This invention relates to a gas injection system for a reflow soldering oven.
BACKGROUND OF INVENTION
[0002] Solder reflow ovens convey electronic components both through-hole and surface mount such as printed circuit boards (PCBS) through successive heating zones to melt and reflow the solder to insure good mechanical and electrical joints. Depending upon the size of the oven and the number of heating zones, the last one, two, three or more of the final heating zones may be where the reflow occurs. Depending upon the type of solder used the presence of oxygen in the oven at the reflow time can invade the process and interfere with the mechanical and electrical quality of the solder joints. To combat this an inert gas, often nitrogen, is fed into the oven at a number of points in the oven housing to generally displace the oxygen that enters at the input and output ends of the oven where the conveyor delivers and removes the PCBs. By inert gas herein and throughout this document is meant one which is non-reactive with the constituents of the components and solder to be reflowed. The nitrogen or other inert gas disperses, mixing and circulating with the hot gas, often air, being delivered by the heating zones as impingements jets against the top and bottom surfaces of the PCBs. Depending upon the particular components and solder the oxygen exclusion may be beneficial at earlier stages in the progress through the oven at initial and/or intermediate heating zones. Once the nitrogen is introduced into the oven there is a low level of control over where and how it flows. The average consumption is 1200 standard cubic feet/hour (scfh) to obtain a desired oxygen molecule count of 50 ppm or less. And this measure may be taken anywhere in the oven, e.g., at the nitrogen input pipe or near it which does not give a good indication of the conditions at the PCB surface in the heating zones where the reflow is occurring and oxygen exclusions should be maximum.
BRIEF SUMMARY OF THE INVENTION
[0003] It is therefore an object of this invention to provide an improved gas injection system for a reflow soldering oven.
[0004] It is a further object of this invention to provide such an provide an improved gas injection system which controls and directs the inert gas within the oven.
[0005] It is a further object of this invention to provide such an improved gas injection system which increases the inert gas pressure and oxygen exclusion at the component during solder reflow.
[0006] It is a further object of this invention to provide such an improved gas injection system which creates a blanket of inert gas right at the component.
[0007] It is a further object of this invention to provide such an improved gas injection system which produces a blanket of inert gas in the heating zone where the hot gas jets drive the inert gas against the component.
[0008] It is a further object of this invention to provide such an improved gas injection system which can utilize the existing conveyor structure of the oven.
[0009] It is a further object of this invention to provide such an improved gas injection system which is simple and inexpensive to make and use.
[0010] It is a further object of this invention to provide such an improved gas injection system which can use less inert gas to obtain a very low oxygen presence accurately measured at the component.
[0011] The invention results from the realization that a truly simple and elegant gas injection system for a reflow soldering oven which assures supply of inert gas at the component during solder reflow can be achieved by disposing alongside the conveyor which transports the components through the oven at least one conduit having a plurality of impingement holes proximate at least one of the heating zones for blanketing the component with an inert gas during the solder reflow to reduce the presence of oxygen.
[0012] This invention features a gas injection system for a reflow soldering oven including a conveyor for moving reflow solder components through the oven from the input to the output through a plurality of heating zones. There is at least one conduit on one side of the conveyor adapted for connection to a source of inert gas and a plurality of impingement holes in the conduit proximate at least one of the heating zones for blanketing the components with the inert gas during the solder reflow to reduce the presence of oxygen.
[0013] In a preferred embodiment the components may be printed circuit boards, there may be a conduit on each side of the conveyor and the conduit may be included in a guide rail of the conveyor. The impingement holes may be spaced along the inner side of the conduit for providing a lateral injection of the inert gas across the components. The impingement holes may be disposed proximate the last heating zone, the last two heating zones, or the last three heating zones. The heating zones may include a plurality of jets of heated gas which are directed toward the components and drive the inert gas down toward the components. The impingement holes may create a dispersion pattern of overlapping diverging cones. Gas dams may be included to constrain the inert gas in the area of the components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other objects, features and advantages will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which:
[0015] [0015]FIG. 1 is simplified diagrammatic sectional view of a reflow soldering oven using a gas injection system according to this invention;
[0016] [0016]FIG. 2 is an enlarged, detailed view of parts of the gas injection system and conveyor of FIG. 1;
[0017] [0017]FIG. 3 is a simplified top plan view of a portion of the conveyor and gas injection system of FIG. 2;
[0018] [0018]FIG. 4 is a side schematic view of a portion of a conveyor guide rail incorporating the conduit and impingement holes for dispersing the inert gas; and
[0019] [0019]FIG. 5 is a simplified diagrammatic sectional view of a portion of a reflow soldering oven incorporating gas dams for constraining the inert gas near the component.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] There is shown in FIG. 1 a reflow soldering oven 10 including the gas injection system 12 according to this invention. Reflow soldering oven 10 is a conventional device such as one of the Profile Series of reflow soldering systems sold by Conceptronic, Inc., of Portsmouth, N.H. and disclosed in U.S. patent applications Ser. No. 09/252,745 filed Feb. 19, 1999, entitled “Reflow Solder Convention Oven Multi-Port Blower Subassembly”, by Tallman et al.; and Ser. No. 09/255,080, filed Feb. 19, 1999, “Reflow Solder Convection Oven With a Passive Gas Decontamination Subsystem”, by Durdag et al., all of which are incorporated in their entirety herein by reference. Oven 10 includes a base 14 and cover 15 which are suitably sealed at gaps 16 and 18 by seals not shown.
[0021] A component which is to be reflow soldered such as PCB 20 moves through oven 10 by means of a conveyor system 22 which moves PCB 20 into the paper as seen by the viewer in FIG. 1. As it moves into the paper it moves through a plurality of heating zones, only one of which, 24 , is shown. Heating zone 24 includes upper and lower heating plates 26 and 28 which interface with plenums 30 and 32 . Air is driven into plenums 30 and 32 by blowers 34 , 36 driven by their respective motors 38 and 40 . As the air moves through heaters 26 and 28 , typically electrical heaters, it moves through a plurality of passages 42 , 44 where it is heated and then directed as a multiplicity of jets directly onto the top and bottom surfaces 46 and 48 of PCB 20 as indicated by the arrows 50 and 52 . The air intake for blowers 34 and 36 are through side ports. Thus blower 34 receives input air through ports 54 , 56 and 58 and blower 36 receives input air through ports 60 , 62 and 64 .
[0022] In accordance with this invention, gas injection system 22 includes at least one conduit on one side of the conveyor for blowing an inert gas onto the surface of the PCB 20 when the soldering reflow is taking place as it is here in FIG. 1 at heating zone 24 . In this particular case there are actually two conduits 70 , 72 making up gas injection system 22 and for convenience and ease of manufacture these conduits 70 , 72 are not separate elements but are rather passages in the guide rails 74 , 76 of the conveyor system which moves the PCB through oven 10 . This of course is not a limitation of the invention as the conduits may be placed on either or both sides and independent of the guide rails.
[0023] The guide rails also provide a mechanism by which the PCB is supported and transported through oven 10 . This can be seen more clearly in FIG. 2 where guide rail 74 has a passage 78 in which is contained a chain 80 similar to a bicycle chain which carries a plurality of pins 82 on which rests one edge of PCB 20 . The other edge of PCB 20 rests on pins 84 which are carried by chain 86 in passage 88 of guide rail 76 . Additional passages 90 in guide rail 76 and 92 in guide rail 74 may be provided if additional conveying systems are desired to operate in parallel with the one shown. A plurality of impingement holes 94 and 96 direct the inert gas from conduits 78 and 72 outwardly in diverging overlapping cones over the surface of PCB 20 . Holes 94 and 96 are positioned high enough so they do not directly hit the elements 100 mounted on the surface of the PCB 20 to avoid dislodging or displacing them by the jets from impingement holes 94 and 96 . The inert gas used in conduits 70 and 72 and creating the diverging overlapping cones 102 , 104 are a gas which does not react with the solder to be reflowed. By “inert gas” herein is meant any gas which is not reactive with the solder being reflowed. Typically these solders include tin, lead, solder and other elements. While inert gases such as helium, argon, neon and xenon may be used it is cheaper, more practical and more common to use an inert gas such as nitrogen which is also non-reactive with the constituents of the solder to be reflowed.
[0024] An added advantage of this invention is the fact that the overlapping diverging conical jets 102 and 104 are driven downwardly against PCB 20 during the reflow process by the jets 50 of fluid such as air as indicated by the arrow vortices 106 . The pattern of overlapping conical dispersions can be seen more readily in FIG. 3 where the top plan view shows them emanating from both conduits 70 and 72 in guide rails 74 and 76 through impingement holes 94 and 96 , in the final heating zone 24 , the second to final heating zone 24 a , and third to final heating zone 24 b . In reflow soldering ovens such as the Profile series referred to hereinbefore, the machines are typically offered with five, eight or eleven heating zones. With five heating zones there is typically but one zone where the reflow soldering takes place, with eight heating zones, typically the last two heating zones are treated as reflow soldering zones, and in the machine with eleven heating zones the last three may be considered reflow solder zones. The inert gas, in this case nitrogen, is fed from a source such as tank 110 through manifold piping 112 into a journal 114 , 116 at one end of conduits 70 and 72 .
[0025] Impingement holes 94 , FIG. 4, are typically spaced one inch apart; thus there would be fourteen where the heating zones are each approximately fourteen inches in length. The diameter of the holes is typically 0.067 inch. Thus, in FIG. 4, D is equal to one inch and d is equal to 0.067 inch. This is dictated by the amount and velocity of the flow required as well as the gas being used and the various flow rates in the oven.
[0026] As shown in FIG. 5, gas dams 117 and 118 are preferably added to rail 74 to segregate the oven into two separate areas—high inert gas/very low oxygen area 119 and moderate inert gas/low oxygen area 120 . Area 119 is where PCB 20 is moving through the oven on the conveyor belt (not shown). This embodiment contrains jets 102 and 104 . There is little or no leakage of inert gas into area 120 , thereby allowing for lower inert gas usage as well as providing more pressure related control of the inert gas in area 119 .
[0027] Although in this particular embodiment the resoldering oven shown is a convection oven, this not a necessary limitation of the invention as, for example, the advantages of this invention and its application are suitable for infrared ovens as well.
[0028] Although specific features of the invention are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention.
[0029] Other embodiments will occur to those skilled in the art and are within the following claims:
[0030] What is claimed is: | A gas injection system for a reflow soldering oven includes a conveyor for moving reflow solder components to the oven from the input to the output through a plurality of heating zones; at least one conduit on one side of the conveyor is adapted for connection to a source of inert gas and a plurality of impingement holes in the conduit proximate at least one of the heating zones blankets the components with inert gas during the solder reflow to reduce the presence of oxygen. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a method and an apparatus for controlling the operation of an internal combustion engine during and after engine braking, thereby improving driver comfort and diminishing the concentration of toxic exhaust components. The invention relates more particularly to a method and apparatus for changing the engine timing in a manner related to the occurrence of engine braking.
During engine braking or overrunning, there exists a state of operation in which the engine delivers no torque to the vehicle but is turned at a speed higher than that which would result from a given load condition and a given throttle position due to the momentum of the vehicle in which it is installed. In such a state of operation, the accelerator pedal would normally be permitted to assume its zero position. In particular, if the accelerator pedal is released while the vehicle is in normal operation, the engine will enter a condition of engine braking. This condition may be accompanied, as is usually the case, by actuation of the wheel brakes but is may also occur, for example, in downhill operation, without application of the wheel brakes.
The engine braking which takes place under these conditions is normally desired. However, to insure the most effective degree of engine braking, the engine must be prevented from delivering a positive torque, i.e., the combustion processes must either be suppressed or must be conducted with such timing as would prevent the delivery of positive torque. Generally, the fuel supply is entirely interrupted which results in fuel economy and is referred to as fuel cut-off or engine braking cut-off. In order to insure that the engine will operate properly at idling speed, however, the fuel supply is restored when the engine speed has dropped to a so-called reinstatement speed hereinafter labeled "nW." Fuel cut-off during engine braking may take place, in principle, in all fuel injection systems and even in engines having carburetors with the aid of solenoid valves associated with the idling mechanism of the engine. Fuel cut-off has the advantage of providing fully effective engine braking and a substantial saving in fuel, especially when the vehicle is operated in heavy traffic.
The invention constitutes an improvement of a fuel supply system for an internal combustion engine in which the fuel supply is shut off during engine braking until a reinstatement speed nW has been reached. Subsequently, the combustion chambers of the engine again receive fuel. It has been shown in practice that, when the fuel supply is reinitiated, the vehicle is subjected to a certain forward lurch or jolt which leads to driver discomfort. In addition, the emission of toxic substances is increased for some time, after the reinitiation of fuel supply because the engine generally is cooled off substantially during engine braking and the formation of a satisfactory optimum mixture is difficult, thereby preventing full combustion.
OBJECT AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and apparatus for so controlling the engine operation during and after engine braking that the aforementioned jolt during fuel resupply is prevented. This object is attained by changing the engine timing in the direction of retardation at a point associated with the onset or the progress of the engine braking or, again, beginning with a particular engine speed. It is a further object of the invention to generate a release signal which permits a return of the engine timing to its normal value according to a selectable function. By shifting the engine timing to a substantial retardation, the combustion processes only serve for heating the engine and do not produce substantial engine torque. The rapid heating insures that the normal engine temperature is reached soon after engine braking stops, thereby permitting the complete and optimum combustion which has a minimum of toxic exhaust gas components. It is a further object of the invention to still further increase the degree of heating of the engine when engine braking terminates by enriching the fuel-air mixture at that time.
In a particular feature of the invention, the spark retardation takes place at the onset of engine braking, whereas the fuel supply is interrupted only at some time thereafter. This combination of features also improves driver comfort by permitting a very gentle transition from normal vehicle operation to engine braking or engine overrunning.
The invention will be better understood as well as further objects and advantages thereof become more apparent from the ensuing detailed description of preferred exemplary embodiments of the invention taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagram depicting the variation of timing angle as a function of engine speed during engine braking;
FIG. 2 is a diagram illustrating the ignition timing angle as a function of time near the termination of engine braking;
FIG. 3 is a diagram illustrating the ignition timing angle as a function of time subsequent to throttle opening and after engine braking;
FIG. 4 is a set of diagrams illustrating the events occurring during engine braking wherein FIG. 4a is a diagram showing the throttle angle as a function of time;
FIG. 4b illustrates the occurrence of the timing retardation signal;
FIG. 4c is a diagram of the fuel delivery signal as a function of time;
FIG. 4d is a diagram illustrating the timing retardation angle as a function of time;
FIG. 5 is an overall block diagram of the method and apparatus of the invention;
FIG. 6 is a circuit diagram of one embodiment of an engine braking recognition circuit;
FIG. 7 is a circuit diagram of an embodiment of an engine timing control circuit;
FIG. 8 is a schematic diagram of a pneumatic timing control according to the invention; and
FIG. 9 is a diagram illustrating the electrical actuation of the solenoids in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The illustration of FIG. 1 depicts the ignition timing angle as a function of engine speed, with the positive ordinate indicating late timing. The engine speed nLL refers to the idling speed, the engine speed marked nW refers to the fuel restoring speed and the time marked nab refers to the fuel shut-off speed. The fuel shut-off speed nab is that speed above which fuel supply will be interrupted with a closed throttle. As the resupply speed nW the fuel supply is reinitiated so as to permit a proper operation of the engine at idling speed. The speed difference between nab and nW serves as a hysteresis to prevent oscillations between fuel supply and fuel shut-off. FIG. 1 illustrates that the timing angle remains retarded as the speed declines down to a speed which lies well below the fuel resupply speed nW and is thereafter returned to an angle shown to be near zero degrees but actually referring to the angle which is proper and suitable for idling operation of the particular engine in which the invention is used.
By changing the engine timing in the manner depicted in FIG. 1, the engine torque is low when fuel is resupplied due to the fact that the timing is still retarded at that time.
FIG. 2 illustrates the reduction of the amount of late timing, i.e., a reduction of the late timing angle α z beginning with the point at which the resupply speed nW is reached by the engine during deceleration. According to the diagram of FIG. 2, the late timing is reduced linearly with respect to time during a period of approximately two seconds. The change in FIG. 1, however, is linear with respect to engine speed.
The diagrams of both FIGS. 1 and 2 treat the case in which the resupply speed nW is reached without any application or depression of the accelerator pedal, i.e., at a closed throttle, so that the engine speed is reduced due to friction or external load.
FIG. 3 illustrates the change in the timing angle α as a function of time in which the timing retardation is reduced at the moment the throttle is reopened. The final timing angle is shown to intersect the abscissa but may be at some angle other than zero degrees. This illustration characterizes the case in which the operator of the vehicle arbitrarily terminates engine braking by application of the throttle.
The general situation occurring during engine braking is depicted in a series of diagrams in FIG. 4. In particular, FIG. 4a illustrates the throttle angle, i.e., the angle of opening of the throttle valve, as a function of time. The throttle is shown to be opened to a constant angle up to a point ts which is the time at which it closes and engine braking may be said to initiate. At that time, a delay of length tv is begun as illustrated in FIG. 4b. At the expiration of the delay tv, fuel shut-off occurs as illustrated in FIG. 4c. In order to insure a smooth and gentle transition from normal engine, i.e., vehicle, operation, to engine braking, the ignition timing is retarded from its normal value (zero or otherwise) to a retarded value beginning at the time marked mvl, and the process of timing retardation is completed before fuel shut-off, as a comparison with FIG. 4c will show. The operation illustrated and discussed above may be performed by an apparatus schematically shown in FIG. 5. This apparatus comprises three sections, namely a timing section 10, a fuel injection section 11 and a sensor section including a tacho-generator 12, a throttle valve position indicator 13 for generating a closed throttle signal and an air flow rate meter 14 which generates a signal related to air flow in the induction tube.
The timing section 10 is chiefly characterized by a timing control circuit 20 which determines the optimum engine timing, i.e., the correct timing angle, on the basis of the prevailing engine speed and signals related to instantaneous pressures. Following the timing control circuit 20 is a timing adjustment circuit 21 which operates in dependence on the output signal or of an ignition timing shifter circuit 22 and actuates a synchronizing circuit 23 which sets the ignition timing angle in relation to top dead center for providing an ignition signal to the spark plugs 24 at the desired time. The timing shifter circuit 22 receives its input signals from an engine braking detection circuit 25, the tacho-generator 12 and from the throttle position transducer 13. The switches in the lines coming from the transducers 12 and 13 serve the purpose of selective connection of the timing shifter on one or the other of the transducers.
The fuel injection section 11 of the apparatus in FIG. 5 includes a control pulse generator 30 which generates a train of fuel injection control pulses having a length tp which depends on engine speed and air flow rate. Following the circuit 30 is a clipper circuit 41 in which the signals from the pulse generator 30 are delayed, shortened, or suppressed. The output signals of the clipper circuit are fed to a fuel injection mechanism including at least one electromagnetic fuel injection valve 32. Finally, the injector section of the apparatus includes an enrichment circuit 33 connected to the pulse generator circuit 30 for providing a fuel mixture enrichment at the end of engine braking by appropriate prolongation of the injection control pulse generated in the pulse generator 30. The illustrated disposition of separate units in the ignition control section 10, i.e., the timing control circuit 20, the timing adjustment circuit 21 and the synchronizing circuit 23, is merely exemplary and may be modified, in particular may be joined in the same circuit, depending on the ignition system. However, this disposition is advantageous when employed in conjunction with an electronic ignition system.
In normal vehicle operation, the ignition section 10 generates ignition pulses at particular times, i.e., at particular timing angles, and in dependence on the commonly used variables induction tube pressure and engine speed. At the same time, the fuel injection control section 11 generates control pulses on the basis of engine speed and induction tube air flow rate and transmits these control pulses to the electromagnetic fuel injection valves 32.
When the engine braking detection circuit 25, which monitors the engine speed and the throttle valve position, detects the condition of engine braking, it actuates the ignition timing shifter circuit 22 which causes a shift of the engine timing toward retardation, i.e., late ignition. In order to perform the readjustment from late ignition to normal engine timing as depicted in the diagram of FIG. 1, the timing shifter circuit 22 must be coupled to the tacho-generator 12. The circuit 22 also requires throttle valve position data so as to initiate the cancelation of late timing when the throttle valve is opened. This latter connection however is not absolutely necessary, in particular if engine braking is defined to include the condition of closed throttle and idling in addition to closed throttle and above-idle speeds.
Depending on the magnitude of the signal of the timing shifter circuit 22, the timing controller 20 shifts the moment of timing in the direction of retardation from the time which corresponds to the instantaneous values of engine speed and pressure, and the synchronizing circuit 23 translates this new value into a particular timing angle.
The fuel enrichment circuit 33 which feeds into the pulse generator circuit 30 includes a component which recognizes the termination of engine braking. Furthermore, it contains a timing circuit which permits the provision of an enriched fuel-air mixture for a predetermined period of time.
Following the pulse control circuit 30 is a clipper circuit 31 which interrupts the supply of fuel to the engine or to the induction tube during engine braking so as to conserve fuel and to permit the full effect of engine braking on the speed of the vehicle. The circuit 31 may act to suppress or cut off the transmission of the fuel control pulses from the pulse control circuit 30 to the fuel injection valves 32.
An engine braking detector such as the element 25 may be embodied as illustrated in FIG. 6 where it is shown to contain a threshold switch 35 which receives the engine speed signal from the tacho-generator 12 as well as a switch 36 between an output line 37 and the ground connection 38. In the illustrated position, the switch 36 shows the conditions at idling speed in which the signal on the line 37 is the output signal of the threshold switch 35 and thus depends on engine speed alone. When the engine operates at other than idling speed, the switch 36 is closed so that the voltage on the line 37 is at ground potential independently of the action of the threshold switch 37 and of engine speed. Preferably, the threshold switch 35 has internal hysteresis so as to provide different thresholds for defining the onset and termination of engine braking.
A timing shifter circuit such as the element 22 in FIG. 5 may be embodied as illustrated in FIG. 7 where it is seen to include an integrator or amplifier 40 as its basic component. An input junction 41 joins two parallel branches which are rejoined at the negative input of the amplifier 40. The first branch includes a resistor 42 and a diode 43 connected to pass positive input signals, whereas the second branch includes series-connected resistors 44 and 45 connected in series with a diode 46 connected in opposite polarity to the diode 43. The resistor 44 may be shunted by a switch 47 which responds to throttle valve position and is open at engine idle. The output 48 of the timing shifter circuit 22 carries an engine brake-dependent output signal and the resistor 42 controls the rate of the change in timing as depicted in FIG. 4d, while the resistors 44 and 45 determine the time behavior of the ignition shift in the vicinity of the termination of engine braking, as depicted in FIG. 2. The resistor 45 and the switch 47 together determine the characteristics illustrated in FIG. 3.
An overall apparatus for utilizing the invention in a pneumatically acting configuration is illustrated in FIG. 8. Shown here are a known ignition distributor 50 having a double-acting pressure cell 51, an air filter 52 ahead of an air induction tube 53 including a throttle valve 54, an intake manifold 55 and a greatly simplified representation of an internal combustion engine. Disposed between one input of the double-acting pressure cell 51 and the induction tube 53 or the induction manifold 55 is an auxiliary volume 61 which is connected to the induction tube 53 via a first branch containing a throttle 62 and a second branch containing a second throttle 63 and a solenoid valve 64. The auxiliary volume 61 is connected to the intake manifold 55 via a throttle 65 and a further solenoid valve 66. The auxiliary volume 61 may in practice be constituted by the internal volume and the connecting conduits of the double-acting pressure cell 51.
The pressure within the auxiliary volume 61 may be controlled in dependence on engine speed and throttle valve angle so that the double-acting pressure cell 51 receives an actuating signal for changing the engine timing. The manner in which the solenoid valves 64 and 66 are controlled is illustrated in FIG. 9. In the unenergized state, the solenoid valve 66 is pneumatically closed while the magnetic valve 64 operates in the reverse sense. FIG. 9 illustrates the series connection of a throttle valve switch 70 with a parallel circuit consisting of a first branch having in it the solenoid valve 64 alone and having a second branch in which an rpm-dependent switch 71 and the solenoid valve 66 are disposed. The entire circuit is connected between a positive supply line 72 and a negative supply line 73. The rpm-dependent switch 71 is preferably provided with hysteresis, i.e., it is closed above the fuel cut-off speed nA and remains closed until the engine speed has dropped below the fuel resupply speed nW. The switch 70 is a throttle valve switch of known construction whose contacts are closed when the throttle valve is closed. The function of the circuit illustrated in FIG. 9 is to open the solenoid valve 64 when the throttle valve is closed. The solenoid valve 66, on the other hand, also depends on engine speed and it opens when the throttle valve is closed and the engine speed is above the fuel cut-off speed nA or below the fuel resupply speed nW. As shown in FIG. 8, the auxiliary volume 61 is always connected to the induction tube 53 via the throttle 62 independently of any throttle valve or engine speed signals.
While the throttle 65 and the solenoid valve 66 jointly determine the time characteristics of the ignition angle as depicted in FIG. 4d, the throttle 63 and 65 together determine the function illustrated in FIG. 3.
A variant of the pneumatic embodiment of the invention illustrated in FIG. 4 would dispense with the throttle 63 and the solenoid valve 64. In that case, the ignition angle shift would be retained on the basis of throttle angle and engine speed.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention. | An ignition control device for changing the ignition timing of an internal combustion engine during and after the occurrence of engine braking, i.e., during a condition of increased speed and low load, as during coasting. The device includes a circuit which receives signals related to engine load and engine speed and determines therefrom the onset of engine braking. The device then retards the engine timing so as to reduce the amount of positive engine torque, whereafter the fuel supply may be entirely shut off. Upon establishment of normal operation or idling, the fuel supply is restored and the ignition timing is gradually returned to the normal setting. | 5 |
TECHNICAL FIELD
[0001] The present invention relates generally to down hole remotely operated oil well wireline tools and, more specifically, to a down hole wireline tool release mechanism.
BACKGROUND
[0002] The ever increasing use of fossil fuels has led to the development of drilling technologies that were unimaginable in the recent past. For instance, the ability to drill a well to a desired depth and then steer the well, with respect to the drilling platform, from a vertical direction to a horizontal direction is now a common practice. The direction of a well can be changed based on factors such as the geological strata or a recovery design plan for optimizing the output from the well.
[0003] The multidirectional drilling capabilities described above have introduced a new series of problems related to determining the operational parameters of the well. For example, a common task in the startup and operation of a well is to deploy one or more wireline tools down a well to collect data. The wireline tools can measure well parameters, employ cameras for optical observation or even perform radioactive irradiations to evaluate the localized geological strata. The key difference is in a well with a straight vertical direction and a well with an orientation that shifts from a vertical direction to a horizontal direction and possibly upwards towards the surface.
[0004] As is easily imagined, retrieving a series of wireline tools from a well with changing direction of bore is more difficult than retrieving the same series of wireline tools from a straight vertical well. For example, the force of gravity combined with the bend of a turn in the well can cause a string of wireline tools to become stuck. This problem can occur either because one of the tools is physically stuck in a bend in the well or the force required to pull the series of wireline tools through the bend is greater than the tensile strength of the wire attached to the wireline tools.
[0005] In another example, when perforating charges are detonated the perforation canister can deform during the explosion and become lodged in the well bore. As described above, the force required to retrieve the deformed perforation canister can exceed the tensile strength of the wire attached to the wireline tools.
[0006] Under the above described circumstances, a system and associated methods are desired allowing the release of the wireline tools above the obstruction without disrupting the ability of the remaining wireline tools to continue performing their intended tasks as the tool string is removed from the well. Additionally, the ability to reconnect wireline tools without requiring replacement of all components retrieved from the well is desirable because the additional benefit of the ability to test a string of wireline tools before insertion into the well becomes possible.
SUMMARY
[0007] Systems and methods according to the present invention address these needs by providing a multifunction down well release tool mechanism with a lost motion design and a flooding valve for disconnecting upper sections of the wireline tool string from lower sections of the tool string lodged in the well. After disconnection, the remainder of the wireline tool string, still attached to the wire, continues to function as the shortened string is removed from the well. The design also provides a nondestructive detachment allowing the wireline tool string to be reconnected with the remainder of the tool string removed from the well or to new elements of a tool string without replacing the elements of the tool string above the disconnect point.
[0008] According to an exemplary embodiment, a linear motion motor-driven reciprocating shaft actuates all aspects of the release process. These aspects include but are not limited to releasing the latching clamps, disconnecting the electrical connections passed to the subsequent tools in the string and actuating the flooding valve for pressure equalization of the release chamber.
[0009] According to another exemplary embodiment, a motor-driven rotating motion shaft rotates a cam mechanism that similarly actuates all aspects of the release process. As described above for the linear motion process, these aspects include but are not limited to releasing the latching clamps, disconnecting the electrical connections passed to the subsequent tools in the string and actuating the flooding valve for pressure equalization of the release chamber.
[0010] In various embodiments, the lost motion included in the actuation stroke protects the drive train from large pressure forces exerted by the well fluid when the tool is released. Accordingly, the design is robust and durable allowing for the reconnection of either new tools or disconnected tools recovered from the well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings illustrate exemplary embodiments, wherein:
[0012] FIG. 1 depicts the release mechanism shown in the connected position, including the electric motor and the gearbox;
[0013] FIG. 2 depicts an enlarged view of the release mechanism drive train chamber and release chamber shown in the connected position;
[0014] FIG. 3 depicts an enlarged view of the release mechanism drive train chamber and release chamber shown with the leadscrew nut advanced to take up lost motion.
[0015] FIG. 4 depicts an enlarged view of the release mechanism drive train chamber and release chamber shown with the flooding valve beginning to open and the latching dogs partially released.
[0016] FIG. 5 depicts an enlarged view of the release mechanism drive train chamber and release chamber with the flooding valve open, the latching dogs released and the reciprocating shaft forced fully open by well fluid pressure in the release chamber.
[0017] FIG. 6 depicts an enlarged view of the release mechanism drive train chamber and release chamber with the release mechanism fully released and the fishing neck disengaging.
[0018] FIG. 7 depicts a method of disconnecting a fishing neck subassembly from a release mechanism.
[0019] FIG. 8 depicts a method of reconnecting a fishing neck subassembly to a release mechanism.
DETAILED DESCRIPTION
[0020] The following detailed description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
[0021] Looking first to FIG. 1 , a detailed diagram of the release mechanism 100 according to an exemplary embodiment is illustrated. As discussed previously, the release mechanism 100 performs aspects of releasing one or more tools from the string of wireline tools. These aspects include, for example and not limited to, releasing the latching clamps 124 , disconnecting the electrical connections passed to subsequent tools in the string 116 / 118 and actuating the flooding valve 120 for pressure equalization of the release chamber 106 .
[0022] In general, a release mechanism is comprised of a motor/gearbox assembly 102 , a drive train chamber 104 and its associated components, a release chamber 106 and its associated components, a flooding valve 120 separating the release chamber 106 from the outside well fluid, a sealed bulkhead 126 separating the drive train chamber 104 and the release chamber 106 , and a reciprocating shaft 108 . The reciprocating shaft 108 is functionally connected to the motor/gearbox assembly 102 through the leadscrew 110 and leadscrew nut 112 assemblies and simultaneously actuates, according to this exemplary embodiment, the electrical spring contact 116 , the latching dogs 124 and the flooding valve 120 .
[0023] The drive train chamber 104 houses the leadscrew 110 and the leadscrew nut 112 in an open area of lost motion 114 of the reciprocating shaft 108 . The lost motion area 114 allows the reciprocating shaft 108 to strike the end of the drivetrain chamber 104 closest to the motor/gearbox 102 when the flooding valve 120 opens and the reciprocating shaft 108 is subjected to the full pressure of the well fluid. This protects the leadscrew 110 and the motor/gearbox 102 from damage.
[0024] In another aspect, the end of the drive train chamber 104 adjacent to the flooding valve 120 provides a conductive ring 118 around the perimeter of the drive train chamber 104 . The conductive ring 118 provides power and data communications conductivity to the reciprocating shaft 108 for connection to additional wireline tools and release mechanisms 100 further along the wireline tool string. When the release mechanism is in the connected position, an electrical spring contact 116 engages with the conductive ring 118 providing a circuit for power and data communications connectivity. The electrical spring contact 116 is connected to the reciprocating shaft 108 and disconnects from the conductive ring 118 as the reciprocating shaft 108 begins to move towards the motor/gearbox 102 .
[0025] A further aspect provides for a sealed bulkhead 126 that prevents well fluid from entering the drivetrain chamber 104 when the release mechanism 100 opens the flooding valve 120 and allows well fluid into the release chamber 106 . Similarly, seals at the release end of the reciprocating shaft 108 located around the sealed electrical connector 128 , prevent well fluid from entering the reciprocating shaft 108 .
[0026] The release chamber 106 houses the fishing neck 122 and the latching dog 124 mechanism for retaining the fishing neck 122 in the release chamber 106 during connected operation. Only one latching dog 124 is shown in the section view of FIG. 1 , However there is a plurality of latching dogs equal spaced around the axis of the tool. A conical latching dog actuator 130 is attached to the reciprocating shaft 108 and engages the latching dogs 124 when the reciprocating shaft 108 is in the connected position. When the reciprocating shaft 108 begins to move to the disconnected position, the conical latching dog actuator 130 is moved towards the flooding valve 120 and releases the latching dogs 124 . Once the latching dogs 124 have released, the reciprocating shaft 108 continues to move towards the disconnected position and the flooding valve actuating cylinder 132 presses on the flooding valve 120 , which causes it to move toward the sealing bulkhead 126 . Once the o-ring seal at the end of the flooding valve 120 closest to the latching dogs 124 disengages from its sealing bore, well fluid flows into the release chamber 106 , which equalizes the pressure in release chamber 106 with the ambient well pressure. Once well fluid has entered the release chamber 106 , the pressure forces both the flooding valve 120 and reciprocating shaft 108 towards the motor/gearbox 102 . Lost motion has been incorporated into both of these mechanisms so that, when they are subjected to well pressure, they are supported by suitably strong structural components. This protects the leadscrew 110 , motor/gearbox 102 and other delicate actuating components from damage. With pressure equalized on the inside and the outside of the fishing neck 122 , the release chamber 106 can easily be pulled from around the fishing neck 122 completing the disconnection.
[0027] The seals on the flooding valve 120 at the end closest to the drive train chamber 104 remain engaged to ensure that the flooding valve 120 is driven by well pressure into the fully open position, therefore accelerating the flooding process and also protecting the more delicate actuating components from damage.
[0028] In another aspect of release mechanism 100 , an electric motor 102 rotates a leadscrew 110 through a high ratio gearbox 102 . The leadscrew 110 drives a leadscrew nut 112 either up or down the axis of the reciprocating shaft 108 . When the leadscrew nut 112 is driven away from the motor/gearbox 102 to the end of travel, the wireline tool attached to the fishing neck 122 is connected. When the leadscrew nut 112 is driven towards the motor/gearbox 102 to the end of travel, the wireline tool attached to the fishing neck 122 is released. Of course those skilled in the art will recognize that according to other, alternative exemplary embodiments it may be possible to reverse the relationship between the direction in which the leadscrew nut 112 is driven and the connected/released mode of the fishing neck 122 .
[0029] The leadscrew nut 112 is captive within a contained area of the reciprocating shaft 108 but is not held rigidly according to this exemplary embodiment. The release mechanism design 100 includes free space on either side of the leadscrew nut 112 producing lost motion 114 or backlash in the actuating stroke. The reciprocating shaft 108 passes through a sealed bulkhead 126 , which defines two different chambers within the release mechanism 100 . The drive train chamber 104 , on the motor/gearbox 102 side of the sealed bulkhead 126 is never entered by well fluid. The release chamber 106 , on the other side of the sealed bulkhead 126 from the drive train chamber 104 becomes flooded with well fluid when a wireline tool disconnect is performed.
[0030] In the drive train chamber 104 , the reciprocating shaft 108 is held within an insulated housing fitted with a conductive ring 118 at the end near the sealed bulkhead 126 . When the reciprocating shaft 108 is in the connected position, the reciprocating shaft 108 is aligned such that an electrical spring contact 116 is in conductive contact with the conductive ring 118 . This allows electrical power and data communications through the center of the reciprocating shaft 108 to the wireline tool attached to the fishing neck 122 . When the reciprocating shaft 108 begins to move to the released position, the electrical spring contact 116 is pulled away from the conductive ring 118 , thereby breaking the electrical and data communication connection to the exposed end of the reciprocating shaft 108 and the wireline tools connected to the fishing neck 122 . This allows tools located above the release tool to continue operating after a tool disconnect is perform.
[0031] In the release chamber 106 , the reciprocating shaft 108 passes through the center of a flooding valve 120 then enters through the top of a fishing neck 122 subassembly. At the other end of the fishing neck 122 subassembly are three latching dogs 124 . The latching dogs 124 are used to hold the fishing neck 122 subassembly in the release chamber 106 . The latching dogs 124 are driven into the latched position by the conical dog actuator 130 attached to the reciprocating shaft 108 . When the reciprocating shaft 108 is in the connected position, the cone of the conical dog actuator 130 pushes outwards on the inside faces of the latching dogs 124 , holding them locked into the release chamber 106 housing. As the reciprocating shaft 108 is moved to the released position, the conical dog actuator 130 is pulled out from under the inside faces of the latching dogs 124 , allowing them to drop out of the locking sleeve in the release chamber 106 and releasing the fishing neck 122 subassembly from the release chamber 106 .
[0032] In another aspect, loosely positioned around the reciprocating shaft 108 between the flooding valve 120 and the conical dog actuator 130 is the flooding valve actuating cylinder 132 . As the reciprocating shaft 108 moves to the released position, the flooding valve actuating cylinder 132 becomes trapped between the conical dog actuator 130 and the flooding valve 120 and pushes the flooding valve towards the sealed bulkhead 126 . Once the seal on the flooding valve 120 exits the seal bores in the release chamber 106 wall, well fluid is allowed to enter the release chamber 106 . The flooding valve 120 also has lost motion on either side, allowing it to move rapidly to the flooding position as well fluid begins to enter the release chamber 106 .
[0033] In another embodiment, the fishing neck 122 subassembly with its associated wireline tools is reconnected to the to the release mechanism 100 by manually pushing the fishing neck 122 subassembly into the release chamber 106 . The motor/gearbox 102 is then run in the reverse direction from a disconnect operation. The leadscrew nut 112 first takes up the lost motion in the opposite direction. After the lost motion is recovered, the reciprocating shaft 108 is then pushed in the direction of the release chamber 106 . The lost motion of the flooding valve 120 is now recovered and the flooding valve 120 is pushed to the closed position. As the reciprocating shaft 108 reaches the end of travel, the flooding valve 120 has completely closed, the conical dog actuator 130 forces the latching dogs 124 back into the locking sleeve in the release chamber 106 and the electrical spring contact 116 engages with the conductive ring 118 restoring power and data communications to wireline tools further along the wireline tool string. Although both the reciprocating shaft 108 and the flooding valve 120 experience lost motion while moving, both are driven to hard stops when in the connected position. This hard stop lockup prevents either from moving accidentally under the effects of shock or vibration.
[0034] Looking now to FIG. 2 , an enlarged partial view of the release mechanism 100 is shown in the connected position. The leadscrew nut 202 is against the hard stop, locking the reciprocating shaft 204 in place to prevent any accidental disconnect from jarring or vibration. The electrical spring contact 208 is in contact with the conductive ring 210 , therefore providing electrical power and data communication connectivity to any wireline tools attached to the fishing neck 122 subassembly. The flooding valve 206 is in the fully closed position and also resting against a hard stop to prevent accidental opening. Finally, the conical dog actuator 212 is engaged with the latching dogs 214 forcing them into a locked position in the locking sleeve 216 of the release chamber 106 .
[0035] FIG. 3 illustrates an enlarged partial view of the release mechanism 100 at the beginning of the disconnect cycle where the leadscrew 302 has rotated to the point where the leadscrew nut 304 has taken up all the lost motion in the reciprocating shaft 306 . At this point, further rotation of the leadscrew 302 will result in movement of the reciprocating shaft in the disconnect direction.
[0036] Looking now to FIG. 4 , an enlarged partial view of the release mechanism 100 illustrates the reciprocating shaft 406 traveling in the disconnect direction with contact broken between the electrical spring contact 402 and the conductive ring 404 . At this point power and data connectivity is no longer provided to any wireline tools connected to the fishing neck 122 assembly or any other wireline tools further down the wireline tool string. The conical dog actuator 412 is disengaging the latching dogs 414 allowing release of the fishing neck 122 assembly from the release chamber 106 . The flooding valve actuating cylinder 410 is just beginning to make contact with the flooding valve 408 . It should be noted that all power connections traversing the release chamber 106 are disconnected before the flooding valve 408 begins to move and allows well fluid into the release chamber 106 .
[0037] FIG. 5 depicts an enlarged partial view of the release mechanism 100 showing a complete disconnect. The reciprocating shaft 502 has reached its maximum disconnect travel location. The flooding valve 504 is in its fully open position and latching dogs 506 are fully released. It should be noted that after releasing the fishing neck 122 subassembly the remaining wireline tools above the release mechanism 100 continue to function in their normal manner and can continue to collect data as they are removed from the well hole.
[0038] Looking now to FIG. 6 , an enlarged partial view 600 of the release mechanism 100 illustrates the disconnected release mechanism 100 being pulled from the fishing neck 602 subassembly. After retrieval of the fishing neck 602 subassembly and its attached wireline tools, the fishing neck 602 subassembly and its attached wireline tools can be reconnected to the disconnected release mechanism 100 and reinserted into the well.
[0039] FIG. 7 illustrates the method 700 of disconnecting the release mechanism 100 from the fishing neck 602 subassembly. Beginning at step 702 , the leadscrew 110 is actuated to recover the lost motion by driving the leadscrew nut 112 to the uphole end of the drivetrain chamber 104 . The leadscrew 110 can be actuated by any power transferring device such as an electric motor and gearbox assembly 102 . After the leadscrew nut 112 reaches the end of its travel, the method proceeds to step 704 .
[0040] At step 704 , all lost motion is recovered and the reciprocating shaft 108 begins to retract towards the uphole end of the release mechanism 100 . The initial reciprocating shaft 108 retraction simultaneously disconnects power and data connectivity through the release chamber 106 by separating the electrical spring contact 116 from the conductive ring 118 and disengages the latching dogs 124 by moving the conical dog actuator 130 towards the uphole end of the release mechanism 100 . After the power is disconnected and the latching dogs 124 are released, the method proceeds to step 706 .
[0041] Continuing at step 706 , the reciprocating shaft 108 continues retracting and opens the flooding valve 120 allowing well fluid into the release chamber 106 . As the high pressure well fluid enters the release chamber 106 the method proceeds to step 708 and the reciprocating shaft 108 and the flooding valve 120 are forced to the protective hard stop at the uphole end of the drivetrain chamber 104 . The flooding valve 120 is now fully open and the entering well fluid has equalized the pressure on the inside and outside of the release chamber 106 . Finally, at step 710 , the release mechanism 100 can be pulled from the fishing neck 602 subassembly allowing removal of the remaining functional wireline tools and providing access to the fishing neck 602 subassembly for attachment of a cable suitable to pull the disconnected wireline tools from the well hole.
[0042] Looking now to FIG. 8 , a method of connecting a fishing neck 602 subassembly to a release mechanism 100 is illustrated. Beginning at step 802 , the fishing neck 602 subassembly is inserted into the release chamber 106 until fully seated. Next, at step 804 , lost motion is taken up by actuating the leadscrew 110 until the leadscrew nut 112 seats against the reciprocating shaft 108 at the uphole end of the reciprocating shaft.
[0043] Continuing to step 806 , the reciprocating shaft begins extending towards the downhole end of the release mechanism 100 and drives the flooding valve to the fully closed position. Next at step 808 , further extending the reciprocating shaft towards the downhole end of the release mechanism engages the latching dogs 124 into the fishing neck 602 subassembly and forces the electrical spring contact 116 against the conductive ring 118 . This step results in a mechanical lockup of the fishing neck 602 subassembly and the release mechanism and provides electrical and data connectivity to the wireline tools connected to the fishing neck 602 subassembly. The wireline tool string is now prepared for insertion into the well hole.
[0044] The above-described exemplary embodiments are intended to be illustrative in all respects, rather than restrictive, of the present invention. Thus the present invention is capable of many variations in detailed implementation that can be derived from the description contained herein by a person skilled in the art. All such variations and modifications are considered to be within the scope and spirit of the present invention as defined by the following claims. No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. | Presented is a system and method for disconnecting a plurality of wireline tools from a string of wireline tools while maintaining operation of the wireline tools remaining with the string of wireline tools. The disconnection is non-destructive and allows a reconnection of the disconnected tools after retrieval from the well. The system also enables testing of the disconnection mechanism before deploying the wireline tool string into the well. | 4 |
This application claims priority of U.S. provisional patent application Ser. No. 60/171,994 filed Dec. 23, 1999.
TECHNICAL FIELD
This invention relates generally to a window glare-reducing assembly for reducing the amount of interior light reflected into a driver's eyes from the windshield of a mass transit vehicle as well as the amount of passenger-perceived glare reflected from side windows of a mass transit vehicle.
INVENTION BACKGROUND
Some mass transit vehicle interior lighting fixtures are known to include louvers or fins spaced axially along the length of an elongated cylindrical light source such as a fluorescent lamp. The louvers extend laterally from the lamps to direct light laterally into passenger seating areas and away from the windshield.
For example, U.S. Pat. No. 2,099,451, issued Nov. 16, 1937 to Schepmoes (the Schepmoes patent), discloses a lighting fixture intended for use in “railroad cars and the like” that includes a plurality of parallel louvers or fins spaced axially along the length of a fluorescent lamp. In addition, U.S. Pat. No. 4,717,992, issued Jan. 5, 1988 to Bartenbach et al. (the Bartenbach et al. patent), discloses a lighting fixture that includes a plurality of parallel louvers or fins spaced axially along the length of a fluorescent lamp. Each louver includes a circular hole sized to fit closely around the lamp.
U.S. Pat. No. 2,299,276 to Kirlin (the Kirlin patent) discloses racks of parallel louvers, each louver having a half-circular cutout sized to receive a fluorescent lamp. Each rack disclosed in the Kirlin patent includes a pair of C-shaped wire clips for clipping the louver racks onto the fluorescent lamp. In the louvers disclosed in the Shepmoes, Bartenbach et al. and Kirlin patents are configured to be supported directly on a fluorescent lamp.
What is needed is a window glare-reducing assembly that allows louvers to be mounted on and removed from an elongated cylindrical light source more quickly and easily.
INVENTION SUMMARY
According to the invention, a window glare-reducing assembly is provided for reducing the amount of glare reflected from a window of a mass transit vehicle by interior vehicle lighting. The assembly includes a first plurality of louvers configured to be supported in an axially spaced-apart disposition along the length of an elongated cylindrical light source. The window glare-reducing assembly also includes a tubular sleeve configured to receive an elongated cylindrical light source such as a fluorescent lamp. The first plurality of louvers is supported on the sleeve in an axially spaced-apart disposition. This allows each louver of the first plurality of louvers to fit closely around the cylindrical light source while simplifying installation and removal of the louvers and installation and replacement of cylindrical light sources that the louvers are supported on. Therefore, a window glare-reducing assembly constructed according to the invention is both easier to install and remove, and allows lamps to be replaced more easily.
According to another aspect of the invention, the sleeve comprises a plastic material, a transparent material and/or a colored material. The color and transparency of the sleeve material may be selected by a customer to complement existing interior color schemes, to control light dispersion, to affect passenger moods and/or to cause passengers to associate a certain color with the particular transport company that uses it.
According to another aspect of the invention, a support shaft is connected to each louver of the first plurality of louvers. The support shaft holds the louvers together making them easier to install on and remove from the tube. The support shaft also serves to stabilize the relative positions and attitudes of the louvers connected to it.
According to another aspect of the invention, the first plurality of louvers and the first support shaft are integrally formed as a single unitary piece. Forming the louvers and shaft as a single unitary piece eliminates the need to manufacture and assembly multiple parts.
According to another aspect of the invention, the assembly includes at least one additional plurality of louvers configured to be supported in an axially spaced-apart disposition along the length of an elongated cylindrical light source and a second support shaft connected to each louver of the additional plurality of louvers. The first support shaft is configured to interconnect with the second support shaft in an end-to-end disposition. Shorter lengths of louvered shafts are easy to manufacture and can easily be assembled end-to-end to cover whatever length of fluorescent tube is being used in a particular lighting fixture.
According to another aspect of the invention, one of the first and second support shafts includes an axial counter bore at one end. The other of first and second support shafts includes a complementary axially extending post at one end configured to be received into the axial counter bore. This pin-and-socket arrangement maintains alignment between adjacent lengths of louvered shafts providing aesthetically pleasing visual continuity.
According to another aspect of the invention, each louver includes a circular through-hole. The circular through holes are configured and coaxially aligned to receive the tubular sleeve. The holes allow the louvers to extend completely around the circumference of the lamp they are supported on thereby directing a maximum amount of light emitted from the host lamp.
According to another aspect of the invention, the louvers comprise non-reflective surfaces to further reduce non-lateral light emissions by absorbing rather than reflecting light.
According to another aspect of the invention, the louvers comprise translucent material to reduce the magnitude and harshness of non-lateral light emissions.
According to another aspect of the invention, the louvers comprise colored material to complement existing interior color schemes, to control light dispersion, to affect passenger moods and/or to cause passengers to associate a certain color with the particular transport company that uses it.
According to another aspect of the invention, the louvers are disposed parallel to each other to direct light evenly along the length of the vehicle.
According to another aspect of the invention, the louvers are disposed perpendicular to the support shaft to direct light exclusively in a lateral direction relative to the lamp.
According to another aspect of the invention, the louvers are angled relative to the support shaft and lamp to direct light toward a predetermined portion of the passenger compartment or away from a predetermined portion of the passenger compartment.
According to another aspect of the invention, the louvers are spaced apart by a distance that provides an interior illumination level of 15 foot-candles at each reading plane at each seat location within a vehicle to be illuminated, where the entire length of each elongated cylindrical light source mounted within the vehicle is disposed within the assembly and a plurality of like assemblies having identically spaced louvers. (Each reading plane is defined as a one square foot plane inclined at a 45 degree angle 33″ above a floor of the vehicle and 22″ in front of a seat back of one of the seats.) This insures that the lighting system meets minimum industry standards for mass transit vehicle interior lighting.
According to another aspect of the invention, each louver includes an inside edge configured to conform generally to the interior contours of a lamp housing in an interior light fixture. The conforming inside edge prevents light from escaping between the inside edge and the lamp housing and provides maximum louver surface area for light deflection.
According to another aspect of the invention, each louver includes an outside edge configured to conform generally to the interior contours of an interior light fixture lens. The conforming outside edge provides a maximum louver surface area for light deflection within the confines of the lens.
According to another aspect of the invention, the louvers are black in color to increase light absorption and to minimize light reflection.
The invention also includes a method for making a window glare-reducing assembly. The method includes molding the louvers and support shaft are together as a single unitary piece. The sleeve is then inserted through the circular through-holes of the louvers and an elongated cylindrical light source is provided within the sleeve. The light source, sleeve, louvers, and shaft are provided in the light fixture such that the light source is electrically connected to a light source power supply of the light fixture and is physically supported by light source receptacles of the light fixture. The method further includes providing a lens on the light fixture. This method greatly simplifies the process of assembling louvers to a lamp.
According to another aspect of the inventive method, the step of molding the louvers and support shaft together as a single unitary piece includes providing a mold including a mold cavity having an interior shape complementing the exterior shape of the louvers and support shaft. The mold also includes a pair of frusto-conical tapered rods configured to be inserted into the mold cavity from axially opposite ends of the mold and to form the circular through-holes of the louvers. The tapered rods are then inserted into the mold cavity from axially opposite ends of the mold and molten material is provided in the mold cavity. The molten material is allowed to harden, the tapered rods are withdrawn, the mold is opened and the finished product is removed. The use of tapered rods allows the rods to be removed easily and without binding within the circular apertures that the rods form in the louvers.
According to another aspect of the invention, a support shaft interconnects the first plurality of louvers to form a louver assembly. The louver assembly is split longitudinally to form interconnectable first and second louver assembly portions. This allows the louver assembly to be closed or assembled around the tubular sleeve rather than forcing the tubular sleeve through the louvers one louver at a time.
According to another aspect of the invention, the louver assembly includes a second support shaft. The incorporation of the second support shaft insures that the individual louvers will remain parallel to each other.
According to another aspect of the invention a method is provided for making a windshield glare-reducing assembly that includes molding interconnectable first and second louver assembly portions as separate pieces then interconnecting the louver assembly portions around the tubular sleeve such that the individual louvers of the louver assembly are supported in an axially spaced-apart disposition along the sleeve.
DRAWING DESCRIPTIONS
These and other invention features and advantages will become apparent to those skilled in the art when considered along with the following detailed description and drawings, in which:
FIG. 1 is a front view of a window glare-reducing assembly constructed according to the invention with a fluorescent lamp disposed within a transparent sleeve of the invention and with the sleeve partially cut away to expose a fluorescent lamp beneath;
FIG. 2 is a cross-sectional side view of the glare-reducing assembly and fluorescent lamp of FIG. 1 taken along line 2 — 2 of FIG. 1;
FIG. 3 is a front view of the glare-reducing assembly of FIG. 1 with the fluorescent lamp and transparent sleeve removed to show only a louver assembly of the glare-reducing assembly of FIG. 1;
FIG. 4 is a cross-sectional side view of the louver assembly of FIG. 3 taken along line 4 — 4 of FIG. 3;
FIG. 5 is a cross sectional front view of a window glare-reducing assembly constructed according to the invention and installed in a lighting fixture;
FIG. 6 is a partial perspective view of the sleeve of FIG. 1 disposed around a fluorescent lamp and within a louver assembly constructed according to a second embodiment of the invention;
FIG. 7 is a partial perspective view of the sleeve of FIG. 1 disposed within a louver assembly constructed according to a third embodiment of the invention;
FIG. 8 is a top view of the louver assembly and sleeve of FIG. 7 with first and second portions of the louver assembly shown split apart; and
FIG. 9 is a cross-sectional side view of the louver assembly and sleeve of FIG. 7 taken along line 9 — 9 of FIG. 8 .
DETAILED DESCRIPTION
A first embodiment of a window glare-reducing assembly for reducing the amount of driver-perceived glare reflected from the windshield of a mass transit vehicle and the amount of passenger-perceived glare reflected from side windows by interior vehicle lighting is generally indicated at 10 in FIGS. 1, 2 and 5 . Second and third embodiments are generally indicated at 10 ′ in FIG. 6 and 10 ″ in FIGS. 7-9. Reference numerals with the prime (′) designation in FIG. 6 and the double prime (″) designation in FIGS. 7-9 indicate alternative configurations of elements that also appear in the first embodiment. Unless indicated otherwise, where a portion of the following description uses a reference numeral to refer to the FIGS., we intend that portion of the description to apply equally to elements designated by primed numerals in FIG. 6 and double-primed numerals in FIGS. 7-9.
The glare-reducing assembly 10 includes a plurality of louvers generally indicated at 12 in FIGS. 1-5. The louvers 12 are configured to be supported in an axially spaced-apart disposition along the length of an elongated cylindrical light source such as a fluorescent lamp 14 . The glare-reducing assembly 10 also includes a tubular sleeve 16 configured to receive or slide over an elongated cylindrical light source 14 . Each louver 12 includes a circular through-hole 18 . The circular through-holes 18 are configured and coaxially aligned to receive the tubular sleeve 16 . The louvers 12 are supported on the sleeve 16 in an axially spaced-apart disposition along the length of the sleeve 16 .
The sleeve 16 comprises a transparent plastic material that may be either clear or colored, depending primarily on considerations as aesthetics and transport company identification for advertising and promotional purposes. However, in other embodiments, color choice may also be influenced by functional considerations. For example, it would be desirable to use red colored material in applications (such as law enforcement or military operations) where it is important for passengers to retain or acquire increased night vision capability.
The louvers 12 are connected to and integrally formed with an elongated cylindrical support shaft 20 as a single unitary louver assembly 22 . The louvers 12 and support shaft 20 are formed from a polycarbonate material by a molding process described below. However, in other embodiments louvers 12 may be post-applied to a pre-formed sleeve 16 either by gluing, fasteners, clips or by interference fit. In other embodiments, the louvers 12 and support shaft 20 may also be made of a material other than a polycarbonate material. Each louver assembly 22 in the present embodiment is molded to a length of approximately two feet as measured from one end of the support shaft 20 to the other. Several of the louver assemblies 22 are installed end-to-end in longer light fixtures. The number of louver assemblies 22 installed in each light fixture depends on the length of fluorescent lamps used in a light fixture.
The support shaft 20 of each louver assembly 22 is configured to interconnect with the support shafts 20 of adjacent louver assemblies in an end-to-end disposition. As shown in FIGS. 1 and 3, one end of each support shaft 20 includes an axial counter bore 24 . As is also shown in FIGS. 1 and 3, the other end of each support shaft 20 includes a complementary axially-extending post 26 configured to be received and glued into the axial counter bore 24 of an adjacent louver assembly 22 . In other embodiments, the louver assembly 22 may be formed or assembled to extend the full length of each fluorescent lamp 14 .
The louvers 12 and support shaft 20 are opaque, black in color, and comprise non-reflective front and back surfaces 28 , 30 . However, in other embodiments the louvers 12 may comprise colored material coordinated with the sleeve color and/or interior colors of the vehicle they will be installed in. The louvers 12 may also alternatively comprise translucent material
As is best shown in FIG. 3, the louvers 12 are disposed parallel to each other and perpendicular to the support shaft 20 and the fluorescent lamp 14 they are supported on, primarily to prevent light from shining directly from the fluorescent lamp 14 onto a vehicle windshield then reflecting into a driver's eyes. However, in other embodiments the louvers 12 may be cast or attached at an angle other than perpendicular or at varying angles, depending on their position in the vehicle, to direct light into various desired locations.
The louvers 12 of each louver assembly 22 are preferably spaced apart by a distance that provides an interior illumination level of 15 foot-candles at each reading plane at each seat location within a vehicle to be illuminated. This assumes that the entire length of each elongated cylindrical light source 14 mounted within the vehicle is disposed within the assembly and a plurality of like louver assemblies having identically spaced louvers 12 . Each reading plane is defined as a one square foot plane inclined at a 45 degree angle 33″ above a floor of the vehicle and 22″ in front of a seat back of one of the seats. The 15 foot-candle illumination standard described above is a minimum requirement established by the American Public Transit Association (APTA). See Passenger Interior Lighting , STANDARD BUS PROCUREMENT GUIDELINES, Section 5.4.4.6; April, 1999. The object is to provide minimum interior lighting levels while complying with the APTA standard. The approximate 2-inch spacing of the louvers 12 shown in the drawings and photographs met the above standard almost exactly in one bus. However, the optimum louver spacing is likely to differ from vehicle to vehicle.
To minimize axial light leakage and to maximize the area of the louver surfaces 28 , 30 within the confines of a lamp housing, an inside edge 32 of each louver 12 is shaped to conform generally to the interior contours of a lamp housing in an interior light fixture as shown in FIG. 5 . Similarly, an outside edge 34 of each louver 12 is shaped to conform generally to the interior contours of an interior light fixture lens that fits over and closes the lamp housing. By conforming the inside and outside edges 32 , 34 of each louver 12 to the respective interior contours of the lamp housing and the lens, each louver 12 is formed to include a maximum surface area for directing light emitted from the lamp 14 they are mounted on.
Each windshield glare-reducing assembly 10 is made by first molding louvers 12 and a support shaft 20 together as a single unitary piece. This includes providing a mold 36 including a mold cavity 38 having a shape complementary to that of the louvers 12 and support shaft 20 . The mold 36 also includes a pair of frusto-conically tapered rods 40 configured to be inserted into the mold cavity 38 from axially opposite ends of the mold 36 and to form the circular through-holes 18 of the louvers 12 . The tapered rods 40 are then inserted into the mold cavity 38 from axially opposite ends of the mold 36 . Molten material 42 is then provided in the mold cavity 38 and is allowed to harden. The tapered rods 40 are then withdrawn, the mold 36 is opened and the louver assembly 22 is removed. The sleeve 16 is then inserted through the axially aligned circular through-holes 18 of the louvers 12 . A fluorescent lamp 14 is then slid into the sleeve 16 and the lamp 14 , sleeve 16 and louver assembly 22 are installed in a light fixture by installing the lamp 14 in lamp receptacles formed in the light fixture such that the light source 14 is electrically connected to a light source power supply of the light fixture. Finally, the lens is fastened over the lamp housing.
The rods 40 are tapered to provide an approximate 2-degree draft to prevent the rods 40 from sticking within the circular through-holes 18 after the molten polycarbonate has hardened. To minimize the resulting difference circular through-hole diameters along the length of each louver assembly 22 , the length of each louver assembly 22 is limited to approximately 2 feet and two, rather than one, taper rods 40 are used.
The window glare-reducing assembly 10 may be configured for installation in new light fixtures and shipped with the fixtures from the factory. The glare-reducing assembly 10 may alternatively be configured for retrofitting into the lamp housings of existing light fixtures.
Supporting the louvers 12 on a tube as described above allows the louvers 12 to be formed to fit closely around the cylindrical light source 14 while simplifying louver installation and removal. Closer fitting louvers 12 more efficiently direct light emitted from the lamp 14 in the desired lateral direction and minimize axial dispersion. Louver installation and removal are simplified because the sleeve 16 is disposed in the circular through-holes 18 to act as an interface between the louvers 12 and the fluorescent lamp 14 the louvers 12 are supported on. The sleeve 16 allows lamps 14 to be quickly and easily installed and replaced within the through-holes 18 because it maintains the holes 18 in axial alignment and guides lamps through the holes 18 .
In other embodiments, such as the embodiment shown in FIG. 6, the louvers 12 ′ may be connected together by a small diameter metal rod 44 and spaced apart by plastic spacers 46 . In such an embodiment spacers 46 of varying lengths may be used to produce a glare-reducing assembly 10 ′ especially suited to a particular application. This type of embodiment also lends itself well to experimentation required to determine optimum louver spacing in a particular application. The spacers 46 may all be of the same length as shown in FIG. 6, or may be graduated in size along the length of a light fixture. Once the optimum uniform or graduated spacing has been determined, the lower cost injection molding method described above may then be used to mass-produce assemblies having the optimum spacing.
According to the third embodiment shown in FIGS. 7-9, the louvers 12 ″ are interconnected by upper and lower elongated support shafts 50 , 52 to form a louver assembly 22 ″. The louver assembly 22 ″ is split longitudinally to form interconnectable first and second louver assembly portions 54 , 56 . The upper and lower support shafts 50 , 52 are connected to each louver 12 ″ at respective diametrically opposite locations relative to the circular through-hole 18 ″ in each louver 12 ″ and adjacent respective upper and lower edges 32 ″, 34 ″ of each louver 12 ″.
The upper support shaft 50 is rectangular in cross section and is split vertically and longitudinally to form interconnectable first and second elongated upper support shaft portions 58 , 60 . Likewise, the lower support shaft 52 is rectangular in cross-section and is split vertically and longitudinally to form interconnectable first and second elongated lower support shaft portions 62 , 64 . The upper and lower support shaft portions 58 , 60 ; 62 , 64 are interconnectable along their respective lengths to form the respective upper and lower support shafts 50 , 52 and to interconnect the first and second louver assembly portions 54 , 56 forming the first louver assembly 22 ″.
The first and second upper support shaft portions 58 , 60 include fastener holes 66 , 68 at corresponding spaced-apart locations along their respective lengths. As best shown in FIGS. 8 and 9, the fastener holes 66 of the first upper support shaft portion 58 are coaxially aligned with the fastener holes 68 of the second upper support shaft portion 60 . Likewise, as is best shown in FIG. 9, the first and second lower support shaft portions 62 , 64 include fastener holes 70 , 72 at corresponding spaced-apart locations along their respective lengths. The fastener holes 70 of the first lower support shaft portion 62 are coaxially aligned with the fastener holes 72 of the second lower support shaft portion 64 . As shown in FIG. 7, rivets 74 or other suitable fasteners are disposed in the aligned holes 66 , 68 ; 70 , 72 of the upper and lower support shaft portions 58 , 60 ; 62 , 64 and hold the first and second portions of the upper and lower support shafts 50 , 52 together around the tubular sleeve 16 ″.
The louver assembly 22 ″ is configured to connect end-to-end with adjacent identical louver assemblies as shown in FIG. 8 . The window glare reducing assembly includes as many of these interconnectable louver assemblies 22 ″ as are required to cover whatever length tubular light source is required for a particular application.
As best shown in FIGS. 7 and 8, the first and second portions 58 , 60 of the upper support shaft 50 of each louver assembly 22 ″ are longitudinally offset from each other. As is also best shown in FIGS. 7 and 8, the first and second portions 62 , 64 of the lower support shaft 52 of each louver assembly 22 ″ are longitudinally offset from each other. Consequently, at each end of each louver assembly 22 ″, upper and lower support shaft end sections 76 , 78 that extend from endmost louvers 12 ″ of each louver assembly 22 ″, each include first and second end section portions 80 , 82 ; 84 , 86 that differ in length. In other words, one end section 80 , 84 of the each support shaft portion of each louver assembly 22 ″ extends farther than does the corresponding end section 82 , 86 of the mating support shaft portion.
As shown in FIG. 8, the longer end sections 80 , 84 of the upper and lower support shafts 50 , 52 of one louver assembly 22 ″ are configured to overlap and connect via rivets or other suitable fasteners to the longer end sections 80 , 84 of the upper and lower support shafts 50 , 52 of an adjacent louver assembly 22 ″ while abutting the shorter end sections 82 , 86 of the upper and lower support shafts 50 , 52 of the adjacent louver assembly 22 ″.
In practice, a windshield glare-reducing assembly constructed according to the third embodiment shown in FIGS. 7-9 can be assembled by first molding the interconnectable first and second louver assembly portions 54 , 56 as separate pieces. The first and second louver assembly portions 54 , 56 are then interconnected around the tubular sleeve 16 ″ such that the individual louvers 12 ″ of the louver assembly 22 ″ are supported in an axially spaced-apart disposition along the sleeve 16 ″. A fluorescent bulb or other suitable elongated cylindrical light source is then slid into the sleeve 16 ″. The fluorescent bulb and surrounding tubular sleeve 16 ″ and louver assembly 22 ″ are then installed in the light fixture by plugging axially opposite ends of the fluorescent bulb 16 ″ into respective bulb sockets in a light fixture.
This description is intended to illustrate certain embodiments of the invention rather than to limit the invention. Therefore, it includes descriptive rather than limiting words.
Obviously, it's possible to modify this invention from what the description teaches and one may practice the invention other than as described. | A windshield glare-reducing assembly includes a tubular sleeve configured to receive an elongated light source such as a fluorescent lamp. Louvers are supported along the sleeve so as to fit closely around such a lamp without touching or being mounted directly on the lamp. The louvers are shaped, spaced and positioned to reduce the amount of light emitted from the lamp towards a vehicle windshield and then reflecting from the windshield into the driver's eyes. The sleeve is shaped to allow the sleeve and louvers to be easily installed on and removed from a lamp and to ease replacement of burned-out and damaged lamps. | 6 |
FIELD OF INVENTION
This invention relates generally to fly fishing and more particularly to a multi-strand, twisted, tapered, leader made from a single length of monofilament line as well as a method of making such leader and an apparatus for making the twisted leader. The strands of the leader are twisted together except for a minor portion at each of opposite ends thus providing a multi-strand, twisted, tapered, leader having integral therewith a loop at each of opposite ends thereof.
BACKGROUND OF INVENTION
Fly fishing is enjoyed by many and quality manufactured equipment is available. Fishermen in some instances hand make their own flies. The rest of the equipment including leaders is commercially premanufactured.
Fly line leaders that are braided are known and for this reference may be had to pages 48 and 49 of a catalogue of the Orvis Company Headed "Orvis® Spring Fishing and Outdoor 1995 Authentic Products of Lasting Quality for Over 100 Years".
The known braided leader has excellent fishing characteristics, but it is expensive because it requires complicated and expensive factory installed machinery to manufacture the same. This known leader has a loop at each of opposite ends thereof, one for attaching to the loop end of the fly line and the other for attaching thereto the loop end of the tippet. To form these loops the leader end portion is folded back upon itself and the free end interwoven with or braided into the main length of the line. This results in an enlargement in the line near the loop end.
These known leaders are available in specific lengths of 71/2, 9, 12 and 16 feet.
SUMMARY OF INVENTION
An object of the present invention is to provide a leader that is simple and inexpensive to manufacture and yet has excellent fishing characteristics.
A further object of the present invention is to provide improved characteristics in a leader made from a monofilament line.
A still further object of the present invention is to provide a simple easy way to make a fly fishing leader whereby the individual fisherman can make his own as needed and with characteristics desired by that individual.
A still further object of the present invention is to provide a relatively inexpensive leader that can be individually custom made incorporating characteristics as dictated by the fish to be caught and/or the fishing conditions as well as in any reasonable length that may be desired.
A still further object of the present invention is to provide a simple apparatus for making applicant's twisted tapered leader.
LIST OF DRAWINGS
FIG. 1 is a diagrammatic elevational view representing step one in making a leader from a single length of monofilament line;
FIG. 2 is a diagrammatic elevational view of the monofilament line attached to a twister mechanism and represents steps 2 and 3 in making the leader;
FIG. 3 is a diagrammatic view representing step 4 in making the leader;
FIG. 4 is similar to FIG. 3 representing step 5 in making the leader;
FIG. 5 is a top plan view of the twister mechanism taken essentially along line 5--5 of FIG. 3;
FIG. 6 is a sectional view taken essentially along line 6--6 of FIG. 5;
FIG. 7 is a view of a partially completed twisted leader of the present invention; and
FIG. 8 is a view of a completed twisted tapered leader of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the drawings FIG. 1 illustrates a single length of monofilament line 10 suspended from a fixed in position anchor hook 20. The monofilament line 10 has respective opposite ends 11 and 12 and mid-way therebetween the length of monofilament line is looped one and one half times (i.e. 540°), as indicated at 13, around the anchor hook 20. The monofilament line, preferably nylon, thus as illustrated has respective first and second strand parts 14 and 15 each of which is approximately half the length of the single stand 10.
A twister mechanism 30, to be described in more detail hereinafter, is diagrammatically illustrated in FIGS. 2, 3 and 4 with certain operative details thereof shown in FIGS. 5 and 6. The twister mechanism 30 is shown in its simplest form comprising a drive gear 31 meshing with a pair of planetary gears designated respectively 32 and 33. These gears are located within a suitable casing or housing 34 and by any suitable bearing means are journalled for rotation on the housing. The planetary gears 32 and 33 have respective centrally disposed recesses or through holes 35 and 36 into which the ends 11 and 12 can be inserted. The strand ends 11 and 12 are anchored to the planetary gears by suitable wedging mechanisms, for example a tapered pin such as a toothpick, designated respectively 41 and 42.
Gear 31 of the twister mechanism has a drive shaft 37 secured thereto and projecting therefrom beyond the casing and which can be readily inserted into the chuck 40 of an electric power drill.
Referring now back to FIG. 2, with the ends 11 and 12 anchored to the respective planetary gears (described briefly above with reference to FIG. 6) gear 31 is driven via shaft 37. The sun gears 32 and 33 rotate (both in the same direction as best seen with regard to the gear rotation arrows 55 illustrated in FIG. 5) providing a twist to the respective strand parts 14 and 15 in the same direction as seen from strand rotation arrows 56 in FIG. 2. By way of example a twist of about 200 revolutions per meter length of nylon strand has been found to be suitable. The amount of twist can vary substantially depending upon the characteristics desired for the leader. Less twist provides a softer leader and one with less mass while more twist results in a stiffer leader and one with greater mass. By selecting the amount of twist and/or the diameter of the monofilament line, which can vary from 0.1 mm to 0.5 mm, one can make a leader with desired characteristics. Each leader can thus also be adapted to the fly line which can vary from a #2 to a #14. The weight of unit 30 (or weights attached thereto) is sufficient to keep the twisted strands 14 and 15 straight. Typically the unit will be from 4 to 6 ounces in weight.
With strand parts 14 and 15 each twisted the desired amount and with a hook 50 inserted into the loop lower portion 13a (FIG. 2), the hook is pulled down and attached to the twister mechanism. By way of example the hook 50 may have a threaded stem 51 which threads into a threaded recess 38 in the gear 31. This is diagrammatically illustrated in FIG. 3 and with reference to the same the strand part 14 has now become strand portions 14a and 14b and strand part 15 has become strand portions 15a and 15b. Each strand portion is approximately one quarter the length of the initial single strand and each strand portion has an equal amount of twist. It will be apparent there are in this illustrated embodiment four strand portions to be twisted together.
With the arrangement as illustrated in FIG. 3 the free hanging leader twister mechanism 30 (suspended from the hook 20 by the four twisted strand portions) is allowed to rotate freely and it is permitted to do so until it comes to rest. The direction of rotation as seen by rotation arrow 57 in FIG. 4 is opposite to that of the initial twist in the strand parts 14 and 15. Created by the foregoing is a multi strand leader with a loop 60 at one end provided by two strand portions 14a and 15a merging as continuations thereof into respective strand portions 14b and 15b. At the other end there is a loop 70 where strand portion 14b merges into strand portion 15b. The other two strands terminate adjacent loop 70 in the free ends 11 and 12.
The strand portions which have been twisted together form a twisted leader of a desired preselected length from a single length of monofilament line with such single length providing a loop at the respective opposite ends of the leader. The leader may be in the range of from 1' to 20' in length. The thus formed leader is illustrated in FIG. 7 and in reference to the same there is the loop 60 at one end and the loop 70 at the other end. The strand ends 11 and 12 are secured to the leader by for example knotting, e.g. a needle knot, or otherwise suitably anchored to prevent unravelling. Before being secured these ends 11 and 12 are preferably unravelled back to different lengths to provide a tapered leader which comprises four strands, then three strands, then two strands all formed from the single length of monofilament line.
The finished product is diagrammatically illustrated in FIG. 8. The tapered leader comprises a first portion from A to B of four strands, a second portion from B to C of three strands and a third portion from C to D of two strands. Integral with the leader are loops 60 and 70 at respective opposite ends thereof.
The term integral herein, with reference to the loops, is meant to exclude constructions of forming loops by knotting, tying or interweaving. The loop is the result of the path followed by the single length of monofilament line from one end 11 to its other opposite end 12, i.e. a portion in the transition from one strand portion to the next.
The leader of the present invention can readily be made by a fly fisherman to suit his needs. The number of turns per meter length of line can be varied so that the leader may be soft or stiff or most anything therebetween. Nylon monofilament line can be purchased as a limp line or a stiff line or most anything therebetween. The nylon as mentioned can also be purchased in diameters ranging from 0.1 mm to 0.5 mm. The maker of the leader can experiment using these different variables to construct a leader having characteristics as may be desired.
The twister mechanism is a simple device that might for example be 2" in diameter, have a thickness of 1/2" to 3/4" and weigh about 4 ounces to 6 ounces.
The casing 34 comprises a pair of plates 34a and 34b held in spaced relation by a spacer 34c. The spacer 34c may be a continuous wall, i.e. an annular sleeve or a number of posts and the unit is held together by a number of threaded fasteners 34d or other suitable means. The gears have hubs that project into recesses or pass through apertures in the plates. The plates and gears may be metal and nylon bushings may provide suitable journals for the gear hubs. Alternatively the gear hubs themselves may be made of a nylon material or the gear hubs may be metal and the plates made of nylon.
The leader described and illustrated in the foregoing comprises four strands twisted together with those four strands being provided by a single continuous length of a monofilament line fold upon itself. There may be additional strands if desired and additional planetary gears may be added to the twister mechanism permitting twisting those additional strand lengths. Thus one can make a leader with more than four strands, e.g. 6, 8 or even more.
Some advantageous features of the present invention include:
1. The leader is better balanced in mass and flexibility to the fly line than any leader on the market today;
2. It has a loop-to-loop system without the use of any extra components like braided end loops;
3. The action of the leader can be chosen according to application by using limp or stiff nylon material or a combination of both;
4. The leader can be produced by the individual fisherman to his own liking;
5. A self produced leader is inexpensive;
6. The leader has extraordinary floating quality because of the locked air in the twisted surface of the leader; and
7. The leader has extraordinary sinking quality when the surface of the leader material before twisting and the twisted surface of the leader is coated with sinking material. | A fly line leader made from a single length of monofilament line that is folded upon itself to provide at least four strand portions that are twisted together. The leader has a loop at each of opposite ends thereof provided by the single length of monofilament line with the result of no enlargement at the transition from the main portion of the leader to the loop. The monofilament line preferably is nylon with a cross-sectional diameter in the range of 0.1 mm to 0.5 mm. A simple twister mechanism is described whereby the fisherman can make his own leader matched to his own preferences by selection of line stiffness, line diameter, and degree of twisting. | 0 |
BACKGROUND OF THE INVENTION
1. Technical Field:
This device relates to windmill type apparatus that convert air velocity and movement into mechanical motion that can be used for a variety of useful pursuits. Multiple shaped blades are driven by &he wind usually in a rotary fashion and can be combined with gear reduction units to enhance the power output therefrom.
2. Description of Prior Art:
Prior Art devices of this type have relied on a variety of different blade and airfoil designs that are engaged and moved by the wind, see for example U.S. Pat. Nos. 3,895,872, 4,097,190 and U.S. Pat. No. 4,347,036.
In U.S. Pat. No. 3,995,972 a wind machine with reciprocating blades is disclosed which has a plurality of reciprocating blades that move vertically on a pair of spaced guide rods. Each blade is pivoted about its longitudinal axis mounting means and is correspondingly directionally reversed by changing its angle of attack about its pivot point by a resilient cushion engaging the blade at its maximum point of travel within the cycle.
U.S. Pat. No. 4,097,190 discloses a wind motor having blade rotating on a crank assembly with an offset counter weight. The blade is characterized by a power stroke and a return stroke driving the blade and associated counter weight crank assembly around a drive axle.
U.S. Pat. No. 4,347,036 describes a fluid energy converter method and apparatus in which the kinetic energy of moving air is converted into useful motion. A plurality of vertically aligned and spaced airfoils utilize a flutter phenomenon in which a rapid flutter oscillation of the foil occurs within a limited parameter which can be achieved with less wind velocity required than for a single large movable blade. A control system is used in which each foil has a pair of electrical coils to generate alternating current by their rapid oscillation within a modified armature.
SUMMARY OF THE INVENTION
A single airfoil device to convert air flow into useful mechanical motion using a variable angle of attack airfoil dependent on the reciprocal vertical direction of the foil within a restricted guide &rack. Pivoted off center cranks and connecting rods affixed to the foil to vary the attack angle within the reciprocal motion.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the wind device in operation;
FIG. 2 is an enlarged broken away view on lines 2--2 of FIG. 1;
FIG. 3 is a diagramacal illustration of the travel pass of the airfoil and related crank assembly position;
FIG. 4 is an enlarged broken away perspective view of a portion of the airfoil and related crank assembly; and
FIG. 5 is a diagramacal illustration of the variation of angles of attack of the airfoil and relative crank positions during movement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 of the drawings, a wind device can be seen having a support frame 10 comprised of a rectangular support base 11 having spaced parallel rails 12 and 13 and a pair of interconnecting end rails 14 and 15 secured to the respective free ends of said parallel rails 12 and 13 with a plurality of support legs 16, each of which extends from the intersection of said above referred to rails. Diagonal braces 17 interconnect and stabilize each of said legs 16 with the rectangular support frame 11 as is well known in the art. A pair of transversely extending cross members 18 and 19 are positioned on said rectangular support base 11. A axle 20 is rotatably secured to the cross members 18 and 19 and will become, under operational conditions, the power take off to be used to drive any type of associated mechanism required.
A pair of oppositely disposed track supports 21 and 21A extend vertically from the respective rails 14 and 15 midway along their length and have vertically ascending guide tracks 22 and 23 respectively extending therefrom. Each of said guide tracks has parallel U-shaped channels facing one another with multiple interconnecting brackets 24 holding said U-shaped channels in spaced parallel relation to one another.
Referring now to FIGS. 1, 2, 4 and 5 of the drawings, an airfoil 25 can be seen having a longitudinal spar 28 and a number of spaced contoured ribs 27 along its length. Each of the contoured ribs 27 defines in cross-sectionally distinctive wing shape of the foil which is characterized by a rounded leading edge 28 and a tapered trailing edge 29. The wing shape is symmetrical in cross-section and as such requires no further explanation or descriptions to those skilled in the art.
The contoured ribs 27 are encased with a surface forming material defining the airfoil's surface S. A guide reel 30 and axle assembly 31 extends independently from the respective free ends of said spar 26 and are of a determined size so as to register within the adjacent guide tracks as best seen in FIG. 2 of the drawings affording free vertical and axial movement of said airfoil 25 within the guide tracks 22 and 23.
A airfoil support assembly 32 comprises a pair of crank arms 23 each secured to the respective free ends of said axle 20. The contoured weight 34 is affixed to the other end of each of said crank arms 33 and connecting rods 35 are pivotally secured to the respective free ends of said crank arms 33. Each of the connecting rods 35 are affixed to the airfoil spar. 26, as best seen in FIG. 4 of the drawings.
Referring now to FIGS. 1, 3, and 5 of the drawings, the operation of the wind device is as follows. Upon engagement with a wind flow the airfoil 25 moves vertically either up or down dependent on the airfoil's position since the foils angle of attack is fixed around 12° either up or down depending on the position of the connecting rods relative the crank arms 33. As the airfoil moves down at D1, its angle of attack is 12° downwardly. As the airfoil reaches its lowest point at D2 the angle of attach is momentarily neutral as it passes D2. The angle of attack changes to 12° upwardly as the crank arm responds to the counter weight 34 moving the airfoil to a U1 position. The angle of attack changes again at the airfoil's highest point at U2 then being forced downwardly by the wind on the foil itself.
It will be evident from the above description that the airfoil is engaged and moved by the air flow over it between its lowest point at D2 and the highest point at U2, thus powering the airfoil and associated crank ar assembly within the limits of same and said guide tracks.
Referring, again, to FIG. 5 of the drawings the interim airfoil positions are indicated for both directions by 36D illustrating graphically the relative angles of attacks of the airfoil as it travels both upwardly in its vertical track and downwardly as hereinbefore described.
it can thus be seen that by the use of the off center crank which is rotatably secured midway along its length to the axle 20 that the connecting arms 33 are pivotally secured to the crank arm's free end thus defining a circular motion which when transferred into a restrictive vertical plane as defined by the restrictive vertical travel in the guide tracks of the airfoil will vary the airfoil s angle of attack by the nature of the crank configuration.
It is by this combination that the airfoil can, in reality, change its relative angle of attack to the air stream on its alternating reciprocating vertical strokes utilizing the force of the air against the respective surface S of the foil. The foil and associated support assembly are balanced by the counter weight to neutral no wind position shown in FIG. 5 at N.
Such a device, once activated, will maintain the vertical oscillations within the guide track provided as long as there is a constant air flow of a determined strength across its airfoil surface.
It will be evident that due to the foil's supporting structure that the actual angle of attack will change on each stroke as described above. A relative angle of attack for the foil into the airstream is inherent in the foils shape and fixed position will change as the air speed verses oscillation or foil reciprocation increases. Thus as the vertical oscillation accelerates, the efficiency of the foil decreases reaching a maximum oscillation speed thereby governing itself.
Thus, it will be seen that a new and novel windmill device has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention. | An apparatus for converting air flow into mechanical motion using a single variable direction airfoil movable within a vertical track. Change in vertical direction of the airfoil and associated angle of attack is self-determined within a pre-set range dependent on work requirement. | 5 |
TECHNICAL FIELD
The invention relates to a vane pump for supplying fuel, the pump having associated means for regulating the pressure of fuel supplied by the vane pump. In particular, the invention relates to a vane pump for supplying fuel under pressure to a fuel injection pump.
BACKGROUND OF THE INVENTION
In diesel engines, it is usual to use a transfer pump to supply fuel under pressure to a diesel fuel injection pump. The fuel pressure supplied to the fuel injection pump must be regulated and, in mechanically driven fuel injection pumps, this can be done by using a rotary vane pump as the transfer pump. An associated pressure regulator serves to control the fuel pressure supplied to the fuel injection pump from the outlet of the vane pump.
One type of conventional vane pump comprises a driven rotor arranged within a cylindrical member, commonly referred to as a liner, the liner having a non circular bore arranged eccentrically to the centre line of the driven rotor. The rotor rotates within the liner between two closure plates, an upper closure plate, commonly referred to as the distribution plate, and a lower plate. Apertures within the upper and lower closure plates define an inlet port and an outlet port within the vane pump housing.
Fuel is introduced into the vane pump through the inlet port and is carried around the pump by means of blades extending from the rotor and biased towards the inner surface of the liner. Fuel from the outlet port is supplied to a regulator arranged remotely from the vane pump which serves to regulate the fuel pressure supplied to a downstream fuel injection pump by recirculating some of the fuel from the vane pump outlet back into the vane pump inlet.
The regulator usually consists of a cylindrical body housing a spring biased piston. It is necessary to form several drillings within the regulator body to accommodate the piston and to provide the channels required to effect the regulatory function of the device. Where the regulator body is within a housing common to the vane pump and/or the fuel injector pump itself, it is also necessary to form additional drillings in the housing. The construction of a conventional vane pump is therefore complex and manufacture is difficult and expensive. In addition, the device can be bulky as the regulator is arranged remotely from the rotary part of the vane pump.
It is an object of the present invention to provide a vane pump of reduced complexity which alleviates the manufacturability problems of the prior art. It is a further object of the present invention to provide a vane pump which has a reduced size.
According to the present invention, there is provided a vane pump, having an inlet for receiving fuel and an outlet from which fuel is supplied, comprising;
a generally cylindrical member;
a driven rotor arranged within the cylindrical member; and
a closure member, the cylindrical member and the closure member co-operating to define a recirculation passage interconnecting said outlet and said inlet, the output pressure of fuel discharged from the pump being regulated by resiliently biased valve means controlling the flow of fuel through said recirculation passage.
In one embodiment of the invention, the closure member may form part of the pump housing.
The cylindrical member may have a first channel defined therein co-operating with a second channel defined in the closure member, the first and second channels defining the recirculation passage.
Alternatively, the recirculation passage may be defined by a channel formed in the cylindrical member, the closure member cooperating with the cylindrical member to define an inner surface of the recirculation passage.
As the only machinings required for the regulatory function are the first and second channels within the closure member and the cylindrical member, the vane pump of the invention is considerably less complex than a conventional vane pump, therefore providing advantages in terms of manufacturing difficulty and cost. Additionally, as the means for regulating the fuel pressure are arranged within the cylindrical member and closure member assembly, the vane pump is of reduced size.
The valve means may be in the form of a compression spring housed within the recirculation passage, the spring biasing an abutment member into communication with an opening of the recirculation passage to control the flow of fuel supplied to the recirculation passage. Conveniently, the abutment member may be a ball.
In an alternative embodiment, the biasing means may be a leaf spring biased into communication with an opening of the recirculation passage to control the flow of fuel supplied to the recirculation passage. In a further alternative embodiment, the vane pump may comprise a third passage defined within the cylindrical member and communicating with the recirculation passage, the supply of fuel to the third passage being regulated by means of a piston member operating under a spring biasing force. This embodiment is particularly useful for supplying fuel to a mechanically driven fuel injection pump, requiring a speed dependent fuel pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example only, with reference to the following drawings in which;
FIG. 1 is a diagram of a conventional vane pump, including a regulator for regulating the fuel pressure supplied by the vane pump;
FIG. 2 is a diagram of a vane pump in accordance with one embodiment of the present invention;
FIG. 3 is a cross-sectional view on a line X—X of the vane pump shown in FIG. 2; and
FIGS. 4 and 5 are similar cross-sectional views to FIG. 3 of first and second alternatives.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a conventional vane pump, referred to generally as 10 , comprises a cylindrical liner 12 and an inlet port 14 for receiving fuel from an associated fuel tank (i.e. in the direction of arrow 16 ). The pump also comprises a rotor 18 which is usually driven by the driveshaft driving an associated fuel injection pump (not shown) to which the vane pump supplies fuel. The rotor 18 carries blades 20 maintained in contact with the inner surface of the liner 12 by means of a spring 22 ; fuel pressure at their radially inner ends, centripetal forces, or a combination of all three. Fuel is introduced at the inlet 14 and, as the blades 20 are rotated past the inlet 14 , fuel becomes trapped in a gap 24 between the liner 12 and the rotor 18 and fuel is carried by the blades 20 as the rotor 18 rotates.
Eventually, the blades uncover an outlet port 26 such that fuel is expelled from the vane pump in the direction of arrow 28 . Fuel is then either supplied to the downstream fuel injection pump or is returned to the vane pump inlet 14 through a regulator 30 . The regulator 30 serves to regulate the fuel pressure supplied to the fuel injection pump by returning some of the fuel expelled from the outlet 26 to the inlet 14 .
The regulator 30 comprises a body 38 , housing a piston 34 biased by a spring 36 , and a retention cap 32 . In order to construct the regulator 30 it is necessary to form several drillings in the regulator body 38 and also in the fuel injection pump downstream. Thus, the construction of the vane pump is complex and manufacture is difficult. The vane pump arrangement, including the regulator, is also rather bulky.
FIG. 2 illustrates a vane pump of the present invention, into which fuel is introduced at the inlet 14 , as indicated by arrow 46 . The vane pump comprises a rotary member 18 carrying blades 20 biased into contact with the inner surface of a cylindrical member 50 , commonly referred to as the vane pump liner. The liner 50 has a non circular bore arranged eccentrically to the centre line of the rotor 18 . The inlet 14 and the outlet 26 may be defined in an upper closure plate or closure member (not shown in FIG. 2 ), commonly referred to as a distribution plate, facing the closure member or closure plate 56 (as shown in FIG. 3) and located on the opposite side of the rotor 18 to the closure plate 56 . Alternatively, the inlet 14 and the outlet 26 may be defined by apertures in the upper and lower closure plates. In addition, a partial inlet and outlet may be defined within the liner 50 .
The blades 20 carried by the rotor 18 are biased into contact with the liner 50 by means of a spring 22 , fuel pressure at their radially inner ends, centripetal forces, or a combination of all three. As the blades 20 move with the rotor 18 past the inlet 14 , fuel becomes trapped in the gap 24 defined by the liner 50 and the rotor 18 between adjacent blades 20 . Due to the shape of the liner 50 , fuel is expelled through the outlet 26 when blade rotation causes the outlet 26 to be uncovered. Fuel expelled from the outlet 26 either exits the vane pump, in the direction of arrow 48 , to a fuel injection pump located downstream (not shown) or is recirculated back to the inlet 14 by means of a recirculation passage 49 defined partly within the liner 50 .
The construction of the recirculation passage 49 can be seen more clearly in FIG. 3 which shows a cross-sectional view on the line X—X of the vane pump shown in FIG. 2 . The liner 50 is cooperably engaged with a lower closure plate 56 . The liner 50 has a channel or groove 52 defined therein, the channel 52 being formed in the axial end-face of the liner 50 . The closure plate 56 has a channel or groove 54 defined in its uppermost face which, together with the channel 52 , defines the recirculation passage 49 for fuel at the vane pump outlet 26 . A spring 58 is housed within the recirculation passage 49 and biases a ball 60 into a seating 62 such that the ball 60 closes an opening 64 to the channel 52 , thus preventing the flow of fuel into the channel 52 , and hence the recirculation passage 49 , from the outlet 26 .
At a predetermined pressure of fuel at the outlet 26 , acting on the ball 60 through the face of the opening 64 , the force of the spring 58 is overcome and the ball 60 is moved out of the seating 62 allowing fuel to flow through the passage 49 from the pump outlet 26 , thus serving to regulate the amount of fuel recirculated to the pump inlet 14 . As the fuel pressure at the outlet 26 decreases, the force applied to the ball 60 is reduced and, when the biasing force of the spring 58 overcomes the force of the fuel pressure, the spring 58 biases the ball 60 into communication with the seating 62 so that the opening 64 is closed to fuel. The spring-biased ball 60 therefore provides regulatory control of fuel entering the recirculation passage 49 and recirculating back to the inlet 14 . Fuel which does not enter the recirculation passage 49 is expelled from the outlet 26 (in the direction of arrow 48 in FIG. 2) for supply to the fuel injection pump downstream.
The arrangement of the recirculation passage 49 within the cylindrical liner 50 and the closure plate 56 , and the spring-biased ball 60 provides a simplified means of regulating the fuel pressure supplied by the vane pump. In particular, channels 52 , 54 in the cylindrical liner 50 and the closure plate 56 are simpler to form than the complex arrangement of passages required in a conventional regulator.
A second embodiment of the invention is shown in FIG. 4 and comprises a leaf spring 70 housed within the channel 52 of the liner 50 . The leaf spring is biased into contact with a seating 72 within the channel 52 and serves to regulate the amount of fuel recirculating back through the recirculation passage 49 in a similar way as described in relation to FIG. 3 . Thus, when the pressure of fuel at the vane pump outlet 26 , and thus opening 64 , overcomes the biasing force of the leaf spring 70 , the spring 70 is moved away from the seating 72 to allow fuel to enter the recirculation passage 49 . In this way, the pressure of fuel expelled from the vane pump to the fuel injection pump downstream can be regulated.
A third embodiment of the invention is shown in FIG. 5, in which regulation of fuel pressure is provided by means of a piston member 82 , or plunger, biased into contact with a seating 84 defined in the channel 52 by means of a spring 86 . As the fuel pressure at the outlet 26 of the vane pump increases, the force applied to the end-face of the piston 82 increases until, when the spring force is overcome and the piston 82 is moved away from the seating 84 , fuel is able to enter a secondary passage 80 , defined in the body of the cylindrical liner 50 , the passage 80 being in fluid communication with the recirculation passage 49 .
The degree of movement of the piston 82 away from the seating 84 provides graduated regulatory control of fuel entering the secondary passage 80 . The spring-biased piston 82 thereby serves to control the amount of fuel recirculating through the recirculation passage 49 to the inlet 14 of the vane pump, thus regulating the fuel pressure supplied by the vane pump to the fuel injection pump downstream.
The embodiment shown in FIG. 5 is particularly suitable for supplying fuel to a mechanically controlled fuel injection pump requiring a speed dependent pressure signal, such as may be used for advance control and inlet metering purposes.
It is envisaged that other forms of biasing means may be provided within the recirculation passage 49 to control the amount of fuel recirculated to the inlet 14 and the invention need not be limited to the embodiments hereinbefore described.
It will be appreciated that the recirculation passage 49 need not be defined by channels or grooves formed in both the cylindrical liner 50 and the closure plate 56 , but may be defined by a single channel in the cylindrical liner 50 , the closure plate 56 defining an inner surface of the recirculation passage 49 by means of its engagement with the axial end-face of the liner 50 . Thus, the surface of the closure plate 56 closes the channel in the cylindrical member to define the recirculation passage 49 with the channel formed in the liner 50 . A recirculation passage formed in this way is suitable for use with lower fuel flow rates, or if a wider recirculation passage is employed, for example if the outer diameter of the liner is relatively large. | A vane pump, having an inlet for receiving fuel and an outlet from which fuel is supplied, comprising a generally cylindrical member, a driven rotor arranged within the cylindrical member and a closure member. The cylindrical member and the closure member co-operate to define a recirculation passage interconnecting the outlet and the inlet, the output pressure of fuel discharged from the pump being regulated by a resiliently biased valve means controlling the flow of fuel through said recirculation passage. | 5 |
This application is a division of application Ser. No. 09/785,707 filed on Feb. 16, 2001 now U.S. Pat. No. 6,461,081.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is generally related to a lift boat or jack-up rig and more particularly to the mechanism for raising and lowering the legs of a lift boat or jack-up rig.
2. General Background
In offshore work related to the search for and production of oil and gas, a variety of vessel types are used. One type is a lift boat. A lift boat is a vessel that can elevate itself out of the water so as to provide a stable platform at the appropriate elevation to perform a number of marine construction tasks. Lift boats are equipped with retractable legs that each has a footing at the bottom. The footings contact the bottom and are of sufficient size to support the vessel on the seabed. The number of legs can vary from three to as many as six. One or more cranes are fixed to the deck of the vessel and are used to lift equipment onto or off of oil drilling or production platforms. A larger version of the lift boat called a jack-up rig typically is outfitted with drilling equipment. From this point on all mention of lift boats shall also be understood as including jack-up rigs.
At least one gear rack is typically incorporated into each leg of a lift boat. The legs of a lift boat are either constructed as a lattice type or as a tubular type. One or more pinion assemblies operate along each gear rack. A pinion assembly typically consists of a pinion, gear box, braking mechanism and either an electric or hydraulic motor. The pinion assemblies are either rigidly fixed to the vessel or can be of the floating type. As the pinions of the lift boat rotate, the lift boat is either raised out of the water or lowered toward the surface of the water depending upon the direction of pinion rotation.
The legs can be somewhat self-centering if multiple gear racks are used on the legs and if the gear racks are arranged properly. Even if the racks are ideally numbered and positioned some side loading of the legs will occur due to sea, wind, and vessel loading conditions. The current generation of lift boats employs a linear metal bearing guide to restrict leg movement. This guide system consists of metal bearing strips attached to the vessel or to the jacking apparatus. The guides may ride along the gear rack, the leg cords, or attachments to either the leg or gear rack. Smaller lift boats have leg towers constructed from tubular members and have tubular legs with outside diameters slightly smaller than the inside diameters of the leg towers. The leg tower is the sole guide. The shortcomings of these types of guide apparatus are that friction between the leg and guides increases the jacking force required to operate the lift boat and much of the lubricant used on the guides is dropped into the sea.
SUMMARY OF THE INVENTION
The present invention addresses the above needs in a straightforward manner. What is provided is an apparatus for efficiently guiding the legs of a lift boat. Roller assemblies are used to guide the legs. The rollers may be placed at any location or in any number either vertically or around the leg to adequately center the leg. The roller can either have a metal surface that rolls along the leg or be coated with a resilient material. The base of the roller can either be rigidly mounted to the vessel or incorporate resilient material between the roller and the vessel. A means of adjusting the clearance between the leg and roller may be incorporated in the roller assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention reference should be made to the following description, taken in conjunction with the accompanying drawings in which like parts are given like reference numerals, and wherein:
FIG. 1 is an isometric view of a lift boat.
FIG. 2 is a detail view of a jacking and guide apparatus.
FIG. 3 is an isometric view of the guide roller assembly.
FIG. 4 is an exploded view of the guide roller assembly.
FIG. 5 illustrates an alternate embodiment of the invention.
FIG. 6 is a detail view of the alternate embodiment of FIG. 5 .
FIG. 7 is a detail view of another alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, it is seen that a typical lift boat is generally indicated by the numeral 10 . For ease of illustration the lift boat's deckhouse, cranes and all deck equipment have been omitted. The lift boat is generally comprised of a hull 12 and a plurality of legs 14 . The hull 12 is a buoyant hull that has sufficient buoyancy to support the hull, legs, and any equipment placed on the hull. As seen in FIG. 1, the lift boat is elevated above the water's surface 30 . As seen in FIG. 2 each leg 14 is received through a leg well 34 provided near each corner of the hull 12 . The outer diameter of each leg 14 is less than the diameter of the leg well 34 so as to be movable through the hull 12 . Although only a tubular column 20 is shown, it should be understood that the legs 14 may be formed from either a tubular or lattice column. Each leg 14 is provided with a rack 22 and a footing 24 . The legs 14 may have singular or multiple racks 22 . The leg 14 is raised and lowered through the hull 12 by a pinion tower 18 . Each rack 22 may have singular or multiple pinions 32 . Multiple pinion towers 18 may be separately attached to the hull 12 or may be integrated into a unit attached to the hull 12 . The footings 24 are of sufficient size to provide resistance to the seabed 28 to allow the pinion tower 18 to elevate the hull 12 above the surface of the water.
Referring to FIGS. 2-4, it is seen that the invention is generally indicated by the numeral 26 . Guide roller apparatus 26 is generally comprised of a support box 36 , a pivot arm 38 and a roller 40 .
The support box 36 is formed from two or more support box side plates 42 that are attached to a support box back plate 46 and a support box bottom plate 44 . A support box pin 48 connects the pivot arm 38 to the support box 36 . A keeper 50 prevents the support box pin 48 from sliding out of the support box 36 . The keeper 50 is attached to the support box 36 by any suitable means such as by welding, mechanical fastener, or by the use of an adhesive.
The pivot arm 38 is of suitable shape to transfer forces from the leg 14 to the hull 12 . The pivot arm 38 is formed from two or more pivot arm side plates 52 that are attached to a pivot arm back plate 68 . A pivot arm pin 56 connects the roller 40 to the pivot arm side plate 52 . A keeper 51 prevents the pivot arm pin 56 from sliding out of the pivot arm side plates 52 .
The roller 40 is of suitable shape to transfer forces from the leg 14 to the hull 12 . A bushing 58 , an inner core 60 , and an outer core 62 are assembled together to make up the roller 40 . The bushing 58 is of suitable shape and material to allow it, the inner core 60 , and the outer core 62 to rotate around pin 56 . The bushing 58 may be constructed of non-lubricated or lubricated material. The bushing 58 is attached to the inner core 60 by interference fit, bonded, or keyed to prevent relative movement. The inner core is constructed of suitable rigid material such as steel and attached to the outer core 62 by interference fit or bonded to prevent relative movement. The outer core 62 is formed from a suitable resilient material such as neoprene.
One or more spacer plates 64 are of suitable shape and material to transfer forces from the leg 14 to the hull 12 . Resilient plate 66 is of suitable shape and material to transfer forces form the leg 14 to the hull 12 . Spacer plates 64 may be of varying thickness and number to adjust the nominal distance between the roller 40 and the leg 14 from a clearance to a compressed pre-load. In a pre-load condition the resilient outer roller 62 and the resilient plate 66 are deformed so that during normal operating conditions there is no clearance between roller 40 and leg 14 .
The guide roller apparatus 26 may be securely attached to either the hull 12 , pinion tower 18 or, as seen in FIG. 2, to a guide roller tower 16 . The guide roller apparatus 26 may be the sole means of guiding the leg 14 or may be used in conjunction with bearing strips or any other suitable guide apparatus. The guide roller apparatus 26 may be set to a desired clearance or pre-load to the leg column 20 , rack 22 , or any attachment to either. The roller apparatus 26 is of sufficient size, number and location to adequately restrict the leg 14 to movement with the hull 12 . The guide roller tower 16 may be attached directly to the hull 12 or incorporated into the hull 12 , pinion tower 18 or other parts of the lift boat 10 .
In operation, as the legs 14 are moved up or down through the hull 12 , the guide roller apparatus 26 on each leg 14 confines each leg 14 to a near perpendicular orientation relative to the deck of the hull 12 . The advantage this provides is that it prevents any out of alignment movement, which decreases the efficiency of the driving system and increases the possibility of damage.
An alternate embodiment of the invention is generally indicated by numeral 70 in FIG. 5 and 6. Track guide apparatus 70 is generally comprised of track 92 , rail structure 90 , idlers 76 and rollers 86 . For ease of illustration, the hull and pinion tower are not shown.
A leg tower 74 is attached to the lift boat and is sized to allow movement of the leg 14 therethrough. The leg tower 74 is provided with an elongated opening 72 . Track guide apparatus 70 is attached to the leg tower 74 and contacts the leg 20 through the elongated opening 72 in the leg tower.
As best seen in FIG. 6, the track 92 is comprised of link plates 88 , link pins 78 , and track pads 84 traveling around idlers 76 . The force exerted upon the track 92 by the leg 20 is transferred to the rail structure 90 via the rollers 86 . The rollers may be of a similar design as shown in FIG. 4 or of any other design suitable to transfer the force. The rail structure generally indicated by numeral 90 is comprised of a rail 82 and rail flanges 80 . The rail flanges 80 are attached to the leg tower 74 .
FIG. 7 illustrates a second alternate embodiment of the invention. The alternate track guide apparatus is generally indicated by the numeral 102 . The link 94 and pins 96 are similar to the link and pin shown in FIGS. 5 and 6. Roller 98 contacts the rail 100 and the leg, not shown. Roller 98 may be incorporated with the pin 96 as one component. For clarity, the rail flanges that attach the rail to the tower are not shown.
Because many varying and differing embodiments may be made within the scope of the inventive concept herein taught and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein re to be interpreted as illustrative and not in a limiting sense. | An apparatus for guiding the legs of a lift boat. Roller assemblies are used to guide the legs. The rollers may be placed at any location or in any number either vertically or around the leg to adequately center the leg. The roller can either have a metal surface that rolls along the leg or be coated with a resilient material. The base of the roller can either be rigidly mounted to the vessel or incorporate resilient material between the roller and the vessel. A means of adjusting the clearance between the leg and roller may be incorporated in the roller assembly. | 4 |
The present application claims the priority of British patent application No. 0104845,3, filed on Feb. 27, 2001. The disclosure of this prior related application is hereby fully incorporated by reference herein.
FIELD OF THE INVENTION
This invention relates to lamp assemblies, and more particularly to lamp assemblies for use in the printing and coating industry for the fast curing of inks and the like on a large variety of substrate materials.
BACKGROUND OF THE INVENTION
It is well known to cure inks on a substrate by application of ultra-violet radiation from one or more medium-pressure ultra-violet lamps. It is also well known to provide each lamp in an assembly with a reflector which includes a reflective surface partly surrounding the lamp for reflecting radiation therefrom onto the substrate. The reflective surface has a concave profile which is commonly elliptical or parabolic, the lamp being mounted on the symmetrical centerline of the profile and adjacent the apex.
The reflector increases the intensity of the radiation received by the curable material. The penetration of the radiation into the material is an important factor in curing and, whilst penetration varies with different colors and materials, the higher the intensity the better the penetration.
One problem with known arrangements is that the angular spread of the radiation output from the reflector may be quite high with the consequence that radiation is received across a wide band of the substrate at varying levels of intensity. The highest intensity locations will depend on the degree of focusing provided in the assembly but there may be regions where the level of intensity is low. The large angular spread means that the substrate has to be moved more slowly than is desirable if the intensity of radiation is to be sufficiently high.
Another problem which arises with known arrangements is that part of the radiation is reflected back onto the lamp itself, which reduces the amount of radiation energy available for curing and leads to heating of the lamp which can adversely affect lamp operation and increase the already large amount of heat given off by the assembly which may cause warping and distortion of the coating and/or the substrate.
This problem has been recognized in French Patent 2334966 which describes a reflector in the form of two half-shells, each of which is pivotal about a longitudinal axis within the cavity to the sides of the symmetrical centerline thereof. The French Patent proposes deforming the top region of the reflector to give it, externally, a generally concave shape across the width of the lamp by bending the top edge of each half shell down towards the lamp.
The apparatus disclosed in French Patent 2334966 has disadvantages as a result of its basic form in that a complicated system will be necessary to achieve the desired pivoting action and space has to be provided to accommodate the half-shell pivoting which is inconsistent with the current industry desire for smaller curing assemblies. Cooling of the half-shells will be difficult, again because of the need to accommodate the pivoting action. Problems will also arise as a result of the solution proposed in the French Patent to the problem of lamp self-heating. The distortion of the reflector towards the lamp will lead to excessive heating of the distorted portion and will make cooling of the adjacent region of the lamp much more difficult.
The desire in the industry for smaller curing assemblies mentioned above gives rise to a problem in that decreasing the width of the assembly to enable it to occupy a smaller space in a line can have the result of increasing the angular spread of the emitted radiation. This in turn gives rise to the problems already discussed above.
The efficient and effective cooling of lamp assemblies has been a constant problem which has become even more important as ever increasing lamp powers have been employed to give faster curing such that substrate speeds can be increased. For example, at the date of the French Patent, 1975, lamp powers were only in the region of 250 Watts per inch (100 Watts per cm). Lamp powers of 200-400 Watts per inch (80-160 Watts per cm) are now common and lamps of even higher powers, 500-600 Watts per inch (200-240 Watts per cm) are increasingly being used. Furthermore, the advantages of UV curing, including cleanness and quality, have led to a demand for curing systems capable of operating with a wide variety of substrates, including substrates which are very vulnerable to heat damage.
Earlier assemblies were generally cooled by air alone. In the first air-cooled systems, air was extracted from within the reflector through one or more openings provided above the lamp to draw out the heat. In later systems, cooling air was blown into the assembly and onto the lamp, again through openings located adjacent the lamp. A problem with air cooling is that the blowers required increase the size of the assembly making it difficult to install between the stands of a multi-stand press.
This, and the increasing cooling requirements due to higher lamp powers, led to the use of water cooling alone or in conjunction with air cooling. The cooling water is fed through tubes attached to or integrally formed in the reflector. In addition, a number of designs have been proposed with filters comprising one or two tubes of quartz provided between the lamp and the substrate through which liquid is passed, typically de-ionized water. As well as contributing to the cooling, the filters have the primary effect of filtering infra-red radiation, which tends to heat the substrate, and focusing the light from the lamp onto the substrate. The liquid coolant is circulated to and from all the tubes through cooling or refrigerating means.
As lamp powers increase, ever more efficient and effective cooling systems are required to keep temperatures within acceptable limits, not only to prevent damage to the substrate, but also to prevent harm to adjacent equipment and to operators of the printing system.
One known design of lamp assembly has a reflector in the form of a block with a cavity on the surface of which the reflective surface is provided. The reflective surface may be formed by polishing the cavity surface or a specific reflector member can be attached thereto. In either case it is known to provide coatings on the reflective surface of heat-absorbing material.
British Patent No. 2315850 discloses a lamp assembly in which the reflector block is formed in two parts. The reflector surface is provided by two reflector plates, each of which is fitted between a flange extending into the cavity and a clamp attached to an end of the reflector block half by tightenable fastening means.
It is known to water cool reflector blocks by forming one or more passages therein for flow of cooling water. With two-part blocks, this requires water inlet and outlet pipes for both parts, that is, four pipes in total. The need to accommodate these pipes and to maintain the integrity of the water seals between them and the block passages makes the assembly as a whole unwieldy and furthermore makes it difficult to move one block part relative the other.
A further problem with block form reflectors, and indeed other reflectors, is that the radiation source is often relatively inaccessible and so it takes a significant time to change the source. This means that there may be significant down time when the lamp or other type of radiation source has to be changed.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide a lamp assembly which overcomes one or more of the problems associated with known assemblies, as discussed above. It is a more particular object to provide a lamp assembly which can be of small size but still provide high intensity radiation by reducing the angular spread of the radiation. It is a further particular object to provide a lamp assembly with a water cooling system, which has minimal equipment and is easier to accommodate in the assembly. It is a still further particular object to provide a lamp assembly in which the lamp or other radiation source can be readily accessed and so easily changed.
A lamp assembly in accordance with a first aspect of the invention comprises an elongate source of radiation, a reflector with an elongate reflective surface partly surrounding the source and having an opening for emission of radiation down towards a substrate for curing a coating thereon, the reflector comprising two body members each having a shaped surface which combines with the other when the body members are held in a first relative position to form a cavity in which the source is located and on the surface of which the reflective surface is provided, at least one passage through each body member for cooling water flow, and a tube for cooling water flow located in the vicinity of the emission opening wherein the or a passage in one body member is connected to the tube which is connected to the or a passage in the other body member.
The advantage of this is that only one water inlet tube and one water outlet tube is required, the outlet water from one body member being inlet to the other body member via the cooling tube. Thus the cooling tube is used as part of a flow path between the two body members and the number of water tubes is halved from four to two in comparison with known arrangements where the reflector is formed from two body members.
In accordance with another aspect of the invention, there is provided a lamp assembly comprising an elongate source of radiation, a reflector with an elongate reflective surface partly surrounding the source and having an opening for emission of radiation down towards a substrate for curing a coating thereon, the reflective surface having a generally concave profile and the source being located near the base of the concavity, wherein the reflector comprises two reflector elements each having a shaped surface which combines with the other when the elements are held in a first relative position to form a cavity in which the source is located and on the surface of which the reflective surface is provided, and wherein the source is mounted such as to be movable with one element to a second position relative the other element in which the source is located in a user accessible position.
This arrangement overcomes the problem found with lamp assemblies that a significant time is required to change the radiation source. By mounting the radiation source such that it is movable with one element of the reflector relative the other into a user accessible position, repairing or replacing the radiation source can be more quickly performed.
Preferably the reflector elements each comprise a body member having at least one passage for cooling water flow and the first and second aspects are combined with the passages in the body members being connected via a tube for cooling water located in the vicinity of the emission opening.
The combination is particularly efficient if the movable body member is pivotable relative the other body member about a pivot axis parallel to the longitudinal axis of the cooling tube. The cooling tube acts in effect as a rotary union and allows access to the radiation source without any potential adverse effect on the integrity of the water seals.
In a still further aspect, the invention provides a lamp assembly comprising an elongate source of radiation, a reflector with an elongate reflective surface partly surrounding the source and having an opening for emission of radiation down towards a substrate for curing a coating therein, the reflective surface having a curved generally concave profile between the edges of the emission opening which is symmetrical about a centerline on which the source is located, wherein the reflector has two elongate radiation diverting surfaces extending down from the edges of the emission opening and arranged to reflect radiation reflected by the reflective surface and divert it toward the centerline, thereby to reduce the angular spread of radiation reaching the substrate.
It has been found that by providing the radiation diverting surfaces extending down from the emission opening, it is possible to focus the radiation into a narrow beam which also has the effect of increasing the intensity of the radiation reaching the substrate. The provision of diverting surfaces is particularly useful when the width of the assembly as a whole has been reduced since, as discussed above, this may otherwise give rise to potential for wide angular spread and the problems which result therefrom.
The diverter surfaces may extend at an angle away from the centreline and may be flat or slightly curved. If so arranged, their primary effect is to turn radiation emitted from the lower sides of the source which would tend to be at a relatively large angle away from the centerline back in towards the centerline and so combine that radiation with the radiation emitted from the top and bottom of the source to give a focused beam of comparatively constant high intensity.
The reflector may comprise a body having a cavity in which the source is located and on the surface of which the reflective surface is provided and the diverter surfaces may be provided on separate end pieces mounted on the body. If the known arrangement whereby the reflective surface comprises at least one plate secured by a clamp on either side of the emission opening is adopted, then the clamps can act as the end pieces. Whatever form the end pieces take, they are suitably made of, or coated with, a reflective material, the first alternative being preferred.
All three aspects may be combined to result in a lamp assembly which can be small but still produce high intensity radiation of low angular spread whilst being water cooled by a single water inlet and water outlet tube. Furthermore the assembly is efficient in use since the radiation source can readily be accessed and so down time when the source needs to be repaired or replaced is minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further described by way of example with reference to the accompanying drawings in which:
FIG. 1 is an end view of part of a lamp assembly in accordance with the invention in a first, closed position;
FIG. 2 is an end view of the lamp assembly part of FIG. 1 in a second, open position;
FIG. 3 is a perspective end view of a lamp assembly in accordance with the invention in the first, closed position;
FIG. 4 is a perspective view of the lamp assembly of FIG. 3 in the second, open position,
FIG. 5 shows a radiation pattern produced with the lamp assembly in accordance with the prior art, and
FIG. 6 shows a radiation pattern produced by a lamp assembly in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show a reflector 2 forming part of a lamp assembly 4 illustrated in FIGS. 3 and 4.
The reflector 2 comprises two reflector body members 6 , 8 each of which is formed as an extrusion. The extrusions 6 , 8 each have a shaped surface 10 , the shaped surfaces combining when the extrusions 6 , 8 are in a first relative position shown in FIG. 1, to form a cavity 12 .
A lamp 14 is mounted in the cavity 12 for emitting radiation down onto a substrate (not shown) passing below the reflector 2 via the cavity opening designed between the bottom edges of the shaped surfaces 10 . The substrate may be continuous or comprise multiple sheets that are fed past the lamp in succession and may carry a coating capable of being cured by the radiation from the lamp 12 . Radiation emitted from the bottom of the lamp 14 is directly transmitted to the substrate whilst radiation emitted from the sides and top is reflected from a pair of reflector plates 16 mounted to the extrusions 6 , 8 against the shaped surfaces 10 . The reflector plates 16 may be formed from or coated with a dichroic material. Each is held in place between a flange 18 of the extrusion 6 , 8 and a clamp 20 fitted to the extrusion 6 , 8 at the lower end of the shaped surface 10 by bolts 22 .
The clamps 20 are generally triangular in cross-section and are fitted with the extrusions 6 , 8 such that the surfaces 24 which define the hypotenuse of the triangular cross-section extend generally transverse to the adjacent portions of the shaped surfaces 10 of the extrusions 6 , 8 . The clamp surfaces 24 act to divert radiation received thereon by virtue of formation of the clamps 20 of suitable reflective material such as silver. Alternatively, the clamps 20 can be formed of non-reflective material and the diverter surfaces 24 coated with reflective material.
Between the ends of the shaped surfaces 10 , and hence also between the clamps 20 , a cooling tube 26 is mounted. The cooling tube 26 is sized and located such that substantially all the radiation emitted by the lamp 14 passes through the tube 26 , either directly or following reflection from the reflector plate 16 .
The cooling tube 26 is preferably formed of quartz and is fed with de-ionised water. Therefore, in addition to cooling the lamp assembly 4 , the cooling tube 26 will act to filter infrared radiation from that emitted by the lamp 14 and also to focus that radiation onto a substrate passing below the reflector 2 .
The lamp assembly 4 is also cooled by flow of cooling water through passages 28 formed in the extrusions 6 , 8 . The passages 28 are shaped such as to surround the cavity 12 and so maximize the dissipation of the heat generated in the cavity 12 by operation of the lamp 14 .
The extrusions 6 , 8 are formed with end pieces 30 , 32 respectively, one of each of which can be seen in FIGS. 3 and 4. At the end of the lamp assembly 4 shown in those Figures, the end piece 30 of extrusion 6 is formed with a lamp mount 34 whilst the end piece 32 of extrusion 8 is formed with a cooling tube mount 36 . The ends are handed so that at the opposite end of the lamp assembly 4 , the end piece 30 of extrusion 6 is formed with a cooling tube mount 36 whilst the end piece 32 of extrusion 8 is formed with a lamp mount 34 .
The cooling tube mounts 36 have a generally circular cross-section and are received in corresponding sized and shaped recesses 38 of the lamp mounts 34 . The combination of the mounts 36 and recesses 38 form pivots about which the extrusion 6 can rotate relative the extrusion 8 between the closed position show in FIGS. 1 and 3 and the open position shown in FIGS. 2 and 4. In the closed position of FIGS. 1 and 3 the extrusions 6 , 8 are held together by a bolt 40 held captive in extrusion 8 which is engaged in a bolt hole 42 provided in extrusion 6 .
In the closed position, as already noted, the shaped surfaces 10 combine to form the cavity 12 . In the open position with extrusion 6 rotated relative extrusion 8 , the cavity 12 is broken open from above making the lamp 14 accessible and so allowing repair or replacement. Thus, by employing the cooling tube 26 as, in effect, a rotary union, the lamp 14 is made readily accessible, so facilitating servicing and replacement and hence reducing the downtime involved in such servicing and replacement.
The cooling tube 26 , by virtue of its mounting, remains stationary when the lamp assembly 4 is moved from the open to the closed position and vice versa. This allows the cooling tube 26 to be used a part of a cooling liquid supply to the passages 28 of the extrusions 6 , 8 . This, in turn, enables the number of water pipes required for the lamp assembly 14 to be reduced. As shown in FIGS. 3 and 4 the lamp assembly 4 has only two water pipes 44 , 46 . Cooling water is fed via one of these pipes 44 , 46 to one of the extrusions 6 or 8 . The water passes along the passages 28 of that extrusion 6 or 8 and thence to the cooling tube 26 via one of the cooling tube mounts 36 . The cooling water then passes via the other cooling tube mount 36 to the other extrusion 6 or 8 , along the passages of that extrusion and out via the second water pipe 46 .
In use with the lamp assembly in the closed position and water supplied via pipes 44 , 46 , the lamp 14 is energized via a lead 48 and a high voltage electric cable 50 . A second cable 50 supplies low voltage to a temperature indicator (not shown). Radiation is emitted from the lamp 14 as illustrated in FIG. 6 . As that Figure shows nearly all the emitted radiation passes through the cooling tube 26 . Furthermore all the radiation that passes through the cooling tube 26 has been reflected at most once only from the reflector plates 16 .
The shaping of the surfaces 10 , and hence the cavity 12 , is also such that the radiation emitted from the cavity opening has relatively wide angular spread. This is because the cavity 12 is shaped such that it narrows towards the opening which enables the lamp assembly 4 overall to be narrower than known assemblies such as that illustrated in prior art FIG. 5 .
The wide angular spread of the radiation is however reduced by the diverter surfaces 24 . These act to focus the radiation into a narrower beam by diverting radiation exiting the cooling tube 26 sideways back inwards towards the centerline 52 of the cavity 12 , on which the centers of the lamp 14 and cooling tube 26 lie. The focusing of the radiation produced by the diverter surfaces 24 also has the effect of increasing the UV intensity which reaches the substrate.
The lamp assembly 4 has a number of significant advantages. Firstly, it is narrow due to the shape of the cavity 12 which makes it easier to incorporate in a line. This is achieved however, without sacrificing curing efficiency because of the use of the diverter surfaces 24 to focus the emitted radiation into a narrower beam which also results in an increase in the UV intensity reaching the substrate.
In addition, the structure of lamp assembly 4 is simplified in comparison with known lamp assemblies because the number of water pipes is minimized. Operation is also simplified because the lamp can be moved to a user accessible position. These advantages are achieved by feeding the water into one extrusion, through the cooling tube and then into the other extrusion and arranging the water cooling tube to act as a rotary union.
While the present invention has been illustrated by a description of various embodiments and while these embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method, and illustrative example shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' general inventive concept. | A lamp assembly comprising an elongate source of radiation, a reflector with an elongate reflective surface partly surrounding the source and having an opening for emission of radiation down towards a substrate for curing a coating thereon. The reflective surface has a generally concave profile and the source is located near the base of the concavity. The reflector includes two reflector elements each having a shaped surface which combines with the other when the elements are held in a first relative position to form a cavity in which the source is located and on the surface of which the reflective surface is provided. The source is mounted to be movable with one element to a second position relative the other element in which the source is located in a user accessible position. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/990,253, filed May 8, 2014 and herein incorporated by reference.
BACKGROUND OF THE INVENTION
A standard four-piece drum kit consists of a snare drum, a bass drum, a floor-mounted tom-tom drum (also referred to as a “floor tom”) and a tom-tom drum that is somewhat elevated and attached to a hanging device or rack (also referred to as a “rack tom”). Besides the drums, the kit generally includes cymbals, a floor pedal, and hardware for attaching the drums in their preferred configuration (as well, in some cases, a seat for the drummer). For every performance, this equipment needs to be packed, transported and then unloaded. When the performance is over, the equipment must once again be packed, transported home and unloaded. Not only is this tedious, but transportation space (such as in a car) is usually very limited. In most cases, the drums are packed in separate suitcases or trunks, making the entire collection of baggage a significant load.
SUMMARY OF THE INVENTION
The present invention addresses this problem, providing a storage container that is particularly configured to house a relatively small bass drum. The container is also used to transport other percussion instruments, such as a snare drum, a floor tom and a rack tom. These other drums are then removed from the container during a performance (while the bass drum remains in the container). The container itself may be formed of a size of approximately 32″ tall by 20″ wide and 20″ deep.
In accordance with the present invention, the use of a relatively small bass drum (e.g., a 16″ bass drum as opposed to a 20-24″ bass drum) is compensated for by incorporating an acoustic configuration within the container (i.e., an acoustic chamber, channel and aperture) and positioned behind the bass drum. Additional baffling elements may be formed within the acoustic chamber in the container that propagate the sound created by the small bass drum through the container in a manner that creates the desired, deep resonant tone.
A particular embodiment of the present invention comprises a drum kit container of generally rectangular form, the container including an acoustic configuration and comprising a main compartment including an upper section and a lower section, the lower section including a first area and a second area configured in a front and back configuration such that the first and second areas are both disposed below the upper section, the first area for housing a bass drum with a drumhead facing outward, and the second area including at least a portion of the acoustic configuration and comprising an acoustic chamber, the main compartment further comprising an acoustic channel in acoustic communication with the acoustic chamber and extending upward along a side surface of the main compartment, terminating in an aperture, the combination of the acoustic chamber, acoustic channel and aperture forming the acoustic configuration.
Another embodiment includes, in addition to this main compartment, a secondary compartment having the same surface area dimensions as the main compartment such that the secondary compartment is capable being disposed over and attached to the main compartment, the combination of the main and secondary compartments forming a container for housing a bass drum and other drum equipment in a portable, compact arrangement.
Other and further arrangements, advantages and embodiments of the present invention will become apparent during the course of the following discussion and by reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings, where like numerals represent like parts in several views:
FIG. 1 is an isometric view of an exemplary drum kit container formed in accordance with the present invention, the illustration of FIG. 1 showing the container in its open position, with a bass drum disposed within its defined location and other components of drum equipment stowed within other compartments of the container;
FIG. 2 illustrates drum kit container in its “closed” position, with all equipment stowed therein so as to be easily transported from one location to another;
FIG. 3 is another isometric view of the inventive drum kit container in its open position, in this case with a portion of the equipment removed from the container (in particular, from the secondary (“lid”) portion of the container);
FIG. 4 shows the inventive drum kit with all necessary components removed, and a bass drum remaining in its performance position within the container;
FIGS. 5-8 are alternative view of a complete drum kit set up, using components stored within the drum kit container of the present invention;
FIG. 9 is a cut-away side view of the main compartment area of the inventive drum kit container, the view of FIG. 9 illustrating an exemplary acoustic configuration disposed behind the bass drum and used for optimizing the sound of the bass drum;
FIG. 10 is a front view of the main compartment shown in FIG. 9 ; and
FIG. 11 is a cut-away view of an alternative acoustic configuration as formed within the main compartment, in this case including a number of baffles within the acoustic chamber.
DESCRIPTION OF THE INVENTION
FIG. 1 is an isometric view of an exemplary drum kit container 10 , formed in accordance with the present invention. In this view, container 10 is shown in its “open” position, showing in detail a relatively deep main compartment area 12 and a relatively shallow secondary compartment area 14 . In this particular embodiment the two compartments are connected together via a hinge member 16 . Drum kit container 10 can be thought of as being similar to a “trunk”, with main compartment area 12 similar to the storage area and secondary compartment area 14 similar to the lid. Indeed, FIG. 2 illustrates drum kit contain 10 in its “closed” position, and its similarity to a trunk is noticeable.
Returning to the description of the present invention as shown in FIG. 1 , main compartment area 12 of container 10 is shown as used to store a relatively small bass drum 18 in a lower section 20 . As mentioned above, the inventive acoustic configuration of container 10 allows for a relatively small drum (i.e. a 16″ drum as opposed to a more conventional 20″-24″ drum) to be used. The particulars of the acoustic configuration will be discussed hereinbelow in association with FIGS. 9-11 .
Main compartment area 12 of container 10 also includes an upper section 22 , used for storing the remaining drums 24 (e.g., floor torn, rack tom, snare, etc.). As will be shown below, these drums 24 are removed from container 10 when the kit is being set up for a performance. Bass drum 18 , in contrast, remains stored within lower section 20 during performance.
Secondary compartment area 14 of drum kit container 10 (the shallower of the two compartment areas) includes, in this embodiment as shown in FIG. 1 , an upper section 26 and a lower section 28 . In this particular example, seat components 30 are stored in upper section 26 and drum stand elements 32 (hereinafter referred to as “hardware”) and floor pedals 34 are stored in lower section 28 .
FIG. 3 illustrates drum kit container 10 in an intermediate form as the kit is being set up for a performance. In this view, seat components 30 have been removed and assembled, as shown. Hardware 32 and floor pedals 34 have been removed from upper section 26 of secondary compartment area 14 . In this particular embodiment, secondary compartment area 14 is itself formed as a hinged component, including a hinge member 34 disposed across the interface between upper section 26 and lower section 28 . A floor pedal 34 is shown in FIG. 3 as being positioned for use with bass drum 18 .
FIG. 4 illustrates drum kit container 10 at a further point in the drum kit set-up process. As shown, the remaining drums 24 have been removed from upper section 22 of main compartment area 12 and attached to the proper hardware 32 .
In further accordance with the present invention, first and secondary compartment areas 12 and 14 of drum kit container 10 may be formed to include a plurality of attachment components 40 at specific locations, with these attachment components functioning as locations for attachment of some of the hardware 32 (and/or several cymbals that may be included in the fully set up drum kit. In this specific example of this aspect of the present invention, FIG. 2 illustrates a pair of attachment components 40 - 1 and 40 - 2 formed on its exterior surface and FIG. 3 illustrates an attachment component 40 - 3 formed in the upper wall 28 -U of lower section 28 (and thus visible when secondary compartment area is opened). With reference to FIGS. 2, 3 and 4 , it is shown that attachment components 40 - 1 , 40 - 2 and 40 - 3 are used to provide attachment of a portion of hardware 32 to drum kit container 10 . These hardware connections may be used to support, for example, cymbals that are used in the fully assembled drum kit.
FIGS. 5-8 illustrate an exemplary drum kit as set up for performance, utilizing drum kit container 10 of the present invention. Evident in each of these views is that bass drum 18 remains in position within container 10 , which is formed in the specific manner shown below to provide the necessary acoustics for this relatively small-sized bass drum.
As mentioned above, container 10 is specifically formed in accordance with the present invention to include an acoustic configuration that allows for the relatively small bass drum 18 contained within lower section 20 of main compartment area 12 to create the richer, deeper sound generally attributed to larger (standard size) bass drums.
FIG. 9 is a cut-away side view of main compartment area 12 , showing the elements forming an acoustic configuration 50 which in this embodiment includes an acoustic chamber 52 disposed in a second area of lower section 20 , behind bass drum 18 . A channel 54 is formed to be in acoustic communication with chamber 52 and is disposed to extend upwards within a back wall 12 -B of main compartment area 12 . As shown in FIG. 9 , channel 54 terminates at an aperture 56 (such as a slot) formed in a top surface 12 -T of main compartment area 12 . FIG. 10 is a front view of the arrangement of FIG. 9 , illustrating the position of drum 18 within lower section 20 . Also shown in this view is a pair of apertures 56 - 1 and 56 - 2 .
In accordance with the present invention, therefore, when “small” bass drum 18 positioned within lower section 20 is struck (such as with a conventional floor pedal), acoustic configuration 50 will allow the sound to reverberate within chamber 52 , travel along channel 54 and outward through aperture 56 . The inclusion of this acoustic configuration 50 improves the sound of “small” bass drum 18 and is critical in allowing for all of the drum kit components to be easily stored in a container of a relatively small size.
FIG. 11 is a side view of an alternative acoustic configuration useful in drum kit container 10 in accordance with the present invention. As with the embodiment described above, main compartment area 12 includes a lower section 20 for holding bass drum 18 . In the arrangement as shown in FIG. 11 , an acoustic configuration 60 is shown as including an acoustic chamber 62 , channel 64 and aperture(s) 66 . Additionally, acoustic chamber 62 is formed to include a set of baffles 68 , which are used to channel the acoustic wave through acoustic chamber 62 in a manner that creates a rich, deep bass drum sound. As with the configuration described above, the sound wave ultimately propagates upward through channel 64 , passing through aperture slots 66 formed in top surface 12 -T of first containment area 12 .
It is to be understood that the specific configuration of baffles 68 is exemplary only and various other arrangements may be used. Indeed, it is to be further understood that a drum kit container formed in accordance with the present invention may include various other configurations and organizations of compartments, sections and attachment components, as long as the section within which the bass drum is located also includes an acoustic chamber. Thus, the spirit and scope of the present invention is not limited by this description, but only by the claims appended hereto. | A drum kit container is configured to house various compartments sufficient to stow all of the equipment needed by a drummer in setting up a drum kit. One compartment is sized to house a relatively small bass drum, with an acoustic chamber formed behind this compartment and used to improve the sound of a small bass drum so that it sounds more like a larger bass drum as generally used in performance. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a novel woodworking tool for precisely measuring difficult inside and outside dimensions critical for fine woodworking and cabinetry. More particularly, it relates to a woodworking gauge that can measure square ends, measure square/mitered end combinations, measure mitered ends, scribe arcs, and check diagonal squareness of cabinets and other structures.
Fine woodworking projects require precise measurements before preforming cuts and/or assembly. Often, numerous tools are required to ensure proper measurements. Accurately measuring inside dimensions of windows or cabinets, for example, is difficult with a measuring tape. Once this gauge is locked to the exact dimensions, the tool can create a pattern for a new piece of trim with mitered or square corners by setting a saw stop, fence, or by scribing a knife line on top of the stock from which you are creating the new piece. Additionally, trammel points for making circles and arcs can be removably affixed at either end. By rotating the trammel points to extend from both ends of the gauge, the gauge can be used to measure diagonals, which is useful for squaring up cabinets and other structures.
Prior art woodworking devices have been to designed to do each of the aforementioned actions; however, no prior art discloses a gauge that does all of the aforementioned actions. Therefore, there is a need for a woodworking gauge that is simple to operate and can measure square ends, measure square/mitered end combinations, measure mitered ends, scribe arcs, and square up cabinets and other objects. This need will be achieved by the novel invention herein disclosed.
SUMMARY OF THE INVENTION
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a multi-use woodworking gauge. The gauge has many of the advantages mentioned heretofore and many novel features that result in a new woodworker's gauge which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof.
In accordance with the invention, an object of the present invention is to provide an improved woodworker's gauge capable of precisely measuring inside and outside dimensions for fine woodworking projects.
It is another object of this invention to provide an improved woodworker's gauge capable of measuring and setting a pattern for square ends.
It is a further object of this invention to provide an improved woodworker's gauge capable of measuring and setting a pattern for mitered ends.
It is a further object of this invention to provide an improved woodworker's gauge capable of measuring and setting a pattern for square/mitered end combinations.
It is still a further object of this invention to provide an improved woodworker's gauge cable of measuring and setting a pattern for a right-handed miter.
It is still a further object of this invention to provide an improved woodworker's gauge cable of measuring and setting a pattern for a left-handed miter.
It is still a further object of this invention to provide an improved woodworker's gauge cable of scribing arcs and circles.
It is yet a further object of this invention to provide an improved woodworker's gauge cable of measuring inside diagonals and hence squaring up cabinets and other structures.
The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements.
Other objects, features and aspects of the present invention are discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a first view isometric projection of the multi function gauge; and
FIG. 2 is a second view isometric projection of the multi function gauge.
FIG. 3A is a top view of the first linear member;
FIG. 3B is a bottom view of the first linear member;
FIG. 3C is a cross-sectional view of the first linear member;
FIG. 4A is a top view of the second linear member;
FIG. 4B is a bottom view of the second linear member
FIG. 4C is a cross-sectional view of the second linear member;
FIG. 5 is a proximal end view of the second linear member;
FIG. 6 is an is a proximal end view of the first linear member;
FIG. 7 is a bottom view of the second scribe retaining device;
FIG. 8 is a bottom view of the first scribe retaining device;
FIG. 9 is a top view of the second scribe retaining device;
FIG. 10 is a top view of the first scribe retaining device;
FIG. 11 is a is a side view of the second scribe retaining device;
FIG. 12 is a side view of the first scribe retaining device;
FIG. 13 is an end view of the second scribe retaining device partially frictionally affixed to the first linear member;
FIG. 14 is a end view of the first scribe retaining device frictionally affixed to the second linear member;
FIG. 15 is a top view of a first assembly configuration of the multi function gauge;
FIG. 16 is a top view of a second assembly configuration of the multi function gauge;
FIG. 17 is a top view of a third assembly configuration of the multi function gauge;
FIG. 18 is a top view of a fourth assembly configuration of the multi function gauge;
FIG. 19 is a top view of a fifth assembly configuration of the multi function gauge;
FIG. 20 is a top view of a sixth assembly configuration of the multi function gauge;
DETAILED DESCRIPTION
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the 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 invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
Looking at FIGS. 1 and 2 the main elements of the multi purpose adjustable measuring gauge 2 can be best seen. The first linear member 4 is extendably engagable with second linear member 6 by virtue of the insertion of the T-shaped track 8 into the matingly conformed T-shaped groove 10 . Linear locking thumbscrew 12 tightens to frictionally bind the first linear member 4 and the second linear member 6 in any of the extended configurations of these elements.
Referring now to FIGS. 3-6 the first linear member can be best illustrated and described. First linear member 4 is of generally linear quadrilateral configuration, comprised of a uniform thickness A, a first planar face 14 and a second planar face 16 , a proximal end 18 , a distal end 20 , and a T-shaped track 8 . The proximal end 18 is squared and the distal end 20 is at a 45 degree angle (although alternate angles may be used this angle is the most common for woodworking applications.) Track 8 lies along the centerline of the first planar face 14 and extends the entire linear length of the first planar face 14 to slidably engage the matingly conformed groove 10 of the second linear member 6 (although different track and groove configurations may be utilized, this style has economic advantages.) Additionally, two nuts 22 are disposed and affixed through first opening 24 and second opening 26 and are threading engageable for coupling with a thumbscrew 28 ( FIGS. 11 and 12 ). The heads of nuts 22 are recessed in the second face 16 so as to remain at least flush with the second face 16 .
The second linear member 6 is of generally linear quadrilateral configuration of uniform thickness B substantially similar to the thickness A of first linear member 4 . The second linear member 6 comprises a third planar face 30 , a fourth planar face 32 , a squared proximal end 34 , an angled distal end 36 of 45 degrees, and a groove 10 extending along its entire linear length matingly conformed to the track 8 for slidable engagement with the first linear member 4 . The second member 6 further comprises a proximal end plate 38 having a substantially similar thickness as that thickness A and B of both the first and second linear members 4 , 6 matingly affixed to the forth planar face 32 via three pop rivets 40 to the second linear member's proximal end 34 (although in a different type of fabrication the proximal end plate 38 and the second linear member 6 may be integrally formed.) Additionally, the proximal end plate 38 has a nut 22 disposed through an third opening 42 to be coupled with a thumbscrew 28 in a similar fashion as that described above. The nut 22 is recessed in the proximal end plate 38 so as to remain at least flush with the exposed face 44 . A distal end plate 46 having a substantially similar thickness as that of thickness A and B of the first and second linear members 4 and 6 and that of proximal end plate 38 , is matingly affixed via three rivets 40 to the third planar face 30 of second linear member's distal end 36 . The distal end plate 46 and the proximal end plate 38 reside on opposite planar faces of the second linear member 6 . The proximal end plate 38 matingly conforms to the distal end 20 of the first linear member 4 , and the distal end plate 46 matingly conforms to the squared proximal end 18 of the first linear member 4 . A thumb screw 28 is used to lock the first linear member 4 to the second linear member 6 .
Looking at FIG. 5 the proximal end view of the second linear member 6 showing the groove 10 can be seen. This view is also identical for the distal end of the second linear member 6 when the second linear member is rotated end for end about the X-Y horizontal axial axis of the second linear member 6 .
Looking at FIG. 6 the proximal and distal end view of the first linear member 4 showing the track 8 can be seen.
Referring now to FIGS. 7 to 12 , two scribe attachment devices can be seen. The first scribe attachment device 48 has a first planar face 50 a second planar face 52 , and four substantially similar edge faces differing only wherein a first edge face 54 has an orifice 56 therein to accept and frictionally or mechanically constrain a scribe 58 . The second scribe attachment device 60 has a first planar face 62 a second planar face 64 , and four substantially similar edge faces with the four faces differing only wherein a first edge face 66 has an orifice 68 therein to accept and frictionally or mechanically constrain a scribe 58 .
The first and second scribe attachment devices each have a central orifice (not illustrated) formed therethrough for the entry of thumbscrew 28 but differ in the configuration of their first planar faces 50 and 62 . The first scribe attachment device 48 has a square plate 64 formed centrally thereon dimensioned so as to be received by groove 10 on the second linear member 6 . There is a central orifice formed therethrough (not illustrated.) In this manner the square plate 64 of the first scribe attachment device 48 may be placed into groove 10 and the thumbscrew 28 tightened into the nut 22 recessed into third opening 42 of proximal end plate 38 so as to secure the first scribe attachment device 48 in a non rotatable fashion so as to be squared with the proximal end 34 of the second linear member 6 . A retaining clip 70 is affixed to thumbscrew 22 to hold it on the first scribe attachment device 48 . The first scribe attachment device 48 may be locked into any of four orientations each 90 degrees apart so that the scribe 58 may extent parallel or perpendicular to the longitudinal axis of the gauge 2 .
The second scribe attachment device 60 has four substantially similar squared platforms 72 formed at its corners so as to form a depressed region 74 there between in the shape of a cross so as to allow the track 8 to reside in the depressed region 74 in any of the possible 90 degree rotations of the second scribe attachment 60 . In this manner the second scribe attachment device 60 may be placed onto track 8 in any of the possible 90 degree rotations and the thumbscrew 28 tightened into the nut 22 recessed into first opening 4 of the first linear member 4 so as to secure the second scribe attachment device 60 in a non rotatable fashion so as to be squared with the proximal end 18 of the first linear member 4 . A retaining clip 70 is affixed to thumbscrew 28 in a recess 76 to hold it on the second scribe attachment device 60 similar to that discussed above. The second scribe attachment device 60 may be locked into any of four orientations each 90 degrees apart so that the scribe 58 may extent parallel or perpendicular to the longitudinal axis of the gauge 2 .
FIG. 11 shows a side view of the assembled second scribe attachment device 60 and FIG. 12 shows a side view of the assembled first scribe attachment device 48 .
FIG. 13 shows a side view of the second scribe attachment device 60 partially engaged with the first linear member 4 and FIG. 14 shows a side view of the first scribe attachment device 48 fully engaged with the second linear member 6 .
FIGS. 15 to 20 show the various configurations of the gauge 2 as can be accomplished by inverting and rotating the linear members. The interchangeablity and reversability of the first and second linear members allowing sliding engagement will be discussed with reference to the individual FIGS.
FIG. 15 is a configuration of the gauge 2 for measuring the distance between mitered edges. In this configuration the proximal end 18 of the first face 14 of the first linear member 4 engages the proximal end 34 of the third face 30 of the second linear member 6 such that the first face 14 of the first linear member 4 is in frictional contact with the third face 30 of the second linear member 6 .
FIG. 16 is a configuration of the gauge 2 for measuring the distance between a square end to a left hand miter. In this configuration the proximal end 18 of the first linear face 14 of the first linear member 4 engages the distal end 36 of the fourth face 32 of the second linear member 6 such that the first face 14 of the first linear member 4 is in frictional contact with fourth face 32 of the second linear member 6 .
FIG. 17 is a configuration of the gauge 2 for measuring the distance between squared ends. In this configuration the distal end 20 of the first face 14 of the first linear member 4 engages the distal end 36 of the fourth face 32 of the second linear member 6 such that the first face 14 of the first linear member 4 is in frictional contact with the fourth face 32 of the second linear member 6 .
FIG. 18 is a configuration of the gauge 2 for measuring the distance between square end to a right hand miter. In this configuration the distal end 20 of the first face 14 of the first linear member 4 engages the proximal end 34 of the third face 30 of the second linear member 6 such that the first face 14 of the first linear member 4 is in frictional contact with the third face 30 of the second linear member 6 .
FIG. 19 is a configuration of the gauge 2 for measuring diagonal distances. In this configuration the distal end 20 of the first face 14 of the first linear member 4 engages the distal end 36 of the fourth face 32 of the second linear member 6 such that the first face 14 of the first linear member 4 is in frictional contact with the fourth face 32 of the second linear member 6 . The first scribe attachment device 48 is fictionally affixed onto the proximal end of the third face 30 of the second linear member 6 such that the scribe 58 extends parallel to the longitudinal axis of the gauge 2 . The second scribe attachment device 60 is frictionally affixed onto the proximal end 18 of the first face 14 of the first linear member 4 such that the scribe 58 extends parallel to the longitudinal axis of the gauge 2 .
FIG. 20 is a configuration of the gauge 2 for scribing arcs or circles. In this configuration the distal end 20 of the first face 14 of the first linear member 4 engages the distal end 36 of the fourth face 32 of the second linear member 6 such that the first face 14 of the first linear member 4 is in frictional contact with the fourth face 32 of the second linear member 6 . The first scribe attachment device 48 is locked onto the proximal end of the third face 30 of the second linear member 6 such that the scribe 58 extends perpendicular to the longitudinal axis of the gauge 2 . The second scribe attachment device 60 is locked onto the proximal end of the first face 14 of the first linear member 4 such that the scribe 58 extends perpendicular to the longitudinal axis of the gauge 2 .
The multi function gauge 2 could be formed from wood, light weight metals, steels, alloys, plastics, or any combination thereof. Although described as use for woodworking, the present invention is equally applicable to use in all other fields where precise measurement is critical such as metalworking, drafting, pattern making and the like.
The above description will enable any person skilled in the art to make and use this invention. It also sets forth the best modes for carrying out this invention. There are numerous variations and modifications thereof that will also remain readily apparent to others skilled in the art, now that the general principles of the present invention have been disclosed. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. In the way of an example, it is known that different fabricating methods such as extrusion, welding, riveting etc. may result in the incorporation of two or more elements into a monolithic structure. Such may be the case of the incorporation of the distal and proximal end plates with either of the linear quadrilateral members. | The present invention relates to novel woodworking tool. This tool allows for precise measurements of square ends; square/mitered end combination, and mitered ends. Additionally, this tool can scribe arcs and circles and square up cabinets and other structures. This simple to operate tool will ensure proper measurements for difficult inside and outside dimensions critical for fine woodworking and cabinetry. | 1 |
FIELD OF THE INVENTION
This invention relates to an apparatus and a process for unloading catalysts from multi-tube reactors quickly and with maximum dust containment. The invention is particularly applicable to jacketed multi-tube reactors used in the production of ethylene oxide, phthalic anhydride, and maleic anhydride, but is not limited to such uses.
BACKGROUND OF THE INVENTION
Each of the reactions for producing ethylene oxide, or the production of phthalic anhydride or maleic anhydride, is highly exothermic, involving the controlled oxidation of organic substances. Thus, it is necessary that the heat generated by the reaction be removed as efficiently as possible so as to prevent a run-away reaction in which undesirable products are produced and in which expensive raw materials are wasted. Accordingly, it has been the practice to utilize catalytic tubes of extremely narrow diameter. Thus, for example, it is not unusual for a catalyst tube to have an I.D. of 1.25 inches and to be 60 feet long. The reactor, however, may contain as many as 2500 to 9000 tubes. In one instance, for example, the reactor had tubes which were only 22 feet tall, but each tube had an I.D. of 3/4 inches and the reactor contained 8600 tubes. Each of the tubes are connected at each end to a tube sheet, and the entire bundle of tubes and tube sheet is jacketed and filled with a heat transfer fluid or medium, as, for example, Dowtherm, mercury, or molten salt solutions. Due to the heat given off by the reaction, the space velocity is maintained at an extremely high rate so that there is considerable abrasion of the catalytic spheres within the small diameter tubes. Additionally, hot spots can occur within the reactor. When this occurs, the catalyst bridges over and that tube may be lost from service. This, of course, depends upon the severity of the spot. Additionally, in the case of ethylene oxide, for example, one patentee points out that the optimum temperature for the reaction is in the range 225°-250° C. If the temperature falls below 225° C., the conversion rate is insufficient to be economically feasible. If the temperature goes above 250° C., the ethylene oxide selectivity decreases significantly with the concommitant loss of the desired end product. It is obvious, of course, that if the reaction gets too far out of hand that the end product is carbon dioxide and the catalyst becomes fused throughout the length of the 20-60 feet of small-diameter tubes.
DESCRIPTION OF THE PRIOR ART
In the past, the practice has been to increase the temperature as the activity begins to decrease to compensate for the decreased activity. As just pointed out, however, this has limitations, since once the temperature is increased above a certain limit, there is sufficient loss of the desired end product to make the process economically unfeasible. It then becomes necessary to unload the catalyst, which by this time has some fused spheres bridging across portions of the tubes, dust, and possibly even carbonaceous deposits on the catalyst. In the past, this has been practiced by the lowest paid laborers in the plant. These laborers would utilize flexible steel rods, or "fish tapes", which would extend the length of the tubes, and reciprocate them whenever they found an obstruction due to stuck catalytic material. This allowed the catalyst to fall by gravity to the bottom of the reactor to be collected. Unfortunately, all of the dust which had formed over the one or two years of operation would also fall directly onto the workmen. Ultimately, OSHA ordered that it would be necessary for the workmen to wear complete protective equipment containing an external source of air supply.
SUMMARY OF THE INVENTION
According to this invention, several tubes can be unloaded by gravity, and the stuck or bridged-over catalyst can be dislodged by reciprocation or by air jets with essenytially complete containment of dust and with complete recovery of catalyst. Since, in the case of ethylene oxide, the catalyst comprises silver oxide on alpha alumina spheres, recovery of the dust is in itself a worthwhile goal. Additionally, because of the containment of the dust, the health of the workmen is not deleteriously affected. Furthermore, since the dust contains valuable metals, recovery is economically justifiable on this basis alone. The reactor is unloaded by the provision of three or more guide tubes extending vertically from the bottom of the receiving trough in registry with the tubes of the reactor. Guide means are provided on the sides of the trough so as to properly align the guide tubes with the tubes in the reactor, and the tubes open at the bottom so as to allow the flexible steel rods or "fish tapes", with or without high-fluid pressure tubes, to be fed into the catalytic reactor tubes so as to dislodge the stuck catalyst, either by reciprocation of the steel rods or by injection of high-pressure jets of air. An outlet collar is in communication with the side or bottom of the receiving trough, and is connected to an outlet line, which in turn carries the catalyst and the dust, which falls by gravity, into the receiving trough and thence to storage containers. The line preferably is a vacuum line which assists in conveying the catalyst and the dust to the receiving drums or other receptacles. The materials preferably may first be fed to a solids-dust deparator, wherein the dust is filtered and recovered, and the solids are screened, sized, and collected. Any additional dust formed in the screening process is carried off by vacuum lines, and again filtered and recovered.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view with parts partially broken away, illustrating a multi-tube catalytic reactor with the receiving troughs of this invention attached to the tube sheet and feeding by gravity through outlet lines into recovery troughs.
FIG. 2 is a perspective view of the recovery trough of this invention.
FIG. 3 is another embodiment of the receiving trough of this invention.
FIG. 4 is a diagrammatic view of a multiple trough arrangement with vacuum lines leading from each trough to a vacuum manifold.
FIG. 5 is a fragmentary view with parts in section illustrating the relationship of the receiving trough and the steel strips or rods feeding through the guide tubes and into the reactor tubes.
FIG. 6 is a fragmentary view partially in perspective illustrating the use of multiple air-lances in the form of high-fluid pressure tubes in the guide tubes of the receiving trough.
FIG. 7 is a fragmentary view of the air-lance and nozzle attached to the supporting steel rod or "fish tape" and its relationship to the guide tube of the receiving trough.
FIG. 8 is a view in perspective of the receiving trough of this invention used on the top tube sheet of the reactor with multiple air-lances.
FIG. 9 is a sectional view taken along lines 9--9 of FIG. 8.
FIG. 10 is a diagrammatic flowsheet of the solids-dust separation apparatus, including catalyst screening, sizing, and storage apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As previously mentioned, this invention finds its application in processes involving the partial oxidation of ethylene to ethylene oxide, the partial oxidation of naphthalene or other organic materials to phthalic anhydride, and the partial oxidation of benzene or other organic materials to maleic anhydride.
When an attempt is made of oxidize ethylene over a heated silver catalyst, two reactions may occur:
(1) C 2 H 4 +1/2O 2 =C 2 H 4 O=32.3 kg cal
(2) C 2 H 4 +3O 2 =2CO 2 +2H 2 O=316.6 kg cal
The first of these reactions results in the production of ethylene oxide, while the second, which is one of complete oxidation, results in the generation of a much larger amount of heat. From the figures given in the above reactions, it is apparent that controlled oxidation is largely tied in with the removal of heat from the system, and that for efficiency in the production of ethylene oxide, heat removal is all important. As the yield increases and the complete oxidation of the second reaction decreases, the heat generation and the heat transfer medium necessary to remove the heat are greatly reduced. Thus, for example, a 50% yield produces about 8000 kg cal per kg of C 2 H 4 O, whereas an 85% yield produces about 2000 kg cal per kg of C 2 H 4 O. Because of the exothermic nature of the reaction, the catalyst is enclosed in small-diameter tubes containing the silver oxide catalyst on carriers, such as pellets, but preferably on spheres of alpha alumina. A large commercial converter for the catalytic oxidation of ethylene may thus contain a large number of small tubes, each filled with a catalyst on the carrier and with the tubes enclosed in a large chamber in which they are surrounded by heat transfer fluid. Furthermore, the space velocity is maintained quite high so that the contact time of the gases with the catalyst is very short. As previously mentioned, the I.D. of the tubes runs in the range of from greater than 1.5 inches to less than 3/4 inch, and the lengths of the tubes range from 10 feet to 60 feet. Some reactors will contain 2500 tubes, while some of the even larger reactors will contain more than 20,000 of the small-diameter tubes. The production of phthalic and maleic anhydrides are also highly exothermic. Phthalic anhydride may be prepared by the partial oxidation of naphthalene, which is melted and pumped to a vaporizer, where it is vaporized by bubbling primary pre-heated air through the molten material. Additional secondary air is added to the primary air-naphthalene vapor stream in a mixing section in the exit pipe from the vaporizer to bring the air-naphthalene ratio to 25:1 by weight. This vapor mixture is then led to a converter consisting of multiple tubes filled with supported vanadium pentoxide catalyst. Heat (8000-10,000 Btu/lb naphthalene) is removed from the tube skins of the fixed catalyst, either by mercury under suitable pressure, or by pumping molten salt solutions across the tube bank. In the converter, the naphthalene is oxidized to phthalic anhydride, carbon dioxide, and water, at a temperature ranging from 675°-850° F., and a contact time of 0.1 seconds. Careful adjustment of reaction conditions is necessary. The ever-present danger of over-oxidation to maleic anhydride, and of complete combustion to carbon dioxide and water, necessitates the choice of relatively low temperatures and contact times. At excessively mild operation conditions, on the other hand, the extent of hydrocarbon conversion will be economically insufficient. Phthalic anhydride can also be produced by the partial air-oxidation of xylene and other substituted benzenes utilizing supported vanadium pentoxide catalysts. Again the diameter of the tubes is about 25 mm (I.D.) and they may range in height from 10 to 40 feet. Maleic anhydride, of course, is a by-product, usually unwanted, of the production of phthalic anhydride. The production of maleic anhydride, in and of itself, is usually through the partial oxidation of benzene, which is vaporized with compressed air at a pressure of 2-3 atm to obtain the correct benzene:air ratio. Theoretically, about 106 ft 3 of air is required per pound of benzene, oxidized according to the reaction; ##STR1##
Again, the vapor mixture is blown through a multi-tube converter containing vanadium pentoxide catalyst supported on alundum spheres. The reaction is highly exothermic, and, once initiated, is self-supporting. The temperature of 400°-450° C. is maintained by efficient heat removal. The heat liberated ranges from 10,500-13,500 Btu per pound of benzene reactant. Special cooling means, such as circulating mercury or fused salts across the tube banks, are necessary, as well as a high space velocity and a low contact time of approximately 0.1 second at about 1 atm pressure.
Due to the extreme exothermic reactions involved in the production of these chemicals, the raw material and air mixtures are fed through the catalytic tubes at extremely high space veliocities, under normal U.S. practice, so as to help in the elimination of heat from the tubes through the skin wall to the heat transfer medium. As has been previously pointed out, the selectivity of the process is extremely important, and if the reaction temperature can be maintained to produce the desired product, the amount of heat liberated is minimized. However, once the undesired reaction starts, the amount of heat liberated is increased so that the amount of heat removal required to maintain the temperature is increased, and inevitably hot spots occur in the catalyst tubes, or in some of them, so as to cause bridging or partial bridging of the catalytic particles together. As this occurs, the activity of the catalyst decreases, and it is necessary to increase the temperature to maintain the proper outlet with the concommitant problems of loss of activity and disproportionate increase of the temperature within the catalytic tubes. It is thus seen that the transfer of heat from the center of the tube to the skin of the tube through to the heat transfer medium on the outside of the tube is critical.
After a period of time, the activity of the catalyst is so much diminished, and the selectivity of the catalyst is so much diminished, that it becomes economically unfeasible to maintain operation with the same catalyst. It thus becomes necessary to unload the catalyst from each of the small-diameter tubes, which, as has been previously indicated, range from 3/4 inch to greater than 1.5 inches I.D. Again, the number of tubes in a reactor may range anywhere from 2500 to 20,000, and the length of the tubes may range anywhere from 10 feet to 60 feet. Needless to say, the loss of income during downtime is enormous, and it is essential that the catalyst be unloaded and transferred to proper receptacles as quickly and as effortlessly as possible.
As has previously been pointed out, in the case of the ethylene oxide catalyst, the active catalytic material is silver, which is of substantial value and worthy of recovery. In the production of phthalic and maleic anhydrides, the catalyst is vanadium pentoxide, again on alundum or alpha alumina spheres, and the metal dust is of considerable value. Furthermore, the dust which is released in the gravity unloading of the tubes is so great as to cause health hazards, and OSHA has ordered that workers involved in unloading the catalyst be required to wear completely protective gear with a completely separate source of breathing atmosphere.
Referring now to the drawings, it will be seen that, by the practice of this invention, the catalyst can be unloaded, several tubes at a time, into a receiving trough which is detachably connected to the tube sheet. Referring now to FIG. 1, the reactor 1 has an outer jacket 2 and an inner jacket 3, which has been pulled away at the bottom for purposes of illustration. An insulation layer 5 has also been pulled away, for the most part, so as to illustrate the reactor. The catalytic tubes 6 are shown imbedded in the tube sheet 4 at one end, and are similarly anchored to a tube sheet 4 at the top at the other end, and the space 7 between the tubes is allowed for the liquid heat transfer medium. As is illustrated in FIG. 1, the whole bottom portion of the reaction has been pulled away and a temporary platform 10 and stairway 11 has been built up for the workmen. The receiving trough 15 has sides 16 and 17 and ends 18 and 19 and a bottom 20. A flange 40 surrounds the periphery of the trough 15 at the top and is equipped with a gasket 41. (See FIGS. 8 and 9.) A series of guide tubes 21, three as illustrated, extend vertically from the bottom 20 of the receiving trough, and have openings 23 in the bottom 20 of the receiving trough 15 for reception of flat flexible steel rods or "fish tapes" 45, which are guided through the guide tubes 21, which are on center with the catalytic tubes 6. Thus, as is shown, a workman can feed two, or as many as three, fish tapes 45 through the guide tubes 21 so as to dislodge any catalyst bridged across the tubes or stuck, which will then fall out of the tubes 6 by gravity. The receiving trough 15 contains a fastening means, which, in FIG. 3, is in the form of a magnet 24, and which, in FIG. 2, is in the form of a pair of toggle clamps 29 attached to a bracket 30 on the side 16 of the receiving trough 15. The toggle clamp 29 consists of an effort arm 31, a middle arm 32 pivoted to the bracket and to the work arm 33, which terminates at the end with a bolt 34, having a threaded shank and a nut at the end. A handle 36 connects the two effort arms, or effort linkages, 31 to each other, and a stop 37 is welded to the side 17 to prevent the handle from moving too far. A pair of cross supports 39 are shown in FIG. 2 across the top of the receiving trough 15 and lend added support to the trough 15. The outlet collar 25 is shown in FIG. 2 and extends from the bottom 20 of the receiving trough 15. In FIG. 3 the collar 25 extends from the end 19 of the receiving trough 15. This collar connects to an outlet tube 43 so that, as the fish tapes are fed through the guide tubes 21 on the tube centers of the reactor tubes 6, the catalyst 42 and dust falling by gravity into the receiving trough can be conveyed through the outlet tube to a drum or other receptacle for proper storage. A pair of guide means or plugs 27, having a plastic covering 28, snugly fit in the tubes 6 of the tube sheet 4 and are mounted on each end 18 and 19 of the trough 15. Expandible plugs, commonly referred to as plumbers' plugs, can serve a dual purpose as guide plugs 27 and as a fastening means 24.
Whenever the workman comes across an obstruction within the catalyst tube 6, he can reciprocate the flexible steel rods and break loose any catalyst 42 which is stuck or bridged over in the narrow catalyst tubes. As is illustrated in FIG. 6, multiple receiving troughs can be used in a particular reactor and the flexible steel rods may be attached to an air-lance made up of an elongated, flexible, small diameter high-pressure fluid hose capable of extending the entire length of the reactor tube 46 and a nozzle 47. The nozzle has an orifice (not shown) ranging in size from about 0.055 to 0.5 inches and has interior walls tapering at an angle of from about 0° to about 10°. In this instance, as is shown in FIG. 7, the fish tape, or flexible steel rod, 45 has a cross-piece 48 which tends to prevent the air-lance and its support in the form of the flexible steel rod 45 from slipping out of the bottom opening 23 of the guide tube 21. In the instance where multiple receiving troughs are used, a vacuum manifold 50, containing a series of nipples 51, is provided so that the vacuum hoses 43 running between the receiving troughs 15 and the vacuum manifold can be connected. In instances where a vacuum is drawn on the outlet tube 43, the flange 40 and the gasket 41 are not used, since ambient air is drawn in around the top of the trough and the dust and catalyst particles are conveyed through the vacuum line 43, ultimately, to the storage drums 65 or other storage receptacles.
However, where the air-lances are used, it is not necessary to reciprocate the steel rods or fish tapes 45 within the catalyst tubes 6, since the jets of high-pressure fluid tend to break loose any catalytic material which tends to be stuck, and the catalyst then falls by gravity to the receiving trough and through collar 25 to the hose 43 to the vacuum manifold, and thence to the proper receptacle for storage, as will hereinafter be pointed out. Furthermore, whenever the air-lances are used the flange 40 and the gasket 41 are preferably employed. Additionally, it is possible, through the use of the air-lances, to attach the receiving trough to the top tube sheet of the reactor, as is illustrated in FIG. 8, and exert sufficient pressure through the air-lances to actually blow the dust and catalyst particles upwardly into the receiving trough 15, wherein the vacuum line 43 would pull the dust and solid material on for further processing.
The further processing is illustrated in FIG. 10, which illustrates a vacuum line 55 running from the vacuum manifold 50 to the cyclone separator 56. The cyclone separator has an air-lock 57, which allows the dust in the top of the cyclone separator 56 to go by vacuum line 58 to the truck containing the vacuum pump and filter for collection, and which allows the solid material to go through the air-lock into the closed housing 60, containing a vibrating screening mechanism 69 and conveyor for screening and sizing the catalyst. A vacuum tube 61 carries away any catalytic dust or fines generated in the screening and sizing operation. Vacuum tube 61 is in operative relation with bag filter 63, which collects any dust from housing 60. The sized and screened catalyst 42 is conveyed through tubes 62 to receiving drums 65, each equipped with domed hoods 64 and dip pipes 68, which are described in detail in U.S. Pat. No. 4,312,388, which belongs to the assignee of this application. As is shown in that patent, air is drawn up around the periphery of the domed hood 64 and goes via line 66 to dust collector 67 for collection of any residual dust or fines which might have developed in the screening and sizing operation within housing 60. The vacuum or low pressure for the dust collectors 63 and 67 is provided by fans 70 and lines 71 As previously mentioned, the air-lance would involve the provision of compressed air or other compressed fluid in the range of from 50 to 2500 psi. If the air-lance were used as illustrated in FIG. 8, from the top tube sheet of the reactor, to force the catalyst and dust upwardly into a receiving trough 15 which had a vacuum drawn on it, a higher amount of pressure would be involved. The gasket 41 and flange 40 arrangement would be essential in this instance.
The amount of vacuum that can be produced by the vacuum pump on the truck is in the range of 3-15 inches of mercury, so that the amount of air running through the trough would be in the range of 300-650 cfm.
While a preferred embodiment of this invention involves the vacuum tube 43 directly connected to the trough, it is not absolutely essential that this be done in this way. The catalyst and dust may be unloaded by gravity so long as the domed hoods 64, as further described in U.S. Pat. No. 4,312,388, are used on the receiving drums 65 and ambient air is drawn through the hood to prevent any dust from escaping to the atmosphere. Thus, the dust and catalyst can be loaded directly into the drums or receptacles 65 in which the removed catalyst is to be loaded and any residual dust drawn to a bag filter for collection.
Many modifications will occur to those skilled in the art from the detailed description hereinabove given, which is meant to be exemplary in nature and non-limiting except so as to be commensurate in scope with the appended claims. | A catalyst trough containing multiple guide tubes in registry with the tubes of a multi-tube catalytic reactor is utilized to unload catalysts therefrom with maximum dust containment and maximum catalyst recovery. The catalyst recovery trough contains an outlet collar connected to an outlet line and a positive fastening means whereby the trough is fixedly but detachably connected to the tube sheet of the reactor. The guide tubes extend vertically upwardly from the bottom of the trough and are open in the bottom so as to allow the provision of flexible steel rods or "fish tapes", which may or may not be equipped with high-fluid pressure tubes as air-lances for feeding into the tubes of the reactor, which are on center with the guide tubes of the trough. In this manmner any catalytic material which is stuck or bridged across the catalytic tubes may be dislodged so as to fall by gravity into the recovery trough and into an outlet line for recovery. | 1 |
FIELD OF THE INVENTION
[0001] The invention relates to a process allowing the at least partial conversion to propylene of a hydrocarbons charge comprising olefins the carbon number of which is for the most part equal to 4 or 5, this cut—which will be called C4/C5 cut in the remainder of the text most often coming from an FCC unit or from a steam-cracking unit.
[0002] The term FCC describes the process of fluidized-bed catalytic cracking of oil fractions with a boiling point above approximately 350° C., for example a vacuum distillate, optionally deasphalted oil or an atmospheric residue.
[0003] C4/C5 olefin cuts are available in large, often surplus, quantity, in oil refineries and steam-cracking installations.
[0004] However, their recycling in refining units is problematic:
on the one hand, their recycling to steam cracking presents problems, because the yields of light olefins are lower than with paraffin cuts and they have a relatively higher tendency to form coke; and on the other hand, their recycling to FCC would require the use of more severe conditions or specific catalysts, which would significantly modify the FCC procedure.
[0007] The charge of the process according to the invention can also comprise C4/C5, or even larger, fractions coming from a chamber or fluidized-bed coking unit, a visbreaking unit or a Fischer-Tropsch synthesis unit.
[0008] The charge can also comprise fractions of a steam-cracked gasoline.
[0009] In summary, the charge of the process according to the present invention is therefore a C4/C5 olefin cut, i.e. typically a light olefin charge, containing for the most part (i.e. more than 50%, preferably at least 60%) C4 and/or C5 olefins, whose final distillation point is generally below 320° C., most often below 250° C. Often, the olefin charge of the present invention also comprises highly unsaturated compounds, such as dienes (diolefins) specially with 4 or 5 carbon atoms (in particular butadiene) and small quantities of acetylene compounds which can have from 2 to 10 carbon atoms.
[0010] The process which is the subject of the present invention successively uses catalytic reactions of selective hydrogenation, oligomerization of the iso-olefins and oligocracking of the n-olefins.
PRIOR ART
[0000]
French patent FR-B-2 608 595 describes the process of metathesis which converts an ethylene+n-butene mixture to propylene.
The process according to the invention does not use metathesis, which avoids the need to use other than C4 and C5 olefins (such as ethylene) in a large quantity, such olefins of course being able to occur as impurities. Therefore it does not require massive consumption of ethylene, a high-cost product. Moreover, if it is applied on a steam-cracking site, the process according to the invention makes it possible not only not to use ethylene as charge, but also to co-produce ethylene with the propylene. As the co-production of ethylene is typically less than that of propylene, this makes it possible to enhance the propylene-to-ethylene ratio of the steam cracker, which is in line with market trends.
The process described in the international application WO-A-01/04 237 is another process for the production of propylene in a single stage from light olefins, that may be considered to be a variant of the FCC process using a catalyst comprising a ZSM-5 zeolite. The typical operating conditions of this process are a temperature close to 600° C. and a pressure of 0.1 to 0.2 MPa (1 MPa=10 6 Pa=10 bar). In these conditions the propylene yield is approximately 30% and can increase up to 50% with recycling of the C4 and C5 cuts which have not reacted. A drawback of this process is that the fluidized-bed technology is costly from an investment point of view and requires relatively sensitive process control. Moreover, it leads to considerable losses of catalyst through attrition.
The process according to the invention is directed toward another type of process and does not use FCC.
In the family of single-stage oligocracking processes (i.e. where there is no prior oligomerization of the C4/C5 fractions), a process can also be mentioned which is described in the article “Production of Propylene from Low Valued Olefins”, which appeared in the journal “Hydrocarbon Engineering” dated May 1999. This is a fixed-bed process in which the catalyst is a ZSM-5-type zeolite acting in the presence of steam. The temperature is close to 500° C. and the pressure is comprised between 0.1 and 0.2 MPa. The reported cycle time is of the order of 1000 hours. The catalyst is regenerated in situ and its total life, i.e. the length of time it is used in the reactor before it is renewed completely, is approximately 15 months. The reported propylene yield is approximately 40%; it could rise to 60% with recycling of the C4 and C5 cuts that did not react.
This process makes it possible to obtain a relatively high propylene yield. However, it requires the use of large quantities of steam, which is not the case in the present invention, where the desired level of partial pressure on the olefins is advantageously obtained. There is no addition of water from outside in the process according to the invention.
A process described in international application WO-A-99/29 805 and in the patents or patent applications EP-B-0 921 181 and EP-A-0 921 179 can also be mentioned. These disclose an oligocracking process using a MFI-type zeolite catalyst with a high Si/Al ratio (from 180 to 1000) to limit the hydrogen transfer reactions responsible for the production of dienes and aromatics. The temperature is close to 550° C., the pressure is close to 0.1 MPa, and the space velocity is comprised between 10 h −1 and 30 h −1 . This process includes the possibility of using fixed-, moving- or fluidized-bed reactors. The catalyst used has a MFI-type zeolite whose Si/Al ratio (silicon/aluminium atomic ratio) is greater than or equal to 180, preferably a ZSM-5 zeolite with an Si/Al ratio comprised between 300 and 1000.
The process described in the patent application EP-A-1 195 424 can also be mentioned. This is an oligocracking process also using a MFI-type zeolite catalyst with a Si/Al ratio of 180 to 1000 or a MEL-type zeolite catalyst with a Si/Al ratio of 150 to 800, these high Si/Al ratios being required in order to limit the hydrogen transfer reactions responsible for the production of dienes and aromatics. The temperature is comprised between 500° C. and 600° C., the olefins partial pressure comprised between 0.01 MPa and 0.2 MPa, and the space velocity comprised between 5 h −1 and 30 h −1 .
U.S. Pat. No. 6,049,017, which can be considered the closest prior art, describes a process for production of ethylene and propylene from an olefin cut comprising the following succession of stages:
a) a separation of the ethylene, the propylene, then the diolefins (for example by selective hydrogenation); b) a separation of the n-olefins and the iso-olefins by conversion of the iso-olefins using an oxidizing agent and an acid catalyst in order to form oxygenated compounds (for example by etherification); c) a separation of the oxygenated compounds and d) a cracking of the n-olefins using a small-pore catalyst (for example zeolitic or preferably non-zeolitic containing a SAPO) in order to obtain ethylene and propylene.
In an alternative, it is proposed to treat part of the effluent from the separation of the oxygenated compounds by oligomerization in order to obtain a flow of olefins, which is recycled to the cracker. The aim of this stage is to eliminate paraffins from the charge entering the cracker.
The present invention also uses a unit separating n-olefins and the iso-olefins, but in a unit which does not use an oxidizing agent. The drawback of such an agent (methanol, ethanol) is that it requires a separation unit (distillation, washing with water, etc.) and poses problems of pollution or even toxicity as regards the methanol.
[0026] Moreover, the process according to the present invention leads to the formation of propylene, but also of an additional quantity of gasoline of excellent quality.
SUMMARY OF THE INVENTION
[0027] The present invention relates to a process for conversion of a C4/C5 olefin C4/C5 cut to propylene and gasoline, comprising the following succession of stages:
1) in the case where the level of diolefin and acetylene impurities is greater than 1000 ppm, selective liquid-phase hydrogenation of said cut on at least one catalyst comprising at least one metal chosen from the group formed by Ni, Pd, and Pt, deposited on a non-acid refractory oxide support, so as to obtain an effluent having an insaturates content of at most 1000 ppm; 2) selective oligomerization of the iso-olefins of at least part of the effluent from stage (1), followed by a distillation, so as to obtain a gasoline fraction and at least one remaining cut containing less than 10 wt.-% isobutenes, and 3) oligocracking of the n-olefins, working in a single stage, on at least a part of the remaining cut of stage (2), on a catalyst comprising at least one zeolite having a shape selectivity and an Si/Al atomic ratio of 50 to 500, followed by a separation in order to obtain a gasoline fraction, propylene and a residual C4/C5 cut.
[0031] The C4 and C5 olefin charge generally comes from a steam-cracking or catalytic-cracking (FCC) unit.
[0032] The aromatics-rich gasoline cut from the oligocracking stage can advantageously be mixed at least in part with the gasoline cut from the selective oligomerization in order to form a gasoline having a RON octane number of at least 94.
[0033] It can also be sent at least in part to an aromatics extraction complex.
[0034] The process according to the invention finally allows a propylene yield of at least 19%, preferably greater than 22%, to be obtained.
[0035] The invention also relates to an installation which comprises:
a selective hydrogenation unit containing at least one catalyst comprising at least one metal chosen from the group formed by Ni, Pd, and Pt, deposited on a non-acid refractory oxide support, the unit being fitted with ducts for the entry of the C4/C5 olefin cut to be treated and the hydrogen and for the exit of the effluent; a unit for selective oligomerization of the iso-olefins, comprising successively a drying unit, a desulphuration unit and a reaction unit containing at least one acid selective oligomerization catalyst, the unit being fitted with ducts for the passage of the effluents between said successive units, for the entry of at least a part of the effluent from the hydrogenation unit and for the exit of the effluent; a distillation column separating a gasoline fraction and at least one remaining cut; a unit for oligocracking of the n-olefins, containing a catalyst comprising at least one zeolite having a shape selectivity and an Si/Al atomic ratio of 50 to 500, fitted with ducts for the entry of at least a part of the remaining cut from the distillation of the oligomerization effluent, and for the exit of the effluent; a distillation column separating a gasoline fraction, propylene and a residual C4/C5 cut; a duct for recycling at least part of said residual C4/C5 cut to the oligomerization unit or to the oligocracking unit and a zone for mixing the gasoline fractions from the oligomerization and oligocracking units.
[0043] In particular in this installation, the hydrogenation unit comprises a fixed-bed reactor with descending flow of the charge, a duct conveying the obtained effluent into a second fixed-bed reactor with ascending co-current of said effluent and hydrogen.
[0044] Optionally, the installation also comprises an aromatics extraction unit fitted with a duct for the entry of the oligocracking effluent and an exit duct for the exit of the dearomatized gasoline.
[0045] FIG. 1 shows the scheme of the process and of the installation according to the invention which will allow a better understanding of the following detailed description.
[0046] The charge to be treated ( 1 ) is introduced into a selective hydrogenation unit (a) and produces an effluent ( 2 ).
[0047] A charge of another origin ( 2 ′) can be added to this effluent ( 2 ), on condition that the insaturates level of said charge ( 2 ′) is comprised between 10 ppm and 1000 ppm, preferably between 50 ppm and 300 ppm. Typically ( 2 ′) can be a FCC gasoline not needing to be hydrotreated.
[0048] The resulting charge ( 2 )+( 2 ′) is injected into the selective oligomerization unit (b). This selective oligomerization unit (b) produces, after separation in a distillation column (d):
at the top, a lighter hydrocarbon cut ( 4 ), constituted for the most part by C4 and C5 fractions and at the bottom, an oligomerate ( 3 ), constituted for the most part by C8 olefins and able to contain a certain proportion of compounds up to C16.
[0051] The C4/C5 cut corresponding to the flow ( 4 ) is sent mixed with the recycling flow ( 5 ), after purging, to the oligocracking unit (c).
[0052] The oligocracking unit (c) produces, after separation in a distillation column (d′):
at the top, an ethylene-rich light cut ( 7 ); a propylene-rich effluent ( 6 ); an intermediate fraction ( 8 ) containing C4 and C5 hydrocarbons constituted for the most part by saturated compounds, at least a part of which fraction is recycled by the flow ( 5 ) to the entry to the oligocracking unit and at the bottom, a heavy effluent ( 9 ) comprising aromatic and olefin compounds, the boiling points of which are situated in the range of gasolines, i.e. typically from 200° C. to 250° C.
[0057] In a variant of the process according to the invention, the recycling ( 8 ) from the distillation column (d′) constitutes a flow ( 5 ′) which is sent to the entry to the selective oligomerization unit (b).
[0058] Of course, a variant in which a part of the fraction ( 8 ) would be recycled by the flow ( 5 ) to the entry to the oligocracking unit and another part would be recycled by the flow ( 5 ′) to the entry to the oligomerization unit remains wholly within the scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0059] The crude charge from a steam cracker or a FCC (catalytic cracking) generally contains diene (diolefin) compounds which are poisonous to the catalysts used in oligomerization and oligocracking units.
[0060] When the level of diene and acetylene impurities is greater than 1000 ppm, the charge is treated by selective hydrogenation in order to reduce the level of impurities. Advantageously, all the charges containing more than 300 ppm of these impurities, or even more than 10 ppm, are treated.
Thus, in the case of a charge (C4/C5 olefin cut) coming from steam cracking, this stage of selective hydrogenation of the dienes and acetylenes to mono-olefins is compulsory. This selective hydrogenation can treat either the crude cut from the steam cracker, or the C4 cut after it has previously been treated in a unit used to extract compounds of diolefin type by adsorption in a solvent. This type of process for the extraction of the butadiene is known to a person skilled in the art. In the case of a charge (C4/C5 olefin cut) coming from catalytic cracking (FCC), the selective hydrogenation stage is optional, but it makes the implementation of the downstream processes easier.
[0063] Thus, in an extremely advantageous manner, in stage (1) a C4/C5 steam-cracking olefin cut is treated and in stage (2) at least a part of the effluent from stage (1) and a C4/C5 catalytic-cracking olefin cut.
[0064] The principal objective of this first selective hydrogenation stage is to convert a the diolefins (or dienes) to mono-olefins. Only the mono-olefins can be converted to propylene according to the process of the invention. It is therefore important to maximize the mono-olefins content of the charge to be treated.
[0065] Another objective of this first stage is to purify the charge of the other impurities present, in particular the acetylene compounds, which are poisonous to the catalysts used in the downstream stages.
[0066] When the diolefins content to be treated is large, the conversion is carried out using two reactors in series, optionally with recycling of a fraction of the effluent to the entry to the selective hydrogenation unit. This recycling also allows control of the global heating of the reaction.
[0067] The insaturates content of the effluent at the end of the selective hydrogenation stage (diolefins or insaturates) is at most 1000 ppm, preferably at most 300 ppm, often comprised between 10 ppm and 1000 ppm, preferably between 50 ppm and 300 ppm.
[0068] The catalysts used in this selective hydrogenation stage are generally constituted by a metal of group VIII (typically Ni or Pd) deposited on a non-acid refractory alumina or oxide support. The external acid surface area must not be too large, in order to limit the polymerization reactions at the surface of the catalyst. The preferred support is constituted by alumina.
[0069] The metal, preferably palladium, content must be comprised between 0.1 and 5 wt.-% and preferably between 0.2 and 0.6 wt.-%. When nickel is used as metal, its content is comprised between 5 and 25 wt.-%, preferably between 7 and 20 wt.-%.
[0070] The operating conditions are chosen such that the effluent remains in the liquid state, i.e. typically from 20° C. to 150° C., under pressures ranging from 5 bar to 40 bar.
[0071] The quantity of catalyst used for the reaction is typically situated between 2 m 3 and 8 m 3 of catalyst per m 3 of fresh charge treated.
[0072] The hydrogen is generally introduced at a rate of 5 mol-% to 30 mol-% above stoichiometry and preferably 10% to 20% above the stoichiometric quantity.
[0073] Advantageously, the reaction is performed in a fixed-bed reactor generally with a descending flow for the principal reaction, (this is the case when there are more than 1.5 wt.-% diolefins present in the effluent to be converted) and with a catalyst preferably constituted by Pd deposited on alumina, generally with ascending co-current with the hydrogen for the finishing phase of the reaction, preferably with a catalyst constituted by Pd/Ag deposited on alumina.
[0074] This arrangement has the advantage of increasing the conversion rate.
[0075] The second stage of the process according to the invention consists of a selective oligomerization of the iso-olefins (isobutenes, isopentenes) of all of the effluent from the first stage, proceeding in two phases.
[0076] The selective oligomerization of isobutene is described in a detailed manner in the patent FR-B-2 492 365.
[0077] The first phase of the selective oligomerization consists of a drying and a desulphuration of the charge.
[0078] The two functions, drying and desulphuration, are performed in the same reactor and use sieves. These sieves are generally constituted by a series of zeolites having different pore sizes (3A, 4A, 5A, 13× zeolites) or optionally activated alumina. The sieves employed in order to carry out the drying and desulphuration are generally used in an alternating reaction-regeneration cycle.
[0079] The drying and desulphuration phase is generally carried out in liquid phase, at a temperature close to ambient temperature (20 to 70° C.), at low pressures comprised between 1 bar and 15 bar.
[0080] The regeneration phase consists of sending to the reactor a dry, hot gas, for example nitrogen, at a temperature comprised between 200° C. and 400° C.
[0081] The second phase of the oligomerization stage consists of a selective oligomerization of the iso-olefins (isobutenes, isopentenes). The selectivity of the operation consists precisely in oglomerizing the isobutenes without oligomerizing the n-olefins (n-butenes, n-pentenes).
[0082] The catalyst used in this stage is an acid catalyst, for example a catalyst of silica-alumina type, a resin or a catalyst of the solid phosphoric acid type. Preferably, the catalyst used in this stage is a catalyst of silica-alumina type such as is described in the patent FR-B-2 463 802, the silica content of which is comprised between 60 and 95 wt.-%, preferably between 70 and 90 wt.-%, and having as additive between 0.1 and 5 wt.-% zinc oxide. This is generally made up to 100% with alumina.
[0083] The operating conditions are generally (and in particular in the case of the above catalyst):
temperature comprised between 20° C. and 80° C. on entering the reactor and comprised between 50 or 65° C. and 95° C. on leaving the reactor; pressure comprised between 10 bar and 50 bar; volume flow rate of charge per mass unit of catalyst comprised between 0.05 h −1 and 5 h −1 , preferably comprised between 0.1 h −1 and 3 h −1 .
[0087] The selective oligomerization stage is generally carried out in a series of N fixed-bed reactors, each of them being followed by a cooler.
[0088] The number N chosen depends on the desired n-butene selectivity. It is typically from 2 to 4. An external recycling to the entry to these N reactors is optionally used to maintain a constant isobutene content at the entry to the process. This recycling is constituted either by the effluent taken directly on leaving the reactor, or the oligomerate recovered at the bottom of the distillation column.
[0089] The temperature of each of the N coolers is adjusted during the operation in order to compensate for the loss of activity of the catalytic system used.
[0090] Downstream of the N reactors, a separation by distillation is carried out in order to separate a gasoline fraction essentially comprising hydrocarbons ranging from C6 to C16, often composed for the most part of C5 hydrocarbons, and therefore comprising C6-C16 or C8-C16 oligomers for example, and to recover one or more remaining C4 and C5 cuts comprising essentially paraffins and C5 n-olefins and iso-olefins.
[0091] This remaining C4/C5 cut typically contains 20 to 80 wt. % olefins, for the most part light olefins with 4 and/or 5 carbon atoms. The rest of the cut is constituted by iso-olefins, essentially C5 iso-olefins, and paraffins.
[0092] The C4 iso-olefins content is generally less than 10 wt.-%.
[0093] At least one C4/C5 cut produced at the end of the selective oligomerization stage (and preferably all the remaining cut) is sent into a catalytic oligocracking unit operating in a single stage.
[0094] Typically, the catalyst used in the single-stage oligocracking unit comprises at least one zeolite having a shape selectivity, this zeolite having an Si/Al atomic ratio comprised between 50 and 500, preferably comprised between 60 and 160 and better still between 75 and 150.
[0095] Moreover, the zeolite having a shape selectivity can belong to a first group constituted by one of the following structural types: MEL, MFI, NES, EUO, FER, CHA, MFS and MWW. Preferably it is chosen from MFI (such as ZSM-5) and MEL (such as ZSM-11).
[0096] The zeolite with shape selectivity can also belong to a second group constituted by the following zeolites: NU-85, NU-86, NU-88 and IM-5.
[0097] In particular one of the following commercial ZSM-5 zeolites can be used:
CBV 28014 (Si/Al ratio: 140) and CBV 1502 (Si/Al atomic ratio: 75) from Zeolyst International, Valley Forge, Pa., 19482 USA, and ZSM-5 Pentasil with a Si/Al 125 atomic ratio from Süd-Chemie (Munich, Germany).
[0100] One of the advantages of these zeolites presenting a shape selectivity is that their use leads to a better propylene/isobutene selectivity, i.e. a higher propylene/isobutene ratio in the effluents of said oligocracking unit.
[0101] The zeolite or zeolites can be dispersed in a matrix based on silica, zirconia, alumina or silica-alumina, the proportion of zeolite often being comprised between 15 and 90 wt.-%, preferably between 30 and 80 wt.-%.
[0102] Si/Al atomic ratios comprised in the preferred range within the framework of the invention can be obtained at the time of manufacture of the zeolite or by subsequent dealumination.
[0103] The preferred catalysts are those constituted by zeolite and a matrix.
[0104] The catalyst is generally used in a mobile bed, preferably in the form of spheres with a diameter generally comprised between 1 mm and 3 mm.
[0105] The catalyst can also be used in fixed-bed state, in which case the reactor or reactors used operate alternately in reaction then in regeneration according to the well known “swing” technique.
[0106] The regeneration phase typically comprises a phase of combustion of the carbon deposits formed on the catalyst, for example by means of an air/nitrogen mixture, of air depleted in oxygen (for example due to recirculation of fumes), or simply air.
[0107] The regeneration can optionally comprise other phases of treatment and regeneration of the catalyst which will not be elaborated on here as they are not a characteristic feature of the invention.
[0108] The catalytic oligocracking unit is usually operated in a single stage at a temperature of approximately 450° C. to approximately 580° C., with a space velocity generally comprised between 0.5 h −1 and 6 h −1 .
[0109] The operating pressure is generally comprised between 0.1 MPa and 0.5 MPa.
[0110] The conditions of regeneration of the oligocracking catalyst generally use a temperature comprised between 400° C. and 650° C., the pressure most often being close to the oligocracking pressure.
[0111] The effluent produced by the oligocracking is distilled in order to separate the propylene and the gasoline fraction; a residual C4/C5 fraction is also obtained.
[0112] The propylene is therefore separated directly by distillation of the effluent. Optionally, a so-called superfractionation distillation column can be added, in order to treat the distilled propylene.
[0113] Generally, the propylene yield per pass in relation to the quantity of olefins contained in the fresh charge of the process is greater than 19 wt.-%, preferably greater than 22 wt.-%.
[0114] The residual C4-C5 fraction can advantageously be recycled at least in part to the entry to the oligocracking unit, and/or the entry to the selective oligomerization unit. Preferably it is recycled at least into the oligocracking stage.
[0115] The recycling flow rate of said C4/C5 cut relative to the flow rate of charge entering the selective oligomerization unit can advantageously vary in a ratio of 1 to 5 and preferably 3 to 5.
[0116] The distribution of the recycle flow rate of the C4/C5 cut from the oligocracking unit to, on the one hand, the oligocracking unit and, on the other hand, the selective oligomerization unit, is carried out according to the wishes of the operator. In particular in certain cases, the whole of this recycling flow rate can be sent to the entry to the selective oligomerization unit and in other cases, the whole of this recycling flow rate can be sent to the entry to the oligocracking unit.
[0117] The gasoline fraction produced by the oligocracking unit in a single stage is an aromatic gasoline which can be mixed completely or in part with the olefin gasoline fraction produced by the selective oligomerization unit (rich in multi-branched olefins), advantageously in order to form a gasoline with an octane number at least equal to 94 RON, or be sent in part or completely to an aromatics extraction complex in order to preferably then be mixed with the gasoline pool.
EXAMPLES
[0118] The examples will be better understood following the different flows using FIG. 1 . The flow numbers which appear on the material balances are those corresponding to FIG. 1 .
Example 1
[0119] The charge ( 1 ) is a crude C4 steam-cracking cut. The charge ( 2 ′) is a crude C4 FCC cut.
[0120] The selective hydrogenation unit uses two reactors:
The first reactor uses a 0.3 wt.-% Pd Pd/Al2O3 catalyst, on an alumina with 69 m 2 /g specific surface area. It operates at 50° C. adiabatically in a descending crossed bed at 30 bar absolute. For the reaction to remain in liquid phase, a recycling equal to 20 times the mass charge flow is used. The overall H2/butadiene ratio is 1.05 mole/mole. The second reactor, called “finishing reactor”, is a reactor with ascending flow, using a Pd+Ag catalyst deposited on alumina, i.e. 0.2 wt.-% Pd, and 0.1% Ag deposited on an alumina with 69 m 2 /g BET surface area. The temperature is set at 35° C., the pressure at 26 bar.
[0123] The performance figures are given in the material balance of Table 1.
[0124] On leaving the selective hydrogenation unit, the crude FCC charge and the charge from the selective hydrogenation are mixed. The resulting mixture is dried and desulphurized on 3A and 13× molecular sieves, marketed by Axens.
[0125] The thus-treated mixture is sent to the unit for selective oligomerization of the isobutenes. This unit operates at a global VVH of 1, on a catalyst comprised 90% of silica and 10% of alumina at a temperature comprised between 30° C. and 50° C. and a pressure of 20 bar.
[0126] A distillation column (d) separates a C4/C5-rich cut from a C8-C16 oligomers-rich gasoline cut.
[0127] A fraction of the C4/C5 cut (recycle rate 1 ton/treated ton, i.e. 50% of the mass) is used as a thermal diluent.
[0128] The oligocracking is carried out in a reactor operating at 2.8 bar absolute, at 510° C., with a PPH of 3.5 h −1 relative to the charge entering the reactor.
[0129] A single adiabatic reactor with a descending flow in gas phase is used.
[0130] The cycle time between two successive regenerations is 48 h.
[0131] The catalyst used is comprised 30% of ZSM-5 zeolite with an Si/Al atomic ratio of 140 and 70% of gamma alumina. It is prepared in the form of spheres with a diameter of 3 mm shaped by the “oil drop” technique and it flows in a moving bed.
[0132] The C4 cut from the oligocracking unit is recycled into the oligocracking process, according to the material balance of Table 1.
[0133] The gasoline cut from the oligomerization unit has a RON of 96.5 and a MON of 84. The gasoline cut from the oligocracking unit has a RON of 96.5 and a MON of 88.5. The mixing of these two gasolines leads to a gasoline with a RON equal to 96.5 and a MON of 85.
[0134] The yield of the C3 cut is 19%. This C3 cut contains 95% propylene.
[0135] The overall yield of the gasoline cut is 43%.
[0000]
TABLE 1
kg/h
(1)
(2)
(2′)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
nC4=
2340
6116
3556
—
9188
2681
—
—
202
—
iC4=
2889
2889
1524
—
221
1720
—
—
129
—
Dienes
3976
2
20
—
—
—
—
—
—
—
Paraf
795
993
4900
—
5893
85362
—
—
6425
—
C1 + C2
—
—
—
—
—
—
—
845
—
—
C3
—
—
—
—
—
—
3830
—
—
—
C5
—
—
—
—
—
—
—
—
1633
—
C6-C12 Aros
—
—
—
—
—
—
—
—
—
2231
Coke
—
—
—
—
—
—
—
—
—
—
C8
—
—
—
9227
3227
—
—
—
—
—
C12
—
—
—
1450
1450
—
—
—
—
—
C16
—
—
—
—
—
—
—
—
—
—
C20
—
—
—
22
22
—
—
—
—
—
Total
10000
10000
10000
4698
20000
85065
3830
845
8390
2231
Example 2
[0136] The data are the same as those of Example 1, with the exception of the following points:
The charge ( 1 ) is a crude C4 steam-cracking cut. The charge ( 2 ′) is a crude, C4 FCC cut. The recycling ( 5 ) involves a fraction of the C4 and C5 cuts as given in the material balance of Table 2.
[0140] The RON of the oligomerate is still 96.5.
[0141] The overall C3 cut yield is 22%.
[0142] The overall yield of the gasoline cut is 38%.
[0000]
TABLE 2
kg/h
(1)
(2)
(2′)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
nC4=
2340
6116
3556
—
9188
3328
—
—
263
—
iC4=
2889
2889
1524
—
221
2136
—
—
169
—
Dienes
3976
2
20
—
—
—
—
—
—
—
Paraf
795
993
4900
—
5893
82371
—
—
6507
—
n + i C5=
—
—
—
—
—
1633
—
—
129
—
Cy
—
—
—
—
—
1436
—
—
113
—
C5 Dienes Inerts
—
—
—
—
—
—
—
—
—
—
C1 + C2
—
—
—
—
—
1558
—
—
123
—
C3
—
—
—
—
—
—
—
975
—
—
C6-C12 Aros
—
—
—
—
—
—
4423
—
—
—
Coke
—
—
—
—
—
—
—
—
—
2576
C8
—
—
—
—
—
—
—
—
—
—
C12
—
—
—
3227
3227
—
—
—
—
—
C16
—
—
—
1450
1450
—
—
—
—
—
C20
—
—
—
—
—
—
—
—
—
—
—
—
—
22
22
—
—
—
—
—
Total
10000
10000
10000
4698
20000
92461
4423
975
7304
2576
Example 3
[0143] The data of Example 3 are the same as those of Example 1, with the exception of the following points:
The charge ( 1 ) is a crude C4 steam-cracking cut. The charge ( 2 ′) is a crude C4 FCC cut The recycling ( 5 ′) is sent to the selective oligomerization unit. The cycle time of the oligocracking unit is extended to 72 h. This recycling ( 5 ′) now involves a fraction of the C4 and C5 cuts as shown in the material balance of Table 3.
[0148] The overall C3 cut yield is 22%.
[0149] The conversion rate of the C4 olefins to the C3 cut is 47%.
[0150] The RON of the oligomerate changes to 94.5 and the MON to 82.
[0000]
TABLE 3
kg/h
(1)
(2)
(2′)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
nC4=
2340
6116
3556
—
11607
2546
—
—
206
—
iC4=
2889
2889
1524
—
302
1634
—
—
132
—
Dienes
3976
2
20
—
—
—
—
—
—
—
Paraf
795
993
4900
—
84841
78948
—
—
6401
—
n + i C5=
—
—
—
—
1249
1249
—
—
101
—
Cy
—
—
—
—
30
30
—
—
2
—
C5 Dienes Inerts
—
—
—
—
—
—
—
—
—
—
C1 + C2
—
—
—
—
2011
2011
—
—
163
—
C3
—
—
—
—
—
—
—
807
—
—
C6-C12 Aros
—
—
—
—
—
—
3658
—
—
—
Coke
—
—
—
—
—
—
—
—
—
2131
C8
—
—
—
—
—
—
—
—
—
—
C12
—
—
—
4385
—
—
—
—
—
—
C16
—
—
—
1970
—
—
—
—
—
—
C20
—
—
—
—
—
—
—
—
—
—
—
—
—
22
—
—
—
—
—
—
Total
10000
10000
10000
6378
100041
86419
3658
807
7007
2131
Example 4
[0151] The data of Example 4 are the same as those of Example 1, with the exception of the following points:
The charge ( 1 ) is a crude C4 steam-cracking cut. The charge ( 2 ′) is a mixture of a crude C4 FCC cut, a crude C5 FCC cut and a crude C5 steam-cracking cut which has also undergone a treatment to eliminate the dienes, similar to that described for the C4 cut. The recycling ( 5 ) is sent to the oligocracking unit. The cycle time of the oligocracking unit is 48 h. This recycling ( 5 ) now involves a fraction of the C4 and C5 cuts as defined in the material balance of Table 4. The cycle time of the oligocracking unit is 48 h.
[0157] The overall C3 cut yield is 28%.
[0158] The conversion rate of the C4-C5 olefins to the C3 cut is 42%.
[0159] The RON of the oligomerate changes to 94.5 and the MON to 82.
[0000]
TABLE 4
kg/h
(1)
(2)
(2′)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
nC4=
2340
6116
3556
—
9188
7133
—
—
1259
—
iC4=
2889
2889
1524
—
221
4577
—
—
808
—
Dienes
3976
2
20
—
—
—
—
—
—
—
Paraf
795
993
4900
—
5893
42168
—
—
7441
—
n + i C5=
—
—
12500
—
12500
3499
—
—
618
—
Cy
—
—
3000
—
3000
84
—
—
15
—
C5 Dienes Inerts
—
—
—
—
—
—
—
—
—
—
C1 + C2
—
—
4500
—
4500
28316
—
—
4997
—
C3
—
—
—
—
—
—
—
2459
—
—
C6-C12 Aros
—
—
—
—
—
—
11151
—
—
—
Coke
—
—
—
—
—
—
—
—
—
6495
C8
—
—
—
—
—
—
—
—
—
—
C12
—
—
—
—
—
—
—
—
—
—
C16
—
—
—
3227
—
—
—
—
—
—
C20
—
—
—
1450
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
22
—
—
—
—
—
—
Total
10000
10000
30000
4698
35302
85777
11151
2459
15137
6495 | The invention relates to a process for production of propylene from a C4/C5 olefin cut (for example from steam cracking and/or catalytic cracking), this process comprising an optional selective hydrogenation, a selective oligomerization of the isobutenes and an oligocracking of the n-butenes.
The invention makes it possible to obtain a high conversion rate with a good propylene yield and to maximize the production of good-quality gasoline. | 8 |
TECHNICAL FIELD
[0001] The present disclosure relates to a boot with a first fastening region and to a system comprising such a boot and also a housing part.
BACKGROUND
[0002] Boots are used in particular for sealing joints, in particular in the automotive industry for sealing constant velocity sliding joints and fixed joints. However, other applications outside the automotive industry are also possible. Boots within the context of the present disclosure can take the form of rolling boots or folding boots.
[0003] Rolling boots of the aforementioned type are known from the prior art. For instance, FIG. 1 of the present application shows a section along a main axis 60 of a rolling boot according to the prior art having a first fastening region 12 intended for fastening to a joint housing and a second fastening region 14 intended for fastening to a shaft. Such a rolling boot, designated by the reference number 10 in FIG. 1 , is mounted on fixed joints, for example. The first fastening region 12 here has an outer part 34 and an inner part 36 , wherein an accumulation of material 38 in the form, for example of a peripheral annular bead is arranged in the inner part 36 so as to provide a seat in a peripheral groove on the outer lateral surface of a housing part. The first fastening region 12 is adjoined by a fold region 16 having a first fold peak region 20 with a first fold flank 22 close to the fastening region 12 and, opposite this first fold flank, a second fold flank 24 , the fold peak region 20 being adjoined by a fold trough 26 . The fold peak region 20 has a fold peak 21 with a maximum M. Furthermore, the rolling boot 10 according to the prior art shown in FIG. 1 is provided in its interior with reinforcing ribs 40 which are arranged in the fold region 16 .
[0004] FIG. 4 of the present application shows a boot 10 according to FIG. 1 mounted on a housing part 54 of a fixed joint. The housing part 54 has an outer lateral circumferential surface 70 and also an end surface 68 , between which surfaces a peripheral edge 55 is arranged. The boot 10 is mounted on the joint housing part 54 by a first fastening element 58 , and on a shaft 56 in a second fastening region 14 using a second fastening element 62 . The first fastening element 58 and also the first fastening region 12 of the boot 10 are in this case completely assigned to the outer lateral circumferential surface 70 of the joint housing part 54 , or to the joint housing part 54 itself, and the first fastening region 12 is directly followed by a fold region 16 having exactly one fold in the example shown in FIG. 1 and FIG. 4 .
[0005] A particular disadvantage with the known prior art as shown in FIGS. 1 and 4 is that, because of the complete overlapping of the outer lateral surface of the joint housing by the first fastening element and the first fastening region, the fold region displays large deformations during operation of the boot, for example when used in a fixed joint. Given the forces which act, particularly at high rotational speeds, and the associated high mechanical loading, it may occur that boots will possibly even burst during operation.
[0006] Therefore a boot and also a system comprising such a boot is needed in which the deformations acting in particular on the fold region, in particular those in the first fold of the fold region that is near the first fastening region, are reduced.
SUMMARY
[0007] A boot is disclosed herein, the boot having a first fastening region, wherein the first fastening region is displaced axially, as viewed in the direction of a main axis of the boot, and with respect to a housing part, such as, for example, a housing part of a constant velocity sliding joint or fixed joint. It is understood that the boot may be used with any other housing part, and may be used on a joint on which the boot can be mounted, in such a way that the first fastening region at least partially projects beyond an edge of the housing part. In one exemplary configuration, the first fastening region is provided with a base surface which makes available a seat for a first fastening element and which at least partially projects beyond the edge of the housing part, with respect to the main axis of the boot.
[0008] By virtue of the projecting length made available according to the disclosure by the first fastening region, there finally occurs an only partial overlapping of the outer lateral circumferential surface by the first fastening region or the first fastening element arranged on the base surface thereof. The fastening element then has, in addition to the known sealing function, a supporting function by virtue of the possibility made available by the first fastening element to make available, in the region of the projecting length, a support for the fold region, and here in particular the first fold of the fold region that is near the first fastening region. As a result, the deformation of the boot during operation is reduced overall and an increased rotational speed stability is thereby achieved. This has a particularly advantageous effect when the boot according to the disclosure is designed as a rolling boot, it also being possible within the context of the present disclosure for the boot to be designed as a folding boot having a plurality of folds in the fold region. However, a double-folding boot design is also possible, for example.
[0009] As already discussed above, the boot according to the disclosure may be used in fixed joints or else constant velocity sliding joints. However, it can also be arranged on any other type of joints, for example on ball joints, or else in pushrods, for sealing tube ends or other housing parts, in order to provide a sufficient degree of sealing and an additional supporting function. The present disclosure is thus not restricted in terms of the type of housing parts on which the boot can be mounted. Examples of applicable housing parts here are also tube ends of any type, including, for example, push rods, shafts or the like, but also joints and their outer joint housing.
[0010] The projecting length of the base surface of the first fastening region of the boot according to an exemplary configuration of the disclosure is advantageously situated in a range from approximately 20% to approximately 45%, preferably approximately 24% to approximately 35%, of a width of the first fastening element. With such a projecting length ratio, there is made available, on the one hand, a sufficient sealing function of the folding boot but also, on the other hand, a sufficient supporting function, provided by the first fastening element. If the projecting length were smaller, that is to say below 20%, a sufficient supporting function would not be provided under certain circumstances; on the other hand, if the projecting length were too large, the sealing function of the boot could be diminished. The use of the word “approximately” in the present connection makes it clear to the person skilled in the art who is being addressed that embodiments somewhat outside the stated range are hereby readily also covered by the scope of protection of the present disclosure. In particular, deviations of approximately plus/minus 10%, preferably approximately plus/minus 5%, of the respective upper and lower limits do not, within the context of the present disclosure, go outside the scope of protection thereof since a sufficient sealing and protective function can still be provided within these ranges.
[0011] In one exemplary configuration, the base surface of the first fastening region at least partially overlaps a transition region, as viewed in the direction of the main axis of the boot. The transition region adjoins the first fastening region in the direction of a second fastening region in the direction of the main axis of the boot, wherein the second fastening region often has a smaller inside and outside diameter than the first fastening region. Subsequently arranged after the transition region is a fold region which comprises at least one fold. If the fold region has exactly one fold, the boot according to the disclosure can be designed, for example, as a rolling boot. If it has two folds, it may be designed, for example, as a double-folding boot, or alternatively, if it has a plurality of folds, it is designed as a multi-folding boot. The transition region between the first fastening region and fold region can here be configured, for example, in such a way that it is thereby possible for the transition region to bear by way of its inner surface or an arrangement thereof closely against a peripheral end surface of a housing part. However, it is also possible to provide in the transition region for example a joint region which entails advantageous properties in the case of certain embodiments of folding boots in particular. Furthermore, additional retaining or orienting elements can also be arranged in the transition region, these elements facilitating a fastening of a first fastening element in the first fastening region. The first transition region is preferably configured in such a way that its inner surface is arranged opposite a peripheral end surface of a housing part, and with further preference is in contact therewith, i.e. bears against this surface. Then, by virtue of the overlapping of this transition region by the base surface of the first fastening region which makes available the binder seat, and after mounting the first fastening element, there is advantageously achieved a situation whereby the forces exerted by the mounting of the fastening element are transmitted into the first transition region, making it possible to further reduce a more pronounced deformation of the boot according to an embodiment of the disclosure. A complete overlapping here means that the base surface overlaps the entire material thickness of the transition region, and in this region makes available a binder seat for the first fastening element. Preferably, as viewed in the direction of the main axis of the boot, the projecting length is arranged axially displaced in the direction of the fold region of the boot and at least partially outside the transition region.
[0012] In a further exemplary configuration, at least two outer ribs bridge the first fastening region and the transition region at least in parts, with respect to a direction perpendicular to the main axis of the boot. The outer set of ribs advantageously achieves a situation whereby the boot according to the disclosure can be designed to be even more compact, and in particular can have a smaller inside volume. The displacement of the first fastening region already advantageously achieves a reduction in the overall height of the boot according to the disclosure, this reduction being further supported by the provision of an outer set of ribs. An outer set of ribs here is particularly advantageous in the case of rolling boots since they provide a sufficient degree of stability during deformation, and, on the other hand, the inside diameter of these boots is reduced, with the result finally that a reduction in the grease pressure is also achieved and higher service lives and a lower susceptibility to wear can be achieved.
[0013] In a further exemplary configuration of the present disclosure, a plurality of ribs are arranged with a uniform distribution on an outer circumferential surface of the boot. Provision may be made for the respective ribs to be arranged oppositely in pairs on the outer circumferential surface of the boot. For example, four, six, seven, eight, nine, ten or more such pairs can be arranged on the outer circumferential surface of the boot, depending on the requirements which are known to the person skilled in the art who is being addressed. Preference is given here to arranging the respective pairs with a uniform spacing from one another.
[0014] In yet another exemplary configuration, at least one of the ribs protrudes beyond the base surface of the first fastening region to form a positioning and/or bearing surface. The first fastening region constitutes a binder seat surface for a fastening element, for example a clamping strap, a clamp or a compression ring. However, other fastening elements known to a person skilled in the art can also be used within the context of the present disclosure. The specific design of at least one of the outer ribs, preferably at least half the number of outer ribs, more preferably all the outer ribs, serves to facilitate the positioning of this fastening element in the first fastening region, it additionally being the case that the fastening element can also bear by way of its peripheral side edge at least partially against the bearing surface formed by the at least one outer rib, i.e. is in direct contact with this bearing surface. Here, contact does not have to be made by the entire side face of the fastening element with respect to the overall height or thickness of the fastening element. Rather, the positioning and/or bearing surface can also only be at most approximately 90 percent, more preferably at most approximately 60 percent, of the overall height of the fastening element. The fastening element will in this case protrude beyond the positioning and/or bearing surface. In an exemplary arrangement, the positioning and/or bearing surface is designed to be substantially perpendicular in relation to the main axis of the boot, and is part of an offset which is arranged between that end of the first outer edge of the outer rib facing the first fastening region and the positioning and/or bearing surface. Here, this offset preferably has a second outer edge for the at least one outer rib, which edge is preferably oriented substantially parallel to the main axis of the rolling boot, and is part of the rib in question. However, provision can also be made here for this second outer edge for the at least one outer rib to have a slightly angled design, with respect to the main axis of the rolling boot, the angle between the second outer edge and the main axis of the rolling boot being smaller than that angle which is defined between the first outer edge of the at least one outer rib and the main axis of the rolling boot.
[0015] In one exemplary configuration, the outer rib preferably has a first outer edge which is directed away from the outer circumferential surface of the rolling boot. In one exemplary configuration, the first outer edge of the outer rib here starts approximately in the fold peak region of the first fold, more preferably exactly at the fold peak, i.e. the maximum of the first fold, and moreover preferably extends linearly and at an angle to the main axis of the rolling boot. However, provision can also be made for the first outer edge to have another design, for example to be curved.
[0016] Furthermore, the present disclosure also relates to a system consisting of a housing part, which may be part of a joint, such as part of a fixed joint, and even a joint itself, and of a boot as defined above. More specifically, an exemplary system according to the disclosure comprises at least a first fastening element, but may also include at least a second fastening element for fastening the rolling boot in a second fastening region, in particular on a shaft. The first fastening element bears at least by way of a portion of a side face against the positioning and/or bearing surface of at least one rib. In one exemplary configuration, the side face of the fastening element protrudes beyond the positioning and/or bearing surface of the rib. The base surface of the first fastening region, which base surface makes available a seat surface for the fastening element, is displaced axially with respect to the housing part and displaced with respect to the main axis of the boot in such a way that the base surface at least partially projects beyond an edge of the housing part, for example of a joint housing. The projecting length of the base surface here is preferably situated in a range from approximately 20 percent to approximately 45 percent, more preferably in a range from approximately 25 percent to approximately 35 percent, of a width of the first fastening element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and further advantages of the present disclosure will be explained in more detail below with reference to the following figures, in which:
[0018] FIG. 1 shows a cross section along a main axis of a rolling boot according to the prior art;
[0019] FIG. 2 shows a cross section on a line B-B in FIG. 3 along a main axis of a rolling boot according to an exemplary embodiment of the disclosure;
[0020] FIG. 3 shows an outer view of the rolling boot according to the disclosure as shown in FIG. 2 ;
[0021] FIG. 4 shows a sectional view through a system according to the prior art comprising a housing part of a fixed joint, a rolling boot in accordance with FIG. 1 , a shaft and first and second fastening elements; and
[0022] FIG. 5 shows a cross section on a line A-A in FIG. 3 through a system according to an exemplary embodiment of the disclosure comprising a joint housing, a folding boot according to FIGS. 2 and 3 and a first fastening elements for fastening the folding boot to the housing part.
DETAILED DESCRIPTION
[0023] It should be stated first of all that the features shown in the figures are not restricted to the individual embodiments. Rather, the features in each case shown and indicated in the description, including the description of the figures, can be combined with one another for development purposes, identical features, including those from the prior art, are designated here by the same references. In particular, the subject of the present disclosure is not restricted to the embodiment, shown in the figures, of the system according to the disclosure for a fixed joint with a rolling boot. Rather, the present disclosure can be applied to boots of any type which are mounted on whatever parts for sealing purposes. In particular, it is also neither envisioned nor intended to restrict the disclosure to fixed joints in automobiles; rather, the boots according to the disclosure can be used in a large number of application areas, in particular in constant velocity sliding joints. Finally, it is also possible, in particular, to design the fold region in such a way that, if appropriate, second or other further folds can be provided.
[0024] FIG. 1 shows the folding boot according to the prior art already described in the background, this boot having in its interior a plurality of inner ribs 40 arranged in the fold region 16 in order to achieve a sufficient degree of rigidity. It is clearly evident from FIG. 1 that the folding boot 10 according to the prior art shown therein is relatively bulky.
[0025] FIG. 4 shows the folding boot 10 according to the prior art as shown in FIG. 1 mounted on a fixed joint housing having a housing part 54 with an outer lateral circumferential surface 70 and a shelf 56 , the folding boot 10 being mounted in the first fastening region 12 on the housing part 54 using a first fastening element 58 and in the second fastening region 14 on the shelf 60 housing a second fastening element 62 . This forms an overall system 74 . The first fastening region 12 receives over its full surface the first fastening element 58 , which comes to lie between a first retaining element 30 and a second retaining element 32 . The first and second retaining elements 30 or 32 in this embodiment of a boot 10 according to the prior art can here be embodied as peripheral webs, but also as interrupted webs, for example also in the form of “ear webs”, which have a rounded outer contour as viewed in a direction perpendicular to the main axis 60 of the boot 10 . In the embodiment of the system 74 as shown in FIG. 4 , in this case the base surface 28 of the first fastening region of the boot 10 is identical to the binder seat surface.
[0026] It is clearly evident from FIG. 4 that the first fastening region, and hence also the base surface 28 thereof, does not project beyond a housing edge 55 which is arranged in the transition from the outer lateral circumferential surface 70 to a peripheral end surface 68 of the housing part 54 .
[0027] FIG. 2 now shows a folding boot 10 according to an exemplary embodiment of the present disclosure with a first fastening region 12 and a second fastening region 14 , wherein an interior 36 of the boot 10 is assigned, in the first fastening region 12 , an accumulation of material 38 , formed as a peripheral annular bead, which can engage in a corresponding peripheral annular groove on a housing part (see FIG. 5 in this respect). The first fastening region 12 makes available a base surface 28 which has a greater width than the width of a fastening element 58 , as can be seen from FIG. 5 . The first fastening region is adjoined by a transition region 50 with an outer base surface 52 and an inner base surface 53 . In the example shown here, this transition region is designed in such a way that it extends substantially perpendicularly to a main axis 60 of the boot 10 , and moreover bears against the outer peripheral end surface 68 of the housing part 54 or is arranged close to it, as can also be seen from FIG. 5 . Following the transition region 50 is provided a fold region 16 which has a first fold 18 with a first fold flank 22 near the first fastening region 12 and, opposite this first fold flank, a second fold flank 24 . The first fold 18 here has a fold peak region 20 with a fold peak 21 and a maximum M. The first fold 18 is followed by a fold trough 26 which is directly adjoined by the second fastening region 14 .
[0028] Furthermore, the boot according to one exemplary configuration of the disclosure as shown in FIG. 2 has an outer rib 42 with a first outer edge 44 , which starts at the maximum M of the fold peak region, i.e. at the fold peak 21 , and a second outer edge 43 which extends substantially parallel to the main axis 60 of the boot 10 . The outer rib 44 here makes available a bearing and/or positioning surface 48 for the fastening element 58 (see FIG. 5 ). For this purpose, the outer rib 42 protrudes somewhat beyond the base surface 28 of the first fastening region 12 , with the result that the second outer edge 43 also protrudes beyond the base surface 28 and in so doing is formed substantially parallel to this surface.
[0029] An angle α, which is approximately 110°, is formed between the outer base surface 52 and an outer side 23 of the first fold flank 22 of the fold 18 . In principle, the angle a within the context of the present invention is measured between an outer base surface 52 of the transition region 50 and an outer side 23 of a first fold flank 22 of the first fold 18 . In one exemplary configuration, the angle α is preferably situated in a range from approximately 90° to approximately 140°, with further preference in a range from approximately 100° to approximately 130°.
[0030] It is also evident from FIG. 2 how a height H of the first fold 18 within the context of the present disclosure is determined. This involves measuring the region between a tangent extending through the maximum M or the fold peak 21 of the first fold 18 , this tangent being oriented perpendicularly to the main axis 60 of the boot 10 , and an inner base surface 53 of the transition region 10 . Since this base surface in the exemplary embodiment is likewise oriented perpendicularly to the main axis 60 of the boot 10 , the tangent extending through the fold peak 21 of the maximum M of the first fold 18 extends parallel to this inner base surface 53 of the transition region 50 . However, provision can also be made for the inner base surface 53 of the transition region 50 to be arranged at an angle in relation to the main axis 60 of the rolling boot 10 .
[0031] In the context of the present disclosure, the depth T of the fold trough 26 is determined by measuring the region between a tangent extending on an inner base surface 27 , i.e. the minimum of the fold trough 26 directed toward the interior of the boot 10 , and perpendicularly to the main axis 60 of the boot 10 , and that tangent which extends through the fold peak 21 or the maximum M of the first fold 18 and perpendicularly to the main axis 60 of the boot 10 . Since both tangents thus extend parallel and perpendicularly to the main axis 60 of the boot 10 , the depth T can be determined simply.
[0032] As can be seen from FIG. 2 , the depth T is approximately 42 percent of the height H.
[0033] FIG. 3 shows the line B-B along which was taken the section of the boot 10 which can be seen in FIG. 2 . Furthermore, FIG. 3 shows particularly clearly that plurality of outer ribs 42 , more precisely a total of 10 rib pairs 42 , that is to say a total of twenty outer ribs 42 , are arranged on an outer circumferential surface 11 of the boot 10 . It can also be clearly seen that the outer ribs 42 fractionally protrude beyond the base surface 28 of the first fastening region 12 so as to form a bearing and positioning surface 48 , the outer edge 43 for this purpose being indicated in FIG. 3 to make this clear.
[0034] FIG. 5 now shows a system 74 according to an exemplary embodiment of the disclosure, comprising a boot 10 as shown in one of FIGS. 2 and 3 and also a housing part 54 , here a fixed joint, together with a first fastening element 58 . FIG. 5 also shows a shaft 56 . The housing part 54 has an outer lateral circumferential surface 70 and an outer end surface 68 , between which surfaces is arranged a housing edge 55 . The fastening element 58 has a first side face 59 . 1 and a second side face 59 . 2 , in one embodiment of the fastening element 58 , for example as a compression ring, are to be regarded as peripheral side faces. Not shown in FIG. 5 is a second fastening element 62 which serves to fasten the boot 10 on the shaft 56 in the second fastening region 14 . In the second fastening region can be clearly seen an offset 64 at which the fold trough 26 merges into the second fastening region 14 . The offset 64 here is designed to be peripheral so as to produce a bearing and/or positioning surface for a second fastening element 16 , not shown in FIG. 5 . Moreover, the section through the system 74 , with respect to the boot 10 , was taken along a line A-A in FIG. 3 .
[0035] In the system 74 according to the exemplary configuration of the disclosure shown in FIG. 5 , the fastening element 58 projects beyond the housing edge 55 by a projecting length 46 . This projecting length 46 is determined by the outer end surface 68 of the housing part 54 on the one hand and, on the other hand, by the bearing and/or positioning surface 48 , made available by the outer rib 42 . This projecting length 46 is a portion of the base surface 28 , but also of the binder seat surface, of the first fastening region 12 . FIG. 5 also shows the width 8 of the fastening element 58 determined by the two outer side faces 59 . 1 and 59 . 2 thereof. The projecting length 46 here is somewhat more than 25 percent of the width of the first fastening means 58 . | A boot which has reduced deformations during operation is disclosed. The boot includes a first fastening region, wherein the first fastening region is displaced axially, with respect to the direction of a main axis of the boot, and with respect to a housing part on which the boot can be mounted, in such a way that the first fastening region at least partially projects beyond an edge of the housing part. | 5 |
FIELD OF THE INVENTION
This invention relates to techniques for treating surfaces with radiant energy. More particularly, it relates to techniques for uniformly and precisely treating tissue and other surfaces with a scanning laser beam.
BACKGROUND OF THE INVENTION
Because of the intensity and precision of their radiation, lasers have many useful applications to the treatment of surfaces. For example, laser heat treating of metals has become a valuable industrial process since it provides a means for selectively hardening specific areas of a metal part. Lasers have also become valuable medical instruments. In dermatological applications, however, the laser has resisted widespread use due to problems such as variable depth penetration, nonuniform exposure, and consequent charring of tissue. Ideal skin resurfacing, for example, requires efficient tissue vaporization over usefully large areas, precise vaporization depth control, and the appropriate depth of residual thermal effects (about 50 to 150 μm). To confine ablation and thermal coagulation to a thin layer, it is necessary to use wavelengths that are easily absorbed in the superficial layer of tissue, for example the 10.6 μm wavelength of a CO 2 laser. Moreover, the laser energy must be delivered in a short time interval (less than 1 ms) in order to prevent thermal damage to surrounding tissue. Finally, the laser beam must have an energy density that is large enough (about 5 J/cm 2 ) to vaporize tissue. Because of these numerous constraints, ideal skin resurfacing has not been possible in the past.
Continuous wave laser treatment for skin resurfacing often involves inadvertent thermal damage and subsequent scarring to healthy tissue. The use of pulsed lasers can reduce the possibility of thermal damage, and make lasers less hazardous, but thermal damage has not been eliminated and persists in discouraging the use of lasers.
Coherent Lasers Inc. of Palo Alto, Calif. has recently introduced an improved pulsed surgical laser system that solves some of the previous difficulties by delivering higher energy pulses (500 mJ/pulse) with higher energy density, shorter duration, and an interpulse duration longer than the thermal relaxation time of tissue. This permits tissue ablation with less thermal damage to the surrounding tissue than caused by previous systems. This system, however, has some significant disadvantages. Since the surgical procedure for skin resurfacing involves evenly "painting" the treatment area, the task of uniformly treating a large surface of skin with a manually controlled laser delivery system is time-consuming and error-prone. Pulsed laser systems are also very expensive. Moreover, the laser beam itself has a nonuniform gaussian intensity profile, causing suboptimal ablation even for single craters, which are needed in hair transplantation techniques.
U.S. Pat. No. 5,411,502 issued May 2, 1995 to Zair discloses a system intended to produce uniform ablation of tissue through the use of automated scanning. As shown in FIG. 1, a continuous laser beam 20 is reflected off two rotating mirrors 22, 24 whose optical axes are tilted at angles with respect to their rotational axes, thus causing the beam to scan the surface uniformly in the pattern of a Lissajous FIG. 26. A refractive lens 28 is used to focus the beam. The scanning movement of the beam over the surface produces a short-duration local tissue interaction similar to that of a pulse. Because of the scanning, a large region is exposed. The exposure, however, is not completely uniform since a Lissajous figure is self-intersecting and is not space-filling. Moreover, the treatment even at a single point along the path is uneven because of the nonuniform intensity profile of the laser beam. In addition, the use of refractive optics introduces its own problems. Lenses limit the wavelengths that can be transmitted by the system and restrict the versatility of the device. Lenses also introduce chromatic aberration that causes a superimposed aiming beam to diverge from the invisible treatment beam.
Sharplan, Inc. of Allendale, N.J. manufactures a laser scanning system for dermatological applications, shown in FIG. 2. Using two microprocessor-controlled mirrors 30, 32 and a focusing lens 34, it directs a laser beam 36 at a constant velocity in a spiral pattern 38 over a circular area. The spiral path produces a more uniform exposure than the Lissajou path, but the exposure is still not optimally uniform. FIG. 3 illustrates the power distribution of the laser beam and the effect of scanning on the tissue. Because the gaussian power distribution 40 of the laser beam is not uniform, the tissue at the center of the spot receives more energy than that at the edges of the spot, resulting in undesired tissue effects 42. Although the spiral scanning pattern 44 helps to reduce these effects, it does not eliminate effects at the edges 46 of the scan or when the device is used to create single craters, as is required in certain applications such as hair transplantation. Moreover, since exposing tissue twice with the low-power edges of the beam is not equivalent to exposing once with the high-power center of the beam, the scan does not entirely eliminate imperfections due to the gaussian distribution of the laser spot. This system also has all the disadvantages mentioned earlier associated with lens-based optical systems because it uses refractive lenses to focus the laser beam.
U.S. Pat. 4,387,952 issued Jun. 14, 1983 to Slusher discloses a laser scanning system for heat-treating metals. The scanning and focusing of the laser beam are produced by two rotating concave mirrors tilted at small angles with respect to their axes of rotation, similar to the system shown in FIG. 1 except without the refractive lens. The mirrors are rotated in phase and in opposite directions resulting in a linear scanning pattern that produces a uniform delivery of laser energy to the surface. The rotation mechanism includes a precision timing drive with phase adjustment. Because this system uses reflective optics, it overcomes the disadvantages of lens-based optical systems. It does not, however, solve the problems due to the nonuniform intensity distribution of the beam and does not teach methods for scanning two-dimensional regions.
U.S. Pat No. 5,128,509 issued Jul. 7, 1992 to the present inventor discloses a delivery system, shown in FIG. 4, which uses reflective optics to steer and focus a laser beam 48. The optical focusing is performed by a convex mirror 50 and a concave mirror 52 facing each other and aligned on a common optical axis 54. The laser beam passes through a small hole 56 in the center of the concave mirror and is reflected by the convex mirror back towards the concave mirror. The concave mirror reflects the beam forward to a focus 58 beyond the convex mirror. Because this system uses reflective optics, it is capable of delivering laser beams of a wide range of wavelengths and to a very small focus. Unlike systems using refractive optics, it can simultaneously deliver coincident far IR and visible beams. Moreover, because reflective optics do not exhibit chromatic aberration, it delivers the two beams to the same focal point. This system, however, does not provide a means for scanning to produce a uniform exposure over a large surface area.
OBJECTS AND ADVANTAGES OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide an improved method and apparatus for treating surfaces with lasers. More specifically, it is an object of the invention to provide a laser system that delivers a laser beam having an improved intensity cross-section. It is a further object of the invention to provide a laser system that delivers two laser beams of differing wavelengths to a coincident focus and eliminates other problems arising from the use of refractive optics. It is an additional object of the invention to provide a laser system that incorporates uniform scanning of a laser beam over a surface in order to produce homogeneous treatment of the surface. It is another object of the present invention to provide a laser system capable of producing precise craters in the treatment surface. It is yet another object of the invention to reduce the thermal damage experienced by skin when it is treated by a laser resurfacing technique.
SUMMARY OF THE INVENTION
These objects and advantages are attained by a new method and apparatus for focusing and delivering a beam of light along a predetermined path on a surface, and for improving the intensity cross-section of the beam. The apparatus includes a concave mirror, a convex mirror, and a rotation control means for controlling the rotational positions of the concave mirror and the convex mirror so that the focal point follows the predetermined path on the surface. The concave mirror has a central hole through which the beam can pass and is rotatably mounted about a first rotational axis. The convex mirror is rotatably mounted about a second rotational axis and positioned to face the concave mirror and reflect the beam back toward the concave mirror. The beam is then reflected forward toward the convex mirror in a converging manner to a focal point beyond the convex mirror so that a central portion of the beam is obscured by the convex mirror.
In a preferred embodiment the first and second rotational axes coincide with a central axis of the apparatus. The optical axis of the concave mirror is fixed at an angle α to the central axis and the optical axis of the convex mirror is fixed at an angle β to the central axis. The focal point of the beam is determined by the rotational positions of the mirrors. In another embodiment the first rotational axis and the second rotational axis each intersects the central axis of the apparatus at a right angle.
The focal point of the beam in this embodiment is also determined by the rotational positions of the mirrors.
The inventor's unique reflective optical delivery system produces a uniform beam intensity cross-section that reduces thermal injury, increases the precision of the surface interaction and allows the creation of craters with sharp edges. Reflective optics provide precise, single-layer vaporization at low power levels without thermal injury to the underlying papillary dermis. Movable optical elements direct the laser beam to the surface in a scanning pattern to completely treat a large area of the surface. A control means controls the position and speed of the focal point so that various scanning patterns may be programmed by the user.
DESCRIPTION OF THE FIGURES
FIG. 1 is a scanning laser system employing two rotating mirrors, as disclosed in the prior art.
FIG. 2 is a scanning laser system employing two vibrating mirrors, as disclosed in the prior art.
FIG. 3 is an illustration of the beam intensity cross-section and tissue effect produced in prior art laser systems.
FIG. 4 is a reflective optical guidance system as disclosed in a prior patent by this inventor.
FIG. 5 is an illustration of the gaussian beam intensity cross-section of the prior art and the improved "Mexican hat" cross-section of the invention.
FIG. 6 is a cross-sectional view of the reflective guidance system of the invention.
FIG. 7 is a perspective view of the reflective guidance system of the invention, including means for controlling the position of the laser beam focal point.
FIG. 8 is an illustration of various types of scanning patterns that may be obtained using the apparatus of the invention.
FIG. 9 is a perspective view of an alternative embodiment of the invention having alternate means for controlling the position of the laser beam focal point.
DETAILED DESCRIPTION
The objects and advantages of the invention are attained by a new method and apparatus for laser treatment of surfaces using a laser spot having a unique power density distribution. The method includes the use of coaxial reflective optics for both scanning and focusing of the laser beam. Because the same optical elements are used for both focusing and scanning, the system is simple and smaller. In a preferred embodiment, the present inventor's unique reflective optical system is used to provide a more uniform beam intensity cross-section that minimizes thermal injury and allows the creation of craters with decreased sizes. As shown in FIG. 4, the convex mirror obscures the central portion of the laser beam. As shown in FIG. 5, the result of this obscuration is to eliminate the central peak of the gaussian distribution 60 to yield a significantly more uniform distribution profile 62 which resembles that of a Mexican hat. The thermal damage 64 to the tissue caused by this "Mexican hat" distribution is significantly less than the thermal damage 66 caused by the gaussian distribution.
The effect of laser energy on tissue is determined by several factors: the thermal relaxation time of the tissue, the absorption cross-section of the tissue, the wavelength of the laser beam, the power density of the laser beam, and the exposure time to the laser beam. Since the wavelength of a CO 2 laser corresponds well with the absorption cross-section of tissue, it is preferable for laser surgery. For a vaporization depth of 15 μm, the critical power density is 6 to 36 kW/cm 2 . (Critical power density is the minimal power density required to vaporize a specified depth of tissue in a time interval less than the thermal relaxation time. The thermal relaxation time of tissue is 0.1 ms to 0.6 ms.)
When laser energy irradiates the tissue surface, evaporation creates a vapor pressure gradient forcing liquefied tissue radially out of the tissue crater. The effective diameter of the crater increases in proportion with the vapor pressure and can be several times larger than the diameter of the laser beam spot. Since the "Mexican hat" intensity profile creates a more uniformly changing vapor pressure gradient, a smaller diameter crater will result. Consequently, the combination of reflective optics to form a smaller spot size and the Mexican hat intensity profile to create more uniform tissue interaction combine to permit the creation of much smaller craters in the tissue.
FIG. 6 shows the optical system used in the preferred embodiment to scan a large treatment area with a predetermined scanning pattern. Concave mirror 68 is rotatably mounted at an angle α to the central axis 70 of the optical system. Convex mirror 72 is rotatably mounted at an angle β to the central axis 70. These mirrors are rotated to move the laser beam 74 at constant speed in a spiral pattern 76 over a circular area.
FIG. 7 further illustrates the control of the rotating mirrors. Motor 78 rotates ring 80, within which concave mirror 82 is mounted at angle α. Similarly, motor 84 rotates ring 86, within which convex mirror 88 is mounted at angle β. Inscribed on rings 80 and 86 are optical codes 90 and 92, respectively. Positioned close to these optical codes are optical reflective sensors 94 and 96 that allow determination of the rotational position, rotational speed, and rotational direction of mirrors 82 and 88, respectively. Such optical reflective sensors containing an LED emitter and matched photodetector are produced, for example, by Hewlett-Packard of Palo Alto, Calif. Output signals from sensors and 96 are sent to a scanning control means 98 containing a microprocessor (not shown) for analyzing the signals. Control means 98 determines the rotational position and speed for the mirrors needed to direct the beam in a particular scanning pattern specified by the user. The appropriate signals are then sent to rotational means 78 and 84. Feedback signals from sensors 94 and 96 provide assurance that the beam is being directed in the appropriate pattern at the desired speed. Control means 98 also provides a signal to control the distance d between the two rotating mirrors. This distance, illustrated in FIG. 6, determines the operating distance of the scanner and is adjusted by a mirror spacing means (not shown) such as a stepper motor. Given specified focal lengths of the mirrors, the distance d between the mirrors, independent rotational positions of the two mirrors, and angles α and β, the position of the focus is determined. Consequently, control means 98 can be programmed to position the mirrors so as to direct the beam to follow the desired pattern.
FIG. 8 shows other scanning patterns generated by the invention. The spiral scanning pattern 100 can be adjusted to cover an elliptical region 102 rather than a circular one. In addition, the pattern can be adjusted to cover annular regions 104 and elliptically annular regions 106. The pattern can be adjusted so that the beam follows a circular 110 or elliptical path 112 rather than a spiral path. The path can also be adjusted to follow other types of paths, such as a Lissajous figure 114. Of course, by fixing the mirrors, the beam may be directed to a single point as well. Since the path of the beam is controlled by the microprocessor programming, the types of paths and patterns are not limited to any single class. In the preferred embodiment, the scanning patterns are adjustable to cover regions from 0.5 mm to 5.0 mm in diameter. The annular pattern 104 is especially advantageous because it will produce a more uniform exposure as it is manually swept over the surface.
Another embodiment of the invention is shown in FIG. 9. A concave mirror 116 and a convex mirror 118 are positioned coaxially as in the previous embodiment. Concave mirror 116 rotates through small angles about a first axis 120 and convex mirror 118 rotates through small angles about a second axis 122. Axes 120 and 122 are perpendicular to optical axis 124 and to each other. The rotation of mirrors 116 and 118 is controlled by rotational means 126 and 128 (for example, galvanometers available from General Scanning, Inc. of Watertown, Mass.). Rotational means 126 and 128 are controlled by a control means 130 which can store the data for angular deflection of the mirrors 116 and 118 in order to obtain predetermined scanning patterns. In general, any pattern can be so obtained and repeated. Patterns can also be changed in real time while scanning. This embodiment is especially useful for scanning an area in an arbitrary pattern defined by horizontal and vertical positioning. It is otherwise identical in operation to the previous embodiment.
In contrast with other laser scanning systems, the two mirrors used in this system are coaxially positioned and are used both for focusing and scanning. This simpler optical arrangement allows smaller and more inexpensive laser scanning systems to be produced. Additionally, the coaxial arrangement of the two mirrors creates a unique beam intensity cross-section that has surprising advantages over systems in the prior art.
It will be clear to one skilled in the art that the above embodiments may be altered-in many ways without departing from the scope of the invention. For example, many various optical codes can be placed on the perimeter of the rotating discs to aid in the determination of their position and velocity. A mirror may be placed in the optical path of the converging beam in order to direct it. The scanning can be used in conjunction with a pulsed laser beam as well as with a continuous laser beam. Any type of laser may be used with the system and it may be used for many applications including other medical applications and industrial applications. Accordingly, the scope of the invention should be determined by the following claims and their legal equivalents. | A method and apparatus are disclosed for laser treatment of surfaces, such as tissue. In a preferred embodiment, the invention employs a unique reflective optical delivery system which produces an improved beam intensity cross-section which reduces thermal injury, increases the precision of the tissue interaction and allows the creation of craters with decreased sizes. Reflective optics provide precise, single-layer vaporization at low power levels without thermal injury to the underlying papillary dermis. Movable optical elements focus and direct the laser beam in a scanning pattern to treat a large area of the surface. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a far infrared radiation health appliance, far infrared radiation health method, and a method for egesting dioxins and active oxygen sources.
[0003] 2. Description of the Related Art
[0004] Conventionally, there has been known a so-called far infrared radiation sauna for irradiating a whole body with far infrared radiation to promote blood circulation and perspiration. This far infrared circulation sauna is taken with the whole body put in a sealed housing, or only the head out. The whole body is heated up by far infrared radiation heating means arranged in the box.
[0005] In general, conventional saunas have had the following defects.
[0006] (1) A users is set on a chair arranged in the housing when heated to high temperatures for forced perspiration. This unfavorably stimulates the blood circulation and muscles of the whole body while the body is strained. Besides, no sebaceous gland will be stimulated together with perspiratory glands in the skin.
[0007] (2) Despite the use for the sake of health, the saunas provide such a temperature condition that one's head is at a high temperature and the feet are at a low temperature, or a condition of keeping one's head warm and feet cool, which contradicts a first principle of health “keeping one's head cool and feet warm. Thus, the saunas cannot be taken in conformity to the principle of health.
[0008] (3) The bathing in an enclosed room increases the risk of inspiring the oxygen-deficient air aspired by others or of getting infected with resistant tubercle bacilli through aerial infection.
[0009] (4) Lower-half bathing is impossible, whereas the lower-half bathing is sometimes effective at reducing invasiveness.
[0010] (5) The saunas are incapable of light bathing which improves the blood circulation and promotes metabolism without perspiration.
[0011] (6) A lie-down, 24-hour continuous use is impossible.
[0012] (7) Cannot be used by those who are sick or bedridden.
SUMMARY OF THE INVENTION
[0013] An object of the present invention is to provide a health appliance and a health method free of such defects of the conventional saunas, and more particularly to provide a far infrared radiation health appliance and a far infrared radiation health method in which sebaceous glands as well as perspiratory glands can be stimulated effectively.
[0014] Moreover, in recent years, there has been a growing interest in dioxins as environmental pollutants. Dioxins, a generic name of polychlorinated dibenzo-p-dioxins (PCDD) and polychlorinated dibenzofurans (PCDF), are generated in the process of chemical synthesis or in the process of combustion. The dioxins are nonpolar fat-soluble organic substances, having high acute toxicity 1000 times that of potassium cyanide, as well as a wide range of toxicity including carcinogenecity, generation toxicity, immunological toxicity, and endocrinopathy. The dioxins, when taken into a human body, are mainly stored into fat tissue. Accordingly, while immediate egestion out of a body is required of dioxins that are ingested and stored in a body, there has been no appropriate method therefor due to the poor metabolizability of the dioxins.
[0015] It is thus another object of the present invention to provide a method for egesting dioxins and/or active oxygen sources ingested and stored in a body to outside the body effectively.
[0016] A far infrared radiation health appliance according to the present invention includes a plurality of semicylindrical members to be axially connected to each other in a bush-like manner, and carbon-black-containing planar heating elements for serving as resistors arranged over the general entire inner surfaces of the cylindrical members. The planer heating elements are energized and heated to a temperature of 55-70° C., and preferably a temperature of 60-65° C.
[0017] A far infrared radiation health method according to the present invention includes the step of making a far infrared irradiation to promote perspiration from perspiratory glands and egestion of sebum from sebaceous glands.
[0018] Another far infrared radiation health method according to the present invention includes the step of irradiating a body surface with far infrared rays from a carbon-black-containing planar heating element energized and heated to a temperature of 55-70° C., thereby promoting perspiration from perspiratory glands and egestion of sebum from sebaceous glands.
[0019] Another far infrared radiation health method according to the present invention includes the step of adjusting a power supply to a planer heating element for radiating far infrared rays, so that the interior of an enclosed dome is adjusted to a temperature not causing perspiration or a temperature right below the point of perspiration for use. The user puts the whole body, or a part, into the semiclosed dome for far infrared irradiation.
[0020] A method for egesting dioxins according to the present invention includes the step of egesting dioxins together with perspiration and sebum from perspiratory glands by using the far infrared radiation health method described above.
[0021] Human skin is an organ which has such apparatuses as perspiratory glands and sebaceous glands, and occupies 16% of the whole body. As the temperature rises, a human exudes perspiration. This perspiration is egested from perspiratory glands. The perspiration egested from perspiratory glands is of almost the same quality as urine, containing such ingredients as water, sodium chloride, uric acid, ammonia, amino acid, potassium, creatine, and urea. In addition to a rise in temperature, the perspiration from perspiratory glands is also promoted by bathing, sauna bathing, exercise, the taking of antipyretics, and so on.
[0022] Meanwhile, sebaceous glands store and egest the same fat as body fat, covering the skin with fat for protection. The perspiration (sebum) from sebaceous glands contains cholesterol, fatty ester, lactic acid, excessive subcutaneous fat, and so on. It is like exudation of human fat/body fat. Moreover, it is said that body fat stores mercury, cadmium, lead and other heavy metals taken into the body through ingested food, drinks, respiration, or percutaneous means, as well as chemicals much talked about nowadays as environmental hormones (extrinsic endocrine disrupting chemicals), carcinogens, and the like. Promoting the egestion of sebum perspiration from sebaceous glands makes it possible to egest such toxic substances dissolved in the body fat to outside the body. Dioxins, known as having a wide range of toxicity such as high acute toxicity, carcinogenecity, generation toxicity, immunological toxicity, and endocrinopathy, are also stored in fat tissue. Therefore, the promoted egestion of sebum perspiration from sebaceous glands also allows the effective egestion of these dioxins dissolved in body fat to outside the body.
[0023] The sebum egestion from sebaceous gland cannot be promoted by bathing, saunas, or exercise. Nevertheless, when cells of a living body are irradiated with far infrared rays having a wavelength of 5-20 μm, which is most favorable for resonance, and resonance absorption phenomena deliver the far infrared rays deep into the body to stimulate sebaceous glands, it becomes possible to promote the sebum egestion. The carbon black planer heating elements energized and heated to a temperature of 55-70° C., or preferably a temperature of 60-65° C., by resistance heating can effectively generate the far infrared rays resonance-absorbable to the cells of a living body, thereby effectively stimulate sebaceous glands.
[0024] As described above, according to the far infrared radiation health appliance of the present invention, the cutaneous function can be activated to improve the cutaneous respiration and blood circulation for more active metabolism, thereby promoting two types of perspiration, namely, high volume of perspiration from perspiratory glands and sebum perspiration from sebaceous glands. In particular, toxic substances (including dioxins) stored in the body can be egested from sebaceous glands effectively to contribute to health enhancement.
[0025] Moreover, when the interior of the enclosed dome is adjusted to a temperature causing no perspiration or a temperature right below the point of perspiration for use, the body temperature is at best increased to 38° C. or so, and maintained without perspiration. According to the latest theories from American Association of Immunologists, a 1° C. rise of body temperature means a 6-times leukocyte immunoactivity. Given that the normal temperature is 36.5° C., the body temperature increased and maintained to 38° C. results in an immunoactivity of (38−36.5=1.5° C.), or 6×6/2=18 times. This is of great help to improve self healing power against bad diseases.
[0026] The nature, principle, and utility of the invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In the accompanying drawings:
[0028] [0028]FIG. 1 is a schematic diagram explaining the general diagram of a far infrared radiation health appliance according to the present invention;
[0029] [0029]FIG. 2 is a cross-sectional schematic diagram of service conditions;
[0030] [0030]FIGS. 3A and 3B are explanatory diagrams of a panel heater (planar heating element);
[0031] [0031]FIGS. 4A and 4B are detailed view of an upper dome;
[0032] [0032]FIG. 5 is a longitudinal sectional schematic diagram of service conditions;
[0033] [0033]FIG. 6 is a chart showing the waveforms on perspiration A exuded in a dry sauna;
[0034] [0034]FIG. 7 is a chart showing the waveforms on perspiration B exuded in a bath;
[0035] [0035]FIG. 8 is a chart showing the waveforms on perspiration C exuded in the far infrared radiation health appliance of the present invention; and
[0036] [0036]FIG. 9 is a chart showing the waveforms on perspiration D exuded in the far infrared radiation health appliance of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a schematic diagram explaining the general configuration of a far infrared radiation health appliance according to the present invention. FIG. 2 is a cross-sectional schematic diagram of the appliance under service conditions. FIGS. 3A and 3B are explanatory diagrams of a panel heater (planar heating element). FIGS. 4 A- 4 C are detailed views of an upper dome. FIG. 5 is a longitudinal sectional schematic diagram of service conditions.
[0038] As simplified in FIG. 1, this far infrared radiation health appliance has an upper dome 11 and lower dome 12 of semicylindrical shape. A user lies in the internal space formed by the upper and lower domes 11 , 12 and a sheet 15 reflecting far infrared rays on the floor. The lower dome 12 has the shape of a semicylinder with a diameter smaller than that of the upper dome 11 . The upper dome 11 and the lower dome 12 are coupled to each other so that they can be moved in a bush-like manner along the axial direction of the domes as semiclosed. Therefore, the length of the entire dome consisting of the upper dome 11 and the lower dome 12 can be adjusted to the height of the user. Besides, the entire dome can be conveniently reduce to about a half in volume when put away. An end of the lower dome 12 is closed by a half-round plate. Electric cords 16 and 17 are extended from the upper and lower domes 11 and 12 , respectively. These cords are connected to a controller 14 . The controller 14 is, in turn, connected through an electric cord 18 to a power supply such as a wall outlet.
[0039] The upper dome 11 has at one end a neck cover 13 , with which the neck of the user is covered softly to keep the dome interior semiclosed. The neck cover 13 may be formed of cloth. Far infrared ray reflective coating may be applied to the surface of the neck cover 13 which faces the dome interior. The far infrared ray reflective coating is achieved, for example, by sewing on an aluminum deposition sheet or the like that reflects far infrared rays. The user lies on a towel or the like put on the floor sheet 15 . The floor sheet 15 preferably consists of an aluminum-evaporated urethane sheet or other material that reflects far infrared radiation. The user may take any posture, such as face up, on the side, and face down. A full bath with head, full bath without head, half bath, lower half bath, foot bath, or the like may be taken freely. In the cases of stiffness on the back or the lower back, face-down use would be effective. Such usage is impossible in conventional saunas.
[0040] Panel heaters for radiating far infrared rays are arranged almost all over the inner surfaces of the upper and lower domes 11 and 12 . In the shown example, the upper dome 11 has two panel heaters 21 and 22 along its curved inner surface (see FIGS. 2 and 4A). The lower dome 12 also has two panel heaters 23 and 24 along its curved inner surface, as well as a panel heater 25 on the half-round end. The two panel heater 21 and 22 arranged on the upper dome 11 typically irradiate the chest (back) and abdomen (lower back and buttocks) of the user lying inside the dome with far infrared rays. The three panel heaters 23 , 24 , and 25 irradiate the femoral regions, anticnemions/calves, and soles of the user with far infrared rays.
[0041] [0041]FIGS. 3A and 3B are explanatory diagrams of a panel heater used in the present invention. FIG. 3A is a plan view, and FIG. 3B a sectional view taken along the line A-A. As shown in the sectional view of FIG. 3B, this panel heater 30 has a three-layer structure including two sheets 31 and 33 sandwiching a carbon black layer 32 . The panel heater has electrodes 34 and 35 on both ends, in contact with the carbon black layer 32 . When the carbon black layer 32 is energized through the electrodes 34 and 35 , the entire carbon black layer 32 heats up by resistance heating, thereby radiating far infrared rays. In the present invention, the power to the panel heaters is adjusted so that the panel heaters reach 60° C. in temperature. The adjustment can be made separately to the upper dome 11 and to the lower dome 12 . The heater temperature can be fine adjusted by operating the controller 14 . Moreover, the controller 14 has a timer function which can be used to set the energizing time of the panel heaters.
[0042] As shown in FIGS. 4A and 4B, the upper dome 11 has a sealing mechanism 40 arranged on the underside of its end overlapping the lower dome 12 . The sealing mechanism 40 seals the gap formed with the topside of the lower dome 12 . This sealing mechanism 40 consists of a hook-side Velcro fastener 41 tacked to the inner end surface of the upper dome 11 , and a felt-like tape 42 having a loop-side Velcro fastener stuck to its backside. By means of the engagement between the Velcro fasteners, the felt-like tape 42 having the loop-side Velcro fastener stuck to its backside is fixed to the underside of the end of the upper dome 11 with the felt-surface outside. This sealing mechanism 40 seals the gap between the bush-coupled upper and lower domes 11 and 12 , and allows the dome space to be freely and smoothly adjusted in length as kept airtight. In the cases of felt deterioration after long-time use, the felt-like tape 42 having the loop-side Velcro faster stuck to its backside is all that can be replaced with a new one to recover the sealing capability.
[0043] The far infrared radiation health appliance of the present invention employs the configuration in which a user lies in the space formed by the semicylindrical upper and lower domes 11 and 12 , and is irradiated with the far infrared rays from the panel heaters 21 - 25 arranged on the inner surfaces of the upper and lower domes 11 and 12 . Therefore, as shown in the general sectional view of FIG. 5, the far infrared rays are applied onto the entire surface of the body, as the focus of a concave mirror falls on the center line of the body. When the user is lying on the far infrared ray reflective sheet 15 , the far infrared rays not absorbed into the user's body can be reflected by the far infrared ray reflective sheet 15 for user re-irradiation, with a further improvement in the irradiation efficiency of the far infrared rays. This also means a certain degree of far infrared ray irradiation on portions of the body not facing the panel heaters directly.
[0044] The peak wavelength of the electromagnetic waves radiated from a heater can be calculated by the Wien's displacement law. Home sauna appliances now on the market often use ceramic heaters of 300-500° C. in surface temperature as their heat sources. For example, a rod heater having a surface temperature of 400° C. (673 K in absolute temperature) radiates infrared rays with a peak wavelength of 4.3 μm (2897/673=4.3). Effective radiation of 8-to-10 -μm far infrared rays easier for a living body to resonance absorb requires the use of heaters having lower surface temperatures. For example, the carbon-black-containing planer heaters of the present invention, heated to 60° C. (333 K in absolute temperature), radiate far infrared rays with a peak wavelength of 8.7 μm (2897/333=8.7). Moreover, heaters of greater radiation areas are required for the sake of suppressing the surface temperature for calorie-efficient radiation. Accordingly, the panel heaters employed in the present invention, using carbon black as the resistors, are extremely reasonable and best suited for the purpose of irradiating a living body with far infrared rays to stimulate cutaneous cells.
[0045] The far infrared radiation health appliance according to the present invention is capable of effectively irradiating cells of a living body with far infrared rays having a most-absorbable wavelength of 5-20 μm. Therefore, it can stimulate skin's perspiratory glands to promote perspiration, and stimulate sebaceous glands to promote sebum egestion as well. This allows the artificial egestion of sebum which cannot be promoted by bathing, saunas, or exercise. Thus, it becomes possible to egest chemicals toxic to a human body, dissolved and stored in subcutaneous fat and body fat, to exterior along with sebum.
[0046] The following Table 1 shows the analyses of the gas chromatography mass spectrometry on the concentrations of dioxins contained in the egesta through the skin of the user while using the far infrared radiation health appliance of the present invention. Aside from the concentrations, the table shows toxicity equivalents. The amount of each sample was 50 ml. The toxicity equivalents (TEQ) were 2, 3, 7, 8-T 4 CDD toxicity equivalents (pg-TEQ/ml). The toxicity equivalency factors were of I-TEF (International-Toxicity Equivalency Factor (WHO/IPCS, 1988)). As for the minimum limits of determination, 4-5 chlorinated compounds: 0.01 pg/ml, 6-7 chlorinated compounds: 0.02 pg/ml, and 8 chlorinated compounds: 0. 05 pg/ml. These analyses show that the far infrared radiation health appliance of the present invention is effective at egesting dioxins in the body.
TABLE 1 CONCEN- TOXICITY TOXICITY TRATION EQUIVAL- EQUIVAL- MEASUREMENT ENCY ENT 50 ml FACTOR (TEQ) UNIT (pg/ml) (1-TEF) (pg-TEQ/ml) 2, 3, 7, 8-T 4 CDD <0.01 1 0 1, 2, 3, 7, 8-P 5 CDD <0.01 0.5 0 1, 2, 3, 4, 7, 8-H 6 CDD <0.02 0.1 0 1, 2, 3, 6, 7, 8-H 6 CDD <0.02 0.1 0 1, 2, 3, 7, 8, 9-H 6 CDD <0.02 0.1 0 1, 2, 3, 4, 6, 7, 8- 0.039 0.01 0.00039 H 7 CDD O 8 CDD 0.17 0.001 0.00017 PCDF S TEQ — — 0.00056 2, 3, 7, 8-T 4 CDF <0.01 0.1 0 1, 2, 3, 7, 8-P 5 CDF <0.01 0.05 0 2, 3, 4, 7, 8-P 5 CDF <0.01 0.5 0 1, 2, 3, 4, 7, 8-H 6 CDF <0.02 0.1 0 1, 2, 3, 6, 7, 8-H 6 CDF <0.02 0.1 0 1, 2, 3, 7, 8, 9-H 6 CDF <0.02 0.1 0 2, 3, 4, 6, 7, 8-H 6 CDF <0.02 0.1 0 1, 2, 3, 4, 6, 7, 8- <0.02 0.01 0 H 7 CDF 1, 2, 3, 4, 7, 8, 9- <0.02 0.01 0 H 7 CDF O 8 CDF <0.05 0.001 0 PCDF S TEQ — — 0 Total TEQ — — 0.00056 T 4 CDD S 0.032 P 5 CDD S 0.027 H 6 CDD S 0.030 H 7 CDD S 0.071 O 8 CDD 0.17 Total PCDD S 0.33 T 4 CDF S 0.045 P 5 CDF S 0.032 H 6 CDF S 0.032 H 7 CDF S 0.035 O 8 CDF <0.05 Total PCDF S 0.14 PCDD S · PCDF S Total 0.47
[0047] The far infrared radiation health appliance according to the present invention is also effective at egesting active oxygen sources in the body. A sauna-exuded perspiration A, a bath-exuded perspiration B, and perspirations C and D exuded in the far infrared radiation health appliance of the present invention were collected as samples, and were measured for induced active oxygen. The perspirations A-D were sampled by 200 μl, and mixed with 20 μl of 5,5′-dimethyl-1-Pyrrolia-N-oxide (DMPO) as the spin trapping agent for active oxygen species. Both before and after five minutes of ultraviolet irradiation, the samples were analyzed in an ESR spectrometer for spin adducts. The reason why the experiments were conducted on both the ultraviolet-irradiated and not is to draw a distinction between active oxygen already in the perspirations and active oxygen induced by ultraviolet irradiation.
[0048] FIGS. 6 - 9 show the ESR spectra of the respective samples. FIG. 6 shows the waveforms of the DMPO-trapped free radicals in the perspiration A exuded in a dry sauna, FIG. 7 the perspiration B exuded in a bath, and FIGS. 8 and 9 the perspirations C and D exuded in the far infrared radiation health appliance of the present invention. The UV(−) s show the waveforms before the ultraviolet irradiation, and the UV(+)s the waveforms after the ultraviolet irradiation.
[0049] The following Table 2 shows the signals of MnO in RIM, the signals of the samples in RIS, and RIS/RIM×100 in S/M (%), with MnO as the Control.
TABLE 2 TYPE OF PERSPIRATION UV RIS RIM S/M (%) A (−) 15.8 156.0 10 (+) 55.6 159.2 35 B (−) 30.8 161.2 19 (+) 142.6 160.2 89 C (−) 72.0 163.2 44 (+) 373.2 161.0 232 D (−) 170.0 153.2 111 (+) 473.4 161.6 293
[0050] The active oxygen in the perspiration A exuded in a dry sauna was as small as 10% without ultraviolet irradiation. It was 35%, or 3.5-times up, after the ultraviolet irradiation. The waveforms cannot be concluded of pure hydroxy radicals, but seem to be *OOH waveforms. The bath-exuded perspiration B was 19% before the ultraviolet irradiation, but was 89%, or 4.7-times up, after the ultraviolet irradiation. Hydroxy radical waveforms were obtained from the perspirations C and D exuded in the far infrared radiation health appliance of the present invention. The irradiated perspirations C and D were increased up to 5.2 times and 2.6 times, respectively, than before the ultraviolet irradiation. The S/M values were as great as 232% in C and 293% in D. As seen from above, the perspirations C and D exuded in the far infrared radiation health appliance of the present invention caused the greatest amounts of active oxygen. These analyses show that the far infrared radiation health appliance of the present invention is effective at egesting components that produce active oxygen in the body.
[0051] Now, it is well known that when a man takes a lying position, the head, heart, and toes become parallel against the gravity, with a three-times improvement of blood circulation than in a sitting position despite less burden on the heart. From old days, those who got sick heal lying abed, not sitting up. The far infrared radiation health appliance according to the present invention can apply far infrared rays to the whole body (up to the soles) of a user who is in a lying position which improves the blood circulation and metabolism. The head can be put in or out of the dome interior.
[0052] Outside the far infrared radiation health appliance of the present invention is air, which facilitate the expansion of peripheral blood capillaries in a warmed body. Thus, the blood circulation can be improved with a less burden on the heart and vessels. In this regard, the appliance differs completely from baths and spas in which the hot water presses a body from outside to hinder the capillary expansion. Accordingly, even those who have an injury in the blood circulation system or cerebral nerves can use the appliance with relative ease and safety.
[0053] Moreover, while a sauna could not be taken for more than 20 minutes, the far infrared radiation health appliance of the present invention can be used over 30 minutes with ease. Even 60 minutes of use will cause no trouble. Lowering the power allows a usage as a weightless blanket in which one can sleep, as well as an allergen-free blanket.
[0054] According to the far infrared radiation health appliance of the present invention, the cutaneous function can be activated to improve the cutaneous respiration and blood circulation for more active metabolism, thereby promoting two types of perspiration, namely, high volume of perspiration from perspiratory glands and sebum perspiration from sebaceous glands. In particular, toxic substances stored in the body, such as dioxins, can be egested from sebaceous glands effectively to contribute to health enhancement.
[0055] While there has been described what are at present considered to be preferred embodiments of the present invention, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover all such modifications as fall within the true spirit and scope of the invention. | A far infrared radiation health appliance which can effectively stimulate sebaceous glands together with perspiratory glands for dioxins egestion. The appliance includes a plurality of semicylindrical members to be axially coupled to each other in a bush-like manner, and carbon-black-containing planar heating elements arranged over the general entire inner surfaces thereof. The planar heating elements are energized and heated to a temperature of 55-70° C. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the invention
This invention relates in general to monitoring pressure remotely, and in particular to an optic fiber pressure transducer having reference and sensing legs and a temperature compensating device for compensating for temperature changes.
2. Description of the Prior Art
There are instances where remote sensing of pressure is a difficult task. For example, in oil, gas or steam wells a typical pressure sensor will mount within the well. Electrical lines will supply power to the sensor to monitor the pressure. Having active electronics in a well environment can be a problem. High temperatures in the well can affect the electronics adversely. Immersion of the electrical cable in the well environment, which is harsh, can cause cable failure.
U.S. Pat. No. 4,859,844 describes a pressure sensing system that utilizes an optical interferometer. The system in the patent employs fiber optics. Light is transmitted through optic fibers. The light splits at an optical coupler/splitter into two legs. One leg is used as a reference. The other optic fiber leg has one end connected to a bourdon tube or other type of pressure transducer.
A difference in pressure sensed by the pressure transducer will cause a change in length of the sensing leg. The light passing through the sensing and reference legs reflects back to the splitter. If the length in the sensing leg changes as a result of pressure change, then the light path length travelled in each leg will not precisely match. This difference can be processed by conventional equipment. The differences can be correlated into the pressure sensed.
The temperature in a downhole well will be elevated. If the temperature changes, both the reference leg and the sensing leg will experience a change in length due to the temperature change. The bourdon tube will also experience a change in length due to temperature effect. The temperature effect could be misread as a pressure change.
SUMMARY OF THE INVENTION
In this invention, an elongated reference compensating member is mounted parallel to the reference leg to apply tension to the reference leg and vary the length of the reference leg. Similarly, an elongated sensing compensated member will be mounted parallel to the sensing leg. The compensating members will each have a coefficient of temperature expansion. Also, the compensating members can be adjusted so that they will selectively vary the lengths of the legs.
Preferably, each compensating member is made of multiple parts, which could each have different coefficients of thermal expansion. Therefore, not only will changing the length of the entire member affect temperature compensation, but the length of each multiple part with respect to the overall length could be adjusted to contribute more or less expansion, due to its individual coefficient of thermal expansion and respective length, to the overall net expansion.
The assembly will be placed in an oven to apply heat to a temperature expected in the well. Pressure will be monitored as the assembly heats. The pressure should be constant during the heating process. If the pressure changes, this indicates that temperature is causing an erroneous reading. The compensating members can be adjusted manually to minimize this erroneous reading.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the sole figure and it is a simplified, sectional view illustrating the downhole portion of a pressure sensing instrument constructed in accordance with this invention.
DETAILED DESCRIPTION OF THE INVENTION
Housing 11 will be located in the well. An optic fiber 13 extends from surface monitoring equipment to housing 11. Optic fiber 13 enters a coupler/splitter 15 which is a known component. Coupler/splitter 15 splits the light beam into two optic fibers 17, 19. The beam will pass through the fibers 17, 19 to the ends of the fibers 17, 19, which are mirrored to reflect the beams back to the coupler/splitter 15.
If one of the fibers 17, 19 changes in length relative to the other of the fibers 17, 19, then the wavelengths of the light coming back to the coupler/splitter 15 will be out of phase. Conventional processing equipment, such as described in U.S. Pat. No. 4,859,844 may be used to process this difference in phase to determine the pressure being monitored.
The forward end of the sensing fiber 17 is connected by a clamp 21 to a wire 23. Wire 23 extends to a cap 25. Cap 25 will clamp the end of wire 23. Preferably, cap 25 is of two parts that can be bolted together to clamp the wire 23 by compression. The details are not shown, and may be varied. Similarly, the reference fiber 19 connects by clamp 27 to a wire 29. Wire 29 is clamped firmly by a cap 31.
The sensing fiber 17 extends from clamp 21 to a rearward clamp 33. Similarly, the reference fiber 19 extends rearward from clamp 27 to a rearward clamp 35. Clamps 33, 35 clamp the optic fibers 17, 19 to wires 37, 39.
Wire 37 leads to the arm 41 of a bourdon tube 43. Bourdon tube 43 has one end exposed to well fluid so that it will receive well fluid under pressure. Pressure changes will cause the arm 41 to rotate slightly in forward and rearward directions. As it rotates in one direction, it will increase tension on the sensing leg 44 of sensing fiber 17. Sensing leg 44 is the portion of sensing fiber 17 from the clamp 21 to the clamp 33. The tension is sufficiently high to cause slight stretching of the sensing leg 44 within elastic limits.
The wire 39 of the reference fiber 19 leads to a cap 45. Cap 45 clamps the wire 39 rigidly. A reference leg 46 will be defined by the portion of the reference fiber 19 between the clamps 27, 35.
Cap 25 is secured by threads to the forward end of a forward tube 47. Forward tube 47 coaxially receives the sensing leg 44. Similarly, cap 31 secures to a forward tube 49. Forward tube 49 concentrically receives the reference leg 46. Each of the forward tubes 47, 49 has a slot 51. Slot 51 is elongated and receives a pin 55. Each pin 55 extends radially inward from the sidewall of housing 11 into one of the slots 51. The pins 55 prevent the forward tubes 47, 49 from rotating relative to housing 11.
Each of the forward tubes 47, 49 also has threads 59 externally formed on the rearward ends. A sleeve 63 has threads 61 that secure to the threads 59 of the sensing forward tube 47. Similarly, sleeve 65 has threads 61 for securing to the threads 59 of the reference forward tube 49.
A rearward tube 67 secures to sleeve 63, and a rearward tube 69 secures to sleeve 65. Both rearward tubes 67, 69 have threads 71 for engaging a set of threads 73 formed in each sleeve 63, 65. The threads 73 are of a slightly different pitch than the threads 61. Threads 73 and 61 are separated by a gap 75. The pitch of the threads 73 is preferably coarser, about 40 threads per inch. The pitch of the threads 61 is preferably 42 threads per inch.
The rearward tubes 67, 69 mount to brackets 77, which although shown schematically to be one, would likely be two separate brackets in actuality. Brackets 77 are rigidly mounted to the housing 11. Each rearward tube 67, 69 has a shoulder 79 that abuts against the forward side of bracket 77. Each rearward tube 67 extends through a hole in bracket 77. A nut 81 will engage threads 83 on each rearward tube 67, 69. Nuts 81, when tightened, will rigidly lock the rearward tubes 67, 69 to the brackets 77. The cap 45 secures to the threads 83 of the reference rearward tube 69.
To calibrate the instrument, preferably the downhole temperature to within about 10 degrees will be known. The instrument will be assembled as shown in FIG. 1, with an initial tension applied to the legs 44, 46. Leg 44 will be sized slightly greater than leg 46, preferably about 0.0015 inch. The processor signals will be watched while tension is applied.
Tension will be applied first by rotating rearward tubes 67, 69 relative to the sleeves 63, 65. A tool will be used to hold sleeves 63, 65 stationary. Nuts 81 will be loosened for this rotation. For each revolution of one of the tubes 67, 69, the length of the legs 44, 46 will change by 1/40th of an inch. Once the approximate tension has been reached, nuts 81 are tightened to prevent the rearward tubes 67, 69 from rotating.
Then, fine adjustments are made. The fine adjustments are made by rotating the sleeves 63, 65 relative to the tubes 67, 69. Rotation of the sleeves 63, 65, in one direction will cause forward movement of the forward tubes 47, 49 relative to the sleeves 63, 65. Similarly, the same rotation in the same direction will cause the sleeves 63, 65 to move rearward relative to the rearward tubes 67, 69, which will not move axially. The difference in the thread pitch will cause a slight net axial movement of the forward tubes 47, 49 relative to the rearward tubes 67, 69. For each rotation of the sleeves 63, 65 in one direction, the legs 44, 46 will lengthen by 1/840th of an inch. The processor will monitor the signals until a proper pressure reading has been achieved.
Then, the assembly will be placed in an oven to heat it to the selected temperature. The pressure should remain constant, normally atmospheric. If the pressure changes, this indicates that the bourdon tube or other mechanical mounting is erroneously affecting the pressure indication due to temperature change. The operator will adjust one or more of the sleeves 63, 65 to change the lengths of the legs 44, 46. Eventually, the thermally induced pressure change can be nullified. The instrument will then be thermally compensated.
The coefficient of temperature expansion of the various tubes 47, 49, 67, 69 and sleeves 61, 63 can be the same or can be different. These coefficients of temperature expansion cause expansion of the tubes and a stretching or application of tension to the legs 44, 46 upon the application of heat.
Also, the direction of polarization of the light in the two legs 44, 46 can be set with the assembly. Rotating the caps 25, 31 and 45 will apply torque, which is transmitted to the fibers 44, 46. This rotation or torque allows for alignment of the polarization individually in each leg so that maximum interference is achieved at the coupler/splitter 15.
The invention has significant advantages. The temperature compensating tubes allow the instrument to be precisely calibrated so the temperature does not affect the pressure reading. The telescoping tube assemblies allow precise arrangement of the lengths of the legs. The telescoping tubes will also allow proper polarization.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention. | An interferometer for measuring pressure using optic fibers has a temperature compensating device. The instrument has an optic fiber sensing leg and an optic fiber reference leg, both of which are clamped in tension. An elongated reference compensating member extends parallel to the reference leg. A similar sensing compensating member compensates parallel to the sensing leg. The compensating members will apply selected tension. The compensating members are expansible in response to temperature change. The lengths of the compensating members can be changed, as well. | 4 |
TECHNICAL FIELD OF THE INVENTION
[0001] The invention relates to a method for the preparation of different molecularly imprinted polymers for recognition of a target molecule and to a device containing different molecularly imprinted polymers for recognition of a target molecule.
TECHNICAL BACKGROUND
[0002] Molecularly imprinted polymers (MIPs), or so called artificial antibodies, are plastics programmed to recognize target molecules, like pharmaceuticals, toxins or environmental pollutants, in complex biological samples 1-3 . During the last years, applications of the materials as affinity phases in solid phase extractions, 4, 5 as recognition elements in sensors, 6 as stationary phases for preparative purifications 7 or separations of enantiomers 8, 9 as catalysts 10 or as adsorbents for medical use 11 are being actively pursued. Among these applications, solid phase extraction (SPE) is the area where the materials on a short time scale are expected to find their most widespread use. SPE is used to clean up and enrich analytes (i.e. drugs or metabolites, pesticides, toxins) present in complex biological samples such as blood, urine or environmental waters (FIG. 1).
[0003] Current methods for drug analysis are strongly depending on efficient SPE techniques. Due to their high potency, many new drugs are now being administered in very low doses. Therefore, the conventional clean-up methods are not efficient enough. However, MIPs can be used to selectively extract the drug from the sample with a high affinity. In an alternative method biological antibodies can be used for the same purpose. It should be noted that MIPs can be produced much faster and in a more reproducible fashion than biological antibodies which are produced by immunisation of laboratory animals. MIPs can be produced and tested within 1-2 weeks compared to 6-12 months for biological antibodies.
[0004] Since the biological monitoring of new drug candidates often constitutes bottlenecks in drug development, the rapid availability of efficient analytical methods is expected to bring significant savings in time in the development of new pharmaceutical products. With a new target analyte in hand it is thus important to provide a selective extraction material for the target in a short time.
SUMMARY OF THE INVENTION
[0005] The molecular imprinting protocol presently in use is based on polymerisation of one or more functional monomers with an excess of a crosslinking monomer in presence of a target template molecule, exhibiting a structure similar to the target molecule that is to be recognised (FIG. 2).
[0006] A key in this development is the identification and optimisation of the main factors affecting the materials structure and molecular recognition properties. These factors can be the type and concentration of functional monomer, crosslinking monomer, the polymerisation temperature, pressure or solvent of polymerisation. This can be achieved by scaling down the MIP synthesis allowing rapid screening for the recognition properties of large numbers of materials (mini-MIPs) (FIG. 3) 12 . Thus, the present automated procedure allows parallel synthesis of 60 MIPs in small autosampler vials. This is followed by an assessment of the recognition properties in a batch equilibrium binding experiment. A problem with this way of evaluating the materials is that no information about the kinetics of the equilibrium reaction is possible to obtain. For this purpose techniques allowing the materials to be directly assessed in the chromatographic flow through mode would be desirable.
[0007] The object of the present invention is to provide a screening technique using monolith MIPs and grafted MIPs in a flowthrough format. The characterising features of the present invention are defined in the appended claims.
[0008] In accordance with the invention this object has been achieved by a method
[0009] a) providing particles, frits or monoliths having initiator confined to the surface thereof in separate compartments;
[0010] b) adding different monomer mixtures that may contain a template molecule to each compartment;
[0011] c) polymerising said mixtures;
[0012] d) removing the template and excess monomer(s) from the compartments.
[0013] In accordance with the invention this object has also been achieved by a device
[0014] a) providing particles, frits or monoliths having initiator confined to the surface thereof in separate compartments;
[0015] b) adding different monomer mixtures that may contain a template molecule to each compartment;
[0016] c) polymerising said mixtures;
[0017] d) removing the template and excess monomer(s) from the compartments.
[0018] Preferred embodiments of the invention are defined in the dependent claims.
SHORT DESCRIPTION OF THE DRAWINGS
[0019] The invention will now be described in more detail giving some preferred and nonrestrictive examples. The following products and methods are claimed as new and of decisive importance for a successful outcome of MIP development. In the drawings
[0020] [0020]FIG. 1 is a scheme illustrating the principle of solid phase extraction (SPE).
[0021] [0021]FIG. 2 is a scheme illustrating the principle of molecular imprinting.
[0022] [0022]FIG. 3 is a scheme illustrating a system for small scale automated synthesis and screening of MIPs.
[0023] FIGS. 4 - 7 are schemes illustrating the methods of invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] 1. Combinatorial grafting of MIPs on particles with defined pore and particle sizes and subsequent packing of SPE wells.
[0025] WO 01/19886 describes synthesis of MIPs on initiator modified particles and the resulting composite MIPs forms the basis of the invention. Thus imprinted polymer can be prepared by confining the chain growth to the surface of the particles (FIG. 4). This implies that a robust and continuous method for MIP production can be set up (FIG. 5). Alternatively, since chain growth in solution can be neglected, the grafting can be performed in situ in SPE well or on planar substrates. In this invention the particles will be packed in specially designed microtiter plates. The first of these are solvent resistant microtiter plates with frits with a sealable outlet (Alt 1 ). The other is a solvent resistant plate where the particles after grafting can be transferred to standard SPE plates (Alt 2 , FIG. 6). The solvent resistant plate as shown in FIG. 6 is preferably a microtiter plate of Teflon® coated aluminium. Each well of the microtiter plate contains initiator modified particles. The amount of initiator modified particles in each well is preferably about 10-20 mg. The bottom of each well is provided with a one-way capillary for subsequent transfer of the MIP particles as described below. The top of the microtiter plate is provided with a glass lid for UV polymerisation. After filling about 10-20 mg particles in each well different monomer mixtures containing the template molecule are added in Step 1 (FIG. 6) to each well just enough to wet the particles. After polymerisation in Step 2 by UV or heat, the MIP grafted particles are transferred into standard microtiter plate extraction units in Steps 3 and 4 by stacking and inverting. In Step 3 a standard microtiter plate is stacked tightly upside down on top of the MIP containing microtiter plate obtained in Step 2 . In Step 4 the stacked microtiter plates of Step 3 are inverted and the MIP particles are transferred from the solvent resistant microtiter plate to the standard microtiter plate. Efficient transfer is assured by rinsing and vacuum application. The resulting plates are then ready for use. This invention can thus be used for convenient combinatorial MIP synthesis and evaluation. As an alternative to the use of initiator modified particles, initiator modified frits or monoliths may also be used.
[0026] 2. Combinatorial synthesis of MIPs as stripes for TLC evaluation of recognition properties.
[0027] This embodiment of the invention is illustrated in FIG. 7. In Step 1 initiator modified particles are used to coat a glass plate according to standard methods for TLC-plate fabrication. After coating lanes or stripes are separated by cut crevices (solid black lines in FIG. 7), which are used to prevent mixing of neighbouring monomer mixtures. In step 2 different monomer mixtures containing template giving MIPs (T 1 to T 5 ) and in absence of template giving blanks (B 1 to B 5 ) are then added to each lane, and in Step 5 polymerisation is started by UV or heat after coating the surface with a glass plate. After polymerisation template and excess monomer are removed by washing. The recognition properties can then be directly assessed (Step 4 ) in a flow through mode by TLC of the template and analogues. Development of the plates is done using the standard methods for TLC development. Thus by impregnating the plate with a fluorescent label, fluorescent detection is possible. Otherwise various group specific reagents can be used. This is expected to yield a high throughput alternative to MIP development for SPE or chromatography.
[0028] 3. Detection of bound-nonbound substrate or analyte based on fluorescence-, UV-, IR-, Raman- or radioactivity measurements.
[0029] After synthesis of the MIPs, rapid methods for estimating release and rebinding of template are needed. Until now this have been measured using time consuming HPLC or FIA quantification in a serial mode. Paralell methods for quantification are highly desirable. For this purpose it is possible to apply sensitive techniques to measure what is bound to the polymer in situ. However, such techniques are expected to be limited due to the complex composition of MIPs particularly since monomers and templates vary considerably in adsorption characteristics. Of more general utility would be methods relying on quantification of nonbound substrate. Thus after having separated supernatant from polymer, by pipetting or filtering, the unbound fraction can be measured by a variety of techniques depending on the nature of the template. Thus amines will be labelled with fluorescent reagents such as orthophtalaldehyde (OPA), acids can be esterified with a fluorescent or UV absorbing reagent and if radioactive labelling is available scintillation counting is possible. Thus having access to these techniques in combination with Microtiter plate Readers (Fluorescence-, UV/Vis-, Scintiallation-reading) a fast high throughput technique for MIP synthesis is possible.
REFERENCES
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[0035] 6. Turkewitsch, P., Wandelt, B., Darling, G. D. & Powell, W. S. Anal. Chem. 70, 2025-2030 (1998).
[0036] 7. Joshi, V. P., Karode, S. K., Kulkarni, M. G. & Mashelkar, R. A. Chem. Engn. Sci. 53, 2271-2284 (1998).
[0037] 8. Sajonz, P., Kele, M., Zhong, G., Sellergren, B. & Guiochon, G. J. Chromatogr. 810, 1-17 (1998).
[0038] 9. Armstrong, D. W., Schneiderheinze, J. M., Hwang, Y. -S. & Sellergren, B. Anal. Chem. 70, 3304-3314 (1998).
[0039] 10. Davis, M. E., Katz, A. & Ahmad, W. R. Chem. Mater. 8, 1820-1839 (1996).
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[0041] 12. Lanza, F. & Sellergren, B. Anal. Chem. 71, 2092-2096 (1999). | The invention relates to a method for the preparation of different molecularly imprinted polzmers for recognition of a target molecule by providing particles, frits or monoliths having initiator confined to the surface thereof in separate compartments, adding different monomer mixtures that may contain a template molecule to each compartment, polymerising said mixtures and finally removing the template and excess monomer(S) from the compartments. The invention also relates to a device containing different molecularly imprinted polymers for recognition of a target molecule. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of Swiss Application No. 1464/96, filed Jun. 12, 1996, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention regards a catalyst, particularly a catalyst for usage in polyurethane systems and especially for the use in humidity reactive polyurethanes (PU), its production and its use. Particularly the invention concerns a catalyst which is suitable for being used in adhesive, sealing and coating compositions and pretreatments with a primer, which are storage stable if stored under exclusion of humidity. Said compositions are on the basis of humidity reactive polyurethanes (PU) which are fast curing in the presence of humidity.
BACKGROUND OF THE INVENTION
Adhesive, sealing and coating compositions and pretreatments with a primer on the basis of polyurethane prepolymers which are humidity curing are known and are broadly used for coating, connecting and sealing building and construction materials such as e.g. plastics, glass, ceramics, varnished sheet metals, metals, wood, concrete and other substratums.
Such compositions do advantageously comprise little or no solvents and they contain isocyanate groups comprising prepolymers which are prepared in a known manner by reacting bifunctional or polyfunctional polyols with an excess of diisocyanate or polyisocyanate, whereby the monomers content in the whole formulation is as low as possible, i.e. smaller than 1%, preferably smaller than 0.5%.
In the presence of e.g. humidity, the isocyanate groups of the monomers as well as the isocyanate groups at the ends of the polyurethane (PU) prepolymer chains react with water under formation of an instable carbamic acid group that spontaneously decomposes to amines and carbon dioxides. Said amino group then does fast react with a further isocyanate group under the formation of a urea group. Said cross-linkage reaction causes a molecule growth and leads to a hard or tough elastic composition suitable for adhesive sealing and coating purposes.
By the admixture of catalysts, the reaction of water with isocyanate groups can be accelerated. Known catalysts are titanates, organometal compounds such as e.g. tin or lead compounds that can also be combined with other catalysts, particularly tertiary amines. Generally the catalysts are used in amounts of up to 2% referred to the whole formulation.
If large amounts of catalyst are used to speed up the curing throughout the layer, on the one hand the stability of the PU system is affected, making an application after short storage time impossible due to an enhancement in the viscosity. On the other hand the temperature stability of the cured composition is reduced due to depolymerisation. Desired is a PU system that is still applicable after a storage time of more than 6 months.
U.S. Pat. No. 4,780,520 describes the use of dimorpholinodiethylether (DMDEE) as catalyst for the formulation of a storage stable fast curing PU system, whereby DMDEE is used in an amount of 0.2 to 1.75% referred to the whole composition.
GB patent application No. 2,231,879 shows that the use of 0.2 to 2% of tetramethyl substituted DMDEE also enables the formation of a storage stable PU-system, whereby the strength development at low temperature and low humidity, i.e. at 5° C. and 50% relative humidity, is faster than with a DMDEE catalysed PU-system.
In U.S. Pat. No. 4,705,840 2,2'-dimorpholinylalkylethers are disclosed which at 24° C. and 55% relative humidity show the same early strength as DMDEE, i.e. 7.5 minutes after application of an orthopaedic bandage, at half the concentration of DMDEE, i.e. with 5% by mole.
The use of the above mentioned catalysts for the formulation of fast curing PU systems with fast strength development has the disadvantage that the assembly time is reduced to below 8 to 10 minutes. The assembly time, also termed open time, is defined as the time between the application and the assembling for which a good adhesion is granted. The skinning time according to experience is shorter than or identical with the assembly time and is an efficient method for the approximate determination of the assembly time (see examples).
SHORT DESCRIPTION OF THE INVENTION
The goal of the present invention was to provide catalysts on the basis of morpholine, which catalysts are suitable for the production of fast curing, storage stable PU systems providing a fast strength development at low temperatures and low humidity (e.g. 5° C. and 80% relative humidity or 23° C. and 20% rel. humidity, respectively). Said catalysts provide furthermore, compared to state of the art products, an extended assembly time, i.e. more than 10 minutes, and a good temperature stability.
This goal was achieved by the inventive catalysts of the following formula ##STR2## wherein n+m is >1 and wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 , R 14 independently from each other represent hydrogen or an alkyl group, particularly a methyl group or an ethyl group.
The inventive catalysts primarily enhance the reactivity of the isocyanate groups and therefore are suitable for single-component (sc) systems as well as two-component (tc) systems which cure with water or curing agents on the basis of e.g. reactive OH groups or NH 2 groups. The inventive catalysts can be used alone as well as in combination with each other or in combination with known catalysts, e.g. catalysts on the basis of organometallic tin and/or titanium catalysts (see above).
The inventive catalysts are particularly suitable for humidity curing single-component systems.
The effect of the above described morpholine derivatives in humidity curing systems possibly can be seen in that the hydrophilic part--similar to a crown ether--transports water into the matrix and thus in the proximity of the reactive isocyanate groups, and that the two tertiary amines catalytically assist in the reaction of said water with the isocyanate group.
Therefore the inventive catalysts are very suitable for the use in single-component systems. The catalytic effect possibly involves a proton transfer to the amide nitrogen of the isocyanate group (literature thereto: Herlinger Heinz, Habilitationsschrift "Struktur und Reaktivitat der Isocyanate", Universitat Stuttgart, 1970, p. 24). After the reaction of the isocyanate with water on the one hand carbon dioxide is formed, on the other hand the catalyst, the morpholine derivative, is again liberated. As already mentioned above, this explanation of a possible kind of action is only a probable explanation. Said explanation is not intended to limit the invention in any way.
In a particularly favourable embodiment, the hydrophilic behaviour of the morpholine derivative is enhanced. Said enhancement is achieved by the incorporation of a polyethylene oxide between two morpholine groups. The water absorbing character of the inventive catalysts and therewith the diffusion gradient of the PU system is thus, that the water from the environmental humidity enters the PU composition prior to it being caught by the isocyanate groups present at the surface. Thereby the skinning time is somewhat delayed and the assembly time is extended with simultaneously fast strength development. This combination of features is very advantageous for the user. Furthermore, the traces of water present on the surface of the substratum are transported away from the interface between adhesive and substratum due to the hygroscopic character of the PU composition. Thereby an immediate cross-linking is avoided leading to an improved wetting of the substratum and thereby to improved adhesive properties.
The inventive PU compositions that are catalysed by the inventive catalysts, due to their excellent stability can be processed at enhanced temperatures, i.e. at temperatures up to 95° C., and thus enable the production of storage stable humidity reactive hot melts. Of all one component curing systems such humidity reactive hot melts have the best strength development due to the enhancement in the viscosity upon cooling after application and due to the binder system that is fast curing upon contact with humidity.
The inventive PU compositions are particularly suitable as adhesives, sealings, coating materials and pretreatments with a primer. They exhibit fast strength development and, in comparison with the state of the art, a delayed skinning time and therewith an extended assembly time. They are suitable for the application on metal, glass, ceramics, wood, cementitious and plastic substratums.
DETAILED DESCRIPTION OF THE INVENTION
The inventive catalyst is a morpholine group comprising compound of general formula ##STR3## wherein n+m is >1 and R 1 to R 14 are independently from each other either hydrogen or an alkyl group, particularly a methyl group or an ethyl group. In preferred catalysts the sum of n+m is between 2 and 10, particularly between 2 and 5. Specific catalysts that are relatively easy to produce are those, wherein
R 1 to R 14 are hydrogen
R 1 to R 4 and R 9 to R 14 are hydrogen and R 5 or R 6 and/or R 7 or R 8 are methyl groups, whereby those R 5 , R 6 , R 7 and R 8 which are not methyl groups are hydrogen,
R 1 , R 3 , R 11 and R 13 are methyl groups and R 2 , R 4 to R 10 , R 12 and R 14 are hydrogen.
The inventive catalysts can e.g. be produced according to methods of the Canadian patent application 2,103,730 of Miles Inc., USA (1992).
They are especially suitable for the use in isocyanate groups containing single-component polyurethane systems and two-component polyurethane (PU) systems. In particular, the inventive catalysts are very suitable for being used in single-component systems.
The isocyanate groups comprising PU prepolymers which are present in the inventive systems as the main component, are the reaction products of isocyanate groups comprising substances with any compound that is reactive towards isocyanate groups (isocyanate reactive compound). Such compounds are e.g. compounds comprising aliphatic or aromatic polyol groups, polyamine groups or polymercapto groups, whereby the reaction can be performed in known manner at temperatures of about 80° C. and optionally in the presence of a catalyst, e.g. dibutyl tin dilaurate, usually in stoichiometric amounts, i.e. for each group with an active hydrogen one at least two isocyanate groups comprising monomer.
Usually polyols with a functionality of between 1.5 and 3 as well as with a molecular weight of between 400 and 10,000 are used, preferably such polyols with a molecular weight ranging from 1000 to 6000. Such polyols are e.g. polyalkylene polyols (e.g. polyethylene oxide, polypropylene oxide, polybutylene oxide, polytetrahydrofurane), polycarbonates, polycaprolactones, polyesters etc.
The isocyanate groups comprising monomers can be aliphatic, cycloaliphatic or aromatic monomers such as e.g. 4,4'-diphenylmethane diisocyanate, 2,4-toluene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, perhydro-2,4'-diphenylmethane diisocyanate etc.
The above described PU prepolymers preferably have a content of free isocyanate in the range of 1 to 3%, and usually the prepolymer is present in amounts referred to the whole composition of 20 to 60%, particularly of 20 to 50%.
The PU-systems of the present invention comprise at least one PU-prepolymer and an inventive curing catalyst.
Said systems optionally can comprise usual additives and adjuvants such as e.g. emollients, fillers, latent curing agents, adhesion promoters, dyes, pigments, UV adsorbers, stabilisers, antioxidants, surface active additives, flame-retardants, fungistatically active substances etc. The kind and amount of said additives or adjuvants is dependent on the intended use of the inventive compositions.
The amount of inventive isocyanate/water curing catalyst generally is in the range of 0.1 to 2% by weight, particularly 0.4 to 1% by weight, referred to the total weight of the composition. While with an amount of below 0.1% the desired curing effect is not achieved, an amount of more than 2% affects the storage stability of the PU-System.
If necessary, the inventive catalysts can be combined with other, conventional catalysts, e.g. organometallic catalysts or catalysts on the basis of tertiary amines.
During the production of the inventive single-component compositions care has to be taken that no humidity is introduced. All components used should largely be free of water and it is appropriate to admix to the PU system water binding or water reactive substances such as e.g. calcium oxide, molecular sieves, monofunctional isocyanate groups comprising compounds ortho formate etc. The ancillary processing is made in known manner with humidity exclusion, e.g. in cartridges, barrels etc.
The inventive PU systems can, according to the requirement, be used for assembling, sealing or coating purposes and have numerous applications in the construction field as well as in industry, e.g. in the vehicle production, the marine etc., whereby application on very different materials such as e.g. glass, ceramics, plastics, PU elastomers, metals and varnished metals, is possible. Possibly a pretreatment with a primer is necessary to get the best possible adhesion.
The invention is further described by means of examples regarding single-component adhesives. These examples however, are not intended to restrict the scope of the invention in any way.
EXAMPLES
Examination of the Storage Stability of the Adhesive Compositions
The viscosity of the adhesive composition was determined by extrusion of a cartridge at 23° C. and with a pressure of 6 bars through a 3 mm nozzle resulting in a value in grams per minute. Said measurement was performed after storage at room temperature for 7 days (=>original extrusion rate), 1 month and 3 months, respectively, as well as after heat ageing at 60° C. for 7 days. Additionally the skinning time was determined for each sample in order to examine the influence of the storage conditions on the reactivity of the adhesive or the curing catalyst, respectively.
Storage of the Specimen
The specimen have been stored under two different climatic conditions, in order to determine the influence of said conditions on the open time and the strength development:
climate I: 23° C. and 50% relative humidity (standard climate),
climate II: 5° C. and 80% relative humidity
Determination of the Skinning Time (ST)
The skinning time is the time after application until the sample is track free.
Determination of the Early Strength
The development of the strength was determined using lap shear specimens consisting of two glass plates according to DIN 53504 (cross-head speed: 200 mm/min, thickness of the adhesive layer: 5 mm) after storage of the specimens under the two above defined climatic conditions, whereby the measurement was made after 30 min., 60 min., 90 min. and 3 hours. The value of the lap shear strength (LSS) is indicated in N/cm 2 .
Catalysts
The following catalysts have been compared:
1. DMDEE (2,2'-dimorpholino ethyl ether) of Nitroil, Germany
2. TMDMDEE (tetra methyl-DMDEE) of Nitroil, Germany
3. DMPEG 200 (dimorpholino polyethylene oxide glycol), (n+m about 3)
While the two catalysts 1 and 2 belong to the state of the art, 3 represents an inventive catalyst (for formula, production, see below).
Formulation of the Adhesive Composition
The kind of action of the catalysts was examined in a standard formulation based, besides of carbon black and chalk, on a prepolymer consisting of a trifunctional polyetherpolyol with a molecular weight of about 4500 and an aromatic isocyanate group comprising monomer, MDI (methylene-4,4'-diphenyl diisocyanate). The amount of catalysts was calculated thus that the morpholine content was 0.4% based on equivalents. This is for DMDEE about 0.5% by weight, for TMDMDEE about 0.4% by weight and for the inventive catalyst DMPEG 200 about 0.8% by weight, all % by weight being referred to the whole adhesive formulation.
Preparation of the Inventive Catalyst DMPEG 200 (According to the Canadian Patent Application CA 2103730/Miles Inc. USA/1992)
A) Production of the Dimesylate of PEG 200 ##STR4##
11.41 g polyethyleneglycol 200 (Fluka, pract.), 13.1 g triethylamine and 22 ml methylene chloride (Fluka, puriss.) in a 250 ml three-necked flask, provided with reflux condenser, 25 ml dropping funnel and thermometer, are cleansed with nitrogen. Then the mesylchloride is slowly dropped from the dropping funnel into the flask under inert gas and with stirring by means of a magnetic stirrer. Since the reaction taking place is very exothermic, the flask is cooled in iced water and the dropping speed is regulated in a way that the temperature does not exceed 25° C. During the reaction, a white/yellow precipitate is formed. When the dropping has finished, the funnel is washed with 20 ml methylene chloride that are dropped into the flask. The ice water container is omitted and the mixture is stirred for another 1.5 hours at ambient temperature and then carefully neutralised with a concentrated sodium hydroxide solution (5.1 g NaOH (Fluka No. 71691) in 20 ml water). Thereby the precipitate is dissolved leading to a yellow phase. After stirring for another hour, the phase is concentrated using a water jet pump. Thereby the temperature of the water bath is slowly raised to 70° C. (the collecting flask advantageously is cooled with ice water in order to collect the methylene chloride for a further use). During the concentration, again a yellow precipitate is formed. This intermediate was not further purified. The thus obtained intermediate was directly further processed.
B) Production of DMPEG 200 ##STR5##
The milky residue of the intermediate is diluted with 20 ml methylene chloride and 15.87 g morpholine, 112 ml isopropanol and 20.1 g water free sodium carbonate (Fluka puriss No. 71350) (dried in an oven at 130° C. over night) are added. The reaction mixture is then heated to reflux (bath temperature ˜85° C.) and kept at said temperature for about 5 hours. The reaction product is filtered through a glass frit (porosity 4) and separated from a white residue, from which some further small amounts of the product can be separated by ether extraction. The slightly yellow coloured filtrate is then concentrated by means of a water jet pump and then the bath temperature is raised to 80° C. and kept at this temperature for one hour. During said procedure a small amount of solid again precipitates. Said residue now is separated from volatile parts by means of a vacuum generated by a rotary pump during three hours.
Then 100 ml diethyl ether (Fluka purum, F 31700) (PEROXIDE FREE!) are added, the mixture is stirred for 15 minutes and then filtered through a glass frit (porosity 4). The resulting filtrate is concentrated by distilling the ether under ambient pressure and then for one hour at 80° C. bath temperature under a vacuum generated by a water jet pump. The remaining solution is then completely dried under a vacuum generated by a rotary pump (pressure about 10 -1 .5 mbar) for 2 hours. About 14.7 g of thus cleaned product DMPEG 200 are obtained corresponding to a yield of about 73%. It comprises less than about 0.04% water (determined by Karl-Fischer titration).
Results of the Comparison Tests
The valuation was made in comparison to the DMDEE-catalysed PU adhesive, whereby the symbols used have the following meaning:
same performance
extended skinning time/faster strength development
shorter skinning time/slower strength development
A) ST and Strength Development in Climate I (23° C./15% Relative Humidity (r.h.))
______________________________________adhesive with: DMDEE TMDMDEE DMPEG______________________________________ST (minutes) 10 10 25LSS after 30' 6.6 6.4 7.8LSS after 60' 9.4 9.5 9.7LSS after 90' 14.4 13.7 13.8LSS after 3 h 21.5 20.8 32.1______________________________________
B) ST and Strength Development in Climate II (5° C./80% r.h.)
______________________________________adhesive with: DMDEE TMDMDEE DMPEG______________________________________ST (minutes) 17 17 25LSS after 30' 6.7 6.5 8.7LSS after 60' 8.1 10.7 12.3LSS after 90' 9.0 11.6 13.8LSS after 3 h 14.0 17.6 24.0______________________________________
C. Determination of the Storage Stability
The valuation was made by mentioning the percentual change with regard to the original value. The PU adhesive catalysed with DMDEE, according to experience obtained in practice, has satisfying storage stability.
______________________________________Extruded amount______________________________________adhesive with: DMDEE TMDMDEE DMPEG______________________________________1 month at rt <20% <20% <20%3 months at rt <40% <40% <40%______________________________________Skinning Time______________________________________adhesive with: DMDEE TMDMDEE DMPEG______________________________________1 month at rt <10% <10% <10%3 months at rt <10% <10% <10%______________________________________ rt = room temperature | A morpholine group comprising catalyst of the general formula, ##STR1## wherein n+m is >1 and R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 and R 14 are independently from each other hydrogen or an alkyl group, particularly a methyl or an ethyl group, is described. Said catalyst is particularly suitable for the use in storage stable polyurethane (PU)-compositions usable as adhesives, sealings, coatings or pretreatments with a primer. Said PU compositions have a delayed skinning time and thus an extended assembly time but nevertheless a fast development of strength, and they are suitable for the application on metal, glass, ceramics, wood, cementitious substratums and plastic substratums. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 13/081,488, filed Apr. 6, 2011, entitled “Repositionable Medium And Stack Thereof”, by Jay K. Sato and Douglas W. Wilson, which is a continuation-in-part of U.S. patent application Ser. No. 12/829,386, filed Jul. 2, 2010, entitled “Note Sheet and Pads Thereof and Related Method” by Jay K. Sato, Eric Kim, Susan L. Broyles, Darren S. Ferris, Cheng-Chung Chang, and Tsun-Rung Hsu, which is a continuation-in-part of U.S. patent application Ser. No. 29/355,485, filed Feb. 8, 2010, entitled “Note Sheets and Related Pads of Note Sheets” by Jay K. Sato, Eric Kim, Susan L. Broyles, Darren S. Ferris, Cheng-Chung Chang, and Tsun-Rung Hsu, and a continuation-in-part of U.S. patent application Ser. No. 29/361,471, filed May 11, 2010, entitled “Note Sheets and Related Pads of Note Sheets” by Jay K. Sato, Eric Kim, Susan L. Broyles, Darren S. Ferris, Cheng-Chung Chang, and Tsun-Rung Hsu. U.S. patent application Ser. Nos. 13/081,488, 12/829,386, 29/355,485, and 29/361,471 are all incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
The present invention relates generally to media of the type including a repositionable adhesive and relates more particularly to a novel medium of the aforementioned type, to a plurality of such media arranged in a stack, the method of manufacturing such media, and the method of using such media.
BACKGROUND
Media of the type including a repositionable adhesive are commonly used in a variety of venues including, but not limited to, homes, workplaces, and schools, and for a variety of applications, such as note-taking. One common type of medium having a repositionable adhesive is often referred to in the art as a repositionable note paper and includes a small sheet of paper having a top surface and a bottom surface, the top surface is receptive to markings, the bottom surface having a repositionable adhesive applied to a portion thereof, typically as a band of adhesive applied alongside one edge of the sheet.
In use, a handwritten or machine-printed marking is made on the top surface of the sheet, and the sheet is adhered to a desired object by pressing the adhesive band directly against the object. Often, prior to use, a plurality of identical such media are stacked on top of each other and held together using the adhesive bands to form a pad. The media can be stacked with their respective adhesive bands aligned with one another. For such stacks, markings can be made on the top sheet prior to separating the top sheet from the remainder of the pad, or the top sheet can be separated from the pad prior to applying a marking to the separated sheet.
In another type of stack, the media can be arranged in an alternating pattern in which each sheet is rotated 180 degrees relative to its adjacent neighbors with respect to their respective adhesive bands. The aforementioned type of stack is often referred to as an “accordion stack” or as a “Z-stack,” due to the appearance of the stack from its side when the top and bottom sheets of the stack are gently pulled in a direction away from one another. Such stacks can be used in conjunction with a slotted dispenser so that individual sheets can be separated from the stack by pulling the free end of the top sheet up through a narrow slot in the dispenser. Once the sheet has been removed from the dispenser, it can be marked and adhered to a desired substrate. Such stacks can also be used without a dispenser, in which case the marking can be applied to the sheet either before or after separating the sheet from the remainder of the stack.
Another common type of repositionable medium is often referred to in the art as a repositionable flag and includes a rectangular strip of polymeric film divided laterally into a first portion and a second portion, the first portion is usually longer than the second portion. The first portion, which can be translucent, has a repositionable adhesive applied to the bottom surface thereof and has a coating applied to the top surface thereof that is receptive to handwritten or machine-printed markings. The second portion can be devoid of adhesive on its bottom surface and can have a coating over its top surface that is receptive to handwritten or machine-printed markings In addition, the top surface of the second portion can be coated with a colored ink and can additionally include pre-printed information.
The above-described repositionable flags are often arranged in “Z-stacks,” with individual flags being dispensed from the “Z-stack” using a slotted dispenser. In use, a flag is dispensed from the “Z-stack,” and the flag is adhered to a desired object, such as a sheet of paper. If desired, markings can be made on the first portion and/or the second portion of the tape, either before or after the tape is adhered to a desired object. When the desired object is paper, the tape is can be positioned relative to the sheet of paper so that the second portion of the tape extends outside the boundaries of the sheet of paper, with the first portion of the tape positioned within the boundaries of the sheet. In this manner, the second portion can serve as a flag to identify a portion of the paper of interest, with the first portion of the tape being translucent so as not to obscure any printed matter located therebeneath.
Still another common type of repositionable medium includes a sheet of polymeric film divided into a first portion and a second portion, the second portion extending laterally from the first portion as a tab. The first portion, which can be translucent, can have a repositionable adhesive applied to the bottom surface thereof and has a coating applied to the top surface thereof that is receptive to handwritten or machine-printed markings The second portion can be devoid of adhesive on its bottom surface and can have a small sheet of paper, which can be colored, adhered to its top surface, the sheet of paper is receptive to handwritten or machine-printed markings Analogously to the repositionable note flags discussed above, markings can be made on the paper sheet and/or on top of the coated first portion, and the first portion can be adhered to a desired object.
However, in contrast with the aforementioned repositionable note flags, these tabbed media are not arranged in a “Z-stack” prior to use, but rather, are stacked so that all of the first portions of the polymeric film are aligned with one another and so that all of the second portions of the polymeric film are aligned with one another. The reason why a “Z-stack” has not been used for this type of medium is that, if a “Z-stack” arrangement were to be used, the adhesive area on the bottom of a first medium would come into direct contact with the paper portion of a second medium located directly beneath the first medium. Such contact between the adhesive area of the first medium and the paper of the second medium would undesirably result in the delamination or splitting of the paper from the second medium as the first medium is pulled away from the second medium.
It should, therefore, be appreciated that there is a need for a repositionable medium that can resist delamination when removed from a “Z-stack” arrangement. The present invention satisfies this need.
SUMMARY
The present invention includes a repositionable medium. The repositionable medium includes a base having a top surface, a bottom surface, a first end edge, and a second end edge. The repositionable medium also includes a paper fixedly coupled to the top surface of the base proximate to the first end edge. The paper has an inner edge and an outer edge, with the outer edge being closer to the first end edge than the inner edge is to the first end edge. The inner edge is spaced from the first end edge of the base by a first distance. The repositionable medium also includes a first repositionable adhesive fixed to the bottom surface of the base. The first repositionable adhesive not being present in a first low adhesion area at a line across a width of the base and spaced from the second end edge of the base by a second distance. The second distance is equal in length to the first distance.
In other, more detailed features of the invention, the first low adhesion area extends entirely across the width of the base. Also, the first low adhesion area can be devoid of adhesive. Also, the repositionable medium can further include a second repositionable adhesive. The second repositionable adhesive occupies at least a portion of the first low adhesion area. The second repositionable adhesive is less tacky than the first repositionable adhesive.
In other, more detailed features of the invention, the second repositionable adhesive is the same as the first repositionable adhesive and the second repositionable adhesive has a lower coat weight than the first repositionable adhesive. Also, the first low adhesion area can extend entirely across the width of the base and can extend from the second end edge of the base to slightly beyond the line spaced from the second end edge by the second distance. Also, the first low adhesion area can extend entirely across the width of the base from a third distance slightly less than the second distance to a fourth distance slightly greater than the second distance. Also, the first repositionable adhesive can be applied to the bottom surface of the base from the second end edge of the base to the third distance. The first repositionable adhesive can also be applied to the bottom surface of the base from the fourth distance to a fifth distance, with the fifth distance spaced from the first end edge and can be greater than the first distance.
In other, more detailed features of the invention, the first repositionable adhesive is not present in a second low adhesion area positioned along the second end edge of the base. The first repositionable adhesive can occupy at least some of the space between the first low adhesion area and the second low adhesion area. Also, the second repositionable adhesive can occupy the first low adhesion area and the second low adhesion area. Also, at least one of the first low adhesion area and the second low adhesion area can be devoid of adhesive. Also, both the first low adhesion area and the second low adhesion area can be devoid of adhesive.
In other, more detailed features of the invention, the base can include a polymeric film. Also, the polymeric film can be translucent. Also, at least a portion of the polymeric film can be coated with a marking-receptive coating. Also, at least a portion of the polymeric can be coated with a marking-receptive coating and a writable release coating.
In other, more detailed features of the invention, the paper can be coated with a writable release coating. Also, the paper can be fixedly coupled to the base using an adhesive.
The present invention also includes a stack of repositionable media including a plurality of repositionable media. Each of the plurality of repositionable media includes a base. The base has a top surface, a bottom surface, a first end edge, and a second end edge. Each of the plurality of repositionable media also includes a paper fixedly coupled to the top surface of the base proximate to the first end edge. The paper has an inner edge and an outer edge. The outer edge is closer to the first end edge than the inner edge is to the first end edge and the inner edge is spaced from the first end edge of the base by a first distance. Each of the plurality of repositionable media also includes a first repositionable adhesive fixed to the bottom surface of the base. The first repositionable adhesive is not present in a first low adhesion area at a line across a width of the base and spaced from the second end edge of the base by a second distance. The second distance is equal in length to the first distance. The plurality of repositionable media is arranged in a Z-stack. The inner edge of the paper of a first repositionable medium is aligned with the first low adhesion area on a second repositionable medium positioned directly thereover.
The present invention also includes a repositionable medium. The repositionable medium including a base. The base has a top surface and a bottom surface. The repositionable medium also includes a paper fixed to the top surface of the base, a first repositionable adhesive fixed to the bottom surface of the base in a first high adhesion area, and a second repositionable adhesive fixed to the bottom surface of the base in a first low adhesion area. The first low adhesive is different than the first high adhesion area and the second repositionable adhesive having less adhesive strength than the first repositionable adhesive. Also, the paper can cover a portion of the top surface of the base.
The present invention also includes a stack of repositionable media including a plurality of repositionable media. Each of the plurality of repositionable media includes a base, and the base has a top surface and a bottom surface. Each of the plurality of repositionable media also includes a paper fixed to the top surface of the base, a first repositionable adhesive fixed to the bottom surface of the base in a first high adhesion area, and a second repositionable adhesive fixed to the bottom surface of the base in a first low adhesion area. The first low adhesion area is different than the first high adhesion area, and the second repositionable adhesive has less adhesive strength than the first repositionable adhesive. The base has a first end edge and a second end edge. The paper has a first edge proximate to the first end edge of the base and a second edge distal to the first end edge of the base. The second edge of the paper is spaced from the first end edge of the base by a first distance. The plurality of repositionable media is arranged in a Z-stack, with the second edge of the paper of a first repositionable medium aligned with the first low adhesion area of the second repositionable adhesive of a second repositionable medium positioned directly thereover.
The present invention also includes a repositionable medium. The repositionable medium includes a base. The base having a top surface and a bottom surface. The repositionable medium also includes a paper fixed to the top surface of the base, and a first repositionable adhesive fixed to the bottom surface of the base in a first high adhesion area and in a second high adhesion area. At least a portion of the first and second high adhesion areas are spaced apart from one another.
In other, more detailed features of the invention, the paper can have a first edge proximate to the first end edge of the base and a second edge distal to the first end edge of the base. The second edge of the paper can be spaced from the first end edge of the base by a first distance and the first high adhesion area of the first repositionable adhesive can be spaced from the second end edge of the base by a second distance that can be slightly greater in length than the first distance. The second high adhesion area of the first repositionable adhesive can be positioned over at least a portion of the bottom surface and can extend from the second end edge of the base to a third distance from the second end edge of the base. The third distance can be slightly less in length than the first distance.
In other, more detailed features of the invention, the repositionable medium can further include a second repositionable adhesive applied to the bottom surface of the base in a first low adhesion area. Also, the first low adhesion area can be located between the first high adhesion area and the second high adhesion area.
The present invention also includes a stack of repositionable media including a plurality of repositionable media. Each of the plurality of repositionable media includes a base. The base has a top surface and a bottom surface. Each of the plurality of repositionable media also includes a paper fixed to the top surface of the base, and a first repositionable adhesive fixed to the bottom surface of the base in a first high adhesion area and in a second high adhesion area. At least a portion of the first and second high adhesion areas are spaced apart from one another. Each of the plurality of repositionable media also includes a second repositionable adhesive applied to the bottom surface of the base in a first low adhesion area. The second repositionable adhesive has less adhesive strength than the first repositionable adhesive. The base has a first end edge and a second end edge. The paper has a first edge proximate to the first end edge of the base and a second edge distal to the first end edge of the base. The second edge of the paper is spaced from the first end edge of the base by a first distance. The second edge of the paper of a first repositionable medium is aligned with the first low adhesion area of the second repositionable adhesive of a second repositionable medium positioned directly thereover.
The present invention also includes a repositionable medium. The repositionable medium including a base that has a top surface and a bottom surface, a paper fixed to the top surface of the base, a first repositionable adhesive fixed to the bottom surface of the base, and a release coating applied to a top surface of the paper.
In other, more detailed features of the invention, the release coating can be applied to only a portion of the top surface of the paper. Also, the release coating can be applied to the top surface of the paper only along at least one of the inner edge and the outer edge of the paper. Also, the base can have a first end edge and a second end edge and the paper is located closer to the first end edge of the base than to the second end edge of the base.
The present invention also includes a stack of repositionable media including a plurality of repositionable media. Each of the plurality of repositionable media includes a base having a top surface and a bottom surface, a paper fixed to the top surface of the base, a first repositionable adhesive fixed to the bottom surface of the base, and a release coating applied to a top surface of the paper. The plurality of repositionable media is arranged in a Z-stack.
The present invention also includes a repositionable medium. The repositionable medium includes a base that includes a top surface and a bottom surface, a paper fixed to the top surface of the base, a first repositionable adhesive fixed to the bottom surface of the base, and a non-adhesive layer applied to the top of the paper along at least one edge for adhering the paper to the base.
Other features of the invention should become apparent to those skilled in the art from the following description of the preferred embodiments taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention, the invention not being limited to any particular preferred embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are hereby incorporated into and constitute a part of this specification, illustrate various embodiments of the invention and, together with the description, serve to explain the principles of the invention. It should be noted that the drawings are not drawn to scale. In the drawings wherein like reference numerals represent like parts:
FIGS. 1( a ), 1( b ), and 1( c ) are top plan, side elevational, and bottom plan views, respectively, of a first embodiment of a repositionable medium;
FIGS. 2( a ), 2( b ), and 2( c ) are top plan, side elevational, and bottom plan views, respectively, of the base shown in FIG. 1( a ) ;
FIGS. 3( a ) and 3( b ) are top plan and side elevational views, respectively, of the overlay shown in FIG. 1( a ) ;
FIG. 4 is a simplified side elevational view, partly in section, of a plurality of the repositionable media of FIG. 1( a ) in a “Z-stack,” the “Z-stack” being disposed in a slotted dispenser;
FIGS. 5( a ) and 5( b ) are bottom plan and side elevational views, respectively, of a second embodiment of a repositionable medium;
FIGS. 6( a ) and 6( b ) are bottom plan and side elevational views, respectively, of a third embodiment of a repositionable medium;
FIGS. 7( a ) and 7( b ) are bottom plan and side elevational views, respectively, of a fourth embodiment of a repositionable medium;
FIGS. 8( a ) and 8( b ) are bottom plan and side elevational views, respectively, of a fifth embodiment of a repositionable medium;
FIGS. 9( a ) and 9( b ) are top and bottom plan views, respectively, of a sixth embodiment of a repositionable medium;
FIGS. 10( a ) and 10( b ) are top and bottom plan views, respectively, of a seventh embodiment of a repositionable medium;
FIG. 11 is a flowchart for a method of manufacturing a repositionable medium; and
FIG. 12 is a flowchart for a method of using a repositionable medium.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention is embodied in a repositionable medium, a stack of repositionable media, and related methods. The repositionable media come in a multitude of configurations. A few non-limiting examples of repositionable media, stacks thereof, and related methods are discussed below.
As noted above, the present invention is directed at the above-described problem of delamination occurring within a “Z-stack” of repositionable media of the type including a paper sheet fixed to a base having a repositionable adhesive. According to one approach of the present invention, this problem can be ameliorated by providing a lower strength repositionable adhesive in one or more low adhesion areas that can be aligned with one or more of the edges of the paper for the medium positioned thereunder, with a higher strength repositionable adhesive provided in one or more high adhesion areas. As used herein, adhesive strength means peel adhesion or tack adhesion as determined by Pressure Sensitive Tape Council test methods PSTC-101 and PSTC-16. According to another approach, this problem can be ameliorated by not providing any adhesive in one or more of the low adhesion areas that can be aligned with one or more of the edges of the paper for the medium positioned thereunder. According to yet another approach, this problem can be ameliorated by providing a release on top of the edges of the paper sheet to inhibit adhesion with the repositionable adhesive of the medium positioned thereover. According to still yet another approach, this problem can be ameliorated by gluing or taping the edges of the paper down to its respective base.
Referring now to FIGS. 1( a ), 1( b ), and 1( c ) , there are shown top plan, side elevational, and bottom plan views, respectively, of a first embodiment of a repositionable medium, the repositionable medium being represented generally by reference numeral 11 . (For illustrative purposes, certain features of medium 11 are not shown in all views.)
Medium 11 can include a base 13 , which is also shown separately in FIGS. 2( a ) through 2( c ) . Base 13 , which can be a one-piece structure having a top surface 13 - 1 and a bottom surface 13 - 2 , can be made of a translucent polymeric film, for example, a translucent (clear or tinted) polyethylene terephthalate (PET) film. Such a PET film can have a thickness, for example, of about 125 μm. Base 13 can be shaped to include a first end portion 15 , a second end portion 17 , and an intermediate portion 19 , first end portion 15 and second end portion 17 are spaced apart from one another, with intermediate portion 19 extending between and interconnecting first end portion 15 and second end portion 17 .
The first end portion 15 can have a generally trapezoidal shape when viewed from above and can be shaped to include a first side edge 15 - 1 , a second side edge 15 - 2 , and an end edge 15 - 3 . The corner where end edge 15 - 3 meets first side edge 15 - 1 and the corner where end edge 15 - 3 meets second side edge 15 - 2 can be rounded. In addition, first side edge 15 - 1 can have a slight concavity 16 - 1 just before meeting intermediate portion 19 , and second side edge 15 - 2 can have a corresponding concavity 16 - 2 just before meeting intermediate section 19 . Second end portion 17 can have a generally trapezoidal shape when viewed from above and can be shaped to include a first side edge 17 - 1 , a second side edge 17 - 2 , and an end edge 17 - 3 . The corner where end edge 17 - 3 meets first side edge 17 - 1 and the corner where end edge 17 - 3 meets second side edge 17 - 2 can be rounded.
In addition, first side edge 17 - 1 can have a slight concavity 18 - 1 just before meeting intermediate portion 19 , and second side edge 17 - 2 can have a corresponding concavity 18 - 2 just before meeting intermediate portion 19 . Intermediate portion 19 can have a generally rectangular shape when viewed from above and can include a first side edge 19 - 1 and a second side edge 19 - 2 . Base 13 can be symmetric about both its longitudinal centerline and its lateral centerline, and first end portion 15 and second end portion 17 can be mirror-images of one another.
Exemplary dimensions for base 13 can include a length l 1 measured from end edge 15 - 3 to end edge 17 - 3 of approximately 38.1 mm and a width w 1 measured from side edge 19 - 1 to side edge 19 - 2 of approximately 25.4 mm. In addition, each of portions 15 and 17 can have a length l 2 of 14.3 mm, and portion 19 can have a length l 3 of approximately 10.3 mm. In other embodiments, length l 1 can range from approximately 28.5 mm to approximately 47.7 mm, lengths l 2 and l 3 can range from approximately 9.5 mm to approximately 15.9 mm, and width w 1 can range from approximately 25.4 mm to approximately 76.2 mm.
Referring back to FIG. 1( b ) , medium 11 can further include a topcoat 23 , which can be applied directly over top surface 13 - 1 of base 13 in at least the areas corresponding to end portion 17 and intermediate portion 19 . Topcoat 23 can be a conventional writing-receptive coating and can be used to render base 13 receptive to handwritten markings, such as those made, for example, by pen, marker and/or pencil, and/or to machine-printed markings, such as those made, for example, by typewriter and/or printer. Writable release coat 25 , which can be applied directly over the entirety of topcoat 23 or a portion of topcoat 23 , can be a conventional writable release coating and can be used to minimize adhesion of base 13 to a repositionable adhesive brought into contact therewith.
Medium 11 can also include an overlay 31 , which is also shown separately in FIGS. 3( a ) and 3( b ) . Overlay 31 can be securely fixed to top surface 13 - 1 of base 13 in first end portion 15 using a suitable adhesive 33 , which adhesive can be, for example, an adhesive coating or a strip of double-sided tape. Overlay 31 can have a generally trapezoidal shape and can include a first side edge 31 - 1 , a second side edge 31 - 2 , an outer edge 31 - 3 , and an inner edge 31 - 4 . Overlay 31 can be dimensioned so that first side edge 31 - 1 , second side edge 31 - 2 and outer edge 31 - 3 lie substantially flush with first side edge 15 - 1 , second side edge 15 - 2 , and end edge 15 - 3 , respectively, of first end portion 15 , with inner edge 31 - 4 of overlay 31 lying inwardly from end edge 15 - 3 a short distance from intermediate portion 19 . Where, for example, base 13 has the dimensions specified above, overlay 31 can have a length l 4 , a first distance, from outer edge 31 - 3 to inner edge 31 - 4 of approximately 12.7 mm. In other embodiments, length l 4 can range from approximately 9.5 mm to approximately 15.9 mm. A phantom line 20 on the medium can be defined extending from first side edge 17 - 1 to second side edge 17 - 2 spaced at a distance equal to length l 4 , a second distance, measured from end edge 17 - 3 . See FIG. 2( a ) .
Overlay 31 can be a non-translucent material and can include, for example, a sheet of paper 35 that is receptive to handwritten markings, such as those made, for example, by pen, marker and/or pencil, and/or to machine-printed markings, such as those made, for example, by typewriter and/or printer. Paper 35 can include colored paper or white paper and can be either coated or uncoated. A writable release coating 37 can be applied to at least a portion of the top surface of paper 35 to minimize adhesion of overlay 31 to a repositionable adhesive of another medium 11 brought into contact therewith.
Referring back to FIG. 1( c ) , medium 11 can further include a plurality of adhesive patches 41 , 43 and 45 located on bottom surface 13 - 2 of base 13 . As used herein, the term “plurality” means two or more. Adhesive patch 41 , which can include, for example, a coating of a relatively low-tack repositionable, ultraremovable adhesive, a low coat weight adhesive, a pattern-coated adhesive, or a detackified adhesive, can have boundaries including a first side edge 41 - 1 , a second side edge 41 - 2 , an outer edge 41 - 3 , and an inner edge 41 - 4 . First side edge 41 - 1 can lie substantially flush with a portion of first side edge 17 - 1 of base 13 , and second side edge 41 - 2 can lie substantially flush with a portion of second side edge 17 - 2 of base 13 . Outer edge 41 - 3 can be located at a distance, a third distance, from end edge 17 - 3 that is slightly less than the length l 4 of overlay 31 as measured from outer edge 31 - 3 to inner edge 31 - 4 , and inner edge 41 - 4 can be located at a distance, a fourth distance, from end edge 17 - 3 that slightly exceeds the length l 4 of overlay 31 as measured from outer edge 31 - 3 to inner edge 31 - 4 . The locations of first side edge 41 - 1 , second side edge 41 - 2 , outer edge 41 - 3 , and inner edge 41 - 4 define a first low adhesion area.
In this manner, as will be seen below, in a “Z-stack” of two or more media 11 , adjacent media 11 will be arranged so that the inner edge 31 - 4 of overlay 31 of the lower medium 11 is aligned between outer edge 41 - 3 and inner edge 41 - 4 of the upper medium 11 . Where medium 11 has the dimensions discussed above, outer edge 41 - 3 and inner edge 41 - 4 can be spaced apart from one another by a distance of, for example, approximately 3.0 mm. In other embodiments, outer edge 41 - 3 and inner edge 41 - 4 can be spaced apart from one another by a distance ranging from approximately 2.0 mm to approximately 5.0 mm.
Adhesive patch 43 , which can include a coating of a relatively high-tack repositionable or ultraremovable adhesive, can have boundaries including a first side edge 43 - 1 , a second side edge 43 - 2 , an outer edge 43 - 3 , and an inner edge 43 - 4 . First side edge 43 - 1 can lie substantially flush with a portion of first side edge 17 - 1 of base 13 , second side edge 43 - 2 can lie substantially flush with a portion of second side edge 17 - 2 of base 13 , outer edge 43 - 3 can lie substantially flush with end edge 17 - 3 of base, and inner edge 43 - 4 can lie substantially flush with outer edge 41 - 3 of patch 41 . The first side edge 43 - 1 , second side edge 43 - 2 , outer edge 43 - 3 , and inner edge 43 - 4 also define a first high adhesion area.
Adhesive patch 45 , which can be identical in composition to adhesive patch 43 and which can include a coating of a relatively high-tack repositionable or ultraremovable adhesive, can cover a second high adhesion area on the bottom surface of base 13 extending laterally substantially the full width of base 13 and extending longitudinally from inner edge 41 - 4 to a boundary 45 - 1 substantially aligned with inner edge 31 - 4 of overlay 31 . Boundary 45 - 1 is located a distance, a fifth distance, from the first end edge 15 - 3 , and the distance is greater than length l 4 .
As discussed above, adhesive patch 43 and adhesive patch 45 can include relatively high-tack repositionable or ultraremovable adhesives, and adhesive patch 41 can include a relatively low-tack repositionable or ultraremovable adhesive. It should be understood that adhesive patches 41 , 43 , and 45 can include the same repositionable or ultraremovable adhesive that is detackified or pattern-coated to provide the necessary relative tack required for each patch. Alternatively, adhesive patch 41 can be a lower coat weight of the same adhesive used for adhesive patch 43 or adhesive patch 45 . In one embodiment, the coat weight of adhesive patches 43 and 45 can range between approximately 5.5 grams/square meter (gsm) to approximately 6.5 gsm, and the coat weight of adhesive patch 41 can range between approximately 5.5 gsm to approximately 6.5 gsm. In other embodiments, the coat weight of adhesive patches 43 and 45 can range between approximately 3 gsm to approximately 12 gsm, and the coat weight of adhesive patch 41 can range between approximately 3 gsm to approximately 12 gsm.
Ultraremovable adhesives are discussed in the following patents and patent publications, all of which are incorporated herein by reference herein in their entireties: U.S. Pat. No. 6,328,518 to Wong, issued Dec. 11, 2001; U.S. Pat. No. 6,315,851 to Mazurek et al., issued Nov. 13, 2001; U.S. Pat. No. 5,656,705 to Mallya et al., issued Aug. 12, 1997; and U.S. Patent Application Publication No. US 2002/0047263 A1 to McCarthy et al., published Apr. 25, 2002. Additionally, a primer can be used with removable or ultraremovable adhesives to increase the anchorage of the adhesive to the base.
Referring now to FIG. 4 , there is shown a simplified side elevational view of three identical media 11 - 1 , 11 - 2 , and 11 - 3 arranged in a “Z-stack,” the “Z-stack” being represented generally by reference numeral 51 . (For ease of illustration and understanding, certain features of “Z-stack” are not shown.) As can be appreciated, although “Z-stack” 51 is shown including three stacked media, “Z-stack” 51 is not limited to a stack of three stacked media and could include, for example, a greater or lesser number of media. In FIG. 4 , the uppermost medium 11 - 1 is shown being dispensed from a slotted dispenser 61 , shown partly in section. Dispenser 61 can be similar to conventional dispensers but dimensioned appropriately for “Z-stack” 51 .
As can be seen, to dispense the uppermost medium 11 - 1 from dispenser 61 , a user can pull the exposed end of medium 11 - 1 away from the remainder of “Z-stack” 51 , for example, by pulling the combination of end portion 15 of base 13 and overlay 31 of medium 11 - 1 through slot 61 - 1 in the direction indicated by arrow A. Although overlay 31 of middle medium 11 - 2 is in contact with adhesive on the bottom of uppermost medium 11 - 1 , the separation of uppermost medium 11 - 1 from the remainder of “Z-stack” 51 is less likely to result in the delamination of overlay 31 from middle medium 11 - 2 than would otherwise be the case. This is because inner edge 31 - 4 of overlay 31 of middle medium 11 - 2 is in contact with adhesive patch 41 of uppermost medium 11 , adhesive patch 41 is relatively low-tack, as compared to adhesive patches 43 or 45 . Since the initiation of delamination is most likely to occur along inner edge 31 - 4 of overlay 31 when pulling medium 11 - 1 in the direction indicated by arrow A, the reduction in adhesion between 31 and medium 11 - 1 due to the use of adhesive patch 41 , instead of the use of an adhesive similar to that of patches 43 and 45 , is likely to result in a reduction in the occurrence of delamination.
Medium 11 can be marked and/or applied to objects in the conventional fashion. Referring now to FIGS. 5( a ) and 5( b ) , there are shown bottom plan and side elevational views, respectively, of a second embodiment of a repositionable medium, the repositionable medium being represented generally by reference numeral 111 .
Medium 111 can be similar in most respects to medium 11 , the principal difference between the two media being that, in medium 111 , the area occupied by patch 43 of medium 11 can be occupied with the combination of an adhesive patch 112 , occupying the first high adhesion area, and an adhesive patch 113 , adhesive patch 113 extending along edge 17 - 3 of base 13 and occupying a second low adhesion area. Adhesive patch 112 can be identical in composition to adhesive patch 43 and can include a relatively high-tack repositionable or ultraremovable adhesive. Adhesive patch 113 can be identical in composition to adhesive patch 41 and can include a relatively low-tack repositionable or ultraremovable adhesive. Patch 113 can serve to inhibit the initiation of delamination along outer edge 31 - 3 of overlay 31 .
Medium 111 can be stacked, dispensed, marked, and/or adhered to an object analogously to medium 11 .
Referring now to FIGS. 6( a ) and 6( b ) , there are shown bottom plan and side elevational views, respectively, of a third embodiment of a repositionable medium, the repositionable medium being represented generally by reference numeral 211 .
Medium 211 can be similar in most respects to medium 111 , the principal difference between the two media being that, in medium 211 , no adhesive is positioned in the corresponding areas occupied by patches 41 and 113 of medium 111 . Instead, medium 211 can include a first non-adhesive area 213 provided in the area corresponding to patch 41 of medium 11 , and a second non-adhesive area 215 can be provided in the area corresponding to patch 113 of medium 11 . In another embodiment (not shown), second non-adhesive area 215 can be occupied with an adhesive similar to that of patch 41 or similar to that of patches 43 and 45 , with first non-adhesive area 213 remaining unoccupied by adhesive.
Medium 211 can be stacked, dispensed, marked, and/or adhered to an object analogously to medium 11 .
Referring now to FIGS. 7( a ) and 7( b ) , there are shown bottom plan and side elevational views, respectively, of a fourth embodiment of a repositionable medium, the repositionable medium being represented generally by reference numeral 311 .
Medium 311 can be similar in most respects to medium 11 , the principal difference between the two media being that adhesive patches 41 and 43 of medium 11 can be replaced in medium 311 with an adhesive patch 313 . Adhesive patch 313 can be identical in composition to adhesive patch 41 and can include a relatively low-tack repositionable or ultraremovable adhesive.
Medium 311 can be stacked, dispensed, marked, and/or adhered to an object analogously to medium 11 .
Referring now to FIGS. 8( a ) and 8( b ) , there are shown bottom plan and side elevational views, respectively, of a fifth embodiment of a repositionable medium, the repositionable medium being represented generally by reference numeral 411 .
Medium 411 can be similar in most respects to medium 211 , the principal difference between the two media being that patches 45 , 213 and 112 of medium 211 can be replaced in medium 411 with an adhesive patch 413 . Patch 413 can include an adhesive similar to that of patch 45 of medium 211 .
Medium 411 can be stacked, dispensed, marked, and/or adhered to an object analogously to medium 11 .
Referring now to FIGS. 9( a ) and 9( b ) , there are shown top and bottom plan views, respectively, of a sixth embodiment of a repositionable medium, the repositionable medium being represented generally reference numeral 511 .
Medium 511 can be similar in many respects to medium 11 . One difference between the two media can be that medium 511 can include a single adhesive patch 513 covering the areas corresponding to the areas covered by patches 41 , 43 and 45 of medium 11 . Patch 513 can include a repositionable or ultraremovable adhesive similar to that of patches 43 and 45 of medium 11 . Another difference between medium 511 and medium 11 can be that medium 511 can further include a strip of non-adhesive coating 517 , for example, a lacquer coating, positioned over inner edge 31 - 4 (shown in phantom) of overlay 31 , with a first edge 517 - 1 of non-adhesive coating 517 adhered to overlay 31 and with a second edge 517 - 2 of non-adhesive coating 517 adhered to base 13 . Non-adhesive coating 517 can serve to inhibit the initiation of delamination of overlay 31 along inner edge 517 - 1 . As can be appreciated, non-adhesive coating 517 could be replaced with other non-adhesive means, such as, for example, a single-sided adhesive tape.
Medium 511 can be stacked, dispensed, marked, and/or adhered to an object analogously to medium 11 .
Referring now to FIGS. 10( a ) and 10( b ) , there are shown top and bottom plan views, respectively, of a seventh embodiment of a repositionable medium, the repositionable medium being represented generally reference numeral 611 .
Medium 611 can be similar in many respects to medium 11 . One difference between the two media can be that medium 611 can include a single adhesive patch 613 covering the areas corresponding to the areas covered by patches 41 , 43 and 45 of medium 11 . Patch 613 can include a repositionable or ultraremovable adhesive similar to that of patches 43 and 45 of medium 11 . Another difference between medium 611 and medium 11 can be that medium 611 can include an overlay 615 , instead of overlay 31 of medium 11 . Overlay 615 can differ from overlay 31 in that, whereas overlay 31 can include a writable release coating 37 applied over the entire top surface of paper sheet 35 , overlay 615 does not include a writable release coating applied over the entire top surface of its paper sheet 617 , but rather, can include a first band 619 - 1 of a writable release coating applied to the top surface of paper sheet 617 along an inner edge 617 - 1 of sheet 617 and a second band 619 - 2 of a writable release coating applied to the top surface of paper sheet 617 along an outer edge 617 - 2 of sheet 617 . Bands 619 - 1 and 619 - 2 of the release coating can reduce adhesion between the overlay 615 of a first medium 611 and adhesive patch 613 on the bottom of a second medium 611 positioned directly thereover and, in so doing, can serve to inhibit the initiation of delamination of overlay 615 along inner edge 617 - 1 and/or along outer edge 617 - 2 .
As can be appreciated, additional bands of the release coating can also be applied to the top surface of paper sheet 617 along each of its two side edges, thereby forming a frame around the perimeter of sheet 617 , to inhibit the initiation of delamination of overlay 615 along either of its side edges.
Medium 611 can be stacked, dispensed, marked, and/or adhered to an object analogously to medium 11 .
Referring now to FIG. 11 , a flowchart for a method of manufacturing a repositionable medium in a “Z-stack” is shown generally at 700 . At step 702 , a base and an overlay are provided. A first adhesive is coated onto the base at step 704 . In step 706 , the overlay is laminated to the base. After steps 702 - 706 , the material is sheeted into sheets at step 708 . At step 710 , the sheets are stacked in a “Z-stack” manner. The number of sheets in the stack is dependent on the number of tabs in the final stack of repositionable media. After stacking, the tabs are die cut at step 712 . After being die cut, the “Z-stack” is placed into a dispenser at step 714 .
In other embodiments of the method of manufacturing, a step of coating the base with a primer before the step of coating the first adhesive can be included. In yet another embodiment, a further step of coating a second adhesive can be included. Additionally, in yet another embodiment, the step of applying a topcoat can be included. In other embodiments, the step of applying a release coating or writable release coating to the overlay, the top surface of the base, or both the overlay and the top surface of the base can be included. In yet another embodiment, before the sheeting step, the unsheeted material can be rolled into roll form. The steps of sheeting, stacking, die cutting, and placing the “Z-stacks” into dispensers can be performed at different location than the coating steps.
Referring now to FIG. 12 , a flowchart for a method of using a repositionable medium is shown generally at 750 . In step 752 , a first medium is removed from the dispenser, whereupon the second medium becomes accessible. In another step 754 , the first medium is adhered to a substrate, and in another step 756 , the first medium is written upon.
In any event, it is to be appreciated that in connection with the particular exemplary embodiment(s) presented herein certain structural and/or functional features are described as being incorporated in defined elements and/or components. However, it is contemplated that these features can, to the same or similar benefit, also likewise be incorporated in other elements and/or components where appropriate. It is also to be appreciated that different aspects of the exemplary embodiments can be selectively employed as appropriate to achieve other alternative embodiments suited for desired applications, the other alternative embodiments thereby realizing the respective advantages of the aspects incorporated therein.
Additionally, it is to be appreciated that certain elements described herein as incorporated together can under suitable circumstances be stand-alone elements or otherwise divided. Similarly, a plurality of particular functions described as being carried out by one particular element can be carried out by a plurality of distinct elements acting independently to carry out individual functions, or certain individual functions can be split-up and carried out by a plurality of distinct elements acting in concert. Alternatively, some elements or components otherwise described and/or shown herein as distinct from one another can be physically or functionally combined where appropriate.
In short, the present specification has been set forth with reference to preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the present specification. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | A repositionable medium includes a base, a paper, and a first repositionable adhesive. The base has a top surface, a bottom surface, a first end edge, and a second end edge. The paper is fixedly coupled to the top surface of the base proximate to the first end edge. The paper has an inner edge and an outer edge. The outer edge is closer to the first end edge than the inner edge is to the first end edge. The inner edge is spaced a first distance from the first end edge of the base. The first repositionable adhesive is fixed to the bottom surface of the base and is not present in a first low adhesion area at a line across a width of the base and spaced a second distance from the second end edge of the base. The second distance equals the length of the first distance. | 1 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to water and soap dispensers for kitchen faucets and, more particularly, to a water/soap sprayer which includes a nozzle and handle combination, the handle including individual controls for water and detergent flow, a nozzle including a removable cleaning brush, the handle being further connected to a water source and a detergent source.
2. Description of the Prior Art
Since the invention of the dish, there has been a need for a simple and efficient way to clean them. Dish towels, sponges, rags, brushes, and steel wool have all been used for many years with varying degrees of success. With the advent of the dishwasher, many of the problems encountered in cleaning dishes were apparently solved. However, dishwashers to this day remain expensive and cannot be used in many older homes or apartments without major structural modification of the kitchen area. Also, there are numerous other cooking and serving devices which cannot be cleaned in a dishwasher, including electric frying devices, china, crystal, roasting pans, cookie sheets and assorted other dinnerware and cookware. Therefore, while a dishwasher remains one of the best dish cleaning tools available, there remains an unfulfilled need for a tool that can accompany a dishwasher or take the place of a dishwasher where no dishwasher is present. The search is thus continued for an easily operable and efficient cleaning device.
Several examples are found in the prior art which disclose improvements of dish cleaning devices. For example, Gottwald, et al., U.S. Pat. No. 4,662,768, discloses a hand held kitchen sink spray apparatus with cleaning attachments attached by a quick-release connector. Various brushes and nozzles may be fitted onto the head of the sprayer unit in order to provide different types of cleaning (i.e., water spray, brush, etc.) Several other patents found in the prior art also disclose sink sprayer heads and/or attachments thereto, including Shames, et al., U.S. Design Pat. No. 288,228 and Nicholson, U.S. Design Pat. No. 317,988. It should be noted that none of these references, however, include a means for dispensing soap from the cleaning device, thus requiring that the user of the device add soap from a soap dispenser or the like. There is therefore a need for a sink sprayer which will be capable of dispensing detergent soap in addition to dispensing water therefrom.
Improved attempts at solving the problem of washing dishes are found in the prior art also, including such devices as Manville, U.S. Pat. No. 2,508,958 and Weber, U.S. Pat. No. 2,540,064. Both of these inventions provide improvements over the dish washing devices found previously, yet each include inherent drawbacks. Specifically, while both Manville and Weber disclose dispensing means for liquid soap, neither device includes any means whatsoever to prevent water flow through the system except by turning off the water at the faucet or deactivating the diverter valve which is located on the faucet. This design flaw is unacceptable for several reasons, the most important being that when an individual is cleaning a dish within the sink, one hand will be supporting the dish itself while the other hand is using the cleaning device to clean the dish. As the majority of people in this world only have two hands, the individual cleaning the dish cannot shut off the water flow without setting the dish down. Of course, when the dish is set down, it may become dirty again if water remains in the sink, thus rendering the entire cleaning process meaningless. There is therefore a need for a sink sprayer which includes a cutoff valve for the water on the handle of the sink spray unit itself.
Finally, the position of any such cutoff valve for water on the handle of the sink sprayer unit must be such that it will not interfere with the dispensing of soap into the water stream. Many of the sprayers presently used include a water cutoff valve directly adjacent the nozzle of the sprayer unit. Clearly, the positioning of the water cutoff valve in such a manner would interfere with the placement of any detergent addition mechanism within the sprayer unit. There is therefore a need for a sprayer unit designed such that the water cutoff valve and detergent flow valve will not interfere with the operation of each other.
Therefore, an object of the present invention is to provide an improved water/soap sprayer for kitchen faucets.
Another object of the present invention is to provide a water/soap sprayer for kitchen faucets which includes separate and individually operable water cutoff and detergent dispensing valves.
Another object of the present invention is to provide a water/soap sprayer for kitchen faucets which includes a detergent and water mixing chamber operative to enable the sprayer to dispense a water/detergent combination through a single nozzle.
Another object of the present invention is to provide a water/soap sprayer for kitchen faucets which can be quickly and easily fitted to existing faucets or can be installed on any faucet with a sprayer connection.
Another object of the present invention is to provide a water/soap sprayer for kitchen faucets in which the valves for the water cutoff and detergent dispenser may be operated by use of a single finger or thumb.
Another object of the present invention is to provide a water/soap sprayer for a kitchen faucet which includes a nozzle, a handle and two fluid delivery tubes extending into the handle end and connected, respectively, to a detergent dispensing repository position under the sink and a water dispensing spigot.
Another object of the present invention is to provide a water/soap sprayer for a kitchen faucet which includes a nozzle to which attachments may be removed or connected, including such devices as brushes, spray directors, and other such attachments.
Finally, an object of the present invention is to provide water/soap sprayer for a kitchen faucet which is relatively simple and inexpensive to manufacture and safe and efficient in use.
SUMMARY OF THE INVENTION
The present invention provides a water/soap sprayer for attachment to a kitchen faucet which includes a sprayer unit having a handle section and a nozzle section having an outflow nozzle end. A water flow conduit extends through the sprayer unit for transferring water through the sprayer unit and to the outflow nozzle end, the water flow conduit including a Venturi passage section for accelerating fluid flow therethrough. A detergent flow conduit extends through the sprayer unit and is connected in fluid connection with the Venturi passage section of the water flow conduit within the sprayer unit. A water flow control valve is mounted within the sprayer unit, the water flow control valve operative to restrict and permit water flow through the water flow tube, the water flow control valve in the water flow conduit positioned upstream from the Venturi passage section of the water flow conduit. A detergent flow control valve is mounted within the sprayer unit, the detergent flow control valve operative to restrict and permit detergent flow into the Venturi passage section of the water flow conduit.
A water flow control valve actuating device such as a lever is mounted on the sprayer unit for actuating and controlling the water flow control valve, and a detergent flow control valve actuating device is mounted on the sprayer unit for actuating and controlling the detergent flow control valve. A flexible water supply conduit is connected at one end thereof to the water flow conduit opposite the outflow nozzle end of the nozzle section and is adapted for connection at the opposite end thereof to a water source. Similarly, a flexible detergent supply conduit is connected at one end thereof to the detergent flow conduit opposite the connection to the Venturi passage section of the water flow conduit, the opposite end of the detergent supply conduit adapted for connection to a liquid detergent source. The sprayer unit is operative to clean items by actuation of the water flow control valve and the detergent flow control valve whereby a water/detergent mix is output through the nozzle section of the sprayer unit and out of the sprayer unit through the outflow nozzle end.
As thus described, the water/soap sprayer of the present invention provides numerous advantages over those devices found in the prior art. For example, because the present invention can be quickly and easily connected to a standard faucet, it can be used in far more situations than those devices found in the prior art. Furthermore, because the present invention includes both a water flow control valve and a detergent flow control valve on the handle unit of the sprayer itself, the device may be more easily and efficiently used than other devices used previously. Finally, because the device may be operated by use of only a single digit with the device held in only one hand, a user can easily hold a dish in one hand while using the present invention to clean the dish. It is thus seen that the present invention provides a substantial improvement over those devices found in the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the water/soap sprayer for kitchen faucets of the present invention mounted adjacent a standard kitchen sink;
FIG. 2 is a side elevational cut away view of the sprayer unit and hoses connected to a faucet and the detergent dispensing repository;
FIG. 3 is a top plan view of the sprayer unit showing the handle section and nozzle section;
FIG. 4a is a partial side elevational detail view of the handle of the sprayer unit showing the narrowed Venturi section of the water tube and connection thereinto of the detergent dispensing tube;
FIG. 4b is a partial end elevational detail view showing the operational features of the detergent flow control valve;
FIGS. 5a, 5b, and 5c are partial side elevational detail views of the sprayer unit, FIG. 5a showing the sprayer not in use, FIG. 5b showing the sprayer unit with the water valve engaged but the soap valve not engaged and FIG. 5c showing the sprayer with both valves engaged;
FIG. 6 is a front elevational detail view of the brush head on the nozzle end of the sprayer unit showing the detachable characteristics of the brush attachment; and
FIG. 7 is a perspective view of the sprayer unit being used to clean a dish within the sink.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The water/soap sprayer 10 of the present invention is best shown in FIGS. 1-5c as including a generally cylindrical handle section 12 and a generally conical nozzle section 70. As shown best in FIG. 3, handle section 12 preferably includes a generally cylindrical forward section 14 and a tapering conical rear section 16. In the preferred embodiment, the overall length of the water/soap sprayer 10 will be between 4" and 12". Of course, the exact shape and size of the handle section 12 is not critical to the invention so long as the handle section may be easily grasped by a user of the water/soap sprayer 10. It is further preferred that handle section 12 be constructed of a medium-weight rigid plastic which may be constructed using any acceptable molding process. Handle section 12 may be hollow in order to further decrease weight and to contain the various internal elements of the water/soap sprayer 10 which will be described in detail below. However, as will be seen below, it is important that no matter what the exact physical characteristics of the handle section 12, the internal elements of the water/soap sprayer 10 must be supported within the water/soap sprayer 10 in certain operating positions.
Pivotably mounted on handle section 12 on forward section 14 thereof is a water flow control valve lever 18, the lever 18 mounted in lever mount bracket 20, which is preferably a generally U-shaped mounting structure mounted on and extending outward from handle section 12 as shown best in FIG. 2. Lever 18 is preferably mounted within lever mount bracket 20 with a pin 22 extending through the mounting end of lever 18 and into the opposite walls of level mount bracket 20. In this manner, lever 18 may be pivoted about pin 22. Lever 18 preferably is wider on the rearward end thereof so that a user of the water/soap sprayer 10 can easily use the lever even with wet, soapy fingers. Lever 18 may also be constructed as including the curved cross-section as shown and may be constructed of plastic or the like, although the exact size, shape and construction of the lever 18 is not critical to the present invention.
FIGS. 5a-5c best illustrate the internal components of handle section 12, which includes both a water flow control valve 23 and a detergent flow control valve 36. Positioned underneath lever 18 is a water valve control rod 24 which is movably mounted generally perpendicular to the axis of rotation of lever 18 such that as lever 18 is depressed, control rod 24 is likewise depressed. Control rod 24 preferably is mounted on a spring 26 which biases control rod 24 upwards and thus pivots lever 18 about lever pin 22 in an upwards direction. The lower end 27 of control rod 24 is preferably pivotably connected to a force transference wheel 28 as shown in FIGS. 5a-5c. Wheel 28 is rotatably mounted in handle section 12 such that the axis of rotation is generally parallel with the axis of rotation of lever 18. It is preferred that the connection of lower end 27 of control rod 24 to wheel 28 be on the forward part of the wheel 28, as shown in FIG. 5a. Pivotably connected to the wheel 28 on the lower part thereof is valve rod 30 which extends rearward from wheel 28 to contact plunger 32 which serves to permit or restrict water flow. The pivotable connections of control rod 24 and valve rod 30 to wheel 28 are preferably spaced approximately 90° apart such that vertical movement of control rod 24 rotates wheel 28 which translates the vertical force from rod 24 into a generally horizontal force applied to valve rod 30, thus moving valve rod 30 forwards and rearwards within handle section 12. As shown in FIG. 5a, control rod 24 is fully extended upwards due to spring 26 and, therefore, wheel 28 is in nonrotated position so that valve rod 30 is fully forward. Plunger 32 is thus seated against annular ring 33 formed within water flow tube 34 and therefore prevents water flow through water flow tube 34. As shown best in FIG. 5b, when water flow control valve lever 18 is depressed, control rod 24 is depressed downward thus rotating the force transference wheel 28 which causes valve rod 30 to be moved rearward. Plunger 32 is moved rearwards away from its seated position on annular ring 33 to an open position which allows for water flow through water flow tube 34. Of course, the water flow control valve as thus described may be changed or modified in any appropriate manner, including replacement of the wheel 28 with another force translation device such as a cog and gear mechanism or an L-shaped section of angled material and movement of the spring to a different location in the valve system, so long as the main function of restricting or permitting water flow is realized.
Detergent control valve 36 is shown best in FIGS. 4a-5c as including a button 38 mounted atop a detergent valve rod 40 which extends downwards through handle section 12. Preferably mounted underneath button 38 and surrounding valve rod 40 is a spring 42 which acts to bias valve rod 40 upwards, thus extending button 38 above the exterior of handle section 12. The valve rod 40, which in the preferred embodiment is a forked rod having left and right branches which extend downwards around the water flow tube 34 and detergent flow tube 52, extends downwards to contact needle valve assembly 44 which includes a base bar 46 which projects to the sides of needle valve assembly 44 to allow the left and right branches of valve rod 40 to engage and connect to base bar 46 without interfering with the operation of needle valve assembly 44. Needle valve assembly 44 preferably further comprises an upwardly projecting generally conical stopper 48 mounted on base bar 46 in the approximate middle thereof. The base bar 46, through its connection to valve rod 40, is biased upwards by spring 42, which thus biases stopper 48 upwards. Detergent flow tube 52 extends through handle section 12 and includes a narrowed portion which connects with water flow tube 34 as best shown in FIG. 4b. Conical stopper 48 extends into this narrowed opening 54 and seals the opening when the stopper 48 is biased upwards by spring 42. In this manner, detergent flow through detergent flow tube 52 is restricted. To permit detergent flow through detergent flow tube 52, button 38 is depressed by contact with water flow control valve lever 18 as shown in FIGS. 4a, 4b and 5c, the depression of button 38 moving valve rod 40 downwards. As valve rod 40 is moved downwards, base bar 46 is likewise moved downwards, thus moving conical stopper 48 downwards and allowing detergent flow through narrow opening 54 into water flow tube 34. Upon release of pressure on button 38, spring 42 biases upwards, thus reseating stopper 48 within narrow opening 54 and preventing further detergent flow.
As shown best in FIG. 4a, the detergent flow tube 52 connects to the water flow tube 34 at approximately the mid-point of the detergent mixing section 56 of the water flow tube 34, which in the preferred embodiment is a Venturi passage section 56. The Venturi passage section 56 is preferably a narrowed section of water flow tube 34 in which the diameter of the water flow tube 34 is decreased so that the volume of water tube 34 at Venturi passage section 56 is decreased. The dynamics of fluid flow are such that a fluid flowing through a narrowing passage will accelerate and flow faster through the narrowed portion of the fluid passage. In the present invention, water flowing through the Venturi passage section 56 accelerates through the passage and then slows down again on the opposite side of the Venturi passage section 56. Under these conditions, water flowing under pressure through the Venturi passage section 56 will create a measure of negative pressure or suction within the Venturi passage section 56 and, therefore, will create a region of suction in the Venturi passage section 56 around the narrow opening 54 of detergent flow tube 52 into water flow tube 34. When conical stopper 48 is removed from narrow opening 54 as described previously, detergent 60 is permitted to flow into the water flow tube 34 through narrow opening 54. The suction created by the Venturi passage section 56 draws detergent 60 through the narrow opening 54 and into water flow tube 34 such that a water/detergent mix continues onwards through water flow tube 34 and out through nozzle section 70. When button 38 controlling detergent flow control valve 36 is released, conical stopper 48 is reseated in narrow opening 54, detergent flow through detergent flow tube 52 is restricted and therefore, a stream of rinse water free of detergent 60 may flow through water flow tube 34 for the rinsing of dishes or the like.
In the preferred embodiment, as shown best in FIG. 2, water flow tube 34 extends outward through the base of rearward section 16 of handle section 12 of the water/soap sprayer 10 and extends as a flexible water supply conduit 80 to connect to a standard kitchen faucet 90 at the third water outlet of a kitchen faucet 90 designed for connection to a water sprayer such as those found in the prior art. The connection of the water supply conduit 80 to the faucet 90 may be by any appropriate means, although it is preferred that a threaded nut and gasket connection 92 such as that shown in FIG. 2 be used to provide the connection for water supply conduit 80. Of course, the water supply conduit 80 may be connected to any desired water source by any of the means commonly used in the art of plumbing, but it is preferred that the above-described connection system be used in order to provide a simple and efficient method of connecting the water/soap sprayer 10 of the present invention to a kitchen faucet 90. The flexible tube may be constructed of any suitable material, although PVC or rubber tubing may be preferable.
It is further preferred that detergent flow tube 52 extend in a flexible detergent supply conduit 82 similar to that described in connection with water supply conduit 80 downwards through the water/soap sprayer seat 94 formed in the sink 104 or the kitchen counter 96, to be connected to a liquid detergent depository 98 which is preferably mounted under the kitchen counter 96 in an easily accessible location. The water/soap sprayer seat 94 is preferably a metal or plastic cylinder extending through the sink 104 or counter 96, the metal or plastic cylinder having an internal diameter which is less than the external diameter of the handle of the water/soap sprayer 10. In this manner, the water/soap sprayer 10 of the present invention may be supported above the counter by the water/soap sprayer seat 94. The water supply conduit 80 and detergent supply conduit 82 extend downwards from handle section 12 through the water/soap sprayer seat 94 and are connected to the above-described outlets, and preferably each would have an overall length of between two (2) and five (5) feet to allow the water/soap sprayer 10 to be used in and around the sink area. The liquid detergent repository 98 includes an outflow valve 100 through which liquid detergent 60 may flow into the detergent flow tube 52 and flow into the water flow tube 34 as was described previously. Outflow valve 100 may be constructed as a one-way valve to prevent detergent back flow into the liquid detergent repository 98, although such a valve is not critical to the invention. In the preferred embodiment, the liquid detergent repository 98 would be a plastic container having a detergent capacity of approximately one quart, the liquid detergent repository 98 fastened to the underside of the kitchen counter 96 in a easily accessible location such that refill of the liquid detergent repository 98 with detergent 60 may be quickly and easily accomplished. Of course, the size and shape of the liquid detergent repository 98 is not critical to the present invention. The nozzle section 70 of water/soap sprayer 10 is best shown in FIGS. 2 and 6 as including a longitudinally extended generally conical sprayer nozzle 72 mounted at one end to the forward section 14 of handle section 12 and having at the opposite end thereof a releasable locking mechanism 74 adapted to releasably secure a variety of sprayer attachments thereon. FIG. 6 shows an annular brush attachment 76 mounted on the end of sprayer nozzle 72 by releasable locking mechanism 74. In the preferred embodiment, the annular brush attachment 76 and all other types of attachments to be used with the present invention would include two or more depending pins which would extend into and be secured by the releasable locking mechanism 74. The pins extend into gaps formed in the releasable locking mechanism 74. It is preferred that the pins each include a head section on the end thereof which have a greater diameter than the body of the pin. The gaps formed in the releasable locking mechanism 74 are of sufficient diameter to accept the head of the pin therein, the gap further including an arcuate slot formed adjacent thereto and connecting therewith, the arcuate slot having a width slightly greater than the diameter of the body of the pin but less than the diameter of the head of the pin. Therefore, when the pins are inserted into the gaps in releasable locking mechanism 74 and annular brush attachment 76 is rotated, the pins are rotated into the arcuate slots with the annular brush attachment 76 being secured on the releasable locking mechanism 74 due to the heads of the pins being secured underneath the arcuate slots due to the larger diameter of the heads of the pins. The same pin/slot arrangement may be used with other sprayer attachments, such as water flow directing nozzles, sponge heads, and other brush structures. Of course, any type of releasable locking mechanism may be used with the present invention so long as the purposes for which the releasable locking mechanism were designed are fulfilled.
FIG. 7 is a perspective view of the sprayer unit 10 of the present invention being used to clean a dish 102 within the sink 104 showing how water and detergent are ejected through the sprayer nozzle 72 and annular brush attachment 76 onto the surface of the dish 102 to allow for rapid and efficient cleaning of the dish. Following use of detergent on the dish 102, the water flow control valve lever 18 may be released slightly to release pressure on button 38 which controls soap control valve 36. Conical stopper 48 thus reseats in narrow opening 54 of detergent flow tube 52 thus preventing further release of detergent 60 through detergent flow tube 52. However, water flow through water flow tube 34 continues due to the continued pressure on water flow control valve lever 18 which keeps open water flow control valve 23. It should be noted that the ease and simplicity by which a dish 102 may be cleaned by the present invention is a substantial improvement over those devices found in the prior art due to the capability for control of both water flow and detergent flow from one location on the handle section 12 of water/soap sprayer 10.
It is to be understood that numerous additions, modifications and substitutions may be made to the present invention which fall within the intended broad scope of the appended claims. For example, the nature and structure of the various valves and fluid flow tube connections may be modified or changed so long as the detergent flow tube 52 connects into the water flow tube 34 at the Venturi passage section 56 of the water flow tube 34. Additionally, the exact size and shape of the water/soap sprayer 10 of the present invention may be modified or changed to provide any particular desired appearance so long as the functional characteristics of the invention are maintained. Finally, the construction materials used in the manufacture of the water/soap sprayer 10 of the present invention may be changed or modified should such modification prove desirable.
There has thus been shown and described a water/soap sprayer which accomplishes at least all of the stated objectives. | A water/soap sprayer for attachment to a kitchen faucet includes a sprayer unit having a handle section and a nozzle section having an outflow nozzle end. A water flow conduit extends through the sprayer unit for transferring water through the sprayer unit and to the outflow nozzle end, the water flow conduit including a Venturi passage section for accelerating fluid flow therethrough. A detergent flow conduit extends through the sprayer unit and is connected in fluid connection with the Venturi passage section of the water flow conduit within the sprayer unit. A water flow control valve is mounted within the sprayer unit, the water flow control valve operative to restrict and permit water flow through the water flow tube, the water flow control valve in the water flow conduit positioned upstream from the Venturi passage section of the water flow conduit. A detergent flow control valve is mounted within the sprayer unit, the detergent flow control valve operative to restrict and permit detergent flow into the Venturi passage section of the water flow conduit. A flexible water supply conduit and a flexible detergent supply conduit are connected, respectively, to the water flow conduit and the detergent flow conduit and respectively to a water source and a detergent repository. The sprayer unit is operative to clean items by actuation of the water flow control valve and the detergent flow control valve whereby a water/detergent mix is output through the nozzle section of the sprayer unit. | 0 |
BACKGROUND OF THE INVENTION
Various types of machinery and equipment employ, in one form or another, a belt drive system in which a belt, trained about two pulleys, serves as the means for transmitting the drive. Typically, such a drive will utilize a third pulley engaging the belt as a belt tightener to keep the belt properly adjusted so as to avoid slippage. It is commonplace to use a spring or other biasing means acting against the tightener idler to tension the belt. One of the problems with this type of drive is that the belt increases in length because of extended use, and consequently, the biasing means must be adjusted to compensate for this by repositioning of the idler. In a simple form of drive, an adjusting screw will be used to increase the biasing force and the mechanic making the adjustment may rely on "feel" as to a properly adjusted belt. It is also known to provide specifications that teach that the belt is properly adjusted when a certain amount of "give" can be detected along one run of the belt. Further, it is known to measure the amount of biasing force by a scale or the like and to indicate that a certain reading on the scale indicates proper adjustment of the drive.
All of these prior means and methods leave too much to conjecture and result in excessive belt wear, over- or under-tensioning and loss of efficiency. According to the present invention, these and other problems are solved by a simple and efficient system employing a pair of coordinated gauge means, one to indicate the position of the idler and the other to indicate the biasing force. The gauge means are so correlated that a certain reading on one gauge will indicate what reading should be attained on the other gauge, all of which is accomplished by making one adjustment which produces proper idler position according to biasing force. The readings are made easier by using identical indicia on the gauge means, preferably numerical and linear, so that when, for example, the number 2 on one gauge appears, the system is properly adjusted when the number 2 appears on the other gauge means. Further improvements are provided by arranging the components in a compact manner, easily accessible to the machine operator and occupying no unnecessary space.
BRIEF SUMMARY OF THE INVENTION
The improved drive comprises, briefly and specifically, a pair of drive pulleys about which a belt is trained, which belt is tensioned by a third or idler pulley biased in a belt tightening direction by an adjustable spring. First and second gauge means cooperate respectively with the idler and the adjusting means to show, respectively, the position of the idler and the amount of force on the biasing means. When adjustment is required, the two readings will be inconsistent. Proper adjustment is achieved by applying spring force until the readings are consistent. It is contemplated that the adjustment can be simply made by a convenient hand tool, such as a wrench, and the gauge means are easily and clearly visible to the mechanic making the adjustment.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial view of the rear part of a forage harvester with shielding removed and portions broken away to reveal inner structure which may be used with this invention.
FIG. 2 is an enlarged view of an outer portion of the structure shown in FIG. 1.
FIG. 3 is an enlarged sectional view of the idler.
FIG. 4 is an enlarged sectional view of one of the drive pulleys or sheaves.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The background structure chosen for purposes of illustration and description is that of a forage harvester, an agricultural machine for accomplishing the harvesting of crops, the subsequent reduction of crops and the delivery thereof to a trailing vehicle (not shown). A superior type of belt drive is a requisite in a machine of this type because of the high speeds and horsepower consumption, and it is important that all adjustments be accurately made and, what is also significant, is that the adjustments be easily made with a minimum of "down time" in the field. The invention is not, however, to be construed as limited to machines of this type.
Referring to FIG. 1, the rear part of the machine comprises a wheeled frame, represented by a housing 10 supported on a pair of wheels (only one of which is shown at 12). The machine is conventionally drawn by a tractor (also not shown) for travel in the direction toward the viewer's right. Crop which is harvested as the machine progresses over the field reaches a pair of feed rolls 14 which feed the crops to the rear across a fixed knife 16 and thus into the path of knives 18 on a rapidly rotating cutterhead 20, the direction of rotation of which is designated by the arrow in FIG. 1. The crops, now reduced, moves downwardly and to the rear to be received by a transverse auger 22 which in turn feeds the crops into a blower housing 24 at the opposite side of the machine. The blower carrier a fan 26 which travels clockwise to propel the crops upwardly through a discharge spout 28 which curves upwardly and rearwardly in a conventional manner (not shown) for discharge into a trailing wagon or the like (also not shown). The fan is fixed to the remote end of a fan shaft 30. This shaft, as well as an auger shaft 32 and cutterhead shaft 34 extend in parallelism across the rear part of the machine. Power is brought into the left end of the cutterhead shaft by conventional means (not shown) and the right hand (near as regards the viewer) of the cutterhead shaft has fixed thereto a pulley or sheave 38 (FIGS. 2, 4), preferably of the multiple-V type, as is a sheave pulley 40 affixed to the corresponding end of the fan shaft 30. A drive belt 42, here of the multiple-V type having a flat exterior, is trained about the two sheaves and is tensioned by a belt tightening means in the form of a split idler pulley 44 (FIGS. 2, 3) journaled on a shaft 46 parallel to the fan and cutterhead shafts. The particular form of idler shown here forms no part of the present invention but rather is the subject matter of assignee's copending applications Ser. Nos. filed concurrently with this application.
Idler 44 is arranged so that it engages the under run or stretch of the belt from below and its belt tightening movement or positioning is toward the upper run or stretch of the belt, an arrangement chosen for its advantages of compactness, efficiency and simplicity. The idler is part of a belt tightening means including a carrier in the form of a bell crank 47 pivoted to the support means or housing at 48 and having a first rearwardly extending arm 50 and a second depending arm 52. Rocking of the bell crank in a clockwise direction causes movement of the idler in its tightening direction, in which direction it is biased by biasing means 54 which includes a coiled tension spring 56, a connecting element 58 and an adjusting means in the form of a screw 60. The screw connects the element to the support means 10 via a bracket 62.
When the machine leaves the factory, the drive is properly adjusted as to belt tension, etc. It will be understood that as the machine is operated over extended periods of time, the belt will stretch and the amount of spring force put in at the factory will not be sufficient to maintain proper tension. Obviously, the belt may be tensioned by effecting an adjustment of the biasing means 54, but there remains the problem of whether the adjustment is correct under the existing operating conditions. If the tension is too little, belt slippage and premature wear occur. Over-tensioning causes excessive loads on the bearings and increases the tendency of the belt to stretch.
According to the present invention, determination of the proper belt tension may be readily and easily effected, quickly and with a minimum of effort and tools. As shown in FIG. 2, this is achieved by the provision of a first gauge means 64 for the idler 44 and a second gauge means 66 for the biasing means. The first gauge means or scale includes a pair of cooperating members, one of which is a member 68 affixed to the near side of the housing 10 and here shown as being substantially vertically disposed in accordance with the general range of movement of the idler. The second member 70 is carried by the idler shaft 46 and, as the idler shaft moves up and down, the member 70 moves closely up and down alongside the member 68, the latter of which is provided with indicia, here in the form of a linear scale of easily visible notches 72, preferably numbered from bottom to top from 1 through 6. Thus, the end of member 70 serves as an indicator which may be read against a notch to show the existing position of the idler according to the existing biasing force on the bell crank 47.
The second gauge means is similarly constructed, comprising a member 74 affixed to the near side of the housing 10, preferably as part of the bracket 62 previously described in connection with the biasing means 54. Member 74 bears indicia in the form of a linear scale of notches 76 numbered 1 through 6 from front to rear. An end member 78 on the spring connecting element 54 serves as an indicator readable against the notches or indicia 76.
Both gauge means are preferably identical for ease of readability. The nature of the belt (as to load-transmitting capacity, etc.), the type and strength of the spring and the positioning of both gauge means are easily calculated to establish identity between both gauge means so that when, for example, both gauge means reveal the number 2, belt tension is correct for existing conditions, and, as the belt stretches, repositioning of the idler and increased force on the spring will require readjustment until, for example, both gauges read at the number 3 and so on.
By way of illustration of the calculations necessary to practice this invention, the following steps are generally necessary:
(i) Belt 42, pulleys 38, 40, 44 and the proper tension in belt 42 are selected in accordance with power requirements of the drive system. Belt tension is preferably the same throughout belt elongation.
(ii) A scale 72 is selected corresponding to the position of idler 44 over the full range of belt elongation necessary to generate the belt tension selected in step (i). As idler 44 is pivoted into belt 42, the force on idler 44 must be increased to generate a constant tension in belt 42 because with the changing direction of application of the idler force, a decreasing proportion of the idler force is applied as a force component on belt 42.
(iii) The force which must be exerted on idler 44 to cause it to assume positions corresponding to scale 72 is calculated.
(iv) The requirements and geometry for bell crank 47 and spring 56 to apply the required forces on idler 44 (calculated in step (iii)) are calculated and selected.
(v) The scale 72 for spring 56 is selected. As illustrated, the selections of step (iv) have been chosen such that those scales are identical, although they need not be. All that is required is that there is an easily made comparison between those scales for simplicity of adjustment to compensate for belt elongation.
It will be understood that what has been disclosed here is a preferred embodiment. The indicia need not, for example, be linear. Different colors rather than numerals could be employed as indicia. The idler could be arranged to move in an opposite direction. These and other variations could be made without departure from the spirit of the invention. | A belt drive system featuring an adjustable belt tightener including coordinated gauge means for designating the proper belt tension according to changing positions of the belt tightener as the belt stretches during operation of the drive. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/101,551 filed Sep. 30, 2008, the entire disclosure is incorporated herein by reference.
BACKGROUND
[0002] Due to its excellent biocompatibility, biostability and physical properties, polyurethane or polyurethane-containing polymers have been used to fabricate a large number of implantable devices, including pacemaker leads, artificial hearts, heart valves, stent coverings, artificial tendons, arteries and veins. Formulations for delivery of active agents using polyurethane implantable devices, however, require a liquid medium or carrier for the diffusion of the drug at a zero order rate.
SUMMARY
[0003] Described herein are methods and compositions based on the unexpected discovery that solid formulations comprising one or more active agents can be used at the core of a polyurethane implantable device such that the active agent is released in a controlled-release, zero-order manner from the implantable device. The active agents and polyurethane coating can be selected based on various physical parameters, and then the release rate of the active from the implantable device can be optimized to a clinically-relevant release rate based on clinical and/or in vitro trials.
[0004] One embodiment is directed to a method for delivering a formulation comprising an effective amount of histrelin to a subject, comprising: implanting an implantable device into the subject, wherein the implantable device comprises histrelin surrounded by a polyurethane based polymer. In a particular embodiment, the polyurethane based polymer is selected from the group consisting of: a Tecophilic® polymer, a Tecoflex® polymer and a Carbothane® polymer. In a particular embodiment, the polyurethane based polymer is a Tecophilic polymer with an equilibrium water content of at least about 31%. In a particular embodiment, the polyurethane based polymer is a Tecoflex® polymer with a flex modulus of about 10,000. In a particular embodiment, the polyurethane based polymer is a Carbothane® polymer with a flex modulus of about 4,500.
[0005] One embodiment is directed to a drug delivery device for the controlled release of histrelin over an extended period of time to produce local or systemic phatinacological effects, comprising: a) a polyurethane based polymer formed to define a hollow space; and b) a solid drug formulation comprising a formulation comprising histrelin and optionally one or more pharmaceutically acceptable carriers, wherein the solid drug formulation is in the hollow space, and wherein the device provides a desired release rate of histrelin from the device after implantation. In a particular embodiment, the drug delivery device is conditioned and primed under conditions chosen to match the water solubility characteristics of the at least one active agent. In a particular embodiment, the pharmaceutically acceptable carrier is stearic acid. In a particular embodiment, the polyurethane based polymer is selected from the group consisting of: a Tecophilic® polymer, a Tecoflex® polymer and a Carbothane® polymer. In a particular embodiment, the polyurethane based polymer is a Tecophilic® polymer with an equilibrium water content of at least about 31%. In a particular embodiment, the polyurethane based polymer is a Tecoflex® polymer with a flex modulus of about 10,000. In a particular embodiment, the polyurethane based polymer is a Carbothane® polymer with a flex modulus of about 4,500. In a particular embodiment, the appropriate conditioning and priming parameters can be selected to establish the desired delivery rates of the at least one active agent, wherein the priming parameters are time, temperature, conditioning medium and priming medium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a side view of an implant with two open ends.
[0007] FIG. 2 is a side view of pre-fabricated end plugs used to plug the implants.
[0008] FIG. 3 is a side view of an implant with one open end.
[0009] FIG. 4 is a graph of the elution rate of histrelin using an implant.
[0010] FIG. 5 is a graph of the elution rate of LHRH agonist (histrelin) from a polyurethane implant.
DETAILED DESCRIPTION
[0011] To take the advantage of the excellent properties of polyurethane-based polymers, the present invention is directed to the use of polyurethane-based polymers as drug delivery devices for releasing drugs at controlled rates for an extended period of time to produce local or systemic pharmacological effects. The drug delivery device can comprise a cylindrically-shaped reservoir surrounded by polyurethane-based polymer that controls the delivery rate of the drug inside the reservoir. The reservoir contains a formulation, e.g., a solid formulation, comprising one or more active ingredients and, optionally, pharmaceutically acceptable carriers. The carriers are formulated to facilitate the diffusion of the active ingredients through the polymer and to ensure the stability of the drugs inside the reservoir.
[0012] A polyurethane is any polymer consisting of a chain of organic units joined by urethane links. Polyurethane polymers are formed by reacting a monomer containing at least two isocyanate functional groups with another monomer containing at least two alcohol groups in the presence of a catalyst. Polyurethane formulations cover an extremely wide range of stiffness, hardness, and densities.
[0000]
[0013] Polyurethanes are in the class of compounds called “reaction polymers,” which include epoxies, unsaturated polyesters and phenolics. A urethane linkage is produced by reacting an isocyanate group, —N═C═O with a hydroxyl (alcohol) group, —OH. Polyurethanes are produced by the polyaddition reaction of a polyisocyanate with a polyalcohol(polyol) in the presence of a catalyst and other additives. In this case, a polyisocyanate is a molecule with two or more isocyanate functional groups, R—(N═C═O)n≧2 and a polyol is a molecule with two or more hydroxyl functional groups, R′-(OH)n≧2. The reaction product is a polymer containing the urethane linkage, —RNHCOOR′—. Isocyanates react with any molecule that contains an active hydrogen. Importantly, isocyanates react with water to form a urea linkage and carbon dioxide gas; they also react with polyetheramines to form polyureas.
[0014] Polyurethanes are produced commercially by reacting a liquid isocyanate with a liquid blend of polyols, catalyst, and other additives. These two components are referred to as a polyurethane system, or simply a system. The isocyanate is commonly referred to in North America as the “A-side” or just the “iso,” and represents the rigid backbone (or “hard segment”) of the system. The blend of polyols and other additives is commonly referred to as the “B-side” or as the “poly,” and represents the functional section (or “soft segment”) of the system. This mixture might also be called a “resin” or “resin blend.” Resin blend additives can include chain extenders, cross linkers, surfactants, flame retardants, blowing agents, pigments and fillers. In drug delivery applications, the “soft segments” represent the section of the polymer that imparts the characteristics that determine the diffusivity of an active pharmaceutical ingredient (API) through that polymer.
[0015] The elastomeric properties of these materials are derived from the phase separation of the hard and soft copolymer segments of the polymer, such that the urethane hard segment domains serve as cross-links between the amorphous polyether (or polyester) soft segment domains. This phase separation occurs because the mainly non-polar, low-melting soft segments are incompatible with the polar, high-melting hard segments. The soft segments, which are formed from high molecular weight polyols, are mobile and are normally present in coiled formation, while the hard segments, which are formed from the isocyanate and chain extenders, are stiff and immobile. Because the hard segments are covalently coupled to the soft segments, they inhibit plastic flow of the polymer chains, thus creating elastomeric resiliency. Upon mechanical deformation, a portion of the soft segments are stressed by uncoiling, and the hard segments become aligned in the stress direction. This reorientation of the hard segments and consequent powerful hydrogen-bonding contributes to high tensile strength, elongation, and tear resistance values.
[0016] The polymerization reaction is catalyzed by tertiary amines, such as, for example, dimethylcyclohexylamine, and organometallic compounds, such as, for example, dibutyltin dilaurate or bismuth octanoate. Furthermore, catalysts can be chosen based on whether they favor the urethane (gel) reaction, such as, for example, 1,4-diazabicyclo[2.2.2]octane (also called DABCO or TEDA), or the urea (blow) reaction, such as bis-(2-dimethylaminoethyl)ether, or specifically drive the isocyanate trimerization reaction, such as potassium octoate.
[0000]
[0017] Isocyanates with two or more functional groups are required for the formation of polyurethane polymers. Volume wise, aromatic isocyanates account for the vast majority of global diisocyanate production. Aliphatic and cycloaliphatic isocyanates are also important building blocks for polyurethane materials, but in much smaller volumes. There are a number of reasons for this. First, the aromatically-linked isocyanate group is much more reactive than the aliphatic one. Second, aromatic isocyanates are more economical to use. Aliphatic isocyanates are used only if special properties are required for the final product. Light stable coatings and elastomers, for example, can only be obtained with aliphatic isocyanates. Aliphatic isocyanates also are favored in the production of polyurethane biomaterials due to their inherent stability and elastic properties.
[0018] Examples of aliphatic and cycloaliphatic isocyanates include, for example, 1,6-hexamethylene diisocyanate (HDI), 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane(isophorone diisocyanate, IPDI), and 4,4′-diisocyanato dicyclohexylmethane (H12MDI). They are used to produce light stable, non-yellowing polyurethane coatings and elastomers. H12MDI prepolymers are used to produce high performance coatings and elastomers with optical clarity and hydrolysis resistance. Tecoflex®, Tecophilic® and Carbothane® polyurethanes are all produced from H12MDI prepolymers.
[0019] Polyols are higher molecular weight materials manufactured from an initiator and monomeric building blocks, and, where incorporated into polyurethane systems, represent the “soft segments” of the polymer. They are most easily classified as polyether polyols, which are made by the reaction of epoxides(oxiranes) with an active hydrogen containing starter compounds, or polyester polyols, which are made by the polycondensation of multifunctional carboxylic acids and hydroxyl compounds.
[0020] Tecoflex® polyurethanes and Tecophilic® polyurethanes are cycloaliphatic polymers and are of the types produced from polyether-based polyols. For the Tecoflex® polyurethanes, the general structure of the polyol segment is represented as,
[0000] O—(CH 2 —CH 2 —CH 2 —CH 2 ) x —O—
[0000] whereby an increase in “x” represents a increase in flexibility (decreased “Flex Modulus”; “FM”), yielding FM ranging from about 1000-92,000 psi. From the standpoint of drug release from these materials, the release of a relatively hydrophobic API decreases as the FM increases.
[0021] For the Tecophilic® (hydrophilic)polyurethanes, the general structure of the polyol segment is represented as,
[0000] —[O—(CH 2 ) n ] x —O—
[0000] whereby increases in “n” and “x” represent variations in hydrophilicity, and yield equilibrium water contents (% EWC) ranging from about 5%-43%. From the standpoint of drug release from these materials, the release of a relatively hydrophilic API increases as the % EWC increases.
[0022] Specialty polyols include, for example, polycarbonate polyols, polycaprolactone polyols, polybutadiene polyols, and polysulfide polyols.
[0023] Carbothane® polyurethanes are cycloaliphatic polymers and are of the types produced from polycarbonate-based polyols. The general structure of the polyol segment is represented as,
[0000] O—[(CH 2 ) 6 —CO 3 ] n —(CH 2 ) O—
[0000] whereby an increase in “n” represents a increase in flexibility (decreased FM), yielding FM ranging from about 620-92,000 psi. From the standpoint of drug release from these materials, the release of a relatively hydrophobic API will decrease as the FM increases.
[0024] Chain extenders and cross linkers are low molecular weight hydroxyl- and amine-terminated compounds that play an important role in the polymer morphology of polyurethane fibers, elastomers, adhesives and certain integral skin and microcellular foams. Examples of chain extenders include, for example, ethylene glycol, 1,4-butanediol(1,4-BDO or BDO), 1,6-hexanediol, cyclohexane dimethanol and hydroquinone bis(2-hydroxyethyl)ether (HQEE). All of these glycols form polyurethanes that phase separate well, form well-defined hard segment domains, and are melt processable. They are all suitable for thermoplastic polyurethanes with the exception of ethylene glycol, since its derived bis-phenyl urethane undergoes unfavorable degradation at high hard segment levels. Tecophilic®, Tecoflex® and Carbothanc® polyurethanes all incorporate the use of 1,4-butanediol as the chain extender.
[0025] The current invention provides a drug delivery device that can achieve the following objectives: a controlled-release rate (e.g., zero-order release rate) to maximize therapeutic effects and minimize unwanted side effects, an easy way to retrieve the device if it is necessary to end the treatment, an increase in bioavailability with less variation in absorption and no first pass metabolism.
[0026] The release rate of the drug is governed by the Fick's Law of Diffusion as applied to a cylindrically shaped reservoir device (cartride). The following equation describes the relationship between different parameters:
[0000]
dM
dt
=
2
π
h
p
Δ
C
ln
(
r
o
/
r
i
)
[0000] where:
dM/dt: drug release rate; h: length of filled portion of device; ΔC: concentration gradient across the reservoir wall; r o /r i : ratio of outside to inside radii of device; and p: permeability coefficient of the polymer used.
[0032] The permeability coefficient is primarily regulated by the hydrophilicity or hydrophobicity of the polymer, the structure of the polymer, and the interaction of drug and the polymer. Once the polymer and the active ingredient are selected, p is a constant, h, ro, and r i are fixed and kept constant once the cylindrically-shaped device is produced. ΔC is maintained constant.
[0033] To keep the geometry of the device as precise as possible, the device, e.g., a cylindrically-shaped device, can be manufactured through precision extrusion or precision molding process for thermoplastic polyurethane polymers, and reaction injection molding or spin casting process for thermosetting polyurethane polymers.
[0034] The cartridge can be made with either one end closed or both ends open. The open end can be plugged with, for example, pre-manufactured end plug(s) to ensure a smooth end and a solid seal, or, in the case of thermoplastic polyurethanes, by using heat-sealing techniques known to those skilled in the art. The solid actives and carriers can be compressed into pellet form to maximize the loading of the actives.
[0035] To identify the location of the implant, radiopaque material can be incorporated into the delivery device by inserting it into the reservoir or by making it into end plug to be used to seal the cartridge.
[0036] Once the cartridges are sealed on both ends with the filled reservoir, they are optionally conditioned and primed for an appropriate period of time to ensure a constant delivery rate.
[0037] The conditioning of the drug delivery devices involves the loading of the actives (drug) into the polyurethane-based polymer that surrounds the reservoir. The priming is done to stop the loading of the drug into the polyurethane-based polymer and thus prevent loss of the active before the actual use of the implant. The conditions used for the conditioning and priming step depend on the active, the temperature and the medium in which they are carried out. The conditions for the conditioning and priming may be the same in some instances.
[0038] The conditioning and priming step in the process of the preparation of the drug delivery devices is done to obtain a determined rate of release of a specific drug. The conditioning and priming step of the implant containing a hydrophilic drug can be carried out in an aqueous medium, e.g., in a saline solution. The conditioning and priming step of a drug delivery device comprising a hydrophobic drug is usually carried out in a hydrophobic medium such as, for example, an oil-based medium. The conditioning and priming steps can be carried out by controlling three specific factors, namely the temperature, the medium and the period of time.
[0039] A person skilled in the art would understand that the conditioning and priming step of the drug delivery device is affected by the medium in which the device is placed. A hydrophilic drug can be conditioned and primed, for example, in an aqueous solution, e.g., in a saline solution. Histrelin implants, for example, have been conditioned and primed in saline solution, more specifically, conditioned in saline solution of 0.9% sodium content and primed in saline solution of 1.8% sodium chloride content.
[0040] The temperature used to condition and prime the drug delivery device can vary across a wide range of temperatures, e.g., about 37° C.
[0041] The time period used for the conditioning and priming of the drug delivery devices can vary from about a single day to several weeks depending on the release rate desired for the specific implant or drug. The desired release rate is determined by one of skill in the art with respect to the particular active agent used in the pellet formulation.
[0042] A person skilled in the art will understand the steps of conditioning and priming the implants are to optimize the rate of release of the drug contained within the implant. As such, a shorter time period spent on the conditioning and the priming of a drug delivery device results in a lower rate of release of the drug compared to a similar drug delivery device that has undergone a longer conditioning and priming step.
[0043] The temperature in the conditioning and priming step will also affect the rate of release in that a lower temperature results in a lower rate of release of the drug contained in the drug delivery device when compared to a similar drug delivery device that has undergone a treatment at a higher temperature.
[0044] Similarly, in the case of aqueous solutions, e.g., saline solutions, the sodium chloride content of the solution determines what type of rate of release will be obtained for the drug delivery device. More specifically, a lower content of sodium chloride results in a higher rate of release of drug when compared to a drug delivery device that has undergone a conditioning and priming step where the sodium chloride content was higher.
[0045] The same conditions apply for hydrophobic drugs where the main difference in the conditioning and priming step is that the conditioning and priming medium is a hydrophobic medium, more specifically an oil-based medium.
[0046] Histrelin acetate is a nonapeptide analog of gonadotropin-releasing hormone (GnRH) with added potency. Where present in the bloodstream, it acts on particular cells of the pituitary gland called gonadotropes. Histrelin stimulates these cells to release luteinizing hormone and follicle-stimulating hormone. Thus it is considered a gonadotropin-releasing hormone agonist or GnRH agonist. Histrelin is used to treat hormone-sensitive cancers of the prostate in men and uterine fibroids in women. In addition, histrelin is highly effective in treating central precocious puberty in children. Effective levels of histrelin in the blood are known and established and can range, for example, about 0.1 to about 4 ng/ml, from about 0.25 to about 3 ng/ml or about 0.5 to about 1.5 ng/ml range.
[0047] The current invention focuses on the application of polyurethane-based polymers, thermoplastics or thermosets, to the creation of implantable drug devices to deliver biologically active compounds at controlled rates for prolonged period of time. Polyurethane polymers can be made into, for example, cylindrical hollow tubes with one or two open ends through extrusion, (reaction) injection molding, compression molding, or spin-casting (see e.g., U.S. Pat. Nos. 5,266,325 and 5,292,515), depending on the type of polyurethane used.
[0048] Thermoplastic polyurethane can be processed through extrusion, injection molding or compression molding. Thermoset polyurethane can be processed through reaction injection molding, compression molding, or spin-casting. The dimensions of the cylindrical hollow tube should be as precise as possible.
[0049] Polyurethane-based polymers are synthesized from multi-functional polyols, isocyanates and chain extenders. The characteristics of each polyurethane can be attributed to its structure.
[0050] Thermoplastic polyurethanes are made of macrodials, diisocyanates, and difunctional chain extenders (e.g., U.S. Pat. Nos. 4,523,005 and 5,254,662). Macrodials make up the soft domains. Diisocyanates and chain extenders make up the hard domains. The hard domains serve as physical crosslinking sites for the polymers. Varying the ratio of these two domains can alter the physical characteristics of the polyurethanes, e.g., the flex modulus.
[0051] Thermoset polyurethanes can be made of multifunctional (greater than difunctional) polyols and/or isocyanates and/or chain extenders (e.g., U.S. Pat. Nos. 4,386,039 and 4,131,604). Thermoset polyurethanes can also be made by introducing unsaturated bonds in the polymer chains and appropriate crosslinkers and/or initiators to do the chemical crosslinking (e.g., U.S. Pat. No. 4,751,133). By controlling the amounts of crosslinking sites and how they are distributed, the release rates of the actives can be controlled.
[0052] Different functional groups can be introduced into the polyurethane polymer chains through the modification of the backbones of polyols depending on the properties desired. Where the device is used for the delivery of water soluble drugs, hydrophilic pendant groups such as ionic, carboxyl, ether, and hydroxy groups are incorporated into the polyols to increase the hydrophilicity of the polymer (e.g., U.S. Pat. Nos. 4,743,673 and 5,354,835). Where the device is used for the delivery of hydrophobic drugs, hydrophobic pendant groups such as alkyl, siloxane groups are incorporated into the polyols to increase the hydrophobicity of the polymer (e.g., U.S. Pat. No. 6,313,254). The release rates of the actives can also be controlled by the hydrophilicity/hydrophobicity of the polyurethane polymers.
[0053] For thermoplastic polyurethanes, precision extrusion and injection molding are the preferred choices to produce two open-end hollow tubes ( FIG. 1 ) with consistent physical dimensions. The reservoir can be loaded freely with appropriate formulations containing actives and carriers or filled with pre-fabricated pellets to maximize the loading of the actives. One open end needs to be sealed first before the loading of the formulation into the hollow tube. To seal the two open ends, two pre-fabricated end plugs ( FIG. 2 ) can be used. The sealing step can be accomplished through the application of heat or solvent or any other means to seal the ends, preferably permanently.
[0054] For thermoset polyurethanes, precision reaction injection molding or spin casting is the preferred choice depending on the curing mechanism. Reaction injection molding is used if the curing mechanism is carried out through heat and spin casting is used if the curing mechanism is carried out through light and/or heat. Hollow tubes with one open end ( FIG. 3 ), for example, can be made by spin casting. Hollow tubes with two open ends, for example, can be made by reaction injection molding. The reservoir can be loaded in the same way as the thermoplastic polyurethanes.
[0055] To seal an open end, an appropriate light-initiated and/or heat-initiated thermoset polyurethane formulation can be used to fill the open end, and this is cured with light and/or heat. A pre-fabricated end plug, for example, can also be used to seal the open end by applying an appropriate light-initiated and/or heat-initiated thermoset polyurethane formulation on to the interface between the pre-fabricated end plug and the open end, and curing it with the light and/or heat or any other means to seal the ends, preferably permanently.
[0056] The final process involves the conditioning and priming of the implants to achieve the delivery rates required for the actives. Depending upon the types of active ingredient, hydrophilic or hydrophobic, the appropriate conditioning and priming media is chosen. Water-based media are preferred for hydrophilic actives, and oil-based media are preferred for hydrophobic actives.
[0057] As a person skilled in the art would readily know many changes can be made to the preferred embodiments of the invention without departing from the scope thereof. It is intended that all matter contained herein be considered illustrative of the invention and not it a limiting sense.
EXEMPLIFICATION
EXAMPLE 1
[0058] Tecophilic® polyurethane polymer tubes are supplied by Thermedics Polymer Products and manufactured through a precision extrusion process. Tecophilic® polyurethane is a family of aliphatic polyether-based thermoplastic polyurethane that can be formulated to different equilibrium water contents (EWC) of up to 150% of the weight of dry resin. Extrusion grade formulations are designed to provide maximum physical properties of thermoformed tubing or other components. An exemplary tube and end cap structures are depicted in FIGS. 1-3 .
[0059] The physical data for the polymers is provided below as made available by Thermedics Polymer Product (tests conducted as outlined by American Society for Testing and Materials (ASTM), Table 1).
[0000]
TABLE 1
Tecophilic ® Typical Physical Test Data
ASTM
HP-60D-20
HP-60D-35
HP-60D-60
HP-93A-100
Durometer
D2240
43D
42D
41D
83A
(Shore Hardness)
Spec Gravity
D792
1.12
1.12
1.15
1.13
Flex Modulus (psi)
D790
4,300
4,000
4,000
2,900
Ultimate Tensile Dry (psi)
D412
8,900
7,800
8,300
2,200
Ultimate Tensile Wet (psi)
D412
5,100
4,900
3,100
1,400
Elongation Dry (%)
D412
430
450
500
1,040
Elongation Wet (%)
D412
390
390
300
620
[0060] HP-60D-20 is extruded to tubes with thickness of 0.30 mm with inside diameter of 1.75 mm. The tubes are then cut into 25 mm in length. One side of the tube is sealed with heat using a heat sealer. The sealing time is less than one minute. Four pellets of histrelin acetate are loaded into the tube. Each pellet weighs approximately 13.5 mg for a total of 54 mg. Each pellet is comprised of a mixture of 98% histrelin and 2% stearic acid. The second end open of the tube is sealed with heat in the same way as for the first end. The loaded implant is then conditioned and primed. The conditioning takes place at room temperature in a 0.9% saline solution for one day. Upon completion of the conditioning, the implant undergoes priming. The priming takes place at room temperatures in a 1.8% saline solution for one day. Each implant is tested in vitro in a medium selected to mimic the pH found in the human body. The temperature of the selected medium was kept at approximately 37° C. during the testing. The release rates are shown on FIG. 4 and Table 2.
[0000]
TABLE 2
Histrelin Elution Rates
WEEKS OF ELUTION
HP-60D-20 (μg/day)
1
451.733
2
582.666
3
395.9
4
310.29
5
264.92
6
247.17
7
215.93
8
201.78
9
183.22
10
174.99
11
167.72
12
158.37
13
153.95
14
146.46
15
139.83
16
129.6
17
124.46
18
118.12
19
120.35
EXAMPLE 2
[0061] FIG. 5 shows a plot of the release rate of histrelin (LHRH agonist) versus time. The polymer in this example had a water content of 15%. The polymer used was Tecophilic® HP-60-D20 from Thermedics. The data points were taken weekly.
EXAMPLE 3
[0062] Tables 2A-C show release rates of histrelin from three different classes of polyurethane compounds (Tecophilic®, Tecoflex® and Carbothane®). The release rates have been normalized to surface area of the implant, thereby adjusting for slight differences in the size of the various implantable devices. Histrelin is very soluble in water. Typically, a Log P value of greater than about 2.0 is considered to be not readily soluble in aqueous solution. The polyurethanes were selected to have varying affinities for water soluble active agents and varying flexibility (as indicated by the variation in flex modulus).
[0063] For applications of the polyurethanes useful for the devices and methods described herein, the polyurethane exhibits physical properties suitable for the histrelin formulation to be delivered. Polyurethanes are available or can be prepared, for example, with a range of EWCs or flex moduli (Table 2). Tables 2A-C show normalized release rates for various active ingredients from polyurethane compounds. Tables 2D-F show the non-normalized release rates for the same active ingredients, together with implant composition.
[0000]
TABLE 2A
Polyurethane Type
Tecophilic
Polyurethane Grade
HP-60D-60
HP-60D-35
HP-60D-20
HP-60D-10
HP-60D-05
Relative Water
% EWC/Flex Modulus
Active
Solubility
31% EWC
24% EWC
15% EWC
8.7% EWC
5.5% EWC
Histrelin
Very soluble
309 μg/
248 μg/
93 μg/
—
—
Acetate
Log P = (n/a)
day/cm 2
day/cm 2
day/cm 2
(M.W. 1323)
2% SA
2% SA
2% SA
50 mg API
50 mg API
50 mg API
[0000]
TABLE 2B
Polyurethane Type Tecoflex
Polyurethane Grade
EG-85A
EG 100A
EG-65D
Relative Water
% EWC/Flex Modulus
Active
Solubility
F.M.: 2,300
F.M.: 10,000
F.M.: 37,000
Histrelin
Very soluble
—
0.3 μg/day/
—
Acetate
Log P = (n/a)
cm 2 2% SA
(M.W. 1323)
50 mg API
[0000]
TABLE 2C
Polyurethane Type Carbothane
Polyurethane Grade
PC-3575A
PC-3595A
Relative Water
% EWC/Flex Modulus
Active
Solubility
F.M.: 620
F.M.: 4,500
Histrelin Acetate
Very soluble
—
0.2 μg/day/cm 2
(M.W. 1323)
Log P = (n/a)
2% SA
50 mg API
[0000]
TABLE 2D
Polyurethane
Tecophilic
Grade
HP-60D-60
HP-60D-35
HP-60D-20
HP-60D-10
HP-60D-05
Relative Water
% EWC
Active
Solubility
31% EWC
24% EWC
15% EWC
8.7% EWC
5.5% EWC
Histrelin
Very soluble
500 μg/day
400 μg/day
150 μg/day
—
—
Acetate
Log P = (n/a)
ID: 1.80 mm
ID: 1.80 mm
ID: 1.80 mm
(M.W. 1323)
Wall: 0.30 mm
Wall: 0.30 mm
Wall: 0.30 mm
L: 24.5 mm
L: 24.5 mm
L; 24.5 mm
1.616 cm 2
1.616 cm 2
1.616 cm 2
[0000]
TABLE 2E
Polyurethane Type Tecoflex
Polyurethane Grade
EG-85A
EG 100A
EG-65D
Relative Water
Flex Modulus
Active
Solubility
F.M.: 2,300
F.M.: 10,000
F.M.: 37,000
Histrelin
Very soluble
—
0.5 μg/day
—
Acetate
Log P = (n/a)
ID: 1.85 mm
(M.W. 1323)
Wall:
0.20 mm
L; 25.56 mm
1.645 cm 2
[0000]
TABLE 2F
Polyurethane Type Carbothane
Polyurethane Grade
PC-3575A
PC-3595A
Relative Water
Flex Modulus
Active
Solubility
F.M.: 620
F.M.: 4,500
Histrelin Acetate
Very soluble
—
0.5 μg/day
(M.W. 1323)
Log P = (n/a)
ID: 1.85 mm
Wall: 0.20 mm
L; 25.25 mm
1.625 cm 2
[0064] The solubility of an active agent in an aqueous environment can be measured and predicted based on its partition coefficient (defined as the ratio of concentration of compound in aqueous phase to the concentration in an immiscible solvent). The partition coefficient (P) is a measure of how well a substance partitions between a lipid (oil) and water. The measure of solubility based on P is often given as Log P. In general, solubility is determined by Log P and melting point (which is affected by the size and structure of the compounds). Typically, the lower the Log P value, the more soluble the compound is in water. It is possible, however, to have compounds with high Log P values that are still soluble on account of, for example, their low melting point. It is similarly possible to have a low Log P compound with a high melting point, which is very insoluble.
[0065] The flex modulus for a given polyurethane is the ratio of stress to strain. It is a measure of the “stiffness” of a compound. This stiffness is typically expressed in Pascals (Pa) or as pounds per square inch (psi).
[0066] The elution rate of an active agent from a polyurethane compound can vary on a variety of factors including, for example, the relative hydrophobicity/hydrophilicity of the polyurethane (as indicated, for example, by logP), the relative “stiffness” of the polyurethane (as indicated, for example, by the flex modulus), and/or the molecular weight of the active agent to be released.
Equivalents
[0067] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from the spirit and scope of the disclosure, as will be apparent to those skilled in the art. Functionally equivalent methods, systems, and apparatus within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof.
[0068] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. All references cited herein are incorporated by reference in their entireties. | This invention is related to the use of polyurethane-based polymer as a drug delivery device to deliver biologically active histrelin at a constant rate for an extended period of time and methods of manufactures thereof. The device is very biocompatible and biostable, and is useful as an implant in patients (humans and animals) for the delivery of histrelin to tissues or organs. | 0 |
This application is a continuation of application Ser. No. 906,301, filed Sept. 11, 1986, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to optical fibre cables, particularly long span aerial cables incorporating optical fibres.
Various cable designs have been proposed for use as aerial cables incorporating optical fibres, for example as earth wires in an overhead power transmission system. When an overhead power transmission system is installed, it is convenient to use the same route for purely telecommunications purposes and it has already been proposed to provide a communication system via an earth wire of the power transmission system. British Patent No. 2029043 B is an example of an overhead earth wire cable for a power transmission system incorporating an optical fibre for telecommunication purposes.
On existing power transmission routes which have not had an optical fibre cable installed in the earth wire, then three alternatives exists in order to install a fibre optic cable in an existing route. The first alternative is to replace the existing standard earth conductor wire with a fibre optic earth wire as mentioned above in British Patent No. 2029043 B; another alternative would be to wrap a fibre optic cable around a power conductor of the system; and a third alternative would be to install a self-supporting optical fibre aerial cable by suspending it from the pylons which support the existing system.
The first two options above are expensive and inconvenient, requiring as they do the complete shutdown of the power transmission system while the modifications are effected.
The third alternative offers the more satisfactory solution. However it is undesirable to install a cable which contains metallic elements because the presence of an additional electrically conductive cable in the vicinity of the power conductors of a power transmission system adversely affects certain aspects of the existing system operation. it is therefore necessary to provide a non-metallic fibre optic cable and such a cable has already been proposed. This known aerial fibre-optic cable is made by Standard Electric Lorenz in Germany and comprises a helically-laid-up fibre optic package surrounded by a glass-fibre reinforced tube acting as the strength member and formed into position around the fibre optic bundle during manufacture of the glass fibre reinforced strength member.
Although such a cable is effective in providing a self-supporting telecommunications link in an existing power transmission system, it nevertheless has certain disadvantages, not least being the cost of the cable and the limited amount of excess fibre which can be achieved in order to minimise damage to the fibre under conditions of use.
It is an object of the present invention to provide a metal-free aerial optical fibre cable which is cheap to produce and effective in its application.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided an optical fibre cable comprising an elongate core member defining a surfacial longitudinally-extending slot and forming the main tensile strength member of the cable, one or more optical fibres located in said slot, and means closing the slot, said core member also forming the main crush-resistant armouring around the optical fibres, there being an excess length of fibres in the slot.
According to another aspect of the present invention there is provided a method of making a fibre optic cable comprising providing an elongate core member defining at least one longitudinally-extending slot, feeding at least one optical fibre into the slot, and applying means to close the slot, wherein the core member is made of a non-metallic material having a high elastic modulus.
According to yet another aspect of the present invention there is provided a method of making an optical fibre cable comprising providing a strength member core having a longitudinal slot in its surface, providing a ribbon-like element containing a plurality of optical fibres held in side-by-side relationship in the ribbon element, feeding the ribbon element into the slot in the core such that there is an excess length of element in the finished cable, and encasing the core in a sheath to retain the element within the slot.
Preferably the slot has a flat bottom and the ribbon optical fibre element lies on the flat bottom and has a width similar to the width of said bottom.
Preferably also there are two such optical fibre ribbon elements lying flat one on top of the other.
Preferably the core member is made of glass reinforced plastics rod and in one example the diameter of the rod is about 10 mm. The glass reinforced plastics may use E, S, R or T glass with polyester, vinyl ester or epoxy based resins.
Very perferably the core member is made by a pultrusion technique.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention can be clearly understood reference will now be made to the accompanying drawings, wherein:
FIG. 1 shows in cross-section a self-supporting optical fibre cable according to an embodiment of the present invention;
FIG. 2 shows a second embodiment of a non-self-supporting optical fibre cable according to the present invention;
FIG. 3 is a schematic drawing of a core part of the cable of FIG. 1 and is used to explain the design of the cable;
FIG. 4 shows schematically part of the manufacturing apparatus for manufacturing the cable shown in FIG. 1;
FIG. 5 shows in cross-section an aerial optical fibre cable according to third embodiment of the present invention;
FIG. 6 shows schematically a manufacturing process for making the cable of FIG. 5, and
FIG. 7 is a diagram explaining some calculations on the dimensions of the core member.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 a non-electrically-conductive slotted core of homogeneous material in the form of a C-section profile 1 is made from glass-fibre reinforced plastics by a Pultrusion or similar process; it could be made from some other fibre-reinforced composite which is non-metallic and which acts as a cable strength member and armour and is resilient with a modulus of at least 40,000 N/mm 2 . For example the fibres could be an aramid fibre (such as Kevlar-RTM) or carbon fibres. The resin is a polyester-based material. A modulus for the glass-fibre-reinforced material would be at least 40,000 N/mm 2 and of the order of 45,000 N/mm 2 and this can be achieved using E-grade glass. However the higher the modulus, the better, and moduli of 70,000 are attainable using T-grade glass (Japan).
A slot 2 runs straight along the profile 1 and is arranged to be on the outside of the profile as it is bent around a capstan 9 to obtain excess fibre, explained in more detail in FIG. 4. The slot 2 accepts optical fibres 3, housed in a loose tube 3A. Around the outside of the C-section profile is a composite plastics sheath comprising a longitudinal tape 13, a woven yarn wrapping 15 and a extruded outer sheath 14. This maintains the optical fibres 3 within the slot 2. There may, optionally, be a filler member 5 (shown in broken line) which closes the slot and prevents the optical fibres 3 from slopping around inside the slot 2, and in that variation, it would not be necessary to have the tape 13.
In manufacturing the cable it is important that the finished cable has an excess length of fibre in the slot 2. Referring to FIGS. 3 and 4 this is achieved, in the preferred embodiment of the method, by running the profile 1 from a storage reel 7 which has a brake 8 which can be applied to brake rotation of the reel 7, over a capstan 9 and on to a storage drum 10. An orientation die 11 projects in to the slot 2 to ensure that the slot is maintained directed radially outwardly with respect to the capstan 9, although it is found that the profile has a natural tendency to offer this slot outwardly when bent. The diameter of the capstan 9 is close to or equal to the designed minimum bend diameter of the cable. As the profile proceeds towards the capstan 9, tubed optical fibres 3, 3A are fed in from a storage reel 12 and the composite sheath is formed by applying a longitudinal polyethelyne tape such as 13 from a reel 13A, with overlapping edges. Over the longitudinal tape 13 is applied a helically-wound binder 15 of polyester material, at station 16. The partially-sheathed profile 1 is then passed around the capstan 9 whose diameter is close to the minimum designed bending diameter of the cable, and would lie in the range 0.6 m for an 8 mm diameter profile core to 1.5 m for a 12 mmm core. The profile would have up to four turns around the capstan and the purpose of the capstan is to induce an excess length of fibre in the cable. Then a low density polyethelyne sheath 14 which is UV stable is extruded over the helically wound binder at station 14A and amalgamates with the longitudinal tape 13 to prevent slippage of the composite sheath relative to the profile 1 for example when it is clamped.
The distance between tubed fibre payoff 12 and capstan 9 is kept short e.g. 1 to 2 meters, although it could be longer provided the excess fibre can be "drawn" by the capstan without feedback around the capstan occurring.
The excess length of tubed optical fibre within the constructed cable is achieved due to the circumferential differences of the optical fibres 3A in the slot 2 of the profile 1. Excess fibre is additionally achieved by shrinking the tube 3A around the optical fibres 3 when the fibres 3 are laid up in the tube 3A in an earlier process, by careful cooling and drying of the tube 3A after extrusion around the fibres 3. Thus as shown in FIG. 3, provided the neutral axis 1A of the profile 1 is beneath the bottom of the slot 2 then an excess of tubed optical fibres 3A will be achieved and become effective when the cable is straightened out in use.
The profile when it straightens out after leaving the capstan 9 shortens at the upper slot side and lengthens on its lower side remote from the slot. It will, in effect, probably rotate or bend about its centre of mass and the element that has been placed in the slot will therefor become slack having acquired excess length over the slot. This will occur provided the "excess" cannot work backwards along the capstan. This requires a reasonably high degree of friction, or a large contact area. This may be able to be provided by a 360° turn around the capstan 9, i.e. 1 turn, but 2, 3 or even 4 turns may be found necessary to prevent feedback from the straight portion between capstan 9 and take-up drum 10 effectively reducing the excess fibre. The take-up drum 10 will be larger than the capstan and similar in size to the reel 7, e.g. 1.2 m to 1.7 m diameter. The degree of excess element in the slot will be determined by the distance of the bottom of the slot from the neutral axis of the profile. The larger this distance then the larger the proportional excess of element which is achieved.
If the profile bends around a radius r (FIG. 3) and the element around a radius r+a+b, where a is the distance of the base of the slot from the neutral axis of the profile, and b is the distance of the axis of rotation of the element from the base of the slot, then the path length difference is ##EQU1##
If r is the minimum bend radius of the profile e.g. 300 mm and a+b is 1 mm, then the excess slack ##EQU2##
This would more than double the maximum tension the cable could endure.
The excess optical fibre is held in by the binding and tape indicated by reference numerals 13, 15 and 14.
There are two suitable sizes for the core 1:8 mm diameter for the profile member, suitable for pylon spans of 1100 to 1400 feet in regions where there is no possibility of ice, e.g. Sudan or India; and 12 mm for countries where ice has to be taken into account, e.g. UK. The maximum diameter envisaged is 14 mm. For the 8 mm size the slot will be 4 mm deep and 3 mm wide, but would optimally be 2.5 mm wide. For the 12 mm profile, the slot depth will be between 4 and 6 mm and the width between 2.5 mm and 3.2 mm.
There will be four or six fibres 3 (although there could be as many as ten) and these are pre-housed in the plastics tube 3A. This has been found to produce a reliable excess of fibre when installed in the slot in the profile. An excess of about 0.2 to 0.25% can be achieved in the tubed fibre by controlled shrinkage of the tube during extrusion and cooling of the tube around the fibres. However this in itself is unlikely to be sufficient and further excess is achieved by the cabling technique already described which provides an additional excess of about 0.5%, making a total of 0.7-0.75%. A better excess may be achievable, allowing 1.00% strain on the finished cable without straining the fibres beyond 0.25%, which is a universally adopted standard.
Thus the excess length of tube compared to cable is greater than the excess length of fibre compared to tube when the cable is straight and untensioned.
The profile has a preferred plane of bend 1B (FIG. 3) which coincides with the central longitudinal plane of symmetry of the slot 2. It may be preferable to modify the tips 1C of the profile, which undergo the greatest strain around the capstan 9, by incorporating fibres having greater ultimate strain at those extremities than for the remainder of the profile. This is possible using the Pultrusion process and ensures that failure of the tip fibres does not occur around the capstan 9.
Referring to FIG. 2, there is shown an alternative design intended to be supported from a support wire. Here a C-section profile 16 of less than 8 mm and about 3 or 4 mm diameter is made of the same material as profile 1 of FIG. 1, and has a narrow slot 17 containing several loose acrylate-coated fibres 3. A composite sheath is applied in the same way as in FIG. 1 and like reference numerals represent like parts. The cable is slung from a support member 18 by a sling 19. Since the cable will suffer less stress than the embodiment of FIG. 1, a large excess of fibre is not required and the fibres 3 can be fed into the slot 17 under no tension while the member 16 is under some tension, to thus provide a slight excess length of fibre in the finished cable. Hence the bottom of the slot 17 will lie at or below the neutral axis of member 16.
The slot 17 is very narrow, much narrower than in FIG. 1.
In both the embodiments of FIGS. 1 and 2 the pultruded profile 1 or 16 provides the sole longitudinal strength member of the cable per se and the solid armour and crush-resistant member of the cable, in a single integrally-formed element. This provides significant economy of production and high speed production. Another advantage of this design of cable is the ease with which the fibres can be accessed by simply cutting through the composite sheath above the slot, and withdrawing the fibres through the side of the slot. Thus there is provided a "weak" line for gaining access to the fibres and it is proposed to incorporate a rip cord (16 in FIG. 1) either in the slot or between the binding 15 and the longitudinal tape 13 to enable access to the fibres by pulling the rip cord. Such a rip cord could be similarly applied to FIG. 2.
Yet another advantage is that glass reinforced plastics does not "creep" in tension, unlike steel and other materials.
The embodiments of FIG. 1 would have a permissible tensile load of 36 kN (12 mm dia. version) and 20 kN (8 mm dia. version). The thermal expansion coefficient of glass reinforced plastics would match very closely that for the optical fibres and would be about 0.7×10 -6 per °C. The permissible span allowing a 12 mm ice radial and a 55 mph wind would be 1100 to 1400 ft at -5.6° C., with an optical safety factor of 1.3 and a mechanical safety factor of 2. At 0° C. the maximum sag with the same ice radial would be about 33 ft.
Referring now to FIG. 5 of the drawings the cable comprises a pultruded core 21 made of glass reinforced plastics using E glass and polyester or vinyl ester resin. In this particular embodiment the core has a diameter of approximately 10 mm and a slot 22 formed in the core during the pultrusion manufacturing process and parallel to the core axis. In this embodiment the slot width is 3.8 mm and the slot base thickness 6.8 mm. It is rectangular in cross-section and the corners have a radius of 0.5 mm.
As shown the slot contains two optical fibre ribbon elements 23 and 24 lying on the bottom of the slot. Each ribbon contains twelve single mode optical fibres and in this embodiment the ribbons are each 3.2 mm wide and 0.35 mm deep. Preferably these optical fibre ribbon elements are made according to the process described in our co-pending British Patent Application No. 8524484 (J. R. Gannon 3-1-1).
This particular embodiment of cable has a maximum cable strain of 0.73% and a maximum allowable tension of 23,700 N, which gives a span capability of up to 540 meters, based on current ESI pylons with typical sags and UK loadings and safety factors.
Around the slotted core 21 is a binder 25 and over the binder 25 is a tape 26.
Over the tape 26 is extruded a plastics sheath 27.
The slot 22 is filled with a viscous filling compound 28 such as one sold under the trade name SYNTEC particularly a soft one such a type FCC210F. This material is a dielectric compound that prevents moisture collection but allows the ribbon cable elements to move up and down in the slot.
Reference will now be made to FIG. 6 of the drawings which shows schematically a manufacturing process for the cable of FIG. 5.
Referring to FIG. 6 it is important in manufacturing the cable that the finished cable has an excess length of fibre in the slot 22. This is achieved, in the preferred embodiment of the method, by running the profile 21 from a storage reel 37, which has a brake 38 which can be applied to brake rotation of the reel 37, over a capastan 39 and on to a storage drum 40. An orientation die 41 projects in the slot 22 to ensure the slot is maintained directed radially outwardly with respect to the capstan 39, although it is found that the profile of the core 21 has a natural tendency to offer this slot outwardly when bent around the capstan. The diameter of the capstan 39 is close to or equal to the designed minimum bend diameter of the cable. As the profile proceeds towards the capstan 39, the ribbon optical fibre cable elements 23 and 24 are fed from storage reels 42 and 43 respectively via a guide member 44 which guides the ribbon elements 23 and 24 one on top of the other in to the slot so that they lie flat on the bottom of the slot 22.
Immediately following the guide member 44 is a binder application stage 45 at which the binder 25 supplied from a reel 46 is wound around the core 21 in order to maintain the ribbon cable elements in the slot 22.
The bound core 21 with the ribbon elements inside is then drawn around a capstan 39 which, in this embodiment has a diameter of approximately 1 meter. The capstan provides an excess length of ribbon elements within the slot when the core leaves the capstan and enters the water blocking filling station 47. Here water blocking viscous material is pumped in to the slot and fills the slot, entering it via the interstices of the binder 25.
The filled cable core then enters a taping station 48 at which the tape 26 is applied to the cable core. The tape is helically wound and closes off the slot. The tape 26 could be made of Kevlar (RTM) to give added protection against physical damage.
The taped core is wound on to a take-up drum 50.
From the take-up drum the taped core is fed through an extruder 49 which extrudes the sheath 27 over the taped core.
The process described above could be modified. For example the process could be divided into two separate processes, the first including the binder 25, capstan 39 and then direct onto the take-up drum 50 for storage. From there the bound cable core would be fed to the filling station 47 and then to the taping station 48.
Thus the bound core with the excess of fibre could be stored and subsequently have the filling material and the tape applied.
The capstan diameter is as stated above 1 meter which is appropriate for a 10 mm core. The centre of bend of the ribbons is (0.25+0.1)/2=0.175 mm above the base of the slot. The centre of bend of the core is measured either by calculating the centre of mass, or modelling the centre of mass. We have found that mesurement is not possible before the core section has been made, and calculations or modelling are subject to the approximation that the tensile modulus is similar to the compressive modulus. If this is valid, then modelling the centre of mass is a reasonable approximation and from these calculations a 0.5-0.6 mm shift for a 10 mm core is obtained. One very simple way is to cut a card or disc cross-section of the core profile on a larger scale, and spin the cross-sectional disc about various approximate centre points to eventually find the balance point i.e. the centre of mass. We have discovered that for a core of approximately 10 mm in diameter the shift amounts to 0.55 mm. This of course is an approximation because it depends on the shape and size of the slot in the core. But it is we believe an allowable approximation since the shape and size of the slot is known within reasonable practical limits. The slot width is normally going to have more effect on the centre of mass than the slot depth.
Therefore the excess length of ribbon fibre element over the length of the core can be calculated thus:
% Excess=(x+h+0.175)·(100/500)
where x=the distance between the centre of the core circle and the centre of mass, h=the distance between the centre of the circle and the bottom of the slot and 0.175=half thickness of the or each optical fibre ribbon element, and that figure for the excess is the excess per meter length of the cable assuming that the diameter of the capstan 39 is exactly 1 meter.
The percentage excess incorporated in the cable depends clearly upon the value of h and also the slot space avaialable. Clearly as h is increased in order to increase the excess, so the slot space decreases. If the slot space is too small for a particular predetermined excess of optical fibre ribbon element, then the optical fibres within the ribbon element will be bent beyond their minimum allowable bending radius. For example this could be about 75 mm and this figure is assumed in the calculations which follow. However it may be possible to achieve a smaler minimum bend radius e.g. 50 mm corresponding to the minimum bend radius of the fibre outside the ribbon containment i.e. bare fibre. As shown in FIG. 7 of the drawings the slot depth is also restricted to some extent by the "dip-in" caused by the oversheathing of the core. Although this is obviously dependent upon the sheath technique used, we have found that for a slot width of 3.2 mm a "dip-in" of approximately 0.28 mm ocurred. The "dip-in" can be regarded as proportional to the slot width so that a 3.8 mm slot will have a "dip-in" of 0.332 mm.
Further space is lost by the fact that the upper tips of the profile shown in FIG. 7 are rounded off so that the tips do not lie on the outside diameter of the profile. If we assume that the slot width is fixed at 3.8 mm plus or minus 0.1 mm, and the rib radius at a nominal value of 0.5 mm, an expression can be derived for space lost versus the core diameter. Space lost is defined as z as shown in formula B in FIG. 7. In the formula E is the radius of curvature of the tips, and F is half the width of the slot 2.
It is therefore possible to tabulate for a variety of tip radii ranging from 0.4 mm to 0.6 mm, a slot width ranging from 3.7 mm to 3.9 mm, a core diameter ranging from 9.8 mm to 10.4 mm, and for each value of tip radius a value for space lost Z can be calculated. This ranges from 0.56 for a tip radius 0.4, a slot width of 3.7 and core diameter of 10.4 to 0.84 for a tip radius of 0.6, a slot width of 3.9 and a core diameter of 9.8.
Another parameter that has to be determined is the load that the cable has to bear. This is determined by the sag, and the span (which are fixed by the National Electricity Distribution Authority) and the cable weight, wind loading and ice loading (which vary with the cable diameter). In the particular application envisaged the span can vary from 330 meters to 500 meters and the sag with a 12.5 mm ice load at 0° C. ranges from 9.58 meters to 21.45 meters. Even 1500 meter span with a large sag is possible to span e.g. a lake or wide river.
The cable weight will depend on the components which are glass reinforced plastics, optical fibres, filling compounds such as SYNTEC, the binder yarn, the tube 16 which in this embodiment is paper, and the sheath compound which in this embodiment is high density polyethelene or cross-linked polyethelene but it could with advantages be made of a material more abrasion-resistent than polyethelene. The cable weight is found not to be a major factor, and the slot is a minor part of the cable weight. It is therefore reasonable to assume that the slot area A equal 3.8×h. In a 10 mm core, a 0.5% excess needs 5-1.9-0.7=2.4 mm for h. This also corresponds to a 75 mm minimum fibre bend radius at 0.54% excess. For a slot area A=3.8×2.4=9.12 mm 2 and if the mean slot density is 1, then the weight will be 0.089 N per metre for the slot.
The core area equal πr 2 -9.12-0.7×1.9 and if the GRP density is 2.07, and the paper which will be partly soaked with filling compound will have its density increased to approximately 0.95 so that the sheath plus the paper/binder with a diameter increment of 2.5 mm from the sheathing gives an overall weight of 0.412 N per meter.
Therefore the weight for the cable can be calculated for a variety of diameters of the core member from 9.8 to 10.4 giving a weight ranging from 177 kilograms per kilometer to 196 kilograms per kilometer.
The table below shows the parameters which apply to a core diameter varying from 9.0 to 10.4 from which it can be seen only a core diameter of 9.7 mm upwards provides a core which can accomodate two optical fibre ribbon elements with the satisfactory amount of excess.
__________________________________________________________________________GRP Space MinDiam Loss Min Space Max Mean Tolerence(mm) (mm) h Needed h h h Comment.__________________________________________________________________________9.0 1.139.1 1.129.2 1.119.3 1.109.4 1.09 1.7 2.1 1.51 -- -- Out of Space9.5 1.08 1.65 2.05 1.62 -- -- "9.6 1.07 1.6 2.0 1.73 1.67 ±0.07 OK, tolerance too fine9.7 1.06 1.55 1.95 1.84 1.7 ±0.15 OK9.8 1.045 1.5 1.9 1.95 1.73 ±0.23 OK9.9 1.04 1.45 1.85 2.06 1.76 ±0.31 OK10.0 1.03 1.4 1.8 2.17 1.79 ±0.39 OK10.1 1.02 1.35 1.75 2.28 1.82 ±0.47 OK10.2 1.09 1.3 1.7 2.39 1.85 ±0.55 OK10.3 1.00 1.25 1.65 2.50 1.88 ±0.63 OK10.4 0.99 1.2 1.6 2.61 1.91 ±0.71 OK__________________________________________________________________________
It is therefore convenient to choose a core diameter of approximately 10 mm. Below 9.7 mm the tolerance on the value of h becomes too critical for normal manufacturing processes.
The choice of slot height h can be anywhere between 1.4 mm and 2.2 mm from the theoretical analysis. As the slot gets smaller the excess fibre increases, but the space for excess decreases. Since too much excess is unlikely to be a problem, it is considered best to err on the high percentage excess side.
The following table illustrates the parameters, particularly the excess generated versus the excess which is allowed by the slot size.
__________________________________________________________________________ Max Eff. XS XS Max Max ratedh slot gener'd all'd Diff. strain ten. ten. Marg.__________________________________________________________________________1.4 2.6 0.405 0.581.5 2.5 0.425 0.561.6 2.4 0.445 0.541.7 2.3 0.465 0.5151.8 2.2 0.485 0.49 Best Match 0.735 23772 21096 26761.9 2.1 0.505 0.472.0 2.0 0.525 0.452.1 1.9 0.545 0.432.2 1.8 0.565 0.404__________________________________________________________________________
However it is to be understood that larger or smaller cables can be made and if the minimum bend radius could be reduced to say 50 mm then an excess as much as 0.8% could be achieved. It is also believe in some designs for very short spans, as little as 0.2% excess may be sufficient.
It can be seen that the best match occurs where h equals 1.8, slot depth equals 2.2 mm, excess generated equals 0.485 and the excess allowed equals 0.49. This gives a maximum strain of 0.735 a maximum tension (N) of 23,772 a maximum rated tension of 21,096, giving a margin of 2,676.
As a result of the calculations described above, the optimum size of core for the cable is as follows:
______________________________________Diameter (2d) 10.0 mm + or - 0.15Slot Width (2F) 3.8 mm + or - 0.1 mmTip Radius (E) 0.5 mm + or - 0.1Slot Corner Radius 0.5 mm + or -0.1h = 1.8 mmh + d = 6.8 mm + or - 0.1 mmOptical Fibre Ribbonthickness 0.175 mm______________________________________
A big advantage of the ribbon element in the single-slot core resides in the ability to scale down the whole cable size for e.g. shorter spans. For example a core diameter of just 5 mm is possible having a slot of 2 mm width, 2 mm depth, containing loosely a ribbon optical fibre element containing say four fibres. In particular this provides a much more flexible cable suitable for e.g. local area telegraph poles or along railway lines.
In a further modification it is proposed to use a tubing die in the extruder 49 and omit the taping operation 48 and put the extruder on-line in the position presently occupied by taping station 48. This enables a single-line production arrangement. What is more the "dip" 27a in FIG. 5 can be avoided by shaping the tubing die profile so that the dip 27a becomes a "flat" bridging directly across between the tips 21A and 21B of the slot walls. This provides more room for the excess fibre than in the embodiment described.
The cables described (apart from FIG. 2 embodiment) are intended to be strung from overhead pylons using conventional cable support clamps with reinforcing overlay and underlay rods and spiral vibration dampers. | An aerial optical fiber cable comprises a glass-fibre-reinforced plastics core member (1) having a slot (2) with a zero lay angle accommodating loose-tubed optical fibres (3, 3A) and sheathed with a longitudinal tape (13) bound with a binder (915) and over-sheathed with a plastics extrusion (14). The cable is self-supporting and completely non-metallic and is suitable for telecommunications and data transmission services alongside overhead power transmission systems. An alternative embodiment (FIG. 2) is not self-supporting but is similar in design and adapted for support from a support wire, and another embodiment has a rectangular slot housing one or more ribbon elements. The cable is simple and cheap to make. | 6 |
This application claims priority from provisional application Ser. No. 60/820,942, filed Jul. 31, 2006, which is incorporated by reference in its entirety. U.S. Pat. No. 6,198,178, entitled: Step Wave Power Converter, issued Mar. 6, 2001, is also incorporated in its entirety.
FIELD OF THE INVENTION
The disclosure relates generally to power converters.
BACKGROUND OF THE INVENTION
The general class of multilevel inverters comprises of, among others, a type known as Cascaded Multilevel Inverters. Cascaded inverters have been used in the industry for high power applications. Among the techniques for controlling these cascade converters include a carrier-based Pulse Width Modulation (PWM) scheme known as phase-shifted carrier PWM (PSCPWM).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a single-phase cascaded multilevel inverter.
FIG. 2 is a diagram of a single-phase step wave inverter.
FIG. 3 is a diagram showing a phase-shifted carrier PWM scheme.
FIG. 4 shows an asymmetrically sampled sine-triangle PWM scheme.
FIG. 5 shows an output voltage from a cascaded inverter.
FIG. 6 shows an output voltage from the step wave inverter shown in FIG. 2 .
FIG. 7 shows the diagram of a 5-level step wave inverter.
FIG. 8 shows waveforms from a 5-level step wave inverter
DETAILED DESCRIPTION
A Phase-Shifted Carrier Pulse Wave Modulation (PSCPWM) scheme is implemented in a step wave power converter for a stand-alone inverter mode of operation. The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment of the invention which proceeds with reference to the accompanying drawings.
FIG. 1 shows a single-phase cascaded inverter 10 . The inverter 10 comprises N II-bridges 12 and is capable of producing (2N+1) voltage levels from a Direct Current (DC) power source 14 . Each bridge 12 consists of switching gates S k1 -S k4 , (k=1, 2, . . . N, where k is the k th bridge and N is the number of bridges) which are controlled in response to signals from a control board (not shown). Each switching gate S k1 -S k4 may be fitted with an antiparallel diode to allow shorting current to flow. The switching gates in certain embodiments could use Insulated Gate Bipolar Transistor (IGBT) modules having four IGBTs or Metal Oxide Semiconductor Field Effect Transistor (MOSFET). However, other type of switching devices could also be used.
Activating gates S 13 and S 12 and deactivating gates S 11 and S 14 in Bridge# 1 creates a voltage V o,1 =V DC,1 . Deactivating gates S 13 and S 11 and activating gates S 12 and S 14 in Bridge# 1 shorts V o,1 =0.
The cascaded inverter topology requires that all the DC sources 14 be isolated from each other. This isolation feature allows the outputs of the H-bridges 12 to be added together vectorially. This fact is illustrated in FIG. 1 . At any time instant t, V o,1 (t), V o,2 (t), . . . , V o,N (t) are the output voltages of Bridge # 1 , Bridge# 2 , . . . , Bridge #N, respectively. Since the DC sources 14 are isolated from each other, the inverter output voltage V op (t), is given by the sum of individual H-bridge output voltages and is expressed by the following equation:
V op ( t )= V o,1 ( t )+ V o,2 ( t )+ . . . + V o,N ( t ) (1)
The schematic of a single-phase step wave power converter 20 with N H-bridges 12 is shown in FIG. 2 . In general, each H-bridge 12 can be supplied from a separate DC source 14 . This is shown in FIG. 2 where the DC voltage sources 14 for Bridge # 1 , Bridge# 2 , . . . , Bridge #N are represented by V DC,1 , V DC,2 , . . . , V DC,N respectively. The inverter 20 also comprises of N transformers 16 . The output of each bridge 12 is tied to the primary winding 16 A of the corresponding transformer 16 .
As seen in FIG. 2 , Bridge # 1 , Bridge # 2 , . . . , Bridge #N are tied to the primary windings 16 A of transformers T 1 , T 2 , . . . , T N respectively. The outputs 18 of Bridge # 1 , Bridge # 2 , . . . , Bridge #N are designated by V o,1 , V o,2 , V o,N respectively, and the output voltage at the corresponding transformers 16 are designated by V SEC,1 , V SEC,2 , . . . , V SEC,N , respectively. The secondary windings 16 B of all the transformers 16 are tied in series. The resultant inverter voltage 22 , V op,SW , is the sum of the transformer voltages. If at any given time instant t, the instantaneous transformer voltages are V SEC,1 (t), V SEC,2 (t), . . . , V SEC,N (t) then V op,SW (t) is given by:
V op,SW ( t )= V SEC,1 ( t )+ V SEC,2 ( t )+ . . . + V SEC,N ( t ) (2)
For both topologies in FIG. 1 and FIG. 2 , the output voltages of the individual H-bridges 12 are isolated from each other and thus can be added up to yield the resultant inverter voltage. For this to happen in a cascaded inverter 10 in FIG. 1 , the DC sources 14 for the individual H-bridges 12 are isolated from each other. This allows the output of one H-bridge 12 to feed into the next H-bridge 12 without causing any circulating currents.
In the case of a Step Wave Inverter 20 in FIG. 2 , the DC sources 14 may or may not be isolated from each other. However, the outputs of the individual H-bridges 12 are isolated from the rest of the bridges in the inverter 20 through the use of transformers 16 . In both the cascaded inverter 10 and the Step Wave Inverter 20 , the outputs 18 of the individual H-bridges 12 are isolated from the rest of the bridges. Since in both the cascaded inverter and the Step Wave Inverter the outputs of the individual H-bridges are isolated from the rest of the bridges, and also because the individual H-bridge outputs get combined to give the resultant inverter voltage, similar PWM techniques can be employed for both the topologies. Applying the same gating signals to control the power transistors in the two topologies will result in inverter waveforms that are identical to each other, differing only in magnitude. This underlying principle is used in this invention whereby a PWM technique commonly used for Cascaded Multilevel inverter is applied for the Step Wave Inverter.
PSCPWM Scheme for Cascaded Inverters
For the case of operation of one single-phase H-bridge inverter 10 with 3-level naturally sampled modulation, the analytical solution for all the harmonics is known. It has also been shown that for series-connected single-phase bridges some dominant harmonics can be cancelled by appropriately phase-shifting the carriers for the bridges. This modulation process is denoted as phase-shifted carrier PWM, or PSCPWM.
The underlying principle of PSCPWM is to retain sinusoidal reference waveforms for the two phase legs of each H-bridge 12 that are phase shifted by 180° and then to phase shift the carriers of each bridge to achieve additional harmonic cancellation around the even carrier multiple groups.
To illustrate, FIG. 3 shows the carrier waveforms 36 and 38 and reference waveforms 30 and 32 for the 2 single-phase H-bridges 12 that are connected in series to form a 5-level cascaded inverter. FIG. 3 shows two sinusoidal reference waveforms 30 and 32 . Each waveform is assigned for one leg of the H-bridge 12 . For instance, in FIG. 3 Sine Ref # 1 is used as a reference for Leg a for both the H-bridges in the inverter 10 , and Sine Ref # 2 is used as a reference for Leg b for both the H-bridges 12 . Sine Ref # 1 and Sine Ref # 2 are phase shifted by 180°. FIG. 3 also shows the carriers, Carrier # 1 and Carrier # 2 that are the carrier waveforms for Bridge 41 and Bridge # 2 respectively.
In general, a cascaded inverter 10 with N bridges 12 will have N carriers where Carrier # 1 , Carrier # 2 , . . . , Carrier #N are the carrier waveforms for Bridge # 1 , Bridge # 2 , . . . , Bridge #N respectively. The two reference waveforms 30 and 32 are phase shifted from each other by 180°, and each reference waveform is assigned to one leg of the H-bridges, as discussed for the case of 5-level inverter. As before, Sine Ref # 1 is used as a reference for Leg a of all the N H-bridges in the inverter, and Sine Ref # 2 is used as a reference for Leg b for all the N H-bridges in the inverter.
In FIG. 3 , the carrier frequency is chosen as 5 times the reference waveform frequency for illustration purposes. For actual inverter operation the carrier frequency is typically a few tens to a few hundreds of times the fundamental frequency. FIG. 3 also shows the normalized amplitudes of the carrier waveforms 36 and 38 and reference waveforms 30 and 32 as 1 and M respectively, where M is the modulation index, and 0≦M≦1.
Modulation index M is the ratio of peaks of the carrier and reference waveforms. In other words, for a single H-bridge 12 , a modulation index of M will result in an output voltage with peak of M*V DC , and the fundamental component of this output voltage has a RMS value of M*V DC /√{square root over (2)}. For N cascaded bridge inverters 10 operating with DC voltage V DC , the RMS value of the fundamental component of the output voltage is given by:
V
op
,
CASC
-
RMS
=
N
*
M
*
V
DC
2
(
3
)
The output voltage waveform also contains harmonics due to switching action of the converter. For sine PWM the dominant harmonics are located near the multiples of the switching frequency. For cascaded bridges, PSCPWM can be used be cancel some of these harmonics. Theoretical analysis has shown that optimum harmonic cancellation is achieved by phase shifting each carrier by (i−1) π/N, where i is the i th H-bridge and N is the number of series-connected H-bridges.
Therefore, for two cascaded H-bridges 12 , the carriers need to be phase shifted by 90°, for three cascaded H-bridges the carriers need to be phase shifted by 60°, and so on. In other words if the carrier waveforms 36 and 38 have periods of ΔT, then for two cascaded H-bridges 12 , the carriers need to be phase shifted by ΔT/4, for three cascaded H-bridges the carriers need to be phase shifted by ΔT/6, and so on. This is illustrated in FIG. 3 where the carriers 36 and 38 for two cascaded H-bridges 12 are shown phase shifted by ΔT/4. It should be noted here that in order for harmonic cancellation to take place all the DC voltage sources should have the same magnitude, i.e.
V DC,1 =V DC,2 = . . . =V DC,N =V DC (4)
FIG. 3 shows the “naturally sampled” sine-triangle modulation, which is quite difficult to implement in a digital modulation system. The modern popular alternative is to implement the modulation system using a “regular sampled” PWM strategy, where the low-frequency reference waveforms 30 and 32 are sampled and then held constant during each carrier interval. These sampled values are compared against the triangular carrier waveforms 36 and 38 to control the switching process of each phase leg, instead of the sinusoidally varying reference.
For triangular carriers 36 and 38 , sampling can be symmetrical or asymmetrical. For symmetrical sampling, the references 30 and 32 are sampled at either the positive or negative peaks of the carriers 36 and 38 and then held constant for the entire carrier interval. For asymmetrical sampling the references 30 and 32 are sampled every half carrier 36 and 38 at both the positive and negative carrier peaks.
Sampling the reference signals 30 and 32 produce a stepped waveform which is phase delayed with respect to the original reference waveforms 30 and 32 . For symmetrical sampling, this delay is one half the carrier interval, while for asymmetrical sampling this delay is one quarter the carrier interval.
In the digital implementation this phase delay can be compensated by phase advancing the reference waveforms 30 and 32 by the appropriate time interval. The most common implementation for a digital PWM controller is using a digital controller around a microcontroller or a Digital Signal Processor (DSP). Good harmonic performance may be achieved by using 3-level asymmetrical regular sampled PWM for each H-bridge 12 in the cascaded inverter 10 . The waveform synthesis for the cascaded converter 10 and step wave converter 20 may be similar. Therefore the 3-level asymmetrical regular sampled PWM is used for also implementing PSCPWM for the step wave inverter.
FIG. 4 shows the switching waveforms for both legs of an H-bridge 12 , selected as Bridge # 1 in FIG. 1 for illustration. FIG. 4 shows two half-periods 36 A and 36 B of the carrier wave 36 , labeled Interval 1 and Interval 2 respectively.
The reference waveform samples for Leg a corresponding to Interval 1 and Interval 2 are Ref_Val 1 a and Ref_Val 2 a respectively, and the reference waveform samples for Leg b corresponding to Interval 1 and Interval 2 are Ref_Val 1 b and Ref_Val 2 b respectively. The reference samples are obtained after adjusting for the one quarter of the carrier period introduced due to sampling.
As can be seen, the switched waveforms for each leg are obtained by comparing the carrier wave 36 with the reference sample values. Each phase leg of the inverter switches to the upper DC rail (V DC ) 14 A when the reference value Ref_Val 1 a , Ref_Val 2 a , Ref_Val 1 b , or Ref_Val 2 b exceeds the carrier wave 36 , and switches to the lower DC rail ( 0 ) 14 B when the reference value falls below the carrier.
Following this scheme, the control signals for the power transistors can be generated. For the H-bridge under example (Bridge # 1 of the cascaded inverter shown in FIG. 1 ) the states of the switches in the H-bridge corresponding to the switching waveforms are as indicated in FIG. 4 .
Waveform 50 A shows the output voltage of Leg b at node 12 B. During Interval 1 the reference value 1 Ref_Val 1 b exceeds the carrier waveform 36 A for the time interval t 0 -t 2 . Accordingly, the output voltage at node 12 B is set to +V DC during the time interval t o -t 2 by activating switch S 13 (i.e. turning the switch ON) and deactivating switch S 14 (i.e. turning the switch OFF). During time interval t 2 -t 3 the carrier waveform 36 A exceeds the reference value Ref_Val 1 b . Accordingly, the output voltage at node 12 B is set to 0 during the time interval t 2 -t 3 by activating switch S 14 (i.e. turning the switch ON) and deactivating switch S 13 (i.e. turning the switch OFF). During Interval 2 carrier waveform 36 B exceeds the reference value Ref_Val 2 b for the time interval t 3 -t 4 . Accordingly, the output voltage is set to 0 during the time interval t 3 -t 4 by activating switch S 14 and deactivating switch S 13 During time interval t 4 -t 6 the reference value Ref_Val 2 b exceeds the carrier waveform 36 B. Accordingly, the output voltage is set to +V DC during the time interval t 4 -t 6 by activating switch S 13 and deactivating switch S 14 .
Waveform 50 B shows the output voltage of Leg a at node 12 A. During Interval 1 the reference value Ref_Val 1 a exceeds the carrier waveform 36 A for the time interval t 0 -t 1 . Accordingly, the output voltage at node 12 A is set to +V DC during the time interval t 0 -t 1 by activating switch S 11 and deactivating switch S 12 . During time interval t 1 -t 3 the carrier waveform 36 A exceeds the reference value Ref_Val 1 a . Accordingly, the output voltage at node 12 A is set to 0 during the time interval t 1 -t 3 by activating switch S 12 and deactivating switch S 11 . During Interval 2 carrier waveform 36 B exceeds the reference value Ref_Val 2 a for the time interval t 3 -t 5 . Accordingly, the output voltage is set to 0 during the time interval t 3 -t 5 by activating switch S 12 and deactivating switch S 11 During time interval t 5 -t 6 the reference value Ref_Val 2 a exceeds the carrier waveform 36 B. Accordingly, the output voltage is set to +V DC during the time interval t 5 -t 6 by activating switch S 11 and deactivating switch S 12 .
The combination of waveforms 50 A and 50 B produce waveform 50 C where the output of Bridge # 1 (V op,1 ) is equal to 0 during the time interval t 0 -t 1 , moves to V DC during the time interval t 1 -t 2 , moves to 0 during the time interval t 2 -t 4 , moves to V DC during the time interval t 4 -t 5 , moves to 0 during the time interval t 5 -t 6 etc.
FIG. 5 shows a sketch of the cascaded inverter output voltage, V op,CASC (before any filtering is performed. It can be seen that the resulting inverter voltage comprises of (2N+1) levels, and each level has the magnitude V DC .
Using PSCPWM in Step Wave Conversion
The PSCPWM is selected for the single-phase configuration of step wave inverter for stand-alone application whereby the converter performs DC-AC power conversion to supply a local load. The details of implementation of PSCPWM for a 5-level step wave inverter given below show that the inherent transformer leakage inductance can be used to eliminate external inductance and filter the output voltage.
Referring again to FIG. 2 , the PSCPWM described above for cascaded inverter 10 in FIG. 1 can also be used with the step wave power converter 20 shown in FIG. 2 . As mentioned for the case of the cascaded inverter, the desired harmonic elimination can be attained when all the DC voltage sources 14 have the same magnitude. This condition has been expressed earlier by Eq. 4. In practice this condition is directly achieved by tying all the H-bridges 12 to the same DC source 14 with magnitude, say V DC .
Any DC voltage source 12 can be used e.g. a battery bank, a photovoltaic array, a fuel cell etc. The N transformers 16 that are part of the inverter 20 are identical, with the primary to secondary winding ratio 1:R. Thus a pulse of V DC on the primary 16 A of any transformer 16 will result in a voltage pulse of R*V DC on the secondary winding 16 B of the transformer 16 .
In applying the PSCPWM technique to the step wave inverter 20 , the sine-triangle modulation and the generation of gating signals for the power transistors is the same as the cascaded inverter. As mentioned previously, the 3-level asymmetrical regular sampled PWM provides good harmonic performance for implementing PSCPWM.
A sketch of the resulting inverter voltage before any filtering is performed is shown in FIG. 6 . As with the cascaded inverter, the inverter voltage comprises of 2N+1 levels. A comparison of FIG. 5 and FIG. 6 shows that there is a difference in the magnitude of each level. For the step wave inverter the presence of transformers results in each level being of the magnitude R*V DC .
For cascaded inverter 10 ( FIG. 1 ) operating with a modulation index M the expression for the RMS value of the fundamental component of the output voltage has been given in Eq. 3. Following the discussion above, for a step wave inverter 20 operating with a modulation index M the expression for the RMS value of the fundamental component of the output voltage is given by:
V
op
,
SW
-
RMS
=
N
*
M
*
V
DC
*
R
2
(
5
)
The PSCPWM scheme was tested with a 3-level asymmetrical regular sampling on a prototype single-phase step wave inverter 20 . The prototype was designed for operation with high-density Li-ion battery pack. The AC output 22 of the inverter 20 was 120V, 60 Hz, 2.4 kW continuous output power. The inverter 20 can be designed for 5-level operation i.e. with 2H-bridges and 2 transformers. One implementation used DC and AC operating voltages resulting in transformer voltage ratio of 1:1.43. The carrier frequency was chosen as 4500 Hz, thus yielding a carrier to fundamental ratio of 4500/60=75.
A digital implementation of PSCPWM is carried out as shown in FIG. 7 using a digital signal processor (DSP) 70 . The two reference waveform tables can be stored in on-chip memory as look-up tables. The PWM signals for controlling the switches in the inverter can be generated by encoding the asymmetrically sampled sine-triangle PWM scheme illustrated in FIG. 4 that has already been described above. In FIG. 7 , the PWM signals for Leg a and Leg b for Bridge# 1 are labeled as PWM 1 a and PWM 1 b respectively and the PWM signals for Leg a and Leg b for Bridge# 2 are labeled as PWM 2 a and PWM 2 b respectively. FIG. 7 also shows the block for deadband circuit 61 for generating control signals for switches, and the block for driver circuit 62 for the necessary gate drive.
FIG. 8 shows the load voltage and load current for the 5-level step wave inverter for a non-linear load comprising of 2 computers and a resistive load bank. For stand-alone inverter operation it is expected that the inverter 20 will supply a near-sinusoidal voltage to an AC load. The limits for the different voltage harmonics are specified in IEEE 519-1992 standard.
In order to attain a sine-wave quality and reduce the harmonic content in the output voltage for all stand-alone inverters, some sort of filtering is applied in the output 22 in FIG. 2 . This kind of filtering can be achieved by some combination of inductors and capacitors. FIG. 2 shows a simple LC-filter 80 , 82 comprised of the components L f and C f and a load 84 at the output 22 of the step wave inverter 20 .
The size and values of the filter components 80 and 82 depend upon the magnitude of harmonics present in the output voltage and the level of attenuation desired. A high harmonic content in the output voltage 22 results in large L f and C f . The superior harmonic performance of the PSCPWM scheme results in output voltage that inherently has a low harmonic content. This ensures that the filter components L f and C f are small.
Furthermore, from FIG. 2 , it can be seen that the leakage inductance of the transformers 16 is in series with the filter inductance 82 . If each transformer 16 has an equivalent leakage inductance of L σ referred to the secondary side 16 B of the transformers 16 , then for N transformers 16 the total filter inductance is given by:
L filter =L f +( N*L σ )
Thus, it can be seen that the transformer leakage inductance contributes to the total filter inductance. This can be used to reduce the size of the external inductance, L f . With a proper choice of the filter capacitance, C f , it is possible to eliminate L f . This useful feature is demonstrated on a prototype step wave inverter with PSCPWM. The leakage inductance of each transformer is measured to be 60 μH, giving a total of 120 μH for the 2 transformers 16 . It is found that using only the leakage inductance of the transformers and a 15 μF filter capacitor gives excellent power quality for the output voltage for different kinds of loads. As can be seen in FIG. 6 the load voltage is nearly sinusoidal and meets all the limits for harmonics specified in IEEE 519-1992.
The system described above can use dedicated processor systems, micro controllers, programmable logic devices, or microprocessors that perform some or all of the operations. Some of the operations described above may be implemented in software and other operations may be implemented in hardware.
For the sake of convenience, the operations are described as various interconnected functional blocks or distinct software modules. This is not necessary, however, and there may be cases where these functional blocks or modules are equivalently aggregated into a single logic device, program or operation with unclear boundaries. In any event, the functional blocks and software modules or features of the flexible interface can be implemented by themselves, or in combination with other operations in either hardware or software.
Having described and illustrated the principles of the invention in a preferred embodiment thereof, it should be apparent that the invention may be modified in arrangement and detail without departing from such principles. I claim all modifications and variation coming within the spirit and scope of the following claims. | A step wave power converter includes a plurality of transformers each configured to receive a Direct Current (DC) voltage from one or more independently generated power sources. Each transformer comprising a primary winding and a secondary winding. A plurality of bridge circuits control different DC voltage inputs from one of the multiple independently generated power sources into the primary windings. One or more processors are configured to use a Phase-Shifted Carrier Pulse Width Modulation (PSCPWM) scheme to operate the bridge circuits in order to produce steps for a step wave Alternating Current (AC) output from the secondary windings. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application is the US National Stage of International Application No. PCT/EP2004/002670, filed Mar. 15, 2004 and claims the benefit thereof. The International Application claims the benefits of German Patent applications No. 10319330.8 DE filed Apr. 29, 2003, all of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The invention relates to a system for influencing the induction gas temperature and thereby the energy level in the combustion chamber of an internal combustion engine, especially of an HCCI-enabled internal combustion engine with a compression device for compressing induced fresh air, which before compression has a temperature T 1 , as well as expansion means which cause the compressed induced fresh air to expand, with the compressed and subsequently expanded fresh air having a temperature T 2 >T 1 .
The invention further relates to a method for influencing the induction gas temperature and thereby the energy level in the combustion chamber of an internal combustion engine, especially of a HCCI-enabled internal combustion engine, in which induced fresh air, which before the compression has a temperature T 1 , is compressed, and the compressed, induced fresh air is expanded, where the compressed and subsequently expanded fresh air has a temperature T 2 >T 1 .
BACKGROUND OF THE INVENTION
Different operating conditions are known in conjunction with direct petrol injection systems. The common factor is that fuel is injected under high pressure directly into a combustion chamber. The mixture is then formed within the combustion chamber. Conventionally a distinction is made between the homogeneous and lean operating modes. In homogenous operation a mixture is present which is distributed homogeneously over the entire combustion chamber. In stratified or lean injection operation there is only a mixture with a excess air in factor the area of the spark plug λ≦1. The remaining volume of the combustion chamber is filled with induced fresh air, an inert gas from the exhaust gas recirculation or a very lean fuel-air mixture, so that overall an excess air factor of λ≦1 is produced.
In addition to these conventional operating modes, a further operating mode is increasingly being seen as promising, which is similar to the operation of the self-ignition diesel engine. This is known as HCCI (Homogeneous Charge Compression Ignition) operation and represents an auto-ignition combustion process, in which the time of ignition and thereby the sequence of combustion is controlled via the reactive quantity of energy in the cylinder. To provide a sufficient energy level use is usually made of exhaust gas recirculation via external setting means within the framework of exhaust gas recirculation or by a suitable gas exchange valve control within the framework of an internal exhaust gas recirculation.
For setting of the temperature level and thereby the energy level in the combustion chamber via the exhaust gas recirculation rate however it is necessary to take into account that this can only take place within specific limits. Since the exhaust gas recirculation rate influences not only the temperature level in the combustion chamber but also the mixture ratio of air, fuel and exhaust gas, it is under some circumstances not possible to select an exhaust gas recirculation rate which is optimum both with regard to the temperature in the combustion chamber and with regard to the said air-fuel mixture ratio. Thus compromises can be necessary when setting the exhaust gas recirculation rate to ensure reliable operation of the internal combustion engine.
In the context of conventionally ignited internal combustion engines it has already been proposed that a cooled exhaust gas recirculation be used, whereby this cooling of the exhaust gas is aimed especially at reducing the nitric oxide emissions. In this context reference is made for example to the German periodical MTZ Motortechnische Zeitschrift 60 (1999) 7/8, page 470 ff.: “Einhaltung zukünftiger Emissionsvorschriften durch gekühlte Abgasrückführung” (complying with future emission regulations using cooled exhaust gas recirculation) by Karl-Heinrich Losing and Rainer Lutz.
SUMMARY OF THE INVENTION
The object of the invention is to overcome the disadvantages of the prior art and especially to provide a system and a method through which setting the temperature in the combustion chamber of the internal combustion engine can be decoupled at least partly from the setting of the optimum mixture ratio of air, fuel and exhaust gas.
This object is achieved with the features of the independent claims.
Advantageous embodiments of the invention are specified in the dependent claims.
The invention builds on the generic system in that the temperature increase of the fresh air from T 1 to T 2 is explicitly used to influence the temperature level and thereby the energy level in the combustion chamber. In this way very fine variations and settings of the energy level in the combustion chamber can be achieved by increasing the temperature or by regulating the air/fuel temperature. In this way the combustion process in the HCCI mode can be precisely controlled. The temperature level in the combustion chamber can in this case be influenced via the level of compression and the subsequent expansion.
The inventive system is developed in a particularly useful way in that an exhaust gas recirculation device to feed in exhaust gas from a previous combustion cycle to fresh air or to a mixture featuring fresh air is provided so as to supply, after the injection of fuel, an air/fuel/exhaust gas mixture with an energy level advantageous for combustion. As well as influencing the temperature level through compression and expansion the exhaust gas recirculation and in this case especially the exhaust gas recirculation rate can also be explicitly used to adjust the energy level in the combustion chamber.
The inventive system can then be used to particularly good effect if the compression device is an exhaust gas turbocharger. This is a frequently used device for increasing the gas density in the induction system, so that in the combustion chamber an increased volume or air can be provided which results in an increase in performance of the internal combustion engine. The compression device is driven by a turbine located in the exhaust gas stream.
The system can also be used to good effect when the compression device is a compressor. This is also used to compress the gas pressure in the induction system, with the drive energy being supplied mechanically by the internal combustion engine. As an alternative the compressor can also be driven by means of electrical energy.
There is useful provision for the compression to be undertaken on a throttle valve. With direct injection systems the throttle valve is used for dosed feeding of fresh air, with the throttle effect causing a reduction in pressure. Finally the air compressed in the exhaust gas turbocharger or the compressor and expanded on the throttle valve has, in accordance with the basic laws of thermodynamics, a higher temperature than the originally induced fresh air.
The invention is developed in a particularly advantageous way in that a temperature sensor to record the temperature T 2 in the direction of flow of the fresh gas is disposed downstream from the expansion means so that this can be taken into account within the framework of a regulation of the induction gas temperature. The temperature of the fresh air downstream from the throttle valve is thus an important input variable in finally advantageously defining the energy level in the combustion chamber for the HCCI operating mode.
In conjunction with a system equipped with exhaust gas recirculation it proves to be especially useful for at least one heat exchanger operating as an exhaust gas cooler for lowering the temperature of the recirculated exhaust gas to be provided and for a cooling means setting valve to be provided so that by influencing the cooling means throughflow through the exhaust gas cooler, taking into account measured values or values determined from a technical model, the induction gas temperature can be set or regulated respectively. The recirculated exhaust gas volume is thus no longer compulsorily coupled to the temperature increase in the combustion chamber achieved by exhaust gas recirculation. Instead the energy content in the combustion chamber can be adjusted within certain limits independently of the exhaust gas recirculation rate via the adjustable exhaust gas cooling. Thus both the mixture ratio and the energy level in the combustion chamber can be set to their optimum values.
The inventive system is advantageously further developed by the exhaust gas cooler being arranged in a separate heat exchanger circuit. The heat exchanger cooler can thus operate autonomously without being influenced by other components of the motor vehicle. Likewise other components of the cooling system of the vehicle are not influenced by the exhaust gas cooler. The autonomous cooling circuit then comprises a separate cooler and a separate coolant pump.
It can however also be useful for the exhaust gas cooler to be arranged in the engine coolant circuit. In this way components of the engine coolant circuit can be used for exhaust gas cooling, so that overall an efficient system is implemented.
Similarly there can be provision for the exhaust gas cooler to be disposed as an engine oil or transmission oil heat exchanger respectively. Existing components of the vehicle can also be used by this.
The invention is developed in a particularly advantageous way by the process values or the values determined using a technical model being assigned to at least one of the following variables:
Exhaust gas temperature, Recirculated exhaust gas mass or quantity respectively, Air/fuel temperature, Air/fuel mass or quantity respectively, Induction gas temperature, Induction gas mass or quantity respectively, Coolant temperature or oil temperature of the coolant or oil flowing through the exhaust gas cooler and Coolant mass or oil mass or coolant quantity or oil quality of the coolant flowing through the exhaust gas cooler.
If the term “quantity” is used below, this can also mean a “mass” and vice versa. The current exhaust gas temperature and the recirculated exhaust gas quantity are known in modern engine controls as engine operation variables. They can either be calculated on the basis of technical models or measured directly via corresponding sensors. The same applies to the air/fuel quality and the air/fuel temperature. The coolant temperatures and the oil temperatures are also known. If the quantity of coolant or quantity of oil respectively flowing through the exhaust gas heat exchanger are further known, with a knowledge of the heat exchanger characteristics the exhaust gas temperature at the heat exchanger outlet and thereby the mixture temperature of the induction air can be determined.
It has proved especially useful for a temperature sensor to record the air/fuel temperature, a temperature sensor to record the exhaust gas temperature at the engine exhaust, an air mass or quantity measurement device respectively to record the air/fuel mass or quantity and an exhaust gas mass or quantity measuring device to record the exhaust gas mass or quantity to be provided. From these variables, with a knowledge of specific models or specific characteristics respectively the significant variables for reliable regulation of the induction gas temperature can be determined.
Thus the system is usefully further developed by the induction gas temperature being calculated in accordance with the equation
T ASG ={dot over (m)} FG C p,FG +{dot over (m)} AG C p,AG
with
{dot over (m)} FG : Air/fuel mass flow {dot over (m)} AG Exhaust gas mass flow T FG : Air/fuel temperature T AG : Exhaust gas temperature T ASG Induction gas temperature c p,FG : Heat capacity of the air/fuel mixture C p,AG : Heat capacity of the exhaust gas.
The induction gas temperature can thus be determined with a knowledge of measured, known variables or also variables calculated from technical models.
In this connection it is useful for the exhaust gas temperature at the heat exchanger output to be calculated using the following equation system:
|Δ{dot over (Q)} KM |=|Δ{dot over (Q)} AG |={dot over (Q)} WT
Δ{dot over (Q)} KM ={dot over (m)} KM C p,KM ( T KM,OUT −T KM,IN )
Δ{dot over (Q)} AG ={dot over (m)} AG C p,AG ( T AG,IN −T AG,OUT )
{dot over (Q)} WT =kAΔT m
with
{dot over (Q)}: Heat flow
KM: Coolant AG: Exhaust gas WT: Heat exchanger C p : Heat capacity k: Heat transfer coefficient of the heat exchanger A: Heating surface of the heat exchanger ΔT m Mean logarithmic temperature difference.
From the knowledge of the characteristics of the heat exchanger, meaning especially in the knowledge of the parameters k and A, taking into account the mean logarithmic temperature difference ΔT m , the heat flow {dot over (Q)} WT present in the heat exchanger can be calculated. From this, in the knowledge of mass flows, heat capacities and further temperatures, the exhaust gas temperature at the heat exchanger output T AG,OUT is produced.
The invention builds on the generic method in that the temperature increase of the fresh air from T 1 to T 2 is explicitly used to influence the temperature level and thereby the energy level in the combustion chamber. In this way the advantages and special features of the inventive system are also implemented within the framework of a method. This also applies to the especially preferred embodiments of the inventive method specified hereafter.
The method is further developed in an especially advantageous manner by exhaust gas from an earlier combustion cycle being fed into fresh air or into a mixture featuring fresh air respectively, in order to provide, after fuel has been injected, an air/fuel/exhaust gas mixture with an energy level advantageous for combustion.
The method stands out as being particularly advantageous if the compression is performed by an exhaust gas turbocharger.
Equally the method is useful if the compression is performed by a compressor.
Usefully there is furthermore provision for the expansion to be performed on a throttle valve.
The method is further developed in an especially advantageous manner by the temperature T 2 being recorded after the expansion, so that this can then be taken into account within the framework of regulating the induction gas temperature.
In an especially preferred embodiment of the inventive method there is provision for exhaust gas to be cooled in a heat exchanger operating as an exhaust gas cooler to lower the temperature of the recirculated exhaust gas for the induction gas temperature to bet set or regulated through influencing of the coolant throughflow through the exhaust gas cooler by means of a coolant setting valve, taking into account measured values or values determined from technical models.
It is especially advantageous for the process values or the values determined from technical models to be assigned to at least one of the following variables:
Exhaust gas temperature, Recirculated exhaust gas mass or quantity respectively, Air/fuel temperature, Air/fuel mass or quantity respectively, Induction gas temperature, Induction gas mass or quantity respectively, Coolant temperature or oil temperature of the coolant or oil flowing through the exhaust gas cooler and Coolant mass or oil mass or coolant quantity or oil quantity of the coolant or oil respectively flowing through the exhaust gas cooler.
It has proved to be especially useful for the air/fuel temperature, the exhaust gas temperature at the engine outlet, the air/fuel mass or quantity respectively and the exhaust gas mass or quantity respectively to be measured.
The method is further developed in a useful manner by the induction gas temperature being calculated according to the equation
T ASG ={dot over (m)} FG C p,FG +{dot over (m)} AG C p,AG
with
{dot over (m)} FG : Air/fuel mass flow {dot over (m)} AG Exhaust gas mass flow T FG : Air/fuel temperature T AG : Exhaust gas temperature T ASG Induction gas temperature c p,FG : Heat capacity of the air/fuel mixture C p,AG : Heat capacity of the exhaust gas.
In this connection it is useful for the exhaust gas temperature at the heat exchanger output to be calculated using the following equation system:
|Δ{dot over (Q)} KM |=|Δ{dot over (Q)} AG |={dot over (Q)} WT
Δ{dot over (Q)} KM ={dot over (m)} KM C p,KM ( T KM,OUT −T KM,IN )
Δ{dot over (Q)} AG ={dot over (m)} AG C p,AG ( T AG,IN −T AG,OUT )
{dot over (Q)} WT =kAΔT m
with
{dot over (Q)}: Heat flow KM: Coolant AG: Exhaust gas WT: Heat exchanger C p : Heat capacity k: Heat transfer coefficient of the heat exchanger A: Heating surface of the heat exchanger ΔT m Mean logarithmic temperature difference.
The invention is based on the knowledge that, by explicitly influencing or explicitly taking into account the air/fuel temperature, very fine and precise control can be exerted on the energy level in the combustion chamber of the internal combustion engine. As well as the principle of exhaust gas recirculation, this makes a further available a further independent instrument for influencing the temperature level and thereby for combustion process control. The invention in particular offers the advantage that, starting from cold-start conditions, under which HCCI operation is not possible because the temperature level is too low, the air/fuel mixture is heated up and thus an earlier switchover into the lower-emission HCCI mode is possible. In an especially preferred embodiment it is especially useful that the controlled setting of the exhaust gas temperature by means of exhaust gas cooling, in addition to the exhaust gas recirculation rate and the principle of compression and expansion, makes available a further independent adjustment variable to influence the temperature level and thereby the energy level in the combustion chamber and thereby an additional means of controlling the combustion process. The influence of the process is exerted in respect of the ignition point of the compressed air/fuel/exhaust gas mixture and the resulting variables produced from it, such as pressure curve and combustion, peak pressure, 50% mass fraction burnt point and speed of combustion. These variables in their turn are decisively responsible for the overall engine behavior in respect of its efficiency, emissions, ride disturbance and acoustics. The invention ties in with the fact that in modern engine management systems all the relevant information and operating variables, for example temperatures and masses of materials or quantities, which are needed for control of the HCCI combustion process by means of exhaust gas temperature regulation are already available. The invention can also be effectively used to allow for changed environmental or operating conditions in combustion engines, as for example is the case for engine hot running or in summer/winter mode at greatly differing ambient temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now explained with reference to the accompanying drawings on the basis of preferred embodiments.
The figures show:
FIG. 1 a temperature-entropy diagram to explain the basic thermodynamic principles in a preferred embodiment of the present invention;
FIG. 2 a schematic diagram of a preferred embodiment of an inventive system;
FIG. 3 a schematic diagram of an inventive system; and
FIG. 4 a functional block diagram to explain the induction gas temperature regulation within the context of a method in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a temperature-entropy diagram to explain the basic thermodynamic principles of a preferred embodiment of the present invention. The diagram shows the temperature-entropy graphs in a gas for two different pressures p 1 and p 2 . If a gas is compressed, starting from a pressure p 1 and temperature T 1 , to the pressure p 2 , this process does not run along an isentrope (process 1 - 2 s ), but under entropy increase (process 1 - 2 ). If an expansion occurs after the compression, meaning that the pressure falls, this does not occur along an isentrope (process 2 - 3 s ), but likewise under an increase of entropy (process 2 - 3 ). The processes for increasing pressure from p 1 to p 2 shown here and the subsequent expansion to the output level p 1 represent a special case. An expansion to any other pressure level also occurs under an increase in entropy. Finally the gas, after compression from of p 1 to p 2 and expansion from p 2 to p 1 , has a higher temperature level than before the compression; The temperature has increased from T 1 to T 3 . The desired temperature change can thus be set for an internal combustion engine via the degree of compression and the subsequent expansion, for example on the throttle valve.
FIG. 2 shows a schematic diagram of a preferred embodiment of an inventive system. It shows an internal combustion engine 10 with an exhaust gas recirculation device 14 and exhaust gas turbocharger 16 . A throttle valve 18 is arranged in the inlet of the internal combustion engine 10 . The exhaust train of the internal combustion engine 10 is equipped with an exhaust gas cooler 32 . The particular features of the exhaust gas cooler 32 are not entered into within the context of the present diagram shown in FIG. 2 . An exhaust gas recirculation valve 36 is provided in the exhaust gas recirculation system 14 . The system further comprises at different points measuring devices or sensors 20 , 22 , 24 , 26 , 28 , 30 respectively, of which the output signals can be fed to a control/computation unit 34 . In detail the following are provided: An air mass measurement device 28 , a temperature sensor 20 , which is arranged in the direction of flow of the fresh air current upstream from the throttle valve 18 to record the fresh air temperature, a temperature sensor 22 to record the temperature of the induction gas before it flows into the combustion chamber 12 of the internal combustion engine 10 , an exhaust gas temperature sensor 24 as well as a temperature sensor 26 for recording the temperature at the air/exhaust gas mixture point. These sensors do not absolutely have to be present to implement the present invention. For example the temperature sensor 26 can be left out if the induction gas temperature is determined in accordance with the calculations explained in conjunction with FIG. 3 . Output signals of these measuring devices and sensors 20 , 22 , 24 , 26 , 28 can be fed to the control/regulation/computation device, which in its turn can activate components of the system, such as for example the exhaust gas recirculation valve 36 , the exhaust gas cooler 32 , the throttle valve 18 and the exhaust gas turbocharger 16 . The function of these components can thus be influenced and in the final analysis can contribute to the desired energy level in the combustion chamber 12 of the internal combustion engine 10 .
The system shown in FIG. 2 operates as follows. Fresh air is sucked in and compressed by the exhaust gas turbocharger 16 which is driven by the exhaust gas flow. This compressed air must pass the throttle valve 18 so that it comes to be expanded. On the basis of the thermodynamic principles shown in conjunction with FIG. 1 the air behind the throttle valve 18 has a higher temperature than the originally induced fresh air. The air reaches the combustion chamber 12 of the internal combustion engine 10 . After combustion the exhaust gas is expelled, to be cooled in an exhaust gas cooler 32 . Part of the cooled exhaust gas is emitted via the exhaust train. Part of the cooled exhaust gas 32 is recirculated via exhaust gas recirculation system 14 and especially the exhaust gas recirculation valve 36 to the inlet side of the internal combustion engine 10 . On the basis of the signal recorded in the measuring devices and sensors 20 , 22 , 24 , 26 , 28 the control/regulation/computation unit 34 can influence the system so that in the final analysis the energy level suitable for the HCCI operation is available in the combustion chamber 12 of the internal combustion engine 10 . A significant part of the exhaust gas temperature regulation is described in conjunction with FIG. 4 .
FIG. 3 shows a schematic diagram of an inventive system, with the especially preferred embodiment with exhaust gas cooler being specifically examined here. An internal combustion engine 10 with an external exhaust gas recirculation device 14 is shown. The exhaust gas recirculation device 14 comprises an exhaust gas recirculation valve 36 via which the exhaust gas recirculation rate can be set. The exhaust gas recirculation device 14 further comprises a heat exchanger 32 operating as an exhaust gas cooler. Furthermore a coolant flows through the exhaust gas heat exchanger 32 via a coolant system 46 . A cooler 48 is provided to cool the coolant. In the present example the exhaust gas heat exchanger circuit is arranged as a parallel circuit. However numerous other exhaust gas cooler variants are conceivable, in which case the cooler 48 can be arranged as a separate cooler; It is also conceivable to use the cooler for engine cooling as well. Cooling can also be performed by the engine or transmission oil.
The coolant system 46 furthermore includes a coolant setting valve 50 , via which the coolant quantity which flows through the exhaust gas cooler 32 can be set.
The system shown operates as follows. Exhaust gas emerging from the internal combustion engine 10 is partly recirculated via the exhaust gas recirculation device 14 to the inlet side of the internal combustion engine 10 . In this case the exhaust gas mass flow m AG can be set by means of the exhaust gas recirculation valve 36 . At the input of the exhaust gas cooler 32 the exhaust gas has a temperature T AG,IN , and at the output of the exhaust gas cooler 32 the exhaust gas has a temperature T AG,OUT , which is generally less than the temperature at the input. The cooling effect of the exhaust gas cooler 32 can be set by setting the coolant mass flow m KM via the coolant setting valve 50 . At the input of the exhaust gas cooler 32 the temperature has the temperature T KM,IN and at the output of the exhaust gas cooler 32 the temperature T KM,OUT , with the latter generally being higher than the temperature at the input. The coolant is then cooled in the cooler 48 . The influencing of the throughflow of coolant through the exhaust gas cooler 32 by the coolant setting valve 50 can thus, taking into account measured values or values determined on the basis of technical models, be used to either set or regulate the induction gas temperature of exhaust gas flowing into the internal combustion engine 10 .
The exhaust gas temperature T AG,OUT at the output of the exhaust gas cooler 32 can in this case for example be calculated using the following equation system:
|Δ{dot over (Q)} KM |=|Δ{dot over (Q)} AG |={dot over (Q)} WT
Δ{dot over (Q)} KM ={dot over (m)} KM C p,KM ( T KM,OUT −T KM,IN )
Δ{dot over (Q)} AG ={dot over (m)} AG C p,AG ( T AG,IN −T AG,OUT )
{dot over (Q)} WT =kAΔT m
with
{dot over (Q)}: Heat flow KM: Coolant AG: Exhaust gas WT: Heat exchanger C p : Heat capacity k: Heat transfer coefficient of the heat exchanger A: Heating surface of the heat exchanger ΔT m : Mean logarithmic temperature difference.
The temperature of the induction gas, referred to hereafter as TASG, can then be determined in accordance with the following equation:
T ASG ={dot over (m)} FG C p,FG +{dot over (m)} AG C p,AG
with
{dot over (m)} FG : Air/fuel mass flow {dot over (m)} AG : Exhaust gas mass flow T FG : Air/fuel temperature T AG : Exhaust gas temperature T ASG : Induction gas temperature c p,FG : Heat capacity of the air/fuel mixture C p,AG : Heat capacity of the exhaust gas.
FIG. 4 shows a functional block diagram to explain the induction gas temperature regulation within the context of a method in accordance with the invention. The functional units shown can be components of the control/regulation/computation device shown in FIG. 1 . The device 38 is provided for calculating the required exhaust gas temperature. This is connected to a device 40 for calculating the coolant throughflow of the exhaust gas cooler 32 shown in FIG. 1 . The device 40 to calculate the coolant throughflow is in its turn connected over a regulation path 42 to a controller 44 . Furthermore signals are shown in FIG. 2 , with signals ending with the letters AV identifying actual values, whereas signals ending with the letters SP identify setpoint values.
The induction gas temperature regulation in accordance with FIG. 4 operates as follows. In accordance with engine operating conditions a setpoint value for the temperature of the induced air in the induction manifold (TIA_IM_SP) is specified. This is fed, together with the actual air/fuel temperature (TIA_AV) and the mass of the air/fuel fed in (MAF_KGH_AV) as well as the recycled exhaust gas (M_EGR_AV) to device 38 to calculate the required exhaust temperature. Taking into account the specific heat capacities of the fresh air (C p, air ) fed in and of the exhaust gas (c p, exhaust gas ) this device calculates the exhaust gas temperature at the mixing point (T_EGR_DOWN_SP) which is required to obtain the desired induction gas temperature in the inlet manifold. In the device 40 for calculating the coolant throughflow the setpoint value determined by the device 38 for calculating the required exhaust gas temperature (T_EGR_DOWN_SP) is compared to the actual exhaust gas temperature at the engine outlet (T_EGR_UP_AV) before the exhaust gas cooler. From the difference a coolant throughflow (M_COOL) through the exhaust gas cooler is determined which is required to obtain the desired exhaust gas temperature at the mixing point (T_EGR_DOWN_SP). This coolant flow is then implemented by a corresponding activation of an electrical coolant pump, with other types of throughflow regulation being just as easily possible. The coolant throughflow is converted in accordance with the control specified here via the regulation path 42 into a specific induction gas temperature in the inlet manifold (TIA_IM_AV) with this being present after an initial settling-down phase. This induction gas temperature in the inlet manifold (TIA_IM AV) is compared with the setpoint value (TIA_IM_SP) in the controller 44 . If the values differ from each other, the coolant throughflow through the exhaust gas cooler is corrected by a value (AM_COOL), so that finally via a suitable exhaust gas temperature at the mixing point (T_EGR_DOWN_AV) the desired induction air temperature (TIA_IM_SP) is set in accordance with the setpoint.
To place the regulation explained in conjunction with FIG. 4 into a better context with the system shown in FIG. 2 shown, details are given below of where the values used for the regulation are to be measured or set respectively. The air mass measurement device 28 determines the value MAF_KGH_AV. The recirculated exhaust gas component M_EGR_AV is known in the context of the exhaust gas recirculation through corresponding activation of the exhaust gas recirculation valve 36 . The air/fuel temperature TIA_AV is measured by the temperature sensor 20 beyond the throttle valve 18 . The induction gas temperature TIA_IM_AV is recorded by the temperature sensor 22 before it enters the combustion chamber 12 of the internal combustion engine 10 . The temperature sensor 24 at the outlet from the combustion chamber 12 of the internal combustion engine 10 records the exhaust gas temperature T_EGR_UP_AV. In additional the temperature TIA_EGR_DOWN_AV at the mixing point can be recorded by the temperature sensor 26 , in which case this is however not absolutely necessary for the regulation described in conjunction with FIG. 4 .
Thus the invention can be summarized as follows: With a HCCI-enabled internal combustion engine, which is preferably equipped with an exhaust gas recirculation device 14 , a system and a method is proposed on the basis of which the setting of the temperature level in the combustion chamber can be improved. As well as setting the temperature via the exhaust gas recirculation device 14 the temperature is influenced independently of this as a result of the compression of the induced fresh air by the exhaust gas turbocharger 16 , with, even after the expansion of the compressed air on a throttle valve 18 , a temperature increase being retained, which in the final analysis can be used to influence the energy content of the combustion chamber 12 .
The features of the invention disclosed in this description, in the drawings and in the claims, can be of importance both individually and in any combination for implementing the invention. | The invention relates to a system and method for use in a homogeneous charge compression ignition (HCCI) combustion engine that is preferably equipped with an exhaust gas recirculation device. This system and method enable an improved adjustment of the temperature level inside the combustion chamber. In addition to adjusting the temperature by using the exhaust gas recirculation device, an influencing of the temperature, which is independent thereof, ensues based on the compression of the induced fresh air by the exhaust gas turbocharger. An increase in temperature is maintained even after the compressed air is expanded on a throttle valve, and this increase in temperature can, in the end, be used for influencing the energy content inside the combustion chamber. | 5 |
TECHNICAL FIELD
The invention relates to the employment of at least one oxygen-fuel burner in a particular manner in cross-fired regenerative furnaces to improve the efficiency of the glass melting, thereby increasing the glass production rate.
BACKGROUND OF THE INVENTION
Cross-fired regenerative furnaces have been commonly employed to manufacture glass. A typical cross-fired regenerative furnace has a melting chamber in which glass forming ingredients such as silica, boric oxide and other additives including stabilizers and fluxes, are heated by air-fuel burners which are placed along the lateral sides of the melting chamber. By combusting fuel in the presence of preheated air from a regenerator, the air-fuel burners provide heat to the atmosphere and walls of the melting chamber, which, in turn, heat the glass forming ingredients in the melting chamber by convection and radiation. Although the thermal efficiency of this heating process is relatively high, the glass production rate may decrease with time because of decreasing regenerator performance and increasing wall losses. The performance of the regenerator, for example, may be deteriorated when the regenerator is partially plugged or partially destroyed due to the presence of chemical contaminants in the resulting combustion gases which pass through the regenerator.
An oxygen enrichment technique has been proposed for increasing the melting capacity of a cross-fired regenerative furnace. The technique involves introducing oxygen in an area of the furnace where a fuel is being combusted in the presence of air. This technique, however, has a number of disadvantages. First, the addition of oxygen has no concentrated effect on a specific area, such as the batchline or in the vicinity thereof, where a high temperature condition is needed to melt floating solid glass batch. The consumption of oxygen is, therefore, high for a low glass production increase. Second, the air flames, which are at a high temperature due to the presence of oxygen, radiate more heat to the roof of the melting chamber. When the roof is subject to such a condition for a long period, its useful life could be reduced.
The use of oxygen-fuel auxiliary burners in a number of glass making furnaces has also been proposed. For instance, oxygen-fuel auxiliary burners have been employed on the sides of a rectangular melting chamber of a conventional U-shape flame regenerator furnace to assist the melting process. However, oxygen-fuel auxiliary burners have not been employed successfully in a cross-fired regenerative furnace. The major factor which is hindering their use in a cross-fired regenerative furnace is the difficult and restricted access to the furnace melting space. This access normally consists of a small (1 m wide) corridor between the regenerators and the melting furnace, not allowing the conventional installation of oxygen-fuel auxiliary burners.
It is, therefore, an advantage of the present invention in installing oxygen-fuel auxiliary burners in a cross-fired regenerative furnace in such a manner to accommodate the restraints imposed by the regenerators.
It is another advantage of the invention in installing oxygen-fuel auxiliary burners in a cross-fired regenerative furnace without drilling any holes in the refractory lining of the furnace.
It is yet another advantage of the invention in maintaining a particular glass production rate even when the regenerators of the furnace are partially plugged or destroyed, or are being repaired.
It is an additional advantage of the invention in increasing the glass production rate without consuming excessive amounts of oxygen and fuel and without overheating the roof of the furnace.
It is a further advantage of the invention in being able to employ non water-cooled oxygen-fuel auxiliary burners.
SUMMARY OF THE INVENTION
According to the present invention, the above advantages and other advantages apparent to those skilled in the art are obtained in a cross-fired regenerative furnace having at least two regenerators which communicate with a melting chamber through a plurality of ports along the lateral sides of the melting chamber having a bottom, a roof, side-walls, glass forming ingredients inlet means and molten glass outlet means, wherein glass forming ingredients and the resulting melt in the melting chamber are heated with burners placed under or adjacent to some or all of said plurality of ports, said burners comprising air-fuel burners and at least one oxygen fuel auxiliary burner positioned to heat a specific area in the melting chamber without substantially disrupting the flame momentum of said air-fuel burners. The flame momentum of the air-fuel burners, for example, is not disrupted when at least one oxygen-fuel auxiliary burner placed under or adjacent to the ports fires its flame toward the same direction as the air-fuel burners, substantially parallel to the air flames, following the firing sequence of the air-burners.
At least one oxygen-fuel auxiliary burner generally comprises a tube coaxially placed within a cylindrical pipe. The first ends of said tube and pipe terminate in a nozzle tip while the second ends of said tube and pipe are connected to and are in communication with a fuel providing means and an oxygen providing means, respectively. The oxygen-fuel auxiliary burner may be bent or angled to direct its flame toward a specific area in the melting chamber, such as the batchline.
The modified refractory block and oxygen fuel auxiliary burner are preferably placed under the port or in the vicinity of a port which is close to batchline. The number of modified refractory blocks employed corresponds to the number of oxygen fuel auxiliary burner employed. The number of oxygen fuel employed may be such that the furnace could be operated entirely with oxygen-fuel burners.
As used herein, the term "the batchline" means the interface of the solid, unmelted glass forming ingredients and the molten glass in the melting chamber.
As used herein, the term "flame momentum" means the direction, movement or pattern of a flame flow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a lateral cross-sectional view of one embodiment of the cross-fired regenerative furnace of the present invention.
FIG. 2 is a plan view of one embodiment of a cross-fired regenerative furnace of the present invention showing right side ports during their firing cycle and left side ports during their exhaust or off-firing cycle.
FIG. 3 is a cross-sectional view of a conventional refractory block for the air-fuel lance.
FIG. 4 is a cross-sectional view of a modified refractory block for the oxygen-fuel auxiliary burner useful in the practice of this invention.
FIG. 5 is a cross-sectional view of one embodiment of a modified refractory block with the oxygen-fuel burner inserted therein.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to the use of oxygen-fuel auxiliary burners with a cross-fired regenerative glass making furnace to provide heat more efficiently to melt batch raw glass forming ingredients. The invention further comprises employing at least one modified refractory block which can enhance the operation of auxiliary oxygen-fuel burners.
Referring to FIGS. 1 and 2, a cross-fired regenerative furnace (1) having a melting chamber (2) flanked by a pair of regenerators (3 and 4) is illustrated in cross-sectional and plan views. Each regenerator (3 and 4) includes a refractory housing (5) containing refractory materials (6) stacked in a checkerboard fashion that permits the alternate passage of air and exhaust gas. Each regenerator (3 and 4) communicates with the melting chamber (2) via a plurality of air ports (7 and 8). Under the ports or in the side-walls adjacent to the ports, at least one air-fuel refractory block (9) and at least one modified refractory block (18) are located. While at least one fuel lance (9a) is placed within at least one air-fuel refractory block (9), at least one auxiliary oxygen-fuel burner is recessed within at least one passageway of at least one modified refractory block (18).
The melting chamber (2), which is in communication with said plurality of ports (7 and 8) and refractory blocks (9 and 18), has a refractory bottom (10), a refractory roof (11), refractory side-walls (12), refractory exit area (13) and a refractory back-wall (14). Glass forming ingredients are fed to this melting chamber (2) from an inlet means (15). The glass forming ingredients are melted with burners located within the ports and then exit through the exit area (13).
The glass forming ingredients are a mixture of high temperature melting raw materials used in the manufacture of glass. The mixture make-up is dependent on the type of glass being produced. Normally, the mixture comprises, inter alia, silica containing materials including scrap glass referred to as cullet. Other glass making raw materials including feldspar, limestone, dolomite, soda ash, potash, borax and alumina may be used. To alter the properties of the glass, a minor amount of arsenic, antimony, sulfates and/or fluorides needs to be added. Moreover, color forming mental oxides can be added to obtain the desired color.
The interior of the melting chamber (2) is heated in part by the combustion of fuel in the presence of preheated air. Various fuels, including gaseous fuels, liquid fuel and powdered fuels may be introduce via at least one fuel lance which is placed in a converging-diverging shape passageway of at least one refractory block (9) as shown in FIG. 3. During an initial combustion cycle, air passes from the left regenerator (3) through a plurality of ports (7) and enters into the melting chamber (2) while the combustion products (gases) are removed through a plurality of ports (8) into the right regenerator (4) where heat is recovered from the combustion products via the refractory checker (6) located in the regenerator (4). In the next combustion cycle, the operation is reversed, with air passing from the right regenerator (4) through a plurality of the ports (8) into the melting chamber (2) and with the combustion product exhausting through a plurality of ports (7) into the left regenerator (3) where heat is recovered by means of the refractory checkers (6) located in the regenerator (3). The air is preheated as it passes through heated refractory checkers (6). The flow of air (the direction of combustion) is periodically reversed, for example, each 30 minutes, in the above manner by using, for example, valves (not shown).
The interior of the melting chamber (2) is also preferably heated in part by at least one oxygen-fuel auxiliary burner (20). The oxygen/fuel auxiliary burners (20) located under or adjacent to a plurality of ports (7 and 8) fire alternately, parallel to the air-flames, following the firing sequence of the air-fuel burners located under or adjacent to the ports (7 and 8). When, for example, the air-fuel burners on the left side fires, at least one oxygen/fuel burner (20) on the same side fires. Meanwhile, all burners (air plus oxygen) located on the right port side are shut down. This firing technique, in addition to a specific placement, enables the oxygen-fuel flame to efficiently provide heat without disrupting the momentum of the air-fuel flames, thereby minimizing the amount of fuel employed.
The oxygen-fuel auxiliary burner (20) may also be used as the sole source for heating the interior of the melting chamber. When the air-fuel burners are no longer effective or operational, a sufficient number of oxygen-fuel burners should be employed so that the glass melting rate of a cross-fired regenerative furnace can be maintained. By installing the oxygen-fuel burners in lieu of the existing fuel lance 9(a), a sufficient number of the oxygen-fuel auxiliary burners can be employed. The oxygen-fuel auxiliary burners can also be used similarly as the air-fuel burners since the oxygen-fuel burners are similarly located as the previously operated air-fuel burners. The furnace, therefore, need not be shut down when the regenerators are being repaired to restore the air-fuel burners to their original, operable state.
The temperature of the flame imparted by the oxygen-fuel auxiliary burner is usually dependent on the quality of the fuel and the oxygen-fuel ratio. The oxygen employed may be in the form of oxygen-enriched air having an oxygen concentration of more than 21 percent or preferably at least 50 percent or may be technically pure oxygen having an oxygen concentration of 99.5 percent or more. The temperature of the flame of a auxiliary oxygen-fuel burner is generally at about 2780° C. In some cases, oxygen-burners with lower flame temperatures could also be used.
The oxy-fuel auxiliary burner (20) includes a cylindrical pipe (21) coupled to an oxygen source (not shown) via a coupling means (22). The cylindrical pipe (21) terminates in a nozzle tip (23) from which the oxygen is emitted. A tube (24) is coaxially positioned within the pipe (21). A fuel source (not shown) is coupled to the tube (24) via a coupling means (22) so that the fuel fed to the tube (24) can be emitted from the nozzle tip (23). The coupling means (22) comprises two separate chambers (22-a) and (22-b), which are connected by binding means including a gasket (22-c) and screws (22-d). The chamber (22-a), which is in communication with the pipe (21), is aligned with the chamber (22-b) to form a coupling means (22) having a cylindrical shape. A water jacket (not shown) can be provided to cool or reduce the temperature of the oxygen-fuel auxiliary burner. Both the cylindrical pipe (21) and the tube (24) of the burner could be bent or angled or straight to fit into a modified refractory block (18) having an inclined or straight passageway.
The modified refractory block (18) in FIGS. 2, 4 and 5 may be substantially in the form of a rectangular-like shape or parallel-piped-like shape. Its size and shape, however, generally correspond to the external size and shape of a conventional refractory block for air-fuel burners (such as the one in FIG. 3) so that it can take the place of a conventional refractory block. The modified refractory block usually comprises sides (33 and 34), a face (30), a back (32), a top (31) and a bottom (35). On the bottom portion of the face (30), a passageway (19) is present. The passageway (19) extends from the face (30) to the opposite surface, the back (32), in an obliquely rising manner. The design of the passageway (19) is such that an oxygen-fuel auxiliary burner can be accommodated to direct its flame toward a specific area, such as the batchline. The shape, size and angle of inclination of the passageway are such that the flame of the oxygen-fuel burner is localized to provide heat to burner a specific area where a high temperature condition is needed without touching the refractory wall, thereby minimizing the amount of oxygen and fuel needed in a glass melting process and minimizing refractory wall losses. The passageway may be cylindrically designed.
The following example serves to illustrate the invention. It is presented for illustrative purposes and is not intended to be limiting.
EXAMPLE
A cross-fired regenerative furnace with a capacity of over 170 TPD (tons per day), having only air-fuel burners, was employed in manufacturing bottle glass. Because of decreasing regenerator performance, the glass production rate subsequently decreases. Using 3% O 2 -enrichment, 360 Nm 3 /O 2 /hr, a maximum production increase of 20 TPD was achieved. However, with the further deterioration of the regenerator, the necessary production rate could not be maintained. To this cross-fired regenerative furnace, oxygen-fuel burners were provided to heat without disrupting the momentum of the air flames. In order to accomplish the task, burners and burner blocks, such as are illustrated in FIGS. 4 and 5, were installed in the furnace.
Two conventional oil burner blocks (one on each side of the furnace) were replaced with two new modified blocks as shown in FIGS. 4 and 5. The oxygen-fuel burners, each with a capacity of about 100 Nm 3 natural gas/hr, were then placed into the passages in the modified blocks, which communicate with the melting chamber. The burners were intensively used and inspected several times. After one month, two additional oxygen-fuel burners (one on each side of the furnace), shown in FIG. 5, were installed so that the total firing could reach about 200 Nm 3 natural gas/hr. An increased production rate of 20 TPD was achieved with a gas flow of about 140 Nm 3 /hr and 260 Nm 3 O 2 /hr, using commercially produced oxygen.
Generally, the installation of at least one oxygen-fuel auxiliary burner in a cross-fired regenerative furnace is difficult due to the restraints imposed by the regenerators located on the lateral side of the furnace. The use of at least one oxygen-fuel burner also may not be economical since it may cause a less efficient fuel usage of the air burners and may reduce the life of a furnace by overheating. Moreover, drilling holes into the refractory lining of the furnace to install at least one oxygen-fuel burner may adversely affect the life of the furnace and the life of the installed oxygen-fuel auxiliary burner. These problems are solved by placing at least one modified block, in lieu of at least one conventional air-fuel block existing in the furnace, to accommodate a particularly designed oxygen-fuel auxiliary burner. The oxygen-fuel auxiliary burner recessed within at least one passageway of the modified block provides its flame in a localized manner to heat a specific area without touching the walls and is operated to avoid disruption of the flame momentum of the air burners. The oxy-burner or oxy-burners installed in this manner are useful in increasing the glass production rate without overheating the furnace and useful in providing flexibility to a glass manufacturing process by being able to operate the furnace even when its regenerators are not functioning properly.
Although the invention has been described in detail with reference to certain specific embodiments, those skilled in the art will recognize that there are other embodiments within the spirit and scope of the claims. | The invention relates to the employment of at least one oxygen-fuel burner in a particular manner in glass melting cross-fired regenerative furnaces. By operating oxygen-fuel burners positioned in particular places in a cross-fired regenerative furnace in an appropriate manner, the glass melting can be accomplished without disrupting the flame momentum of the air-fuel burners, thereby improvidng the efficiency of the glass melting and increasing the production of the glass products. | 8 |
PRIORITY CLAIM
[0001] This application claims the benefit of U.S. provisional patent application No. 61/261,349 filed on Nov. 15, 2009 and of U. S. provisional patent application No. 61/261,352 filed on Nov. 15, 2009, each of which is incorporated herein by reference in its entirety.
STATEMENT OF GOVERNMENTAL RIGHTS
[0002] Part of the work during the development of this invention was made with government support from the National Institute of Health (NIH) under grant number HL069669. The U.S. government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] Methods of treating potential cell grafts comprising hematopoietic stem and progenitor cells with a selective receptor agonist of the EP 4 receptor to enhance their homing, survival, self-renewal and proliferation.
BACKGROUND
[0004] Bone marrow transplantation, including the more popular procedures of mobilized peripheral blood stem cell transplantation and umbilical cord blood transplantation are routinely used as curative procedures for malignant and nonmalignant hematologic diseases and genetic disorders. These procedures require that hematopoietic grafts containing sufficient numbers of stems and progenitor cell populations be harvested from healthy normal donors or from patients at a time of low or absent disease and subsequently administered to patients whose hematopoietic system and presumably disease tissue has been eradicated. After transplantation, the appropriate stem cells travel to or “home” to the appropriate bone marrow micro-environmental niches. Once lodged within the appropriate niches, these cells proliferate and produce new stem cells, a process called self-renewal. The cells also differentiate into lineage restricted progenitor cells and mature cells, thereby restoring the blood forming hematopoietic system for the life of the recipient. Progenitor cells are required in said grafts to also produce mature cells; however since they are not stem cells and cannot self-renew, their participation is limited in lifespan. Successful transplantation procedures require that sufficient cells be collected from the donor and administered to the recipient. The need for large numbers of cells is aggravated by the fact that collection procedures and the process of homing and engraftment are stressful to the graft cells resulting in the loss of a portion of the cells in the graft.
[0005] In particular, umbilical cord blood grafts contain limited numbers of stem cells and for this reason usually cannot be routinely used to transplant adults. Similarly, 10-25% of normal donors and up to 75% of specific patient populations, particularly those exposed to certain chemotherapeutic agents, e.g., fludarabine, fail to mobilize sufficient cells for use in transplant procedures. In general, the greater the number of viable cells that can be transplanted the greater the chances are for a successful treatment. Accordingly, there is a need for novel agents and/or methodologies that can increase the number of hematopoietic stem cells or progenitor cells in the transplant or alternatively to facilitate or enhance their homing to bone marrow. Some aspects of the current invention seek to address this need.
SUMMARY
[0006] Some aspects of the present invention provided methods of treating a donor or donor cells or a recipient of hematopoietic stem or progenitor cells, comprising the steps of providing at least one compound that preferentially interacts with the PGE 2 EP 4 receptor, on hematopoietic stem or progenitor cells, or a pharmaceutically acceptable salt thereof and administering a therapeutically acceptable dose of said compound to a patient in need thereof. These compounds may be selected from the group consisting of: 2-[3-[(1R,2S,3R) -3-hydroxy-2-[(E,3S)-3-hydroxy-5-[2-(methoxymethyl)phenyl]pent-1-enyl]-5-oxocyclopentyl]sulfanylpropylsulfanyl]acetic acid; methyl 4-[2-[(1R,2R,3R)-3-hydroxy-2-[(E,3S)-3-hydroxy-4-[3-(methoxymethyl)phenyl]but-1-enyl]-5-oxocyclopentyl]ethylsulfanyl]butanoate; 16-(3-Methoxymethyl)phenyl-ω-tetranor-5-thiaPGE; 5-{3-[(2S)-2-{(3R)-3-hydroxy-4-[3-(trifluoromethyl)phenyl]butyl}-5-oxopyrrolidin-1-yl]propyl]thiophene-2-carboxylate; [4′-[3-butyl-5-oxo-1-(2-trifluoromethyl-phenyl)-1,5-dihydro-[1,2,4]triazol-4-ylmethyl]-biphenyl-2-sulfonic acid (3-methyl-thiophene-2-carbonyl)-amide]; and ((Z)-7-{(1R,4S ,5R)-5-[(E)-5-(3-chloro-benzo [b]thiophene-2-yl)-3-hydroxy-pent -1-enyl]-4-hydroxy-3,3 -dimethyl-2-oxo-cyclopentyl}-hept-5-enoic acid)
[0007] In some embodiments the compound is 5-[(1E,3R)-4,4-difluoro-3-hydroxy-4-phenyl -1-buten-1-yl]-1-[6-(2H-tetrazol-5R-yl)hexyl]-2-pyrrolidinone (L-902,688). In some embodiments, the patient is recipient of a graft, wherein the graft includes at least one type of cell selected from the group consisting of hematopoietic stem cells and progenitor cells that have treated with an agonist that preferentially binds to the EP 4 receptor.
[0008] Some embodiments include methods of treating a donor, donor cells or a recipient of hematopoietic stem or progenitor cells, comprising the steps of: providing at least one compound that preferentially interacts with the PGE 2 EP 4 receptor, on hematopoietic stem or progenitor cells, or a pharmaceutically acceptable salt thereof; and administering a therapeutically acceptable dose of said compound to a patient in which the patient is a donor or a recipient of hematopoietic stem or progenitor cells. In many of these methods the compound increases the homing and/or the engraftment of the hematopoietic stem or progenitor cells.
[0009] Compounds that interact with the PGE 2 EP 4 receptor include, but are not limited to, compounds selected from the groups consisting of: 2-[3-[(1R,2S,3R)-3-hydroxy-2-[(E,3S)-3-hydroxy-5-[2-(methoxymethyl)phenyl]pent-1-enyl]-5-oxocyclopentyl]sulfanylpropylsulfanyl]acetic acid; methyl 4-[2-[(1R,2R,3R)-3-hydroxy-2-[(E,3S) -3-hydroxy-4-[3-(methoxymethyl)phenyl]but-1-enyl]-5-oxocyclopentyl]ethylsulfanyl]butanoate; 16-(3-Methoxymethyl)phenyl-ω-tetranor-5-thiaPGE; 5-{3-[(2S)-2-{(3R)-3-hydroxy-4-[3-(trifluoromethyl)phenyl]butyl}-5-oxopyrrolidin-1-yl]propyl]thiophene-2-carboxylate; [4′-[3-butyl-5-oxo-1-(2-trifluoromethyl-phenyl)-1,5-dihydro -[1,2,4]triazol-4-ylmethyl]-biphenyl-2-sulfonic acid (3-methyl-thiophene-2-carbonyl)-amide]; and ((Z)-7-{(1R,4S ,5R)-5-[(E)-5-(3-chloro-benzo[b]thiophene-2-yl)-3-hydroxy-pent-1-enyl]-4-hydroxy-3,3-dimethyl-2-oxo-cyclopentyl}-hept-5-enoic acid) or a pharmaceutically acceptable salt thereof. Still another compound that interacts with PGE 2 EP 4 receptor and can be used in some embodiments of the invention is the compound 5-[(1E,3R)-4,4-difluoro-3-hydroxy -4-phenyl-1-buten-1-yl]-1-[6-(2H-tetrazol-5R-yl)hexyl]-2-pyrrolidinone or a pharmaceutically acceptable salt thereof.
[0010] In some embodiments recipient graft includes at least one type of cell selected from the group consisting of hematopoietic stem cells and progenitor cells that are treated with an EP 4 agonist. Either human or animal patients may be treated with these compounds or with cells that were first treated with these compounds either in vivo or in vitro.
[0011] Still other embodiments of the invention include methods of treating a human or an animal patient, comprising the steps of: providing a therapeutically effective amount of a PGE 2 EP 4 agonist or a pharmaceutically acceptable salt thereof; harvesting a hematopoietic stem or progenitor cell from a donor; and contacting said PGE 2 EP 4 agonist to a hematopoietic stem or progenitor cell, wherein said hematopoietic stem or progenitor cell was harvested from the donor.
[0012] Compounds that can be contacted with hematopoietic stem or progenitor cells in order to practice the invention include, but are not limited to, compounds selected from the group consisting of: 2-[3-[(1R,2S ,3R)-3-hydroxy-2-[(E,3S)-3-hydroxy-5-[2-(methoxymethyl)phenyl]pent-1-enyl]-5-oxocyclopentyl]sulfanylpropylsulfanyl]acetic acid; methyl 4-[2-[(1R,2R,3R)-3-hydroxy-2-[(E,3S)-3-hydroxy-4-[3-(methoxymethyl)phenyl]but-1-enyl]-5-oxocyclopentyl]ethylsulfanyl]butanoate; 16-(3-Methoxymethyl)phenyl-ω-tetranor-5-thiaPGE; 5-{3-[(2S)-2-{(3R)-3-hydroxy-4-[3-(trifluoromethyl)phenyl]butyl}-5-oxopyrrolidin-1-yl]propyl]thiophene-2-carboxylate; [4′-[3-butyl-5-oxo-1-(2-trifluoromethyl-phenyl) -1,5-dihydro-[1,2,4]triazol-4-ylmethyl]-biphenyl-2-sulfonic acid (3-methyl-thiophene-2-carbonyl)-amide]; and ((Z)-7-{(1R,4S ,5R)-5-[(E)-5-(3-chloro-benzo[b]thiophene-2-yl)-3-hydroxy-pent-1-enyl]-4-hydroxy-3,3-dimethyl-2-oxo-cyclopentyl}-hept-5-enoic acid) or a pharmaceutically acceptable salt thereof. Still another compound that can be used to practice the invention is 5-[(1E,3R)-4,4-difluoro-3-hydroxy-4-phenyl-1-buten-1-yl]-1-[6-(2H-tetrazol-5R-yl)hexyl]-2-pyrrolidinone or a pharmaceutically acceptable salt thereof. In some embodiments, hematopoietic stem or progenitor cells treated with these compounds or other PGE 2 EP 4 agonist are then administered to a human or an animal patient.
[0013] In some embodiments the therapeutically effective amount of the PGE 2 EP 4 agonist contacted with the hematopoietic stem or progenitor cells is on the order of between about 0.001 μM to about 10 μM per about 1.0×10 6 cell per ml to about 1.0×10 7 cells per ml of said hematopoietic stem or progenitor cells. In some embodiments the hematopoietic stem or progenitor cells treated and used to treat a human or animal recipient are harvested from marrow, umbilical cord or peripheral blood obtained from a human or an animal donor. In some embodiments the donor and the recipient of the hematopoietic stem or progenitor cells are the same human or animal patient.
[0014] Some embodiments of the invention include a method for altering the activity of a cell, comprising the steps of: providing a hematopoietic stem or progenitor cell, wherein the cells express at least one PGE 2 EP 4 receptor; supplying at least one compound that preferentially interacts with the PGE 2 EP 4 receptor or a pharmaceutically acceptable salt thereof; and contacting the hematopoietic stem or progenitor cell with said compound. In some embodiments the hematopoietic stem or progenitor cell are isolated from marrow, umbilical cord or peripheral blood. In some embodiments contacting the cells with the compound(s) increases the homing of said cells and or the engrafting potential of the cells. In some embodiments the compounds contacted with the cells includes, but is not limited to, at least one compound selected from the group consisting of: 2-[3-[(1R,2S,3R)-3-hydroxy-2-[(E,3S)-3-hydroxy-5-[2-(methoxymethyl)phenyl]pent-1-enyl]-5-oxocyclopentyl]sulfanylpropylsulfanyl]acetic acid; methyl 4-[2-[(1R,2R,3R)-3-hydroxy-2-[(E,3S)-3-hydroxy-4-[3-(methoxymethyl)phenyl]but-1-enyl]-5-oxocyclopentyl]ethylsulfanyl]butanoate; 16-(3-Methoxymethyl)phenyl-ω-tetranor-5-thiaPGE; 5-{3-[(2S)-2-{(3R)-3-hydroxy-4-[3-(trifluoromethyl)phenyl]butyl}-5-oxopyrrolidin-1-yl]propyl]thiophene-2-carboxylate; [4′-[3-butyl-5-oxo-1-(2-trifluoromethyl-phenyl) -1,5-dihydro-[1,2,4]triazol-4-ylmethyl]-biphenyl-2-sulfonic acid (3-methyl-thiophene-2-carbonyl)-amide]; and ((Z)-7-{(1R,4S,5R)-5-[(E)-5-(3-chloro-benzo[b]thiophene-2-yl)-3-hydroxy-pent-1-enyl]-4-hydroxy-3,3-dimethyl-2-oxo-cyclopentyl}-hept-5-enoic acid) or a pharmaceutically acceptable salt thereof. In some embodiments at least one of the compound is 5-[(1E,3R)-4,4-difluoro -3-hydroxy-4-phenyl-1-buten-1-yl]-1-[6-(2H-tetrazol-5R-yl)hexyl]-2-pyrrolidinone or a pharmaceutically acceptable salt thereof. In some embodiments the amount of therapeutically effective compound contacting said cells is about 0.001-10 microMolar. In some embodiments the number of cells treated with the compound is on the order of between about 10 6 to about 10 7 cells per mL.
[0015] Other aspects of the present invention provide methods of treating a donor, donor cells or a recipient of hematopoietic stem or progenitor cells comprising the step of administering to the donor, donor cells or recipient a therapeutically effective amount of an EP 4 agonist.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIG. 1 . Graph illustrating that treatment of cells with EP 4 agonist ex vivo specifically up regulates CXCR 4 expression on CD34 + cells.
[0017] FIG. 2 . Graph illustrating that signaling via the EP 4 receptor is responsible for up regulation of CXCR4 expression.
DESCRIPTION
[0018] For the purposes of promoting an understanding of the principles of the novel technology, reference will now be made to the preferred embodiments thereof, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the novel technology is thereby intended, such alterations, modifications, and further applications of the principles of the novel technology being contemplated as would normally occur to one skilled in the art to which the novel technology relates.
[0019] Unless stated otherwise the term, “therapeutically effective amount” refers to an amount of a pharmaceutically active compound that when administered to a human being or an animal patient or to a cell or collection of cells either alone or in combination with other pharmaceutically active ingredients or other components of medicaments that have a desirable effect on the physiological condition of a patient or the cell or collection of cells.
[0020] Therapeutically effective, beneficial or efficacious doses of various compounds that preferentially bind to PGE 2 EP 4 receptors administered in vivo to either a human or an animal patient are in the range of between about 0.1 mg of the compound per Kg of body weight of the patient per day to about 100 mg of the compound per Kg of body weight of the patient per day.
[0021] Compounds that preferentially bind to PGE 2 EP 4 receptors are compounds that have a higher affinity for the EP 4 receptor than for any of the other three EP receptors namely EP 1 , EP 1 and EP 3 .
[0022] Compounds that can be used to practice some embodiments of the invention include, but are not limited to, the following: 5-[(1E,3R)-4,4-difluoro-3-hydroxy-4-phenyl -1-buten-1-yl]-1-[6-(2H-tetrazol-5R-yl)hexyl]-2-pyrrolidinone also referred to as L-902,688 (Young, et al., 2004); 2-[3-[(1R,2S,3R)-3-hydroxy-2-[(E,3S)-3-hydroxy-5-[2-(methoxymethyl)phenyl]pent-1-enyl]-5-oxocyclopentyl]sulfanylpropylsulfanyl]acetic acid also referred to as ONO-AE1-329 (Suzawa et al., 2000); methyl 4-[2-[(1R,2R,3R)-3-hydroxy -2-[(E,3S)-3-hydroxy-4-[3-(methoxymethyl)phenyl]but-1-enyl]-5-oxocyclopentyl]ethylsulfanyl]butanoate also referred to as ONO-4819 (Maruyama et al., 2002; Ohta et al., 2009); 16-(3-Methoxymethyl)phenyl-ω-tetranor-5-thiaPGE 1 (Maruyama et al., 2002); 5-{3-[(2S)-2-{(3R)-3-hydroxy-4[3-(trifluoromethyl)phenyl]butyl}-5-oxopyrrolidin-1-yl]propyl]thiophene-2-carboxylate also referred to as PF-04475270 (Luu et al., 2009); APS-999 Na (El-Nefiawy et al., 2005); [4′-[3-butyl-5-oxo-1-(2-trifluoromethyl-phenyl)-1,5-dihydro -[1,2,4]triazol-4-ylmethyl]-biphenyl-2-sulfonic acid (3-methyl-thiophene-2-carbonyl)-amide](Machwate et al., 2001); and ((Z)-7-{(1R,4S,5R)-5-[(E)-5-(3-chloro-benzo[b]thiophene-2-yl) -3-hydroxy-pent-1-enyl]-4-hydroxy-3,3-dimethyl-2-oxo-cyclopentyl}-hept-5-enoic acid) U. S. Patent application number US2005/0164992A1, Jul. 28, 2005, to Donde Y, Nguyen J H, Kedzie K M, Gil D M, Donello J E and Im W B.
[0023] Unless stated otherwise the term “about” as used herein refers to range of value of plus or minus 10%, e.g., ‘about 1.0’ includes values between 0.9 and 1.1.
[0024] Treatment of bone marrow cells, umbilical cord blood cells, mobilized peripheral blood cells or any hematopoietic cell graft to be used for hematopoietic transplantation with Prostaglandin E 2 (PGE 2 ) or any active analogue or metabolite of PGE 2 or any E series prostaglandin with specificity for the PGE 2 EP 4 receptor, improves the homing, survival and proliferation of the transplanted hematopoietic stem cells. This treatment can be used to increase stem cell engraftment rates and thereby improve the efficiency of hematopoietic stem cell transplantation.
[0025] By some estimates the success of peripheral blood stem cell transplantation requires administration of approximately 2 million CD34 + cells per kilogram of recipient patient body weight. Any agent, combination of agents or manipulations that increases the number of stem cells that can be collected, enhances their survival rates, enhances their ability to home to the appropriate marrow environment and/or enhances their self-renewal and proliferation rates will likely have a positive impact on the efficacy of hematopoietic transplantation procedures. The success of these procedures may be measured in terms of reduced patient morbidity and mortality. Numerous studies have been undertaken to try and expand the number of human hematopoietic stem cells within isolated grafts in ex vivo settings, with limited success (Broxmeyer, 2006; Haylock and Nilsson, 2007). Recently, the CXCR4 antagonist AMD3100 has been shown to enhance mobilization of stem cells (Broxmeyer, et al., 2005; Liles, et al., 2003) and in clinical trials, (Plerixafor; Mozibil) has been shown to enhance collection of mobilized stem cells when used in combination with G-CSF (DiPersio et al., 2007b; DiPersio et al., 2007a). Truncation of chemokines has been used as a method to enhance the body's ability to mobilize stem cells. Some of these methods have been patented, e.g., U.S. Pat. Nos. 6,080,398; 6,447,766B 1; 639053B1; 6,713,052, each of which is incorporated by reference in its entirety. Their ability to more efficiently mobilize stem cells has also been reported (King, et al., 2001; Pelus, et al., 2004). A role for blocking the activity of a surface peptidase (CD26) has been reported as a method for enhancing the homing of hematopoietic stem cells (Christopherson, et al., 2004).
[0026] A number of agents when used in combination with G-CSF have been reported to increase the number of hematopoietic progenitor cells that can be recovered (Pelus and Fukuda, 2007; Herbert, et al., 2007), however, the ability of these agents to mobilize the long-term repopulating stem cells, i.e., the stem cells with self-renewal activity, has not been uniformly demonstrated. A recent study has shown that pulse exposure of mouse bone marrow cells to 16,16 dimethyl pGE 2 (dmpGE 2 ) enhances engraftment of hematopoietic stem cells, however this study provides no evidence of mechanism of action and specifically states that the effect of PGE 2 is not on cell homing (North, et al., 2007). It was unexpectedly demonstrated by Hoggatt, et al., 2009, that PGE 2 increases the CXCR4 receptor on hematopoietic stem and progenitor cells, and that this increase is responsible for increasing the homing to the bone marrow niche, resulting in a subsequent increase in engraftment.
[0027] It is generally believed that PGE 2 interacts with 4 highly conserved G-protein coupled receptors (GPCR); EP 1 , EP 2 , EP 3 , and EP 4 that account for the multiple, sometimes opposing effects attributed to PGE 2 (Breyer, et al., 2001). EP receptor expression levels vary among different tissues, with EP 3 and EP 4 mRNA being most abundant (Sugimoto and Narumiya, 2007a) and EP 2 mRNA expressed at lower levels than EP 4 in most tissues (Katsuyama, et al., 1995). EP 1 activates phospholipase C (PLC) via an unidentified G protein (Tsuboi, et al., 2002), which increases intracellular Ca 2+ coupled to inositol phosphates resulting in activation of phosphokinase C (PKC) (Breyer, et al., 2001). EP 3 receptor ligation results in inhibition of adenylate cyclase and decreased cAMP that is Gα i linked (Sugimoto, et al., 2007). Multiple EP 3 splice variants have been identified and depending on C-terminal splicing, they can couple to multiple G proteins (Namba, et al., 1993). EP 2 and EP 4 both couple to G α s leading to adenylate cyclase activation and increased cAMP, activating protein kinase A (PKA), as well as Rap1, Rac 1, and PKCζ (PKC zeta), a unique isoform implicated in HSC function (Goichberg, et al., 2006). EP 2 and EP 4 are thought to have partially redundant roles in some systems, while in others they play distinct roles (Sugimoto and Narumiya, 2007). EP 4 but not EP 2 can activate the PI3K/Akt pathway in addition to adenylate cyclase (Fujino, et al., 2003). EP 4 has a longer cytosolic domain allowing for more ligand dependent phosphorylation and more rapid desensitization (Nishigaki, et al., 1996) enabling a selective negative feedback loop (Sugimoto and Narumiya, 2007). Lastly, EP 4 is internalized when activated, while EP 2 is not (Desai, et al., 2000). As a consequence, EP 2 and EP 4 can have different roles based upon continuation or attenuation of signals generated by receptor activation (Breyer, et al., 2001). Treating with PGE 2 often exhibits a “bell-shaped” dose-response curve suggesting a different repertoire of EP receptors is activated dependent upon PGE 2 concentration (Hull, et al., 2004).
[0028] Most current strategies to improve hematopoietic transplantation utilizing prostaglandin have used either native PGE 2 or a long acting derivative of PGE 2 , 16,16 dimethylprostaglandin E 2 (dmPGE 2 ). These prostaglandin compounds are thought to activate all 4 EP receptors leading to the numerous downstream signaling events briefly described above. As demonstrated herein, the enhancement in homing and engraftment of hematopoietic stem and progenitor cells is due to up regulation of the CXCR4 receptor by treatment with prostaglandin. Specifically focusing on the EP receptor that is responsible for the increase in CXCR4, (the EP 4 receptor) has the benefit of enhancing the grafting process without activating receptors that may be detrimental to the engraftment process and/or have other unknown possible deleterious consequences.
[0029] Treating With An E4 Selective Agonist Affects Homing and Engraftment Efficiency
[0030] Un-manipulated hematopoietic grafts or purified hematopoietic stem cell populations (e.g., SKL cells in mice or CD34 + cells in humans) are incubated with an EP 4 specific agonist: 5-[(1E,3R)-4,4-difluoro-3-hydroxy-4-phenyl-1-buten-1-yl]-1-[6-(2H-tetrazol-5R-yl)hexyl]-2-pyrrolidinone (i.e. L-902,688), on ice or at room temperature at concentrations of 0.001-10 microMolar agonist per 1-10 million cells in 1 ml of culture medium, e.g. IMDM, for 15 minutes-6 hrs. After incubation, the cells are washed 3 times in sterile media or saline and administered to recipients, intravenously. L-902,688 was a generous gift from Merck Frosst (Kirkland, Canada) (Young, et al., 2004).
[0031] Referring now to FIG. 1 . This graph illustrates that treatment of cells with EP 4 agonist ex vivo specifically up regulates CXCR4 expression on CD34 + cells. The insert shows cytometry histograms of CD34 + cells from cord blood samples showing significant up regulation of CXCR4 on the surface of CD34 + cells after pulse exposure to EP 4 agonist (light line) and dmPGE 2 (dark line) compared to isotype control (grey shaded area). The bar graph indicator data measured from such experiments graphed as a function of different compounds used dmPGE 2 , Butaprostone, sulprostone and EP 4 .
[0032] Referring now to FIG. 2 . This graph illustrates that signaling via the EP 4 receptor is responsible for up regulation of CXCR4 expression. The insert shows data for 3 cord blood samples. Treatment with EP 4 agonist ex vivo up regulates CXCR4 expression on CD34 + cells. The bar chart shows combined data for 8 samples. The bar chart data demonstrates that ex vivo treatment with EP 4 agonist up regulates CXCR4 by about 3 fold. In the bar chart this effort is normalized to 100%. Pretreatment of cells with a specific antagonist of the EP 1, 2 and 3 receptor prior to exposure to EP 4 antagonist had no effect on up regulation of CXCR4 whereas pre-incubation with a selective EP 4 antagonist prior to exposure to EP 4 agonist significantly blocked up regulation of CXCR4. The fact that up regulation of CXCR4 by an EP 4 selective agonist is blocked by a selective EP 4 antagonist, but not by EP 1, 2, 3, antagonist, provides additional evidence that up regulation is mediated through the EP 4 receptor.
[0033] Additional embodiments include administering EP 4 agonists (e.g., on the order of about 0.001-10 microMolar) to patients immediately prior to and daily afterwards after receiving a hematopoietic graft as a means of enhancing stem cell function. Therapeutic effective doses are amounts of the pharmaceutically active agent used either alone or in combination with another pharmaceutical agent or inert material that has a beneficial effect on a so treated human or animal patient. Such benefits may include, but are not limited to, increasing the effectiveness of other steps in a given treatment regimen.
[0034] While the novel technology has been illustrated and described in detail in the figures and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the novel technology are desired to be protected. As well, while the novel technology was illustrated using specific examples, theoretical arguments, accounts, and illustrations, these illustrations and the accompanying discussion should by no means be interpreted as limiting the technology. All patents, patent applications, and references to texts, scientific treatises, publications, and the like referenced in this application are incorporated herein by reference in their entirety.
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